Bokaro Steel Plant Specs

259
STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO (5.77MT Expansion) TECHNICAL SPECIFICATION FOR DESIGN, SUPPLY, ERECTION, TESTING AND COMMISSIONING OF RAW MATERIAL HANDLING SYSTEM (PACKAGE-066) MECON LIMITED RANCHI – 834 002 TS NO.: MEC/S/E24F/11/17/K/01/55/066.R3 December, 2009

Transcript of Bokaro Steel Plant Specs

Page 1: Bokaro Steel Plant Specs

STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO (5.77MT Expansion)

TECHNICAL SPECIFICATION FOR DESIGN, SUPPLY, ERECTION, TESTING

AND COMMISSIONING OF

RAW MATERIAL HANDLING SYSTEM (PACKAGE-066)

MECON LIMITED RANCHI – 834 002

TS NO.: MEC/S/E24F/11/17/K/01/55/066.R3 December, 2009

Page 2: Bokaro Steel Plant Specs

STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved.

ISSUE NO: 01

COPY NO. OF 8

CONTENT

CHAPTER NO.

TITLE TOTAL PAGES

01. INTRODUCTION 1

02. INTENT OF SPECIFICATION 3

03. INSTRUCTION TO TENDERER 3

04. SCOPE OF WORK & BATTERY LIMIT 4

05. BRIEF SYSTEM DESCRIPTION 10

06. TECHNICAL SPECIFICATION

06.01 TECHNOLOGICAL 10

06.02 CIVIL WORKS 7

06.03 STRUCTURAL WORKS 17

06.04 GENERAL LAYOUT & TRANSPORTATION 3

06.05 AREA REPAIR SHOP & SUB STORE 2

06.06 WATER SYSTEM 19

06.07 AIR POLLUTION CONTROL 13

06.08 A/C AND VENTILATION SYSTEM 16

06.09 DRIVE, CONTROL, ILLUMINATION & AUTOMATION SYSTEM

69

06.10 INSTRUMENTATION & CONTROL 7

06.11 TELECOMMUNICATION & VHF SYSTEM 2

07 SPARES, CONSUMABLES, TOOLS & TACKLES AND CONSTRUCTION EQUIPMENT

5

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved.

CHAPTER NO.

TITLE TOTAL PAGES

08 PERFORMANCE GUARANTEE 5

09 PROJECT SCHEDULE & MONITORING 4

10 DRAWING & DOCUMENT TO BE SUBMITTED 1

11 LIST OF DRAWINGS 1

12 SCHEDULES 48 Total no. of pages- 250

Prepared by Checked by Approved by

S.KUMAR, ADE

MH SECTION

R.P.CHAUDHURY, AGM

MH SECTION

P.K.BANERJEE, DGM I/C

MH SECTION

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-01 INTRODUCTION

Page 1 of 1

01.00 INTRODUCTION

General The SAIL Corporate Plan envisages expansion of Bokaro Steel Plant,

Bokaro, Jharkhand, from 4.0Mt/yr to 5.77 Mt /yr of hot metal .The

increase in plant capacity by upgrading Blast Furnace, Sinter Plant &

SMS-II which will lead to increase in consumption of various raw

materials like Iron ore Lump, Iron ore fines, Lime Stone & Dolomite (Flux

Materials) Quartzite, Sinter, Coke, Mn-ore fines, etc.

To handle raw materials required for 5.77MT expansion of BSL, Bokaro

from its present production capacity, additional wagon tippler for receipt

of raw material and new conveyors have been envisaged. This plant

shall deal with receipt, storage, handling of raw materials required to

process / consumer plants like Blast furnace, Sinter Plant and provision

for future new beds and conveyor feed route to new Lime and Dolomite

plant for future Steel Melting Shop (SMS-III) also considered. The

storage and handling of coal and coke has not covered in these TS.

The expansion of the plant will be undertaken through a number of

turnkey / non turnkey packages including a Blast-Furnace, Sinter Plant,

BOF/CCP, Rolling Mill, Lime/ Dolo Plant, Raw Material Handling System

(RMHS) to cater to the needs for the same.

These TS for Raw Material Handling System (RMHS) has been

prepared on the concept of a turnkey package.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-02 INTENT_OF_SPECiFICATION

Page 1 of 3

02.00 INTENT OF SPECIFICATION

Bokaro Steel Plant (BSL), Steel Authority of India Limited (SAIL) has envisaged enhancement of crude steel production capacity from 4.0 Mtpa to 5.77 Mtpa for phase-I expansion of BSL. MECON Ltd., a Govt. of India undertaking, has been appointed as consultant by BSL, SAIL for their expansion programme. In the 5.77 Mtpa expansion, for the receipt and storage of the additional raw material required for the Blast Furnace, Sinter Plant, as well as provision for future beds and conveying route for future Lime /Dolomite calcinations Plant and SMS-III etc shall be covered in the “Raw Material Handling System” (RMHS) Package (Package #66) and is enumerated in details in the following chapters of the Technical Specification (TS). This technical specification calls for complete turnkey execution of the job covering the design, engineering, manufacture, supply, handling, storage, erection, painting, testing, commissioning of plant & equipment complete with civil, structural, electrical & process control, compressed air & water facilities, ventilation & air-conditioning, various facilities like sub-stores, area-repair-shop, electrical sub-stations and control rooms, workers rest rooms etc. and demonstrations of performance guarantee parameters of the RMHS complex in a co-ordinate and integrated manner as per the relevant clauses of the specification. The successful Tenderer shall receive necessary utility services not covered in this TS at battery limits and a predetermined leveled site for installation of RMHS plant. The details of the same have been elaborated in the succeeding chapters.

The technical specification shall be read in conjunction with other tender documents like General Technical Specification (GTS), Notice inviting Tender(NIT), Bid data sheet, Commercial document & Standard bid

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-02 INTENT_OF_SPECiFICATION

Page 2 of 3

document (SBD) of BSL, SAIL and any other document enclosed by Purchaser for design, supply & installation of plant and equipment (Turnkey basis). The provisions given in these documents shall be complimentary to one another. However, in case of any conflict between the provisions of these documents with respect to technical matter, the provisions in the technical specification will prevail. This specification is for guidance only and the design & engineering shall be complete in all respect and any equipment or facility not covered in this specification but considered essential for proper installation and smooth operation, ease of maintenance of Plant/ equipment and demonstration of PG parameters shall be deemed to be included in the scope of the Tenderer. Some alterations in the scope, or any alternative better scheme with respect to the technical specification, if felt necessary by the Tenderer, shall be clearly spelt out in the offer. The tenderer shall study the specification along-with related documents

and satisfy himself thoroughly regarding suitability of the plant and

equipment and system, specified in the tender document and take full

responsibility for guaranteed operation of the equipment with respect to

output, reliable working as well as ease of operation, inspection and

maintenance including replacement with minimum down time.

The tenderer shall satisfy himself before submission of the offer, the

nature and location of work place, kind of equipment, facilities, services,

etc needed during performance of work, general and local conditions as

well as all other matters which can, in any way, affect the work covered

in this specification.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-02 INTENT_OF_SPECiFICATION

Page 3 of 3

The successful tenderer shall be responsible for coordinating the

supplies covered in the different parts of this Specification from different

sources and execute the contract within agreed time schedule.

The tenderer shall endeavor to use maximum indigenous equipment /

facilities which may be available in India / manufactured in India by

Indian associates based on manufacturing drawings to be supplied by

the tenderer / his sub-suppliers. All indigenous equipment / components

shall be selected from the list of Preferred Makes as enclosed in GTS.

The project is scheduled to be implemented within a span of 20 months

from the date of placement of LOI on Successful Tenderer till handing

over the plant to Purchaser.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-03 INSTRUCTION TO TENDERER

Page 1 of 3

03.00 INSTRUCTION TO THE TENDERER 03.01 The Tenderer may furnish their offer on consortium basis. In such case,

all members of the consortium shall be responsible & liable jointly and severally for the execution of the scope of work under the technical specification. However, the leader of the consortium shall be solely responsible for the integration, interfacing, co-ordination & completeness of the total scope of work including PG parameters specified in the technical specification. Eligibility criteria for the consortium shall be as per other relevant document enclosed with this technical specification.

The consortium leader shall be authorized to honour liabilities & receive

instructions from Purchaser for and on behalf of any one or all members of consortium during the entire execution of contract, including payment which shall be done to the consortium leader or with his consent to other consortium members. The leader of the consortium shall operate as single window for all communications.

03.02 Site & meteorological information of plant i.e. location, climate condition,

earthquake factor, connectivity of the site with railways; road, ports etc are furnished in GTS. Tenderer is requested to consider the same while finalization of offer.

03.03 The physical and chemical analysis of the raw materials, wherever

applicable shall be treated as indicative figures only. The successful Tenderer, if he feels necessary, shall take the samples and test them in laboratories (either in India or abroad) as may be required and satisfy themselves from the point of view of firming up of process and sizing of plant & equipment offered by them.

03.04 The Successful Tenderer shall bear full responsibility for deductions and

conclusions as to the nature and conditions under which the work is to be executed, including effect of climate, rainfall etc. Failure to do so shall not absolve the Successful Tenderer of his responsibilities about the proper execution of the job. Since the execution shall be turnkey in

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-03 INSTRUCTION TO TENDERER

Page 2 of 3

nature, no claims for extra payments due to any special site conditions and ignorance of site conditions shall be considered after the acceptance of his quotation.

During engineering stage, if any item or facility felt necessary to be included for proper functioning of the plant which is not envisaged in the offer of Tenderer, the same shall also be provided by the Successful Tenderer without any extra claims.

03.05 Training of Purchaser’s and Consultant’s personnel is required to ensure

smooth operation of various equipment of the RMHS facility and speedy attainment of sustained design indices. For this purpose, the Tenderer shall submit a discipline-wise training plan and a training programme in similar plant in India / abroad.

03.06 The successful Tenderer shall ensure supply of engineering deliverables

and all materials matching the overall project sequence. 03.07 Information to be furnished along with offer in addition to those

mentioned in chapter - 12 (Schedule) but not limited to the followings;

• Technical part in the tender document shall be in the order of sequence of chapters of TS (technical part) starting from chapter no. 06 onwards. The offer shall be complete with technical details, drawings, sketches, and design parameters etc. which are necessary for providing clarity of the offered system / items.

• General description of process with process flow sheet, layout, plan &

sections of each unit.

• Complete list of plant & equipment with equipment parameters including electrics, instrumentation & automation, their tonnage and source of supply.

• Complete drive list

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-03 INSTRUCTION TO TENDERER

Page 3 of 3

• List of drawings and documents to be furnished in various stages of the project.

• Measures taken for fulfilling safety requirement & statutory regulations of

concerned authorities. • Makes of all bought out items as per preferred makes of GTS. • Information on energy saving measures.

• Estimated operating cost of plant & equipment with break-up. • Duly filled in format of time schedule as per SBD for submission of

drawings, documents, supply, erection, testing & commissioning and PG. Further, the dates of deliverables forming part of contract to match with overall time schedule of the project. The Tenderer may please note that Schedules are to be filled in completely without which the technical offer shall be considered as incomplete.

03.08 The enclosed tender drawings are deemed to be sufficient for the Tenderer to assess the nature and quantity of work involved and to quote his prices for the above job. No price increase on account of deviation from tender drawings shall be admissible.

03.09 Un priced format of the offer shall also be included in the technical offer. 03.10 All handling and transport charges of plant and equipment, raw materials

for site fabricated structures etc. including double handling as required for completion of the work in accordance with time schedule are deemed to be included in the scope of work of the Tenderer.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-04 SCOPE OF WORK Page 1 of 4

04.00 SCOPE OF WORK AND BATTERY LIMITS 04.01 SCOPE OF WORK

The broad turnkey scope of work shall be as per the following: 001 Design, manufacture, inspection, shop & primary coat of paint & supply

of complete plant & equipment, fabrication (shop & site) of building structures & technological structures, civil construction materials, power distribution, electrics, instrumentation & automation, illumination, telecommunication, all utilities & services, in-plant road networks, drainage systems, landscaping, fire detection & alarm system, area repair shop, sub-store, fire fighting pump house, as required, for complete & trouble free operation of Raw Material Handling System in an integrated manner.

002 Basic engineering, detail engineering and reference category of drawings, operating software and documents, in requisite copies, for approval of BSL / MECON. Further, the Tenderer will furnish final basic & detail engineering drawings, manufacturing drawings of fast wearing items and non-standard items, as built drawings, erection drawings/ documents, operating software, operation and maintenance manuals in soft editable format.

003 Receipt of material, loading / unloading, storage, civil construction, complete erection, testing, commissioning, handing over of plant to Purchaser, demonstration of performance guarantee and post commissioning services for a period of six months after commissioning. Preparation and approval of erection survey / alignment schemes, grouting clearances, painting clearances, testing of welds, pressure testing protocols and other related site protocols.

004 Deputation of representatives of equipment suppliers and technology

suppliers to site for supervision of erection, testing and commissioning.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-04 SCOPE OF WORK Page 2 of 4

005 Applying final finish coat of paint as per approved procedure & shades before handing over, first fill of lubricant & oil, special tools & tackles, mobile equipment, handling & hoisting equipment etc.

006 Supply of all commissioning spares. A list of such commissioning spares shall be indicated separately as indicated in schedule chapter 12. Tenderer shall quote separately for two years spares and insurance spares along with the main offer.

007 Progress reporting as per agreed formats, providing documentary evidence of purchase orders on sub vendors with addresses of contact persons, attending all site progress review / engineering review meetings at BSL, Bokaro or at MECON, Ranchi, opening an equipped site office with coordinator over seeing all activities.

008 Arrangement of all erection equipment viz. cranes, hoists, winches, etc, and safety appliances as required for erection of plant & equipment. Appointment of safety officer by the contractor shall be included.

009 Specialized training of Purchaser’s / Consultant’s personnel for

operation, maintenance, for smooth handing over the plant.

010 Testing and cold trial run of systems/ sub - systems and integrated testing shall be carried out by the successful Tenderer on continuous basis for complete Raw Material Handling System along with associated facilities followed by commissioning. On successful commissioning of the various sub-systems of the RMHS, PG test of the entire plant shall be carried out as elaborated in the relevant chapter.

011 Receiving delivery of items at site, their proper storage, and handling at site, watch and ward services, removal of debris to a location specified by the Purchaser etc.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-04 SCOPE OF WORK Page 3 of 4

Site shall be handed over to the Purchaser in clean and orderly manner to the satisfaction of the site engineers after commissioning of the project.

012 Getting Purchaser’s/ consultant’s approval for the drawings prepared by the successful Tenderer, obtaining required approval from statutory authorities, providing adequate personnel, equipment, tools & tackles for timely completion of the project.

013 For detailed scope of work and design parameters on various sub-systems & facilities, respective chapters under Chapter-06 of the Tender Specification shall be referred to.

04.02 This is a turnkey project for additional Raw Material Handling System and all the facilities required for proper functioning of the plant and achieving the rated production shall be deemed to be covered in the tender specification, unless specifically excluded from the Tenderer’s scope.

04.03 DELIVERY

The project is schedule up to handing over to Purchaser shall be within 24 months from the date of placement of LOI on successful contractor to handing over. The delivery of plant & equipment shall be FOR, BSL site/ stores at Bokaro, Jharkhand.

04.04 BATTERY LIMITS

Overall battery limits of the Raw Material Handling System have been described in the “Brief System Description” chapter 05 along with the Flow Diagrams – Drawing Nos MEC/S/E24F/11/17/K/01/55/02101, R1.

Battery limits for Raw Material Handling System (RMHS) comprises of the following:

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-04 SCOPE OF WORK Page 4 of 4

• Material receipt at Wagon Tippler WT # 5 and onward transport to the existing Ore fines and flux material storage bed, Reclaiming from the existing beds & transportation to existing conveyor system and also conveying materials coming from wagon tippler directly to the fourth series conveyor for onward transmission to Sinter Plant, Blast Furnace .

• Provision of Intermediate Storage Bunker Building for Lump Iron Ore near BF Stock House.

04.05 OBLIGATIONS OF PURCHASER

001 Purchaser shall allot leveled land with an undulation of about +500mm from the predetermined level as per the layout drawing for installation of the Raw Material Handling System.

002 Purchaser shall provide construction power, drinking water during construction and space for storage and site office as per GTS. The Tenderer shall indicate the details required by them in the prescribed format.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-05 BRF SYS DESCRPTN Page 1 of 11

1

05.00 BRIEF SYSTEM DESCRIPTION The Expansion of Raw Material Handling System comprises of the following sub-systems:

• Material receipt at Wagon Tippler WT # 5 and onward transport

to the Existing Ore fines and flux material storage beds for Stacking.

• Reclaiming from Existing beds & transportation to existing

conveyor system for onward transmission to Sinter Plant, Blast Furnace.

• Conveying materials coming from WT # 5 directly to the fourth

series conveyor system for onward transmission to Sinter Plant, Blast Furnace.

• Receiving Lump Iron Ore from conv. KD1-3 and store in

Intermediate Storage Bunker Building and feed back to conv KD1-3 near BF Stock House.

• Provision shall be kept in the Junction House for conveying

materials to the future storage beds and to future SMS-III /Lime & Dolo Plant.

The raw material to be handled by the proposed system is mainly, Iron Ore Lump, Iron Ore Fines, Lime Stone (BF grade), Lime Stone (SMS grade), Dolomite (BF grade), Dolomite (SMS grade), Quartzite, DRI and Ferro-alloys. These raw materials are mainly required for Blast Furnace, Sinter Plant, Lime-Dolomite Plant and Steel Melting Shop etc. All the raw materials will be received at the plant boundary by rail. The type of Wagon will be BOX, BOXN, BOXN MARK-II, BOXNHA, BOXNHS, BOXNR, BOY, BOBX, BOBS, BKC, BOBRN, BOST, which will transport the raw materials depending upon the location of loading and type of raw materials.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-05 BRF SYS DESCRPTN Page 2 of 11

2

Design Considerations The Raw Material Handling System (RMHS) systems have been planned based on the following assumption:

A. Size of Raw Material 1. Lump Iron Ore : (+) 8 to (-) 30 mm 3. Iron ore fines : (-) 8 mm 4. Lime Stone (BF/SP grade) : (+) 15 to (-) 50 mm 5. Dolomite (BF/SP grade) : (+) 25 to (-) 50 mm 6. Quartzite : (+) 25 to (-) 50 mm 7. Lime Stone (SMS grade) : (+) 25 to (-) 50 mm 8. Dolomite (SMS grade) : (+) 10 to (-) 25 mm

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

To handle raw materials required for 5.77 MT expansion of BSL, Bokaro from its present production capacity, additional wagon tippler for receipt of raw material have been envisaged. This plant shall deal with receipt, storage, handling of raw materials required to process / consumer plants like Blast furnace, Lime and Dolomite plant, Steel Melting Shop, etc.

The Raw materials requirement for 5.77 MT expansions is shown in Table-05.01 with daily consumption, number of stock piles and storage capacities etc. including handling losses as envisaged.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-05 BRF SYS DESCRPTN Page 3 of 11

3

Table – 05.01 Turnover Stock and No. of Stockpile of Raw Material Storage Yard for 5.77 MT Production per year

Daily Consumption

Storage Capacity Sl.

No.

Material Bulk Density,

t/m3

Annual Requirement with

10% losses, t t

Selected Stock Pile

m3 Days

I/O (Lump) (8-25mm) BF Plant 2.2 4581600 13090 5 115000 19

Coke (BF Plant) 0.5 2825600 8073 - - -

I/O (Fines) Sinter Plant 2.4 4715000 14288 5 115000 19

Sinter BF Plant 1.7 6000000 17143 - - -

Lime Stone for Sinter Plant & BF 1.5 550800 1669 2 46000 41

Dolomite for Sinter Plant & BF 1.6 637200 1931 2 46000 38

Lime Stone for Lime Plant (SMS)

1.5 355187 1015 2 46000 68

Dolomite for Lime Plant (SMS) 1.6 156835 448 1 23000 82

L/D Slag, Mn Ore etc. - As required - 1 - -

Coke breeze 0.8 432000 1309 - - -

TOTAL 20,254,222 58,966 18

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STEEL AUTHORITY OF INDIA LIMITED

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RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-05 BRF SYS DESCRPTN Page 4 of 11

The estimation of stockpile/storage capacities have been made based on the following assumption. A. Iron Ore Lump, Iron Ore Fines, Fluxes :

• Stock pile length available = 230m

• Stock pile width = 25m

• Height of stock pile = 8.5m

• Each stock pile volume = 23,000m3

B. No. of Days of working per year :

For Blast Furnace = 350 days

For Sinter Plant = 330 days

C. Material carrying capacity of each wagon shall be 78t (considering

high sided wagon) with gross weight of wagon 110t. All material will

be received in Wagon Tipplers. New Wagon tippler with Side Arm

Charger has been considered for unloading the materials received in

BOXN/BOST/ BOXNHA/BOXNR/ BOXNHS/BOY wagons.

The facilities required for achieving the targeted productions, additional handling facilities has been envisaged. The scheme has been described hereunder.

05.01 UNLOADING AND STACKING OF IRON ORE AND FLUX

One number Wagon tippler WT no.#5 along with side arm charger in addition to 4 numbers existing Wagon Tipplers has been envisaged for unloading Iron ore (lump and fines), Limestone & Dolomite (both SMS grade and Sinter Plant grade), Mn-ore, Quartzite etc.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-05 BRF SYS DESCRPTN Page 5 of 11

The Wagon Tipplers shall be of Rotaside Type capable of unloading BOXN and proposed BOXNHA, BOXNHS, BOXNR and BOY wagons upto a gross weight of 110t and an axle load of 23 t. The rated unloading capacity shall be 20 Tippling/hour. The placement of rakes shall be done by Side Arm Charger capable of handling a full rake BOXN, BOXNHA, BOXNHS, BOXNR and BOY wagons. Two belt feeders below Wagon Tippler # 5 shall feed the raw material on conveyor P1C1 which itself convey up to Jn house JNA1. From Conveyor P1C1, material discharges either on conveyor P11C1 or conveyor P11C1A through reversible shuttle conveyor RSC1-1 in Jn house JNA1 and also provision of feeding material on future conveyor P2C1/P2C2. Conveyor P11C1 will feed material on conveyor P12C1 in Jn house JNA8A. Conveyor P12C1 coming out from JNA8A shall feed material either on fourth series conveyor KP11-0 through fixed tripper in Jn house JNA10 or on existing conveyor KP4-1/KP4-2 & newly envisaged conveyor KP4-0 through reversible shuttle conveyor RSC12-1 in Jn house JNA11. Conveyor KP4-0 feed raw material on conveyor KP5-0 in Jn house JN5 as well as to the existing stacking conveyor through tripper car which then stack material in the existing beds. Conveyor P11C1A will feed material either on existing conveyor KP3-1 or KP3-2 through flap gate in Jn house JNB1 for onward transmission on existing conveyor KP15-1/KP15-2 in Jn house JN3. Conveyor P11C1 and P12C1 will be in the three conveyor structural gallery in which two conveyors will come in future along with new beds and SMS-III. In addition to this, the tail end of existing stacking conveyor KPC-1, KPC-2, KPC-3, and KPC-4 & KPC-5 shall be extended up to the head end of newly envisaged feeding conveyor KP4-0 & KP5-0 for receiving raw materials. There shall also be some modification in existing Jn house JN4, JN5A &

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STEEL AUTHORITY OF INDIA LIMITED

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RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-05 BRF SYS DESCRPTN Page 6 of 11

JN5 to accommodate the drive of newly envisaged conveyor KP4-0 & KP5-0.

05.02 RECLAIMING AND TRANSPORTATION OF IRON ORE AND FLUX

Raw materials from existing yard will be transported through one series of conveyor which will receive material from Junction House no JN3 and discharge material in Junction House no JN 12 for onward transfer of material to Sinter Plant and Blast Furnace. A new conveyor KP11-0 shall be installed from JH- 3A to JH- 1A. Materials (lump & fines) coming from Wagon tippler no-1 & 2 will discharge to either PKP3-1 or PKP3-2 (shuttle conveyors). Shuttle conveyors will discharge either to KP11-1, KP11-2, KP11-3 or proposed conveyor KP11-0. Provision has been kept for feeding coke, coming from Wagon tippler no-3 & 4 by conveyor KP20-1 or KP20-2 and discharge to Shuttle conveyors PKP20-1 &PKP20-2. Conveyor PKP20-1 &PKP20-2 will discharge material (coke) to proposed conveyor KP11-0 or existing conveyor KP15-1 & KP15-2 at JH-20. Proposed conveyor KP11-0 will discharge material to conveyor KP11A-0 at JH-1A. Conveyor KP11A-0 will discharge material to conveyor KP12-0 at JH-1B. A new conveyor KP3A-3 will be built to feed the flux to KP11-0 whenever required. The existing Shuttle conveyors PKP3-1, PKP3-2, PKP20-1 & PKP20-2 will be dismantled and new Shuttle conveyors are to be installed. Conveyor KP12-0 will discharge material to a new shuttle conveyor KPP-12-0 (S-1) through a fixed chute at JH-12. The drive unit of Conveyor KP12-0 will be installed in JH-12. The shuttle conveyor S-1 will discharge material to any of the conveyors W1, W2, W3 and Conveyor DU1. To install new conveyor KP12-0, conveyor KPP-12-0 (S-1) and conveyor W-4, necessary modification shall be made in JH-12. Conveyor W-4 will directly discharge the material either at KD1-3 or KD1-4

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

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Conveyor KP11-1 is presently extended up to JH-7. This conveyor will be extended further to junction house 3 for collecting material from Bed no. 1 & material coming from Wagon tippler. The gravity take up units of conveyor KP11-1 will be modified and to be installed adjacent to JH-3.

05.03 Intermediate storage of lump ore:

One no intermediate storage building for storing of lump ore has been envisaged near Lab building of BF because of inadequate space for lump ore storage in the Stock House. Lump ore will be received from conveyor KD1-3 with the help of fixed tripper to conveyor SBC1 to Storage bldg. and sent back lump ore to the conveyor K1-3 through vibro feeder and conveyor SBC2 onward transport to stock house as per requirement. Total Capacity of these 4 nos. bunkers shall be 15000t. Level indicator also envisaged for these bunkers. Suitable number of electrically operated Under-Slung Cranes, Hoists etc. shall be provided in all floors of Junction Houses and building for maintenance of equipment . Belt- Weigh-Scales, Air-Blasters/ Bin Vibrators shall be provided to make the system complete and smooth Operation / maintenance One no area repair shop and electrical store has been considered beside Conveyor gallery KP16-2 as mentioned in chapter 06.05 For construction of P1C1 tunnel from new Wagon Tippler 5 necessary strengthening scheme shall be implemented by the bidder for the existing rail tracks, so that minimum shut down is required without disturbing the existing Wagon Tippler operation. Dismantling of existing track hopper shall be done for Wagon Tippler no.5 and rest portion of Track hopper to be filled up.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-05 BRF SYS DESCRPTN Page 8 of 11

Wagon Tippler shall be under covered Structural building with crane provision for maintenance.

The list of equipment, conveyors along with brief specification etc., are indicated below:-

LISTOF EQUIPMENTS FOR RMHP AREA

SL.NO

DESCRIPTION LOCATION Qty REMARKS

1 Side Arm Charger (cap to pull 6600T)

Near WT-5 1

2 Wagon Tippler-5 1

3 Belt Feeder – 1 & 2,BW – 1800 Cap.–1650tph. C/C – 5000, Lift – 0

2 Designed Cap. = 2000tph

4 Grating over hopper lot

5 Mn. Steel liner plate/st impregnated rubber for 2 hoppers at Wagon Tippler#5.

lot

6 20/5 t EOT crane x 15.5 m span 1

7 Rod Gate(RH01,RH02)

Wt Bldg.-5

2

8 Conv.P1C1, BW=1400 mm Cap=1650TPH, C/C=243.0 m, Lift- 32.2.0 m, V-2 m/s

WT#5 TO JNA1 1 This conveyor rated as 1650 tph considering future

expansion and presently will run at 1200tph.

9 RSC1-1, BW=1400 mm, Cap=1200TPH, C/C=6.0 m, Lift- 0 m, V-2 m/s

JNA1 1

10 Conv.P11C1A BW=1400 mm, Cap=1200TPH, C/C=36.5 m, Lift- 3.7 m, V-2 m/s

JNA1 TO JNB1 1

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

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© 2009. MECON Limited. All Rights Reserved. CHAP-05 BRF SYS DESCRPTN Page 9 of 11

11 Conv.P11C1 BW=1400 mm, Cap=1200TPH, C/C=97.0 m, Lift- 3.7 m, V-2 m/s

JNA1 TO JNA8A 1 The gallery for this conveyor shall be of three conveyor structure gallery

12 Conv.P12C1 BW=1400 mm, Cap=1200TPH, C/C=345 m, Lift- 7.5 m, V-2 m/s

JNA8A TO JNA11 1 The gallery for this conveyor shall be of three conveyor structure gallery

13 FIXED TRIPPER JNA10 1

14 RSC12-1, BW=1400 mm, Cap=1200TPH, C/C=6.5 m, Lift- 0 m, V-2 m/s

JNA11 1

15 Conv KP4-0, BW=1400 Cap=1200TPH, C/C=155.0m, Lift- 6.0 m, V-2 m/s

JHA11 TO Exist. bldg JN-4

1

16 Conv KP5-0, BW=1400 Cap=1200TPH, C/C=135.0m, Lift- 6.0 m, V-2 m/s

Exist. Bldg. JN-4 TO Exist. Bldg

JN-5

1

17 MANUAL HOISTS - 1T - 2T

VARIOUS JUNCTION HOUSES

7 10

18 ELECTRIC HOISTS -2T -3T

-DO- 2 1

19 CHUTES WITH LINERS -DO- LOT

20 BELT WEIGH SCALE Conv. P1C1, P12C1 & KP11-0

3

21 METAL DETECTOR AND SUSPENDED MAGNET

P1C1 & P12C1 2

22 CCTV Camera At all Junction Houses

Page 24: Bokaro Steel Plant Specs

STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-05 BRF SYS DESCRPTN Page 10 of 11

B. INTERMEDIATE STORAGE BUILDING OF IRON ORE

1 Conv. SBC1, BW = 1200 mm, Cap = 1000TPH, C/C = 204 m, Lift-4 m, V-1.6 m/s

JH-SB to IOSB building

1 75

2 Conv. SBC2, BW = 1200 mm, Cap = 1000TPH, C/C = 203 m, Lift-25mV-1.6m/S

IOSB building to JH-SB

1 160

3 Fixed Tripper JH-SB 1 3.7

4 Bunker building IOSB

5 Vibro feeder 400tph IOSB 4 4x3.7=14.8

6 Mobile Tripper IOSB 1

7 Belt Weigh Scale Conv.SBC2 1

C. 4TH SERIES CONVEYING ROUTE

1 Conv.KP11-0, B/W=1400, Cap.=1200tph, C/C=480m, Lift= 6.0m, V=1.6m/s

JH-3A To JH-1A 1

2 Conv.KP11A-0, B/W=1400, Cap.=1200tph, C/C=27.0m, Lift= 0.0m, V=1.6m/s

JH-1A 1

3 Conv.PKP3-1 & PKP3-2 (Shuttle Conveyors), B/W=1400, Cap.=1200tph, C/C=26.0m, Lift= 0.0m, V=1.6m/s

Existing bldg. Jn-3

2

4 Conv.KP12-0, B/W=1400, Cap.=1200tph, C/C=191m, Lift= 21.0m, V=1.6m/s

JH-1B To Exsting bldg. Jn-12

1

5 Shuttle Conveyor (S-1), B/W=1400, Cap.=1200tph, C/C=40.0m, Lift= 0.0m, V=1.6m/s

Existing bldg. Jn-12

1

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-05 BRF SYS DESCRPTN Page 11 of 11

6 Conv.KP11-1, B/W=1400, Cap.=1200tph, V=1.6m/s, Lift=3.5m

From Existing bldg. Jn-7 To Existing bldg. Jn-3

1 Existing length=325m, proposed extension length=110m

7 Conv.KP3A-3, B/W=1400, Cap.=1200tph, C/C=50.0m, Lift= 0.0m, V=1.6m/s

Existing bldg. Jn-3

1

8 Conv.W-4, B/W=1400, Cap.=1200tph, C/C=29.0m, Lift= 0.0m, V=1.6m/s

Existing bldg. Jn-12

1

9 Conv.PKP20-1 & PKP20-2 (Shuttle Conveyors), B/W=1400, Cap.=1200tph, C/C=20.0m, Lift= 0.0m, V=1.6m/s

Existing bldg. Jn-20

2

Page 26: Bokaro Steel Plant Specs

STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-06.01 TS TECHNOLOGICAL-R

Page 1 of 10

06.00 TECHNICAL SPECIFICATION 06.01 TECHNOLOGICAL 06.01.01 General

Technical specifications for major technological equipments are furnished in this chapter. However, most of the common Material Handling equipment is covered in the “General Technical Specification (MEC/S/E24F/11/38/0/00/00/F1874/R0) – Material Handling Equipment chapter-06”. The equipment covered in the GTS are:- • Belt Conveyors and related equipment, Belt Feeder, Shuttle

Conveyor and Reversible Shuttle Conveyor System • Vibratory Feeders • Gates • Motorised Diverter Gate • Weigh Hoppers • Belt Weigh Scales (BWS) • Vibration Isolation System • Travelling Tripper and Bunker Sealing Arrangement • In-line Magnetic Separator (ILMS) & Suspended Magnetic

Separators • Metal Detectors (MD) & Magnet • Charging hatches • Cranes and Hoists • Transfer Cars • Vulcanising Machine and Mobile Belt Changing units

However for liners in different area such as all storage bins/ bunkers, chutes, skirts, flap gates etc. shall be provided with suitable wear liners ensuring the flow ability as per revised liner schedule as follows:

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

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Page 2 of 10

Bunkers and wagon tippler hopper: For lump size betn. 20mm to 80mm, Special Steel reinforced rubber liner of 40 mm thk (min) / ceramic impregnated rubber liner shall be used for conical portion and 1 m vertical height. Chutes: For lumps of 40mm thk and above material special Steel reinforced rubber liner of 40 mm thk (min) in secondary impact zone and 60mm thk special steel reinforced rubber liner in primary impact zone shall be considered. For material less than 40mm, 20mm thk PU liner/SS-409 M (8 mm)/ ceramic impregnated rubber liner min 30mm thk may be used. Skirts, Fixed hopper & Gates: SS409M (8 mm thk.) Liner shall be used. Belt Weigher: The accuracy of belt weigher scale shall be 0.5%. Any conveyor drives where motor power requirement is more than 200Kw rating, dual LT drive shall be provided on either side of the conveyor drive pulley. Other equipment envisaged in this RMHS Package only are:-

Wagon Tippler with Side Arm Charger The Tenderer may please note that the plant shall be complete with all equipment & facilities. Further, some of the equipment whether specifically mentioned or not in this TS, but which the Tenderer feels it necessary to be included in this TS for successful and trouble free operation of the plant shall also be included in the offer. Technical parameters furnished against each equipment are broad in nature. However, the Tenderer shall confirm the same & furnish various technical parameters and capacity of each equipment in his offer. Any deviation/ exclusion from TS shall be clearly spelt out with justification in the schedules (Chapter 12)

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-06.01 TS TECHNOLOGICAL-R

Page 3 of 10

06.01.02 TECHNICAL SPECIFICATION OF WAGON TIPPLER / SIDE ARM CHARGER

02.01 Scope of Work The scope of work of the Tenderer includes design, engineering,

manufacture, inspection, assembly, shop testing, painting at manufacturer's shop as well as at site after erection, supply at site including dismantling for transportation, packing, loading and transportation, receipt at site, unloading, storage and reconservation at site, erection, testing and commissioning of the following items at plant site.

1. One no. Rotaside Hydraulic Wagon Tipplers for guaranteed 20

tips/hr. 2. One no. Side Arm Charger to pull or push a rake of 58 loaded

wagons of 110T (each) Gross capacity.

02.02 TECHNICAL SPECIFICATION/ DESIGN DATA

02.02.01 Side Arm Charger The Side Arm Charger shall be complete with.

- Trolley with wheels and side guide roller, universal coupling arm

along with hydraulic system for luffing. - Travel drive complete with hydraulic motor, brakes, and hydraulic

power pack. - Rails with foundation bolts & nuts, racks & pinions. - End stops, Festoon Cable & Trolley with heavy duty carriage and

supporting structures. - Hydraulic Side Arm Charger coupler / decoupler. - Operator's cabin mounted on trolley of Side Arm Charger.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-06.01 TS TECHNOLOGICAL-R

Page 4 of 10

- Any other item/ accessory/ fixtures to complete supply of the equipment.

Application The Side Arm Charger shall be used for wagon positioning at the wagon

tippler for unloading of materials. It shall be used for pushing/pulling a rake of 58 wagons of 110T gross weight each and locating wagons one by one on tippler.

Working A train of 58 loaded wagons shall be brought in by a locomotive pushing/

pulling and stopped with the leading wagon within range of the side arm charger using track side marker boards (under tenderer's scope). The loco will be decoupled and dispatched and the charger shall be driven to the leading wagon. Its arm shall be lowered and it shall be coupled to the first wagon of the train. The train shall be hauled forward by the charger until the front of the first wagon is about 4 meters away from the tippler. The charger shall stop and the first wagon shall be uncoupled from the train. The charger shall then inch forward the leading wagon on to the tippler, automatically decouple itself & arm is raised before it travels back to the train. The tippler shall rotate for tippling the wagon. On reaching near the standing train, the charger arm shall be lowered and shall be coupled to the train ready for repeating the cycle. In the next cycle the train shall be drawn up by one wagon length, the front wagon will be decoupled & the next cycle will be repeated. When the next wagon is located on the tippler table the previously tippled wagon shall be ejected simultaneously.

On the out haul side the empties form a new train ready for collection by

a locomotive. Specification The supply includes Side Arm Charger with hydraulic power pack, power

supply system, supports, electrics, buffer stop, rack & pinion, control cabin, automatic coupler/decoupler etc.

The Side Arm Charger shall run on its own track parallel to the main

track. It shall have a stroke of approx. 30m from a point on the inhaul side of tippler to a point on the out haul side.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

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Page 5 of 10

It shall be fitted with an arm pivoted at right angles and operated through a hydraulic system for raising and lowering. The arm shall have an automatic coupler to couple/decouple the wagons.

The charger frame shall consist of a single fabricated frame on which

every other item shall be directly mounted to form a robust compact unit. The charger shall run on four steel wheels mounted on spherical roller

bearings. To resist the moment reaction of the pushing force, two pairs of steel

side guide rollers shall be fitted. They shall be fitted on spherical roller bearings and shall have a simple lockable adjustment for true running and to take up wear. The side guide rollers shall run on the sides of the rail heads of the charger running track.

The arm shall be of welded construction. Raising and lowering of the

arm shall be by hydraulic means. The charger shall have adequate power for pushing a train load of about

6600T. It shall be hydraulically driven through rack and pinion arrangement.

The charger shall be electrically interlocked with tippler for proper

sequential operation with respect to operational & safety requirements. Easy access, adequate maintenance spaces, working platforms,

inspection covers shall be provided for all the equipment located in the Side Arm Charger for safe and quick maintenance. All edges and openings shall be provided with guards. Chequered plates on floor shall be provided to prevent slipping.

Centralized system of lubrication shall be provided for the equipment.

However, all parts of the equipment needing manual lubrication shall be easily accessible. All oil pipes and grease nipples shall be well covered to prevent damage from materials from falling on them.

The Side Arm Charger shall be suitable to push or pull 58 loaded

wagons on straight track and shall be suitable to position all types of wagons at the centre of wagon tippler.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-06.01 TS TECHNOLOGICAL-R

Page 6 of 10

Technical parameters Side Arm Charger

Number - one

Type - With hydraulic travel drive and hydraulically operated coupling/ decoupling arm.

Type of Wagon to be - BOX/BOXN/KC/BKC/BOXNHS/ handled BOXNR/BOXNHA/BOY/BOBS/BOBX/KO No. of wagons - 58 wagons fully loaded to be pulled/ pushed

Gross weight of - 110T each Wagon to be considered for design purpose.

Draw bar pull - 37.5T (pushing/ pulling effort for 58 nos loaded wagons)

Mode of tippler - From operator's cabin, as well as from control located Control Room (either individually or on the charger jointly with Wagon Tippler) Speed - 0.5 m/sec forward, (Max), with full rake of wagons. 0.5 m/sec reverse

Duty - 20 hrs/day (continuous)

Travel length - ~30 m Charger track - ~1300 mm gauge Power supply - Festoon cable system

Travel Drive - Hydraulic motor driven through power packs, positive driven through rack and pinion.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-06.01 TS TECHNOLOGICAL-R

Page 7 of 10

02.02.02 Wagon Tippler

1 (one) no. Rota-side Wagon Tippler with hydraulic clamping for guaranteed 20 tips/hr. complete with.

- Tippler Table with rails, end frame with necessary rack segments,

side beam with rubber pads. - Wagon Tippler hydraulic drive with cylinders, power pack,

necessary hoses etc. - Hydraulic clamping system with cylinders, power pack, necessary

hoses etc. - Vibrator assembly mounted on tippler. - All foundation bolts.

- Control Cabin wherefrom the Wagon tippler and Side Arm Charger can be operated jointly or independently.

- Separate water spray system shall be provided for sprinkling

water on the material in the wagon just before entering the wagon tippler.

- Any other item / accessory / fixtures to complete supply of the equipment.

- Emergency stopper for inhaul wagon rake once it is within

operating range of the side arm charger.

- Dust suppression system. - All related electrics and electrical equipment.

o Supply of Side Arm Charger and Wagon Tippler shall be complete with

its structural, mechanical and electrical components and standard accessories mentioned in the T.S.

o Supply of a tool box each with the Side Arm Charger and Wagon Tippler, necessary tools like torque wrench, a set of spanners, screw

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-06.01 TS TECHNOLOGICAL-R

Page 8 of 10

drivers, hand grease gun, portable hydraulic jack etc. A list of all such tools shall be furnished along with the quotation.

o Supply of all the commissioning spares required for successful

commissioning of the equipment. The list of such spares shall be furnished along with the quotation.

o Supply of initial requirement of oil, lubricants & cleaning/flushing fluid

including replenishment during erection, testing and commissioning of the equipment.

o Supply of Insurance spares and two years normal operation and

maintenance spares of the side arm charger and wagon tippler. The list of such spares along with their item wise price shall be furnished separately.

o Statutory approval shall be taken by the Supplier for the equipment

being supplied by them from relevant state/Central authorities. Application Rota-side Wagon Tippler shall be used for mechanised unloading of

broad gauge wagons as described in chapter 05 carrying raw materials such as lump iron ore, iron ore fines, Mn ore, Quartzite, limestone, Dolomite etc.

The wagon tippler shall be fed with loaded wagons one by one by Side

Arm Charger. Tippled empty wagons shall be collected on the empty side by ejection while placing loaded wagons on the tippler. The wagon tippler shall unload the materials into receiving hoppers for onward transportation to stock yard.

Specification The Wagon Tippler shall be of robust construction and designed for

continuous duty. Wagons shall be clamped automatically by a hydraulic actuated system, and shall be suitable for all types of wagons envisaged in Chapter 05. The geometry of the clamping system shall be designed to accommodate dimensions of full range of wagons mentioned above.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

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Page 9 of 10

The tippler shall consist of the following: - A cradle consisting of a pair of heavy welded steel plate and

sector rigidly connected by a large torsion box girder fitted at each end with pivot shafts. The whole cradle shall be carried on these pivot shafts mounted in spherical bronze bearings, in turn mounted on fabricated steel pedestals.

- A rail table carried on a roller in a slotted bearing supported from

an extension of the end sectors. - Four transverse top clamp beams which shall be carried on arms

pivoted from the main torsion box girder. These arms shall be connected at their lower end to a ballast box which shall carry pawls for mechanical locking.

- Drive unit with hydraulic power pack etc. - To cope with occasional jamming of sticky material, the top

clamps shall be automatically locked while the wagon is in inverted position, and disengage automatically as the tippler returns the wagons to its normal upright position.

- The drive design shall incorporate controlled hydraulic drive and

shall be controlled from remote control post. - The bearing shall be of antifriction type and equipped with dust

seal. Adequate platforms shall be provided around tippler for ease of maintenance.

- The arrangement of the equipment shall offer convenient access

for inspection and maintenance of all parts. Access ladders, working platforms, safety hand railings of min 1000 mm height shall be provided wherever required. All edges and openings shall be provided with toe-guards. Safety devices such as limit switches and mechanical stops shall be incorporated so as to ensure rotation of tippler with in limits.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-06.01 TS TECHNOLOGICAL-R

Page 10 of 10

- Lubrication system shall be provided for the tippler. However, all parts of the equipment needing manual lubrication shall be easily accessible. All oil pipes and grease nipples shall be well covered to prevent damage from materials from falling on them.

- The tippler shall be interlocked electrically with Side arm charger

and succeeding equipment (feeders, conveyers etc.) with respect to operational and safety requirements.

Technical Paramenter

Quantity : 01 (for Ore/fines, Limestone, Quartzite, Mn Ore etc.) Type : Hydraulic Rotaside, indoor type Type of wagon : As described in Chapter 05 Capacity : 110T gross with axle load=25t No. of tips/hour : 20 Rail gauge : 1676 mm Angle of tippling : Minimum 175 deg. anti clockwise looking from wagon entry side. Duty : 24 hrs/day (continuous) Type of clamping : Hydraulic Type of drive : Hydraulic motor

Page 36: Bokaro Steel Plant Specs

STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-06.02 CIVIL CIVIL Page 1 of 7

06.02 CIVIL WORKS

SCOPE OF WORK. The Tenderer’s scope shall include complete engineering and construction on a turnkey basis inclusive of detail design, basic engineering, detailed engineering, supply of all materials, construction and testing in respect of all facilities required for completion and handing over of the work as per technical specification. Board scope of civil work will include. Wagon Tippler Building. Foundation and flooring for Junction House Building. Pent House Buildings. Foundation for Trestles of Conveyor Galleries. Iron ore storage bunker building Work Shop Building Motor room. Construction of other miscellaneous units like gravity take-up, pits, drains, trenches, paved areas, Roads flooring, relocation and diversions of services, if necessary. Design Basis General This specification covers the design criteria for Civil Engineering Works. The term ‘Design Criteria’ includes loading standards, permissible stresses, functional requirements and quality standards to be adopted as a basis for preparation of design and drawings by the Contractor. The design prepared by the Contractor shall not only provide for the requirements indicated in this specification but also consider the overall process requirements, service conditions. The design shall be compatible with the operating conditions in the plant and the atmospheric conditions prevalent at Bokaro Steel City.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-06.02 CIVIL CIVIL Page 2 of 7

Standards and unification shall be carried out to the maximum extent possible and in the interest of standardisation, BSL reserves the right of selecting a particular make of materials and components. The Contractor shall supply materials / components of that particular make, if so required. Standards The design criteria for civil engineering work shall be in accordance with this specification. Detailed instructions on such aspects as are not indicated herein shall be as per the latest standards, codes and recommendations of the Bureau of Indian Standards. In the absence of suitable Indian Standard specification and Codes of Practices other recognized international standards and codes may be followed with the prior approval of Purchaser. In case anything mentioned in this specification is at variance with Indian Standard (IS) specification or other codes of specification mentioned herein, the provisions of this specification shall prevail. Soil Conditions The tenderer shall visit the site and ascertain for himself the existing ground conditions, requirement of site leveling, etc. The tenderer shall conduct soil investigation and proceed with designs on the findings from the exploration. Requirement of piles or open foundations shall also be established from the soil exploration. Plain Concrete and Reinforced Concrete For Structures And Foundations Concrete shall be dense, homogenous, smooth mass including required finishes, possessing required strength and resistance to weathering and abrasion for the structures and foundations.

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STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-06.02 CIVIL CIVIL Page 3 of 7

Apart from the operating loads indicated by the equipment manufacturers, the design of buildings and structures shall be based on dead and imposed loads calculated according to IS:875 Part 1 to Part 3-1987 and load combination shall be as per IS:875 Part 5. Supporting structures and foundations for equipment which may cause vibration shall be designed for the dynamic effect of equipment together with the direct loads. The dynamic loads and other relevant data required for analyzing the dynamic effect shall be taken as per manufacturer’s recommendations. Adequate care shall be taken to ensure that the natural frequency of the supporting structure shall not be in resonance with the forced frequency. The design of buildings and structures shall take into account the loadings due to future extension of units and installation of additional equipment, where necessary in future in the units. Foundations The foundation or structures and equipment shall be proportioned to resist the worst conditions of loadings. Equipment requiring special foundations as a result of dynamic, unbalanced forces shall be designed as per relevant codes of practice. Design Calculations, Drawings And Documents a) Design Calculations, The design calculations along with design drawings shall be submitted by Contractor for approval, prior to submission of construction drawings which shall include but not be limited to the following Super structure and foundation design The design calculation for all the foundations and superstructures for various units and all equipment foundations etc. The design calculations shall include static design calculations for all structures

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and foundations, dynamic analysis for all important structures and foundation subjected to impact vibrations etc induced by equipment and other external forces. Drawings The Contractor shall prepare general layout drawings giving salient levels and dimensions of the whole area showing all over ground and underground services and facilities, buildings, roadways, railways etc. provided for co-ordination with the other areas of the steel plant. Detailed working drawings shall be prepared on the basis of the general layout drawings considering overall foundation layout for the equipment, building, services, etc. space requirement and clearances as necessary. The contractor shall ensure that no further drawing shall be required to be prepared by any other agency for successful implementation of the project. The Contractor shall submit a comprehensive and complete unit wise classified list of drawings in reproducible from. b) The Contractor shall submit for approval of the Purchaser Consultant, general arrangement and detailed working drawings for all concrete, reinforced concrete and other civil work as follows. Excavation drawings Foundation plans and sections. Loading drawings indicating superstructure loading, equipment loading, floor loadings, etc. Comprehensive anchor hole plan along with complete details of anchor bolts and anchor pockets for foundation for building columns and equipment etc. including schedule for bolts and anchor plates. Reinforcement details with bar bending schedules for all reinforced concrete works. Drawings or all types of bolts, inserts, embedment, covers, miscellaneous steel works etc.

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All drawings for masonry work, flooring, floor finishes, trenches, false flooring, false celling, partitions, etc. Drawings for paved areas, drains etc. as required. c) Design Features All civil designs shall be based on IS: 456-2000 for moderate exposure conditions and latest revisions of other relevant IS codes. Construction Features: All materials and workmanship shall be as per relevant IS codes and MECON’S General Specification for Civil works CIVIL-GS-07. All RCC work is envisaged of M25 grade concrete. Brickwork shall be with grade M5 bricks in cement mortar 1:6 PCC apron and RCC drain shall be provided all around the building Grouting below column bases shall be of M30 concrete The hard stand in the yard shall be so constructed as to withstand the load of overburden. SMS slag (-150mm downgraded) may be used in the base course. Existing yard is at an elevated level. The adjoining edge shall be protected with toe-wall / protection wall / retaining wall of suitable strength. Wagon Tippler pit shall be of RCC construction and made leak proof and water tight. Integral water proofing with non shrink polymer modified cementitious grout shall be done. Suitable inserts shall be provided in the walls and raft for fixing of connections. The motor room shall be a framed structure. Inside and outside surfaces to brick masonry wall shall be plastered smooth and finished with paints / colour wash. Steel door and glazed steel windows shall be provided. Track for stacker and reclaimer shall be laid over RCC strip foundation with cross beam connections between the tracks at every 3m interval. Material & Workmanship

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BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

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3.01 Local conditions The Contractor, before submitting his tender, shall visit the site and ascertain the local conditions, labour rules, availability of construction material, traffic restrictions, all obstructions and shall allow for any extras likely to be incurred due to all such conditions in his quoted prices. After the award of work no additional claims will be entertained on these accounts under any circumstances, whatsoever, from the Successful Contractor. 3.02 Setting out and leveling The Successful Contractor shall set out and level the work and will be responsible for the accuracy of the same. He is to provide all instruments and proper qualified staff with labour for getting his work checked by Engineer, if so desired by the Engineer. Such checking, if any, shall not, however, relieve the Successful Contractor in any way, of his responsibility for correct setting out. 3.03 Rubbish The Contractor shall keep the site clear on a continuous basis of all rubbish etc. which may arise out of the work executed him and dispose them suitably in allotted areas within a lead of 8 km. 3.04 Bench Marks, Reference Pillars etc. The Contractor shall protect all benchmark, and reference pillars / lines including ground water gauges from damage or movement during working. In case of any damage, the Contractor shall have to restore the same to its original condition at his own cost. 3.05 Standards Unless otherwise mentioned in the specifications, all applicable codes / standards as published by the Bureau of Indian Standards on the date of award of contract shall govern the work in respect of design, workmanship, quality and properties of materials, method of testing and other pertinent features. In case of variance between this specifications and IS Codes / Standards, the provisions of this specification shall prevail upto the extent of such variance.

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3.07 Nearby Existing Structure Quite a few units are coming close to existing structures. Adequate protection shall be provided to the existing structures to ensure their safety during construction. If any structure / utility are damaged during construction, it shall be made good by the contractor at their own cost. If any utility or service line, over-ground or under-ground is found infringing with the new construction, it shall be suitable diverted / strengthened / modified with the prior approval of the Purchaser. Cost of such diversion / strengthening / modification shall be bourn by the successful Tenderer. 3.06 Drawings Work shall be carried out as per drawings prepared by the Successful Contractor and approved by the Purchaser. The drawings shall include General Arrangement, shuttering, excavation, anchorage plans, bolt plans, insert plan and details, conduit plans, etc required for execution of the job. Also the design calculations shall be submitted in requisite number of copies (as mentioned elsewhere) for the approval by the Purchaser / Consultant. Bar bending schedule shall be submitted for information and record.

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© 2009. MECON Limited. All Rights Reserved. CHAP-06.03-STRL Page 1 of 17

06.03 STRUCTURE WORK 06.03.01 GENERAL

01. This specification for structural works furnished herein are intended as

guidelines for execution of the works satisfying the Owner’s requirements as also complying with all technical norms in totality.

02. Units : List of Units & types of steel structures shall be as described in the

Technological Lay out drawings. However a brief description of units is given as under.

Structural steel work under the scope of this contract cover the following main facilities envisaged for Augmentation of Raw Material Receipt & Handling facilities of Bokaro Steel Plant, SAIL hereinafter referred to as “Owner “in this specification. Technological layout drawing which is issued along with Main Technological Specification shall be referred in this context.

Units broadly shown in Technological layout drg MEC/S/E24F/11/17/K/01/55/02102 Rev 1. They consist of Junction houses, Conveyor Galleries, wagon tippler building, bunkers, bins, pent houses and other misc units etc. Monorail / Hoisting facility: Monorail shall be considered for the ABOVE BUILDINGS.

03. List of Steel Structures Columns ( rolled section or built-up ), column bracings, Crane Girder,

Surge Girder, Gable Platforms, Rails & Fixtures, Monorail beams and supports, Roof Trusses, Roof Girders, Bunker Girder, Bunker, Liner Plate, Purlins, Roof hand rails, Floor Beams, Sheeting Posts, Side runners, Louvres, Bracings, Sag angles, Sag rods, wind-ties on roof, Wind girders, Platforms, Walk-ways, Stairs, Ladders, Hand rails, Gutters and Down comers, Gallery truss, Gallery Trestles, Bracings , rafter & rafter bracings for gallery truss, End portal , Top & Bottom chord Bracings for Gallery Trusses, Roof & side Cladding with GCS/Translucent sheeting etc.

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BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

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04. The work to be performed under this specification consists of design, engineering , dismantling, modification, strengthening ,addition of new floors ,supply, fabrication, erection and cladding, as well as providing all labour, materials, consumables, equipment, temporary works, temporary labour and staff colony, constructional plant, fuel supply, transportation and all incidental items not shown or specified but reasonably implied or necessary for the completion and proper functioning of all the above units and auxiliaries, all in strict accordance with the specifications, including revisions and amendments thereto as may be required during the execution of the work.

05. Supply of all materials including structural steel, roof cladding & side-

cladding sheets, fasteners, paints, consumables like gas, electrodes etc. and all other materials as deemed necessary for proper completion of the work, are included in the scope of the Contractor.

06. The work shall be carried out according to the design/drawings to be

developed by the Contractor and approved by the Owner/Consultant. For all buildings and structures, necessary layout and details are to be developed by the Contractor keeping in view the statutory & functional requirements of the plant and facilities and providing enough space and access for operation, use and maintenance. Certain minimum requirements are indicated in this specification for guidance purpose only. However, the Contractor’s offer shall cover the complete requirements as per the best prevailing practices and to the complete satisfaction of the Owner.

06.03.02 SCOPE OF WORK

The scope of work shall cover, but shall not be exclusively limited to, the following:

• collection of all site related data & conducting site investigations, • design, preparation of all design drawings, fabrication drawings,

• Dismantling, Modification ,Addition of Floors, Strengthening of

Existing Units. • Obtaining Owner’s/Consultant’s approval on general arrangements and

design of structures • Submission of scanned soft copies of all the drgs approved by consultant

with their stamp and signature.

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• Dismantling, retrieval, sorting and storing of any existing structures as directed by the owner.

• supply of all materials viz, raw steel, sheeting for roof and side cladding,

and paints • supply of fasteners like bolts, nuts, washers etc

• supply of consumables like electrodes for welding, gases for gas cutting etc

• supply of plant & machinery, tools tackles, instruments for fabrication and erection

• providing facilities for testing of materials and conducting NDT

• providing facilities for transport and handling

• deploying requisite skilled and unskilled manpower

• making arrangements for all services like approach to site, electricity, water etc

• fabrication of structures , their transport and proper storing at site

• Erection of structures, claddings, gutters, down pipes etc

• application of paints at shop after fabrication and at site after erection

• providing all reasonable facilities for inspection by Owner/Consultant

• conducting NDT as stipulated by the Owner and making test results available to Owner / Consultant for evaluation

• compliance with primary acceptance tests / inspection, liquidation of defects ; compliance with final acceptance tests / inspection, liquidation of defects;

• carrying out field-engineering decisions as desired by the Owner

• preparation of “As Built” drawings for all the structures and hand over to the Owner the completed structural work to the Owner’s full satisfaction.

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• Any other work deemed incidental for the completion of the overall work but not included in the above detailed scope.

06.03.03 DESIGN OF CONVEYOR GALLERIES AND JUNCTION HOUSES 01. Design Considerations a) The general parameters for conveyor galleries shall conform to the

provision of IPSS:2-03-001-81 (Interplant Standards : Steel Industry - Design parameters for galleries and tunnels for belt conveyors in steel plant), and provisions of IS : 11592-1985 unless specified otherwise in Technical Specifications. The structures shall be designed so as to meet functional requirements and shall provide space for operation, maintenance and removal of machinery and give the workers good and safe environment.

b) Gallery floors shall be of pre-cast R.C.C slabs / Chequered plates (as

required) supported on steel beams. c) Steps shall be provided (rise not exceeding 130 mm) along the walkways

if the gallery slope exceeds 12°. In case the slope of gallery is between 6° to 12°, suitable ribs shall be provided on floor (without any sharp edges) at 250 to 300 mm intervals.

d) Provisions shall be made for emergency exit from galleries to ground

level and also for cross-over above conveyor at 100 m intervals (maximum). The width of cross over shall not be less than 600 mm.

e) Roof and side walls of conveyor galleries shall be covered with GCS/

Aluminium/ colour coated sheets. with a provision of gap of 300 mm below roof and 150 mm from top of floor level on the side wall for ventilation.

f) Adequate provision for natural light inside conveyor gallery shall be

made through side walls by providing translucent sheets (FRP sheets as per IS: 12866-1989). Every sixth sheet on side wall shall be FRP sheet and shall be staggered on opposite wall.

g) Roof slopes of conveyor galleries shall be 1:5 (1 vertical, 5 Horizontal). h) The level of underside of the base plate of gallery supporting trestles

shall be 300 mm above the average ground level of the surrounding area. i) Protective hand railing shall be provided along gallery walkways, open

platform, stairways, landings, edges of walkways when the gallery is not

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enclosed, and around erection openings, if any, to ensure safety of operating personnel.

j) Conveyor galleries longer than 150 m shall be provided with

expansion joints with twin trestles/supports. Each expansion block shall have fixed support/rigid trestle with adequate arrangement (provision of top chord and bottom chord bracing to gallery girder etc.) for transferring the transverse and longitudinal forces to the foundation.

k) Gallery girders near junction house shall be preferably supported on

trestle located as close to the junction house as possible, with part of gallery girder between junction house and trestle cantilevered from the trestle. Supporting gallery girders on junction house shall be generally avoided.

l) The underside of the belt conveyor shall be fully covered with 3 mm

sheet in case of conveyors located within the boundaries of the plant. Wherever such covering is not provided (as in case of the mines area or cross country), the covering must be provided where the gallery crosses roads, railway lines or areas of public gatherings.

m) Conveyor gallery over hot metal track:

When underside of gallery is at less than 12m height from track level, heat

shield shall be provided below gallery as well as on sides for a width of track 8 m (i.e. 4 m on either side of center line of the track).

n) When conveyor gallery crosses above or below H.T cables, a

minimum clear distance of 1.0 m between the structural elements/cladding and HT cables shall be maintained.

o) When the conveyor bridge passes over plant roads, clearance

between the road surface and the lowest points of the bridges shall not be less than 8.0 m or the height needed for the passage of the largest individual components of the plant equipment, whichever is the larger.

p) The junction house shall be designed to suit the technological requirements. Number of floors, height of building etc. shall be decided accordingly.

q) In general the junction house shall be designed as framed structures

on shorter span side and vertically braced on longer side to achieve stability. r) Floor of junction houses shall be of RCC slab / Chequered plate

supported on steel beams, unless required otherwise from technological

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consideration. The RCC slab will be connected to steel beams through suitable lugs.

s) Roof and side covering of junction houses shall be with GCS/Aluminum

sheets / troughed colour coated sheets as specified. Roof slope shall be 1: 5 ( 1 Vertical : 5 Horizontal).

t) Suitable access staircase and safety hand railing shall be provided to

all floors of junction houses. u) When hydro-washing of floor of junction house is envisaged , the floor

beam supporting RCC slab shall be laid to a suitable slope to achieve the same, wherever the same is not practicable to achieve through screed concrete. (Minimum slope of floor shall be 1.5%).

v) Wall sheeting shall generally start from the lowest working floor and

extend up to roof level with louvers at each floor level to ensure adequate natural ventilation.

w) Monorails for maintenance hoists shall be provided for maintenance

and repair of various equipments located on the floors.

02. Components of structures

a) Gallery Trusses and Roof

Gallery truss shall be of latticed type construction and shall support roof (for covered galleries) as well as floor deck supporting conveyor system.

The trusses shall be adequately braced at top and bottom chord level to transfer the horizontal wind forces to end portals.

b) Stringer Beam These beams shall be suitably spaced to support the conveyor stringer post

and shall deliver load to gallery trusses. Walkways on either side of the conveyor shall also be supported on these stringer beams.

c) Supporting Trestles

Intermediate trestles shall be two legged and shall deliver loads from gallery

trusses to the foundations. In addition, four legged trestles shall be provided which will act as fixed support to transmit all longitudinal forces between expansion block, in addition to other forces.

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d) Junction Houses

i) Floors - Floor beam layout shall be arranged to suit equipment layout as well as equipment anchoring system.

ii) Columns - In addition to loads from floor and roof, columns shall be designed to transmit horizontal load due to belt tension/snapping of belts to the foundation.

e) Belt Tensioning Device

Suitable structures shall be provided to accommodate belt-tensioning device

which may be located either under the conveyor gallery or in the junction house itself.

f) Wall Structures

i) Wall runners with necessary sag rods shall be provided to support wall

sheeting in conveyor galleries and junction houses.

ii) Walls shall be provided with louvres and translucent sheeting at appropriate levels, to provide natural ventilation and lighting.

g) Access stairs, walkways, platforms, ladders, hand railing etc. i) Wherever possible, access shall be provided by means of stairs. ii) All walkways and stairs leading to working platforms shall have

minimum 800 mm width of walkways/flight of stair. iii) All other walkways and stairs leading to areas for maintenance

purpose, or due to restriction of space, shall have a minimum width of 800 mm of walkway/flight of stair, unless required otherwise.

iv) Staircases shall be generally designed with slope of approximate

37.5° with the horizontal. (In no case the slope shall exceed 40 ° with the horizontal). Intermediate landings shall be provided wherever required such that vertical rise of each flight does not exceed 3000 mm. Risers in one flight shall be equally spaced.

v) Walkway floors and stair treads shall be designed with chequered

plate (or non-slip type plates). Ribbed floor/treads may be provided wherever the possibility of accumulation of dust exists, taking care that such provisions do not crate a nuisance to the operating personnel on the shop floor.

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vi) Rise of treads in staircases shall not exceed 200 mm. vii) A minimum headroom of 2200 mm shall be provided over operating

platforms, visitor's galleries, or other areas with possibility of public gathering. In all other platforms, walkways and stairs, minimum headroom of 2000 mm shall be provided. Only in special cases, local headroom of 1800 mm may be allowed (i.e. at intersection with structural members etc.).

viii) Cat ladders shall be provided for access, wherever provision of

staircase is impractical due to limitations of space, or the access is required very infrequently.

ix) Wherever the height of cat ladder exceeds 4.0 m, safety cage shall be

provided. Intermediate landing shall be provided to cat ladders such that vertical height of single rise does not exceed 8.0 m.

x) Cat ladders shall be designed with following provisions:

i) Width of rung = 500 mm ii) Minimum rise of rung = 250 mm Maximum rise of rung = 300 mm

iii) Minimum clearance from rung of ladder to back of cage (in case of

caged ladders) = 700 mm iv) Minimum clearance from the centre of cage all round = 350 mm v) Slope of cat-ladders:

I. For normal cat-ladders, slope shall be within the range of 75°-90° with the horizontal.

II. For ship-type ladders (i.e cat-ladders with short side handrails)

the slope shall be within the range of 65°-75° with the horizontal.

xi) All walkways, platforms and stairs shall be provided with safety

handrails. All handrails shall be constructed with steel tubes / angles for posts, top and middle rail and plates/sheets for toe plates. In case of stairs, the toe guards need not be provided.

xii) The vertical height of hand-railings on walkways and stairs shall be

minimum 1000 mm above floor level.

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xiii) Hand-railing along edge of roof and gutters shall have a minimum

height of 600 mm over top edge of gutters/sheets. In such hand-railings toe guards need not be provided. (only top handrail and mid-rail shall be provided).

03. Additional design criteria

a) Design of steel structures shall be done in accordance with IS:800-1984. b) In absence of specified dynamic factor to be considered for the load

from the belt conveyor, a dynamic factor of not less than 1.3 shall be considered for the design of floor beams and gallery girders.

c) Gallery trusses and stringers as well as floor beams of junction house

shall be checked for obviating occurrence of resonance and shall be designed such that the ratio of applied frequency to natural frequency shall not lie within the range 0.7 to 1.5.

d) As far as possible gallery structure shall be made independent of

junction houses. A trestle shall be planned close to the junction house to avoid gallery span resting on the junction house.

e) The contractor after the award of work shall submit design criteria to

owner / consultant for approval before submission of design drgs.

f) The design drgs shall be submitted in complete for a unit along with design calculations both in hard copy and soft copy. Design shall be done using STAAD.

g) The effective ratio of utility of all main sections shall be limited to

0.85

h) Structural schematic general arrangement with plans at various levels, elevations along each row and axes, sections, considered loads and load diagrams with location etc. and Structural design drawings with BOQ and Table of members containing design forces shall be submitted for Owner’s/Consultant’s approval. However the approval shall be limited to checking of overall dimensions, general stability of system, effective load transfer and deflection limits etc. The approval shall not relieve the contractor of his responsibility of correct ness in design, adequacy of connections, accuracy etc.

i) Submission of Stability certificate for all the steel structures is under

the scope of the contractor.

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04. Description of loads and loading codes

a) Unless specified otherwise hereinafter, all the live loads shall be considered in accordance with IS: 875 (Part-2) -1987.

b) Wind loads shall be considered in accordance with IS: 875 (Part-3)

-1987.

c) Seismic loads shall be considered in accordance with IS:1893(part 1)-2002 and 1893(part 4)-2005

d) Live loads from conveyor on the gallery floor shall be as per conveyor

suppliers load data.

e) While designing the fixed support/rigid trestles in an expansion block of conveyor gallery the following loads (in addition to wind load) shall be considered.

i) Forces due to difference in frictional resistance of top and return

idle rollers of conveyor. ii) Forces due to inertia of rollers at the time of starting of

conveyor belt. iii) Break down load caused by snapping of belt (in case of

multiple conveyors, snapping of one belt at a time) shall be considered.

iv) Special loads if any

f) Gallery girders and floor shall be designed for the following live loads, inclusive of spillage loads on floors.

i) Walkway/Supporting beams for floor - 4.0 KN/m² ii Under the conveyor belt - 0.75 KN/m² iii) Gallery girder, for floor load of - 3.0 KN/m²

g) Dust load on roof of junction house and conveyor galleries shall be considered as follows:

i) For building and structures located at a distance of 300 m from the

dust producing units - 0.5 KN/m²

ii) At a distance of 300 m to 800 m from the dust producing unit - 0.25 KN/m²

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h) As per technological requirements, provision of supporting the following, and load arising thereof shall be considered in the design of conveyor gallery.

i) Ventilation duct. ii) Electrical cables/cable racks. iii) Fire Fighting equipment.

i) Junction house floors shall be designed for the following loads:

i) Live load on floor - 5.0 KN/m² ii) Tension from conveyor belt

iii) Load due to equipment located on floor. iv) Load due to jamming of chutes. v) Erection loads anywhere on the floor.

j) Combination of loads The various loads specified shall be combined in accordance with clause 8.0

of IS: 875 (Part-5)-1987 to give the most severe loading condition for design of structures.

k) Stress enhancements Permissible limits of stress may be increased, wherever permissible, in

accordance with IS:800-1984. 05. Limiting deflection

a) The deflection shall be limited in various elements of structures in accordance with clause 3.13 IS: 800-1984.

b) In addition following limitation in deflection shall be observed in design

:

i) Gallery Trusses : Span / 400 ii) Top of End portal of gallery

truss : H / 325 where H =

Height of portal above beams

iii) Traverse deflection of top of Trestle

: H/1000 where H = Height of trestle above foundation

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06.03.04 FABRICATION OF STEEL STRUCTURES 4.1 Drawings The Contractor shall prepare fabrication drawings, erection drawings, bill

of materials, drawing office despatch lists / shipping documents, schedule of bolts and nuts and as built drawings. All drawing work shall be in metric system and all writing work shall be in English. The work shall be carried out as described in General Technical Specifications for structural works.

4.2 Material of Construction 4.2.1 All steel and other materials used for steelwork and in association with

steelwork shall conform to appropriate Indian standards. Only tested materials shall be used unless written authority is obtained for the use of untested materials for certain secondary structural members.

Unless otherwise specified in the drawings

a) All rolled sections and plates upto 20 mm thk. Shall conform to Grade- E250 & quality A of IS: 2062-2006 and shall generally be of tested quality.

b) Plates above 20 mm thk. and plated structures subjected to dynamic

loading shall conform to Grade-E 250 & quality B as per IS: 2062-2006. c) For High Tensile steel requirements, material conforming to IS: 8500 or

SAIL- MA (HYA or HYB) shall be used.

4.2.2 Steel sheets shall conform to IS: 1079. 4.2.3 Steel tubes for structural purpose shall conform to IS: 1161 (of Grade Yst

240) 4.2.4 Corrugated Galvanised Sheets shall conform to IS: 277 with appropriate Zinc coating for the selected thickness of sheet on roof and sides. (1.0mm

thk for roof and 0.8mm thk for sides)

4.2.5 Aluminium industrial troughed sheets conforming to IS : 1254 shall be used as follows :

i) On roof - 0.91mm thick ii) On side walls - 0.71mm thick

4.2.6 Translucent sheets shall be fibre glass reinforced polyester sheets of

matching profile as per IS: 12866.

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4.2.7 Colour coated sheets shall be as per appropriate standard. 4.2.8 Gutters shall be of copper bearing steel conforming to Grade "A" as per IS:

2062. 4.2.9 Rails shall conform to IS: 3443. 4.2.10 All black bolts, nuts and locknuts shall conform to IS: 1363 and IS: 1364

(for precision and semi precision hexagonal bolts) of property class 6.4 unless otherwise specified. Washers shall conform to IS: 6610

4.2.11 All tapered washer shall be as per IS: 5372 for channels, and IS: 5374 for

Joists. Spring washers shall conform to IS: 3063. 4.2.12 All HSFG bolts shall conform to IS: 3757. Assembly of joints using HSFG

bolts shall conform to IS: 4000. Nuts and washers for HSFG bolts shall be as per IS: 6623 & IS:6649 respectively.

4.2.13 Covered electrodes for arc welding shall conform to IS:814–2004. Electrode

to be used for submerged arc welding shall conform specification IS: 7280-1974. Alternatively Covered electrodes for arc welding shall confirm to AWS Specifications and shall be as follows.

- E 6013 for all fillet welds of IS 2062 steel dr E250 , quality A & B - E 7018 for all fillet welds of SAIL-MA 350 HYA steel - E 7018 for all but welds including site welds irrespective of the quality of

steel.Viz. IS 2062 gr E250 , quality A , B or SAILMA-350 HYA steel 4.2.14 Certified mill test reports of materials used in the work shall be made

available for inspection by the Owner / Consultant upon request. 4.3 Fabrication 4.3.1 Fabrication of all structural steelwork shall be in accordance with IS:800 or

their equivalent foreign national standard of the country of origin of supply unless otherwise specified, and in conformity with various clauses of the Technical Specification.

4.3.2 Wherever practicable and wherever perfect matching of parts is required at

site, members shall be shop assembled before despatch to minimise site work. Parts not completely assembled in the shop shall be secured, to the extent possible, to prevent damage during despatch.

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06.03.05 ERECTION OF STEEL STRUCTURES 5.1 Scope The scope of work under erection includes in addition to provision of

erection and transport equipments, tools and tackles, consumables, materials, labour and supervision, the following:

a) Storing and stacking at site of erection of all fabricated structural

components/ units/assemblies till the time of erection.

b) Transportation of structures at site.

c) Receiving at site of structures including site handling /movement, unloading, storing and stacking at site of erection of technological structures such as bunkers and the related structures

d) All minor rectification / modification such as :

i) Removal of bends, kinks, twists, etc. for parts damaged during

transportation and handling; ii) Cutting chipping, filing, grinding, etc., if required, for preparation and finishing of site connections; iii) Reaming for use of next higher size bolt for holes which do not register or

which are damaged. iv) Welding of connections in place of bolting for which holes are either not

drilled at all or wrongly drilled during fabrication. e) Other rectification work such as

i) Re-fabrication of parts, damaged beyond repair during transportation and

handling or incorrectly fabricated. ii) Fabrication of parts omitted during fabrication by oversight or subsequently

found necessary. iii) Plug-welding and re-drilling of holes which do not register and which cannot

be reamed for use of next higher size bolt.

f) Fabrication of minor items/missing items or such important items as directed by the Owner / Consultant.

g) Assembly at site of steel structural components wherever required including temporary supports and staging.

h) Making arrangements for and providing all facilities for conducting ultrasonic X-ray or gamma ray tests on welds; getting the tests conducted

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by reputed testing laboratories, making available test films/ graphs, reports and interpretation.

i) Rectifying at site, damaged portions of shop primer by cleaning and touchup paint.

j) Erection of structures including making connections by bolts/high strength friction grip bolts / welding.

k) Alignment of all structures true to line, level plumb and dimensions within specified limits of tolerances as per IS :12843 “Tolerance for Erection of Steel Structures”.

l) Application of second coat of primer paint and two coats of finishing paint at site after erection.

m) Grouting of all column bases after proper alignment of columns and only after obtaining clearance from Owner / Consultant.

n) Conducting preliminary acceptance and final acceptance tests. o) Preparation of as built drawings, preparing of sketches/drawings to suit

field engineering decisions, availability of material, convenience of fabrication, transportation and erection and changes during fabrication and erection.

All such works are subject to approval by the Owner / Consultant. 06.03.06 PAINTING OF BUILDING STEEL STRUCTURES 6.1 All steel structural work shall be painted as follows unless otherwise stated

in the drawing / Technical Specification. 6.2 Surface preparation

The steel surface which is to be painted shall be cleaned of dirt and grease, and the heavier layers of rust shall be removed by chipping prior to actual surface preparation to a specified grade. Following are the type and standards of surface preparation to be followed based on the requirement of a particular painting system or as specified in the design drawings. Manual/Power tool cleaning :- Manual/Power tool cleaning shall be done as per Grade St-2 or St-3 of Swedish Standard Institution SIS 05 5900 or cl. 6.2.1.1 & 6.2.1.2 of IS : 1477 - 1987 (Part - 1).

Grade St-2 :- Thorough scraping and wire brushing, machine brushing, grinding etc. This grade of preparation shall remove loose mill scale, rust

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© 2009. MECON Limited. All Rights Reserved. CHAP-06.03-STRL Page 16 of 17

and foreign matter. Finally the surface is to be cleaned with a vacuum cleaner or with clean compressed air or clean brush. After preparation, the surface should have a faint metallic sheen. The appearance shall correspond to the prints designated St-2.

If no grade of surface preparation is specified, St-2 grade of preparation as per Swedish Standard shall be followed.

6.3 Paint System

i. Surface preparation :- St-2 ii. Primer paint :- Two coats of zinc phosphate in phenolic alkyd medium (35

microns/coat). iii) Finishing paint :- Two coats of synthetic enamel (25 microns/coat)

conforming to IS : 2932 - 1974.

All paints shall be of approved and shade as per Purchaser / Consultant's requirements.

6.4 Paint and Painting Manufacture of paints, mixing of paints, etc. shall be generally according to

the relevant IS codes of practice. Generally compatibility between primer intermediate and finishing paint

shall be certified by the paint manufacturer supplying the paints. Guarantee period shall commerce from the date of completion of finishing

coat of paint on entire structures. The guarantee period shall be indicated depending on the type of surface preparation and system of painting. To fulfill this obligations, the Contractor may obtain from the painting manufacturer, guarantee for the performance of paint/painted surfaces.

Application of paint shall be by spraying or brushing as per IS : 486-1983

and IS : 487-1985 and in uniform layers of 50% overlapping strokes by skilled painters. Painting shall not be done when the temperature is less than 5 degree C or more than 45 degree C and relative humidity is more than 85% unless manufacturer's recommendations permit. Also painting shall not be done in foggy weather. During application, paint agitation must be provided where such agitation is recommended by the manufacturer.

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Painting shall be applied at painting manufacturer's recommended rates. The number of coats shall be such that minimum dry film thickness specified is achieved. the dry film thickness (DFT) of painted surfaces shall be checked with ELCOMETER or measuring gauges to ensure specified DFT.

All structures shall receive one coats of primer paint at shop after

fabrication before despatch after surface preparation has been done as per requirements.

Unless otherwise specified all structures after erection shall be given one

coat of primer and two coats of finishing paint of approved colour and quality. The under coat shall have different tint to distinguish the same from the finishing coat.

The proposed make, quality and shade of paint shall have the approval of

Purchaser / Consultant. 06.03.07 Quantities of Structural Items: The bidder shall indicate the estimated quantities of structural items of

work ie fabrication/ erection tonnage , sheeting in sq.m etc. Bidder shall not make any additional claim if structural quantity of any items required for completion of entire package as per terms of contract exceed the quantity indicated by the bidder.

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RAW MATERIAL HANDLING SYSTEM

© 2009 MECON Limited. All rights reserved 05. General Layout & Transport Page 1 of 3

.

06.04 GENERAL LAYOUT & TRANSPORTATION

04.01 General Layout

Bokaro steel plant is planning to increase the capacity of steel

production to 5.77MTPA. The increase in capacity necessitates receipt

of more raw materials to the plant. Presently the Bokaro steel plant has

4 (four) nos of wagon tipplers for unloading raw materials such as iron

ore lumps, iron ore fines, lime stone & dolomite etc. and 2 (two) nos of

wagon tipplers for unloading coal for coke ovens.

For the capacity augmentation of steel plant to 5.77MTPA, one more

wagon tippler is planned for unloading of incoming raw materials. The

new wagon tippler is planned with side arm charger. The new wagon

tippler complex is proposed by the side of the existing tippler by

dismantling the standby arrangement for manual unloading unit. The

new wagon tippler with side arm charger is provided with full rake

wagon handling facilities for both the side.

04.02 General information about the Project area

The ground level of the existing wagon tippler is about 234.00 m and

the rail top level is 234.60m. The proposed wagon tippler will be

located on track no. 46 & 45 by dismantling the standby unloading

arrangement. Other tracks beyond the tippler towards plant shall be

retained without disturbing. The underground conveyor system shall be

planned below the tracks without disturbing the existing operation.

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.

The Conveyor system from the new wagon tippler shall cross the

existing road & railway tracks etc various locations. Minimum

clearance of about 6.0 m shall be maintained from rail/road top level to

bottom most part of conveyor galleries. The railway track modification

shall be executed by the client under different package.

The conveyor no. KP11-0, KP11A-0 & KP12-0 along with junction

houses JH1A & JH1B shall be located parallel to the existing road no.8

towards Sinter plant. The existing underground facilities shall be

suitably protected.

The proposed Iron ore storage bunker in blast furnace along with

conveyor system shall be located between the existing laboratory for

sintering & blast furnace plant and existing conveyor gallery no.17.

The existing underground facilities shall be suitably protected.

The General layout of the overall plant is enclosed with this specification. This layout has been developed keeping in the view available space, smooth and uninterrupted flow of materials in accordance with the technological requirements, safety clearances and statutory provisions.

Location of services units and auxiliary facilities, viz electrical sub station, area repair shop, motor room, fire water pump house and office buildings etc have been suitably located to meet the technological requirements.

Internal road network has to be planned to cater to the needs of

various junction houses and auxiliary services. These roads will be

connected to main plant roads which are outside the scope of this

package.

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RAW MATERIAL HANDLING SYSTEM

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.

04.03 Underground & above ground service facilities.

The location of the junction houses and alignment of the conveyors etc

are planned on the existing operating area. Many numbers of

underground facilities such as storm water line, drinking & fire water

line, process water line, cable trenches are already available. For

planning new junction houses and supports for conveyor galleries, the

existing underground lines shall be suitably protected or diverted if

necessary.

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RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-06.05AREA-REPAIR-SHOP Page 1 of 2

06.05 AREA REPAIR SHOP & SUB STORE 06.05.01 AREA REPAIR SHOP

The Area Repair Shop for RMHS will have a covered area of 9 x 18 m

and will be suitably/ centrally located near new bed area preferably in

the space adjacent to conv gallery KP16-2. The Area Repair Shop will

have road link and suitable road approach will be provided for effective

movement of material / products to/ from the shop. 3T cap manually

operated U/S crane shall be provided. One no 10T cap tyre mounted

hydra for spare handling shall also be considered.

In the shop there will be a supervisor’s cabin, store-room and toilet

block. Services facilities e.g. compressed air, drinking/industrial water

will be provided from the inter plant distribution network. Minor nature or

repair & maintenance work will be carried out in the area-repair-shop.

The enclosed drawing Mo.MEC/S/E24F/11/17/K/01/55/02105 shows the

scheme / layout of the Area repair shop.

Three rooms (properly ventilated /air conditioned & illuminated) of

dimension 5mX4m adjacent to repair shop shall be provided.

06.05.02 SUB-STORES FOR ELECTRICAL ITEMS

Separate electrical Sub-stores for the Ore Handling Area shall be

provided with a covered area of 15 x 40 m adjacent to conv gallery

KP16-2. Suitable road approaches will be provided for effective

movement of material to and from the Sub-store.

A supervisor’s cabin and a toilet block shall be provided in the Sub-

Store.

A 5t Capacity Single-Girder Under slung shall be provided to handle

various material.

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RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-06.05AREA-REPAIR-SHOP Page 2 of 2

One no 3T capacity fork Lift Truck shall be considered..

List of equipment envisaged for the Area Repair Shop are given hereunder:

Sl No

Equipment Broad Specification Qty

1 Centre lathe SOB -500 mm CD – 1500 mm

1

2 Hydraulic press m/c Suitable capacity 1

3 Shaping machine Stroke= 630 mm 1 4 Bench Drill Cap = 20 mm 1 5 Column Drill Cap in steel 25 mm 1 6 DE Pedestal Grinder Wheel dia = 300 mm 1 7 Power Hacksaw Job dia=300 mm 1 8 Hydraulic puller 15t cap 1

9 Electric Hand grinder 1 10 Welding Transformer Heavy duty type 2 11 Oxy acetylene gas

welding & cutting set 1

12 Marking Plate 1 13 Fitter’s bench with

vice Size = 1500x800x 850 mm 2

14 Tool Cabinet Size = 1200x600x 2000 mm 4

15 Induction type heater Suitable size 1

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06.06 WATER SUPPLY FACILITIES 06.06.01 Scope of Work

The scope of work shall include design, fabrication, manufactures, assembly & supply, erection/construction/laying, commissioning, testing & performance guarantee tests etc of plant & equipment and piping etc of complete water supply facilities including buildings, civil work & technological, structures, electrics, instrumentation, ventilation, material handling & hoisting equipment etc as specified and required for complete water supply, drinking water & water based fire- fighting systems as specified in this chapter as well as various chapters of this tender specification and General Technical Specification (GTS), complete in all respect on turnkey basis. The scope of work shall include the following activities. i) Design, engineering, manufacture /fabrication, assembly, shop

testing, painting, packing sequential delivery FOR site, unloading, unpacking, storage at site, preparation & submission of all drawings for civil, mechanical, structural, piping, electrical & other facilities, construction & erection drawings, supervision of construction & erection as per approved drawings, site testing, painting, commissioning & fulfillment of guarantee of all plant & equipment, sub systems & integrated system of water supply facilities covering make-up water system, drinking water system, dewatering system and water based fire fighting system, associated civil & structural work, handling & hoisting equipment, electrics, instrumentation & control, illumination, telecommunication, air conditioning & ventilation etc in accordance with the water system requirement of the proposed plant and the specifications laid down in various chapters in this document and also as per General Technical Specification (GTS).

ii) Supply of all technical literature, drawings & documents, general

arrangement drawings, assembly & sub assembly drawings of all the plant & equipment, construction & erection & as-built drawings, operation & maintenance manuals, manufacturing drawings, etc.

iii) Submission of all design calculations, data sheets for various

equipments, pipeline sizing calculation and calculation for sizing of various sub systems and integrated systems for approval of Purchaser/ Consultant and finalizing the same as per approval of Purchaser/ Consultant.

iv) Water system shall in general comprise of the following facilities:-

a) Water supply system for air conditioning & ventilation. b) Make up water system

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c) Drinking water system d) Service water system e) Water based fire fighting system f) Dewatering system for Sub station building, g) Dewatering system for Wagon trippler.track hopper, beds,

yard etc. h) Other miscellaneous water systems.

v) Supply of commissioning spares & consumables

vi) Supply of two years operation and maintenance spares (Tender

shall submit an exhaustive list for the same).

vii) Supply of special tools, tackles for construction, erection operation and repair & maintenance of the plant & equipment.

viii) All necessary connections for hook up with Purchaser’s system at

battery limits.

ix) Supply of erection, testing & commissioning materials.

x) Network flushing fluids, chemicals & consumables.

xi) First fill of oils, lubricants, filter media, resins, chemicals reagents and other consumables.

xii) Participation in design conference with the Purchaser & Consultant

as and when called for.

xiii) Pipeline structural stockades, bridges, R.C.C pedestals for overhead pipelines.

xiv) Pipeline supports, thrust blocks/ anchor blocks, etc.

xv) Inspection and performance testing of individual equipment and

system as a whole.

xvi) Water supply system/ systems shall be complete in all respects and any equipment or material not specifically mentioned in this specification, but required for safe, efficient & smooth operation and guaranteed performance of the plant shall be deemed to be included under the scope of work of the Tenderer.

xvii) The tenderer will treat wastewater, contaminated water to minimize

fresh make-up water requirement. Tenderer shall furnish the details of such scheme. No water is to be discharged in to storm water drain.

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06.06.02 Battery Limit 06.06.02.1 Industrial water

Industrial make-up water tapping shall be taken from approximate distance of 100m near Area repair shop. Tenderer to take tapping from existing process water network of DN150 laid on pipe trestles and extend the same with an isolation valve in a valve pit to their proposed systems for the entire plant. Tenderer shall indicate the make-up water quantity requirement, pipe size, end connection, MOC of pipeline, etc. for firewater pump house, dust suppression and service needs.

06.06.02.2 Service water

Successful tenderer shall provide service water system for washing/cleaning of galleries, junction house etc. for the proposed plant by providing pumps of required capacity and head. The pumps shall be installed in the fire fighting cum service water pump house. Successful tenderer will collect contaminated service water for treatment. Tenderer shall furnish the details of such scheme. No water is to be discharged in to storm water drain.

06.06.02.3 Drinking water

Successful tenderer shall extend drinking water pipelines with an isolation valve from the existing underground fire and drinking water network for its entire area/requirement, which is laid approximatey at a distance of 100m near area repair shop. Tenderer shall take tapping with an isolation valve in a valve pit to their proposed systems/ shops, offices, toilets, drinking water platforms, water coolers, etc. for the entire plant and the Tenderer shall indicate the drinking water quantity requirement, pipe size, end connection, MOC of pipeline.

06.06.02.4 Fire-fighting water

For RMHS Yard area, Junction Houses, Conveyor Galleries etc.

To cater to the needs of water based fire-fighting system for the proposed plant, an independent pressurised fire water system shall be planned with provision of FW PH, Piping network, yard hydrants and internal hydrants at regular intervals and with electrics, instrumentation, air conditioning and ventilation, material handling system etc.

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Successful tenderer shall also extend firewater pipelines from the fire-fighting network to the proposed HTSS building of MSDS-IV upto battery limit with an isolation valve. Further successful tenderer shall connect hydrant network of RMHS to the proposed hydrant network of MSDS-IV with an isolation valve. Tenderer to plan complete water based fire fighting system as per as per TAC 2003. The water-based fire fighting system shall be designed, supplied & erected inline with the stipulations under various clauses of GTS.

06.06.03 Scope of work and services

To cater to the needs of fire fighting facilities for RMHS yard area, Wagon tripplers, ground hopper, raw material storage successful tenderer shall plan independent fire fighting system comprising common FW cum service water pumphouse (to house the fire fighting pumps, jockey pumps for hydrants system), Fire water reservoir, Piping network along with yard hydrants and landing valves, fittings, sluice gates, handling and hoisting facilities, air conditioning and ventilation facilities for pump house and control room, etc. Construction of common firewater cum service water pump house, static water tanks and other associated civil / structural work along with mechanical, electrical, instrumentation, ventilation and hoisting and handling facilities shall be carried out by the successful tenderer as per the details covered under respective chapters of this specification as well as GTS. All electrical, mechanical, instrumentation, ventilation and hoisting and handling equipment shall be supplied and erected by the successful tenderer on turnkey basis. Civil work for pump house, MCC room, static water tank and all other associated facilities shall be constructed to suit the technological requirement/approved drawings on turnkey basis.

A Specification, Description & Scope of work for fire water pump house and equipments

The scope of work of the Successful tenderer shall include supply, erection, testing and commissioning of the water based fire fighting system as elaborated below complete with all mechanical, electrical equipment, civil and structural work on trunkey basis.

a) Construction of Firewater pump house with MCC room including ventilation

system and electric hoist, which includes the following:-

1. One firewater Static Water Tank of required capacity (min. 2 hrs. pumping) with the following shall be provided.

• Two compartments

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• Staircase ( RCC ) to go to the top of the tank • Railings all around the static water tank ( on the roof ), along the side of

staircase • Vent pipes on the roof • Manholes ( 2 numbers per compartment) with C.I. manhole cover, CI

frame. • Overflow pipe ( DN 200 ) from top to the nearest drain ( one per

compartment) • Drain pipe ( DN 200 – one number per compartment ) with gate valve and

connecting the same to the nearest drain • Pipe inserts ( with puddle flanges )

2. Network of underground/over ground ring mains (Pipes of DN250/DN200). 3. Hydrants (Internal and External). 4. Pumps, motors, diesel engines, pipes, valves, valve-operating platforms,

handrails along the platforms, staircase, cat ladders, etc. 5. Underslung crane/Electric hoist of required capacity. 6. All electric, illumination, instrumentation, ventilation, etc. All necessary

instrument, power, and control wiring integral to any equipment furnished under this specification. These shall include terminal blocks and internal wiring to these terminal blocks for equipment requiring external connection.

b) Fire Hydrant system at regular intervals for the entire plant including road

periphery around the plant shall consist of internal as well as external hydrants. The following specification of work shall be considered:-

i) Category at hazard - Ordinary(as par TAC-2003) ii) Yard hydrants - at 45 m intervals iii) Internal hydrants - at 30 m intervals iv) Min. pressure at remotest hydrant - 3.5 kg/cm² v) Hose Box for each yard hydrant/landing valves.

• 2 nos. of 15 m long hose shall be provided along with fittings for each yard

hydrant. • 2 nos. of 7.5 m long hose shall be provided along with fittings for each

internal hydrant. All fire hydrants shall be designed generally as per IS: 5290-1993 Type A, i.e. single outlet type. Each hydrant shall consist of valve, matching flange, CAF gasket, nuts, bolts, instantaneous springlock type female outlets with blank cap & chain. Each hydrant shall have a permanent stainless steel nameplate and stainless steel tag fixed on the hydrant indicating the Tag No. Hydrants shall be designed for 100% tight shut off. Material of construction

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for various components shall be as follows;

Body, Bonnet, stop valve, check nut : SS 04Cr 17NiMO2 as per IS:6529-1972

Female coupling and blank cap : SS 04Cr 17NiMO2 as per IS:6529-1972

Hand wheel : CI as per IS : 210-1978 Other Components : As per IS:5290-1993

Companion flanges shall be made of Carbon steel plates conforming to IS 2002 Gr2A’92 and drilled to IS 6392 – 1971 (Reaffirmed 1994) Table 17. Fire fighting ring mains both inside the units & outside the units shall be provided with the following;

Adequate number of single outlet type hydrants and isolation valves. Dismantling of the existing hydrants, blanking of the pipes (from which the

existing hydrant is removed) and installing of dismantled hydrants in the proposed fire hydrants network with isolation valves.

Grid isolation valves along with counter flanges, bolts, nuts, gaskets and washers.

c) Supply of motor operated main pumps, jockey pumps, diesel engine driven pumps and associated auxiliaries/equipments and other mechanical equipment including ventilation fans and hoist shall be as follows :-

For Hydrant System

i) Electric motor driven main firewater pump set of adequate capacity as per

norms and head of 88mWC (indicative) along with complete accessories. ii) Diesel engine driven firewater pump set of adequate capacity as per

norms and head of 88mWC (indicative) along with complete accessories.

iii) Jockey pumps each of adequate capacity as per norms, Head 88mWC (indicative) along with complete accessories.

d) Supply of the following accessories for the each diesel engine : Oil tank : 1 sets Oil piping : 1 sets Coupling ( flexible coupling connecting : 1 Sets

the shafts of pump and engine) Coupling guard : 1 Nos Battery : 2 Nos per diesel engine Battery charger : 2 Nos per diesel engine Cabling : 1 sets Instrumentation : 1 sets Panel for the engine : 1 sets

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Companion flanges (suction and : 1 sets delivery side) of pump along with bolts, nuts, gaskets and washers Exhaust piping along with common : 1 sets

base plate, foundation bolts, nuts and washers

Successful tenderer to provide diesel engine with all standard accessories, battery sets for auto starting, charger for battery, instrument & electrical panels, pressure switches etc. Rated power requirement of the diesel engine shall meet the requirement of clause no.7.4.5.2.3 of TAC manual (latest revision). The engine shall be capable of delivering the rated output continuously; (24 hours operation) shall run steadily at any load within its rated load, as specified in ISO: 3046. Suitable automatic governing system shall be provided. The fuel for the engine shall be high-speed diesel as per IS: 1460-1974. The diesel engine shall conform to Tariff Advisory Committee (TAC) requirements. The details refer to GTS.

e) Piping, valves, etc.

f) All civil, structural and support works.

g) All electrics, Controls and instrumentation.

h) Ventilation facilities for the Common Fire Water cum service water Pump

House, Fire Station Building and other premises of the plant entilation system.

i) Shop and site painting for all equipment, pipes etc.

j) Erection, testing, commissioning and PG test for the complete fire

protection system.

k) Supply of mandatory spares.

l) Supply of Tools & tackles.

m) All the requirements of TAC-2003 for complete FPS shall be incorporated by the successful tenderer in their scope irrespective of whether the details are described in specification and/or shown in the drawings or not.

B Description & Operating Philosophy of Fire Water Pumping System

The fire hydrant system shall be provided considering fully automatic operation of pumps and control systems. Normally, system shall be kept pressurised at a pressure of 8.8Kg/cm². To take care of minor leakages from the systems, two nos. jockey pumps shall be provided. When there is leakage of water, jockey pump shall start automatically so that system pressure is maintained at 8.8 Kg/cm². In case first jockey pump fails,

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second jockey pump, which is a standby, shall start automatically. Jockey pump shall stop on regaining of system pressure at 8.8Kg/cm².

In case of fire, when any Landing Valve/Yard Hydrant is opened, the water pressure in the respective network will drop resulting in automatic starting of main electric pumps in a sequential manner at the preset low pressure in headers.

Sequential starting of main electric motor driven pumps

When the pressure in the hydrant network falls below a preset value, the first pump will start automatically and the jockey pump, which was in operation, should stop. In case the requisite pressure in the network is not increased, the second pump will start automatically. In this fashion, pump should start in sequence. During the above sequential starting, if the first pump fails to start and pressure is not increased to the requisite value, the diesel engine driven pump should start automatically. Complete system shall be provided with Auto as well as local mode of operation. The Local mode of operation shall override the Auto mode. Individual selector switches (Local/Auto/off) shall be provided for drives of Pumps. For Jockey Pumps, the selector switches shall also have a selection for reserve pump. The selection of working and reserve pump shall depend upon the operator’s choice. The status of various pumps (On, Off, Trip) shall be available in the Control Panel.

All Civil and structural works shall be under successful tenderer’ scope as part of turnkey job. Civil works pertaining to construction of valve pits, manholes, reconstruction of open drains, fittings, valves, underground buried pipelines, etc. such as excavation, diversion of pipe / cable, maintenance provision for new facilities, rerouting if required for new facilities, back filling, compacting, laying of encasing pipes below roads /railway tracks, generally with 1.5m earth cover, but maximum cover of 4m near crossing of other underground communications shall also be in the scope of the successful tenderer. In case group of pipes are crossing road, RCC culverts to be provided below the roads and the same are included in the scope of the Successful tenderer. Dismantling of old pipelines wherever the new pipes are to be laid in the same alignment as the old ones is also in the scope of bidder.

C. All civil works for completeness of fire protection systems, which may not have been described but required for the completeness shall be under Successful tenderer’s scope.

D. Supply of mandatory spares required as per the list furnished for operation

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and maintenance, initial fill of consumables up to PG test and tools & tackles for operation and maintenance.

E. Laying/erection of pipelines, fittings, valves etc. in the floor below ground

level on the following; RCC pedestals with sliding/fixed supports wherever possible. Structural supports by providing plate inserts on the face of the RCC

beams, welding the structural members of adequate size with sliding/fixed support.

F. Purchaser during the execution of work, if necessary, may ask the

tenderer to lay, out of sequence, any part of pipeline in the proposed piping route, which may need priority in over all construction planning. The tenderer shall have to abide by such requests.

G. Broad specifications of Fire Water Pumps

Sl. No.

DESCRIPTION - RMHS Yard Area, Junction houses and conveyor gallaries.

A Fire water pumps - Min. 2 Nos. for Hydrant system (1 electrical +1 DE driven)

a. Type of pump - Horizontal centrifugal (Side Suction Side Delivery)

b. Rated capacity of each pump

- To be decided by tenderer during engg.

c. Head developed at rated capacity (excluding losses in pump assembly)

- 88 mwc(Indicative)

d. Pump rated speed - 1500 r.p.m. (Nominal) e. Range of Operation - 0 to 150% f. Number of stages - Multi-Stage (2 max) g. Type of lubrication - Self water lubrication h. Type of coupling - Flexible coupling (pump-motor) i. Pump model -

1 nos. TEFC Electric motors for 1 nos. of above pumps

Voltage - 415 V Frequency 50HZ R.P.M. - 1500 (Nominal) Type of cooling Air cooled Ambient Temp 50 deg.C

j.

Noise level for pump Not more than 80 db at 1.00 m distance.

B Fire water Jockey pumps - 1 Nos.Hydrant system Type of pump - Horizontal centrifugal Rated capacity of each - To be decided by tenderer during

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Sl. No.

DESCRIPTION - RMHS Yard Area, Junction houses and conveyor gallaries.

pump engg. Head developed at rated capacity (excluding losses in pump assembly)

- 88mWC (Indicative)

Pump rated speed - 2900 r.p.m. (Nominal) Range of operation - 0 to 150% Number of stages - Multi stage Type of lubrication - Self water lubrication Type of coupling - Flexible coupling (pump-motor)

Voltage - 415 V Frequency - 50HZ R.P.M. - 3000 (Nominal) Type of cooling - Air cooled Ambient Temp - 50 deg.C

Successful tenderer shall prepare and submit comprehensive manual describing following aspects.

o Description of various facilities.

o Operation philosophy & various interlocks.

o Instruction on occurrence of Fire - daytime and separately for

nighttime.

o Location of portable extinguishers / hydrant points, area wise / floor wise.

H. Dewatering system for substation building, Wagon trippler, track hopper,

beds, yard etc shall be in the scope of the tenderer. Necessary arrangement for dewatering system for the area/building envisaged shall be provided by the successful tenderer.

06.06.04 Pump Sets

1) Separate group of pumps and pipeline headers shall be provided for each system for the proposed RMHS Plant.

2) All the pumps shall be of horizontal centrifugal split casing type, side suction side delivery along with their auxiliary equipment suitable for the required duty conditions and shall be designed and manufactured for continuous duty at full load.

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3) Supply of pumps shall be complete with electric motor, flexible coupling, coupling guard, common base plate, matching flanges, nuts, bolts, gaskets for suction & delivery, foundation bolts, nuts, washers etc.; complete in all respects.

4) Total no. of pumps for a particular group will be selected in the

following manners except for emergency water re-filling pumps, diesel pump etc.

S.No. Total no. of working pumps for a particular group

Minimum no. of reserve pumps for the group

1. 1 Pump 1

2. 2 to 3 2

3. More than 3 but less than

6.

3

5) Type of drainage pumps shall be selected and provided as per requirement of the system and inline with GTS.

No. of drainage pumps required at each location

= 1 no. Working + 1 no. Standby.

6) The material of construction of various pumps may be selected superior to that mentioned in GTS to suit the liquid characteristics.

7) For other requirement, reference may be made to GTS.

06.06.05 Valves

1) Adequate number of isolation valves with stainless steel internals should be provided in the pipeline network for isolation of pipe sections and equipment, control of pressure, flow & level of fluids, venting, draining, pressure relief etc. (working pressure = 16 kg/cm2)

2) Valves shall be suitable for service conditions in all respects and located suitably for ease of operation and maintenance.

3) All control valves shall be provided with hand wheel. 4) Valves shall be provided in line with GTS.

5) For other requirement, reference may be made to GTS.

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06.06.06 Pump House

There shall be a common fire fighting cum service water pump-house to locate all the pumps (fire fighting pumps, jockey pumps, make-up water system requirement, if required), valves, internal piping, MCC room, material handling facility, air conditioning & ventilation facilities, illumination & instrumentation, etc.

The operation of the fire fighting pumps shall be done automatically based on pressure switch signals. The control of fire fighting system shall be done from centralized control room of technological shop with all process and safety interlocks. However, provision of operation of each drive shall be made from local control station also for maintenance purpose with safety interlocks intact. Running, fault signals shall be made available in the centralized and local control room.

1) It shall be made of RCC framed structure with brickwork filling.

RCC roof shall have parapet wall on the roof. 2) The pump foundations in it shall be made of RCC. 3) Underslung/EOT crane of required capacity.

4) Ventilation system along with air washer unit shall be provided. 5) Pump house drainage facilities shall be provided with drainage

pumps.

6) Pump house GA drawing, civil load data and detailed working drawings shall be submitted by the contractor.

7) Other aspects of pump house shall be as per General Technical

Specification (GTS). 06.06.07 Pipes, Fittings & Pipe Supports

1) The pipe work shall be designed, manufactured, assembled and tested as per the latest standards, codes and recommendations of the Bureau of Indian Standards / ANSI/ ASTM/ AWWA/ any international standards. Pipe work shall be complete in all respects including all accessories essential for proper installation, operation

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and maintenance, even though such items are not specifically mentioned in the specification.

2) The Tenderer shall supply all the pipes, valves, fittings, pipe supports, flanges, gaskets etc.

3) Each header shall be provided with suitable number of valves for isolating and maintenance purpose.

4) Dismantling joints near the pumps on both suction and delivery lines on the main header shall be provided at suitable places.

5) GI pipes as per IS: 1239 (part-I)-2004 heavy class shall be used up to size DN 150 mm and all GI fittings up to size 150mm as per IS:1239 (part-II)-1992 shall be used. Pipe above DN 150 shall conform to IS: 3589-2001.

6) MS fittings of size 200mm and above shall be either forged or

fabricated ones from original pipes (miter bends) and less than 200 mm shall be forged. MS pipes/fittings shall have welded joints. (Limiting Minimum thickness of Pipeline DN200 to DN300-6.3mm, DN350 to DN400-7.1mm, DN450 & above-10mm).

7) The pipe laying and erection work shall be carried out according to the standard engineering practice and the drawings and specifications etc. duly approved by the Purchaser/ Consultant. The Contractor shall take care of positioning, leveling, plumbing and alignment of all the pipelines, valves and equipment as well as supporting structures within required accuracy and tolerance limits.

8) RCC thrust block shall be provided at bends, tees and branching offs of the pipelines.

9) For other requirement, reference may be made to various clauses of GTS.

06.06.08 i) Make- Up Water System

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

2. Make up water system will include taking tapping from the existing

process water network of DN150 laid on pipe trestles with isolation

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valve in a valve pit, along with pumps (if reqd.), valves, valve pits, sumps etc., to the circulation system as well as process needs.

3. Online booster shall not be accepted. A makeup water sump with

pumps and piping (pump house and sump are to be provided by the Tenderer), if required, shall be provided.

4. The Tenderer shall provide necessary treatment facility, wherever

required, to make the water suitable for process/system needs and other purposes.

ii) Water Supply System For Air Conditioning & Ventilation

1 The entire system and piping network for water supply for air-

conditioning and ventilation and other systems/ sub-systems are in the scope of the Tenderer.

2 It shall consist of pumps, valves, pipes, fitting, pipe supports and

associated civil, structural, electrical, instrumentation, material handling, air-conditioning & ventilation etc.

3 The details and specification of pumps, valves, pipes, fitting, pipe

supports and associated civil, structural, electrical, instrumentation, material handling, air-conditioning & ventilation etc. as specified for cooling water system is applicable for this system also.

4 Makeup water for the system shall be provided by the Tenderer

from the make-up water network to be provided by the Tenderer within their area. No separate connection at battery limit will be provided for this purpose.

iii) Drinking Water System

1 Successful tenderer shall extend drinking water pipelines with an

isolation valve in a valve pit from the existing underground fire and drinking water network for its entire area/requirement, which is laid approximate at a distance of 100m near area repair shop.

2 If the pressure, as indicated in battery limit parameters, is felt

inadequate for the area under the scope of the Tenderer, Tenderer may provide separate sump and drinking water pumps along with piping and electrics etc. to meet the requirement. Online booster pump shall not be accepted.

3 The details and specification of pumps, valves, pipes, fitting, pipe

supports and associated civil, structural, electrical, instrumentation, material handling, air-conditioning & ventilation etc. for cooling water system is applicable for this system also.

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06.06.09 Erection, Testing and Commissioning

1. The erection of all plant and equipment shall be carried out according to the latest engineering practices and according to the drawings, specifications, Instructions etc. duly approved by the Purchaser. The contractor shall carryout the work in the presence of and /or as per the instructions of site engineer /supervisory personnel deputed by the Purchaser. Highly skilled workmen shall carry out the erection.

2. The Tenderer shall supply all required manpower, tools and related

equipment, all hoisting equipment, all necessary scaffoldings, all necessary transporting equipment, consumables. Construction and erection materials, petrol, diesel oil, Kerosene, solvents, sealing compound, tapes, brazing and soldering materials, welding and brazing gases, erection bolts, nuts and packing sheets/compounds, temporary supports, wooden blocks, spacers, templates, jute and cotton wastes, sand/emery paper etc. as required for the satisfactory completion of work.

3. The Tenderer shall make his own arrangement for handling the

equipment and pipelines at the stores and transporting it to the site for installation.

4. After erection, all equipment having moving part, subject to pressures

or voltages shall be given trial operation. The trial operation shall consist of 24 hours of continuous operation. All modifications and rectifications required during the trial operation or required for proper operation shall be done at his own cost by the Tenderer as accepted by the Purchaser.

5. Adequate segmentation and interconnections shall be provided in the

distribution networks to afford maximum flexibility of operation and maintenance.

6. Rotating equipment shall be checked for proper direction of rotation

and shaft alignment. Equipment subject to pressures shall be carefully examined for leakage. All equipment, such as pressure taps, temperature measurement connections, flow measurement devices etc. shall be provided by the Tenderer.

7. On completion of the work, the Tenderer shall remove and dispose off

all rubbish and other unsightly materials caused by his working to a distance of five kilometer from the proposed plant area or as directed by the Purchaser and thereby leaving the premises in good, clean, safe and operable condition.

8. All the equipment shall be subject to stage inspection by the

successful Tenderer’s own inspecting authority However, Purchaser’s Inspector may visit the works from time to time who shall have free

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access to all the places of the manufacturing premises where any part/parts are under manufacturing.

9. The successful Tenderer’s inspecting authority shall keep a close

surveillance in respect of the job for the design, dimensions, tolerances, surface finish etc.

10. Before giving call for final inspection, all the documents shall be

furnished to the Purchaser. The record of manufacturing details, inspection and tests carried out by the successful Tenderer shall be made available to the final Inspecting Authority. However, approval and final inspection at the manufacturing works shall not relieve the successful Tenderer of responsibility of replacing at his cost any defective part/material which may be detected by the purchaser during erection and commissioning or guarantee period.

11. Inspection of the item will be carried out in line with the approved QAP

of the Purchase Order.

12. All materials required for fabrication, construction, testing and inspection shall be supplied by the Tenderer. No material shall be free issue to the Tenderer.

13. The test shall be conducted at shop for various sub-

assemblies/assemblies of equipment as per common industrial practices, unless otherwise specified.

14. Extent of testing shall be finalized during formulation of detailed QAP.

15. All inspection shall be carried out at the manufacturer’s shop/works.

16. No equipment or part item shall be dispatched without final inspection

and issuance of inspection certificate.

17. All equipment, assemblies, sub-assemblies shall be shop tested as per relevant standards and the test certificates shall be submitted by the supplier.

18. Erection, testing & commissioning of various equipments and piping

etc shall be done also inline with details given in various chapters of GTS.

06.06.10 Painting

All Plant, equipment, valves, piping etc. shall be painted as per the

specification given in general requirements of painting and as per requirement and approval of Purchaser.

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06.06.11 Preferred Makes

(For preferred makes of equipments reference may be made to separate document)

06.06.12 Drawings/Documents to be Furnished along with the Tender

The Tenderer shall submit the following drawings/ documents along with the tender: - 1. Layout drawing showing details at the tapping point for make –up

water, drinking water and the pipeline route to various consumers including requirement of make-up water, drinking water and fire fighting water at battery limits.

2. Scheme of the complete water supply system with descriptive and illustrative literature.

3. P & I diagram of each circuit of the complete water supply system showing all the consumers, flow rate, pipe diameters, broad parameters of each equipment, instruments, interlocks, water losses etc.

4. General arrangement drawings of pump houses showing tentative dispositions of various equipment and piping.

5. Write -up detailing the control logic in the entire water system. 6. General arrangement drawings of pump & other equipments and

valves etc. 7. Catalogues, literatures and GA drawings of all equipments and

valves 8. Pipeline materials and specifications considered for various

systems. 9. Duly filled in data sheets for various pumps, valves and other

equipments as specified in GTS as well as various data of different equipments as specified in various clauses of GTS.

10. List of special tools and tackles. 11. List of commissioning spares. 12. List of spares for two years of normal operation and maintenance

with item wise prices. 13. Specification and capacity of all equipment, pipes, valves etc.

offered by the Tenderer. 14. Details of various drives, instruments, handling & hoisting facilities,

air conditioning & ventilation facilities, etc. 15. Tentative Bill of Quantities covering all equipments, valves,

hydrants, strainers, pipelines, etc. and associated civil, structural, electrics, instrumentation, handling & hoisting facilities, air conditioning and ventilation facilities etc.

06.06.13 Drawings/ Documents to be furnished by the Successful tenderer For

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Approval

1. Process & instrumentation diagrams for the water systems indicating location of all instruments alarms and interlocks functions using ISA symbols.

2. Layout of piping system-indicating pipe routing, location of supports, valves and other fittings as required.

3. General arrangement drawings of pump houses and sump / tank (including civil, structural and other facilities) showing dispositions of various equipment and piping.

4. General arrangement and cross-sectional drawings, characteristics curves and technical details of all the equipments (pumps, valves, fire hydrants, etc.) , valves and piping including GA drawings showing plan, elevation and sectional views of the water system

5. Data sheets, characteristic curves and technical details of all the equipments, valves and pipings.

6. List of instruments comprising bill of materials and instrumentation data sheets.

7. List of safety interlocks. 8. Test procedures for preliminary and final acceptance tests. 9. Quality Assurance Plan. 10. All equipment and piping sizing calculations. 11. GA drawings and details of air conditioning & ventilation facilities. 12. Test certificates for the following:

a) Material test certificate for all major equipment and their components.

b) Hydraulic test of equipment, pipe fittings & valves. c) Static and dynamic balancing of all rotary parts/ equipments

13. GA drawings of material handling equipments. 14. Motor GA drawings, data sheets and performance curves 15. Cable layout drawings and cable schedule. 16. Any other drawing/ documents as required by the Purchaser.

06.06.14 Drawings/ Documents to be Furnished by the Successful tenderer for

Reference and Record

1. The successful Tenderer shall submit required sets of all the approved drawings, documents and manuals for Purchaser’s record and use. After erection of equipment, the Tenderer shall submit one set of linen tracings/ reproducibles in required number of prints along with soft copies in CD (in AutoCAD format) of each “As built drawings”.

2. Operating and maintenance manual. 3. Recommended Spare parts list and price . 4. Instruction for erection and commissioning. 5. Manufacturer’s test certificates.

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6. Lubrication schedule and quantity and quality of lubricant for one year’s normal normal operation.

7. Various equipment assembly drawings and bill of material. 8. Welding procedure. 9. Hydraulic test logs. 10. Equipment GA drawings and bill of materials. 11. Characteristics curves of the pumps, motors and other equipments. 12. Operation and maintenance manuals for all equipments, valves and

complete water system along with soft copies. 13. Test and calibration certificates. 14. Warranty/ guarantee certificates. 15. Technical literature, catalogues and manufacturer’s drawings for all

brought out equipment, valves and other items. 16. All inspection/ test report/ certificates. 17. Any other drawing/ documents as required by the Purchaser.

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TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

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06.07 AIR POLLUTION CONTROL 06.07.1 Scope of work The scope of work of the turnkey supplier of “Augmentation of Raw

Material and Handling Facilities” at Bokaro Steel plant shall include the design, manufacture / procurement, inspection, supply, transportation to site, storage, testing, erection, painting, commissioning and performance testing of dust suppression systems for the new wagon tippler, all conveyor transfer points and junction houses in new route from wagon tippler to existing yard and 4th series conveying system and transportation of lump ore in intermediate building.

Plain water dust suppression system with nozzles shall be provided at

wagon tipper top. Dual fluid (Dry fog) type of dust suppression system (DFDS) shall be provided for wagon tippler bottom, all conveyor transfer points and junction houses and receiving and transportation of lump ore in intermediate building. The water addition in DFDS shall not be more than 0.1% of the weight of material being handled.

Any other item, not specifically mentioned in the TS, but required to make

the dust suppression systems complete in all respects, within the battery limit of this package, shall be included in the scope of work of the Tenderer.

06.07.2 Equipment and System Description

02.1 Dual Fluid Dust Suppression System The Dual fluid dust suppression (DFDS) works of the principle of agglomeration. Dust particles released from a material handling or processing plant which becomes air borne, are made to pass through a blanket of extremely fine fog. The dust particles and the micron sized fog droplets collide and adhere to each other, thus increasing their mass.

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After a series of such collisions, the mass becomes heavy enough to cause settlement of the agglomerates on to the larger mass of the material being handled.

The System uses an Air driven acoustic oscillator nozzle which is capable of producing super fine atomization of water droplets that greatly increase the dust particle to water droplet contact resulting in settlement of dust. The fine droplets evaporate before wetting anything but the dust. The water addition is 0.1% of the weight of material being handled.

The DFDS system comprises of main equipment installed at the application points and auxiliary equipment installed at central water and compressed air supply point. Brief components of both type of equipment are mentioned below:

• Main Equipment

The Main Equipment will include Spray bar assemblies fitted with Dual-fluid air driven acoustic oscillator atomizing nozzles, pressure regulating units and flow activation stations for ON-OFF control of the system and instrumentation for auto operation. Spray bar assemblies

The spray bar assemblies shall be manufactured from stainless steel tubing drilled and tapped for connection of nozzle adapters. A specially designed and selected dual fluid atomizing nozzle shall be fitted into each of the adapters. These nozzles are fitted with acoustic oscillators for atomizing the water into droplets of micronic size by passing them through a field of high frequency sound waves. The nozzles shall be of stainless steel while the adaptors shall be of Brass. Each Spray bar shall be provided with mounting brackets and flexible hoses for connection to the Air & Water Pipeline.

Pressure regulating units (PRU)

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The performance of Dual Fluid Type Dust Suppression System is critically related to the size of water droplets. The nature and particle size of dust generated in the material handling system changes with change in size and characteristic of the material. In practice, the sizes of the dust particles have a very wide spectrum (1-800 microns). A careful control of air and water flow & pressure is therefore necessary to obtain optimum dust suppression results. For this purpose, Pressure regulating units shall be provided in the system. The Pressure regulating unit shall consist of diaphragm type pressure regulating with pressure gauge and ball valve for isolation in air and water line. The operator can adjust both the air and water pressures independently to change the fog characteristics to obtain optimum dust suppression results vis-a-vis the site requirements. The Pressure Regulators shall be installed in a metallic enclosure with inspection door with rubber sealing arrangement. Flexible hose shall be provided for connection of PRU to the Air & Water Pipeline.

Flow activation stations (FAS)

The Flow activation station shall consist of Solenoid valves in air & water line, pressure switch in the airline, selector switch, and indication lamps. Isolation ball valves shall be provided in the air & water line. All the equipment shall be installed in a metallic enclosure with inspection door with rubber sealing arrangement. Flexible hoses shall be provided with each FAS for connection to air and water pipeline.

The "ON - OFF" control of the fogging system shall be through the flow activation stations with facility for both manual and auto mode. A three-position selector switch shall be provided to select the mode of operation. The switch when energized shall open the electric solenoid valves, which shall permit compressed air and water to enter into the pressure regulating units and spray bars.

In addition, a pressure switch shall be installed in the airline to ensure that air and water solenoid valves are energized only when sufficient air pressure is available in the line. This will ensure that the system cannot

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operate without sufficient air pressure to the nozzles and reduces the chance of un-atomized water to pour into the dust source. Flow activation shall have indication for : -

- System ON - System OFF due to lower Air Pressure Auto operation

The flow activation stations shall have provision for both manual and automatic operation. For manual operation, the system shall become operational with selector switch in manual mode and in auto mode, the fogging operation starts on receiving a signal either from a Speed Switch cum belt load monitor or limit switches installed at a strategic location in the material conveying line or potential free contract from the drive motor of equipment as per requirements.

The dust suppression system shall be divided into independent circuits taking into account the flow diagram, operational requirements, distances between dust suppression locations etc. Flow activation stations with instruments for auto operation are provided for each circuit for ON/OFF control of the Dust suppression system.

• Auxiliary Equipment

The Auxiliary Equipment will include water storage and pumping unit with duplex water filter compressors with air receivers and associated electrical works, air and water piping, enclosures etc.

Air compressors

Air compressors shall be provided to cater to the requirement of compressed air of the "DFDS" System. The compressed air system shall have 50% standby capacity i.e. a minimum of 3 compressors of same capacity (2 operating + 1 standby) shall be provided. The compressor shall be heavy-duty industrial type, air

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cooled, oil injected screw compressors directly coupled, electric motor driven with control panel and acoustic enclosure. An air receiver of adequate capacity fitted with pressure gauge, safety valve and drain valve is to be provided near the air compressor. Additional air receivers shall be provided in each building / junction house where the total compressed air requirement exceeds 250 m3/hr. The detailed equipment specification for the compressors and the driers is given in GTS.

Water pumping unit

The water pumping unit for each pumping station shall consist of the following: -

a) Duplex filter with SS filter element to remove all suspended particles exceeding 100 microns

b) Water storage tank to provide minimum of 2 hours storage of water in MS construction with low level switch, float valve, vent, drain etc.

c) Multistage centrifugal pump of adequate capacity with 100% standby

While selecting the discharge capacity of the water pumps, 20% should be added over the theoretical requirement and the head of the pump should take into account the elevation of the spray bars and line losses so that the net head available at the PRU is 1.5 to 2.0 bar.

• Design Criteria

The efficiency of the DFDS system shall be such that the work zone dust concentration should not be more than 1 mg/Nm3 at 5-8 m from the source over and above the ambient.

• Specification of Air Compressor

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© 2009. MECON Limited. All Rights Reserved. Page 0 of 13

Dedicated air compressor shall be provided for DFDS system. The compressor shall be reciprocating, multi-stage, lubricated design with balanced opposed arrangement driven by electric motor through V-belt drive arrangement. The compressor shall be designed to supply the desired air volume at the requisite discharge pressure at the outlet of after-cooler. The compressor shall be housed in the DFDS pump house cum compressor building and shall be designed for continuous operation. Depending on the design more than one pump house cum compressor building may be required and the same is to be provided as required.

02.2 Plain Water Dust Suppression System for Wagon Tippler Top

Plain water dust suppression system shall be provided at wagon tipper top at the time of tippling. Necessary pumps with 100% standby, pipes, fittings, valves, nozzles, etc. as required shall be provided. The operation of this dust suppression system shall be interlocked with the operation of the wagon tippler.

Page 90: Bokaro Steel Plant Specs

STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. Page 0 of 13

06.07.3 Data to be furnished by the Tenderer along with the Offer

a) GENERAL

Sl. No.

Characteristics Unit Value

1. Make of equipment 2. Design water flow quantity 3. Design compressed flow requirement 4. Work zone dust concentration 5. Total power requirement 6. Total water requirement 7. Any specific design consideration

8. Noise level at 1m distance from the dust suppression equipment

dB(A)

9. Support / Structure / Weathering shed DS system

10. List of drive 11. Spray nozzle make rating, quantity 12. Spray nozzle material of construction

13. Load monitoring switch type, quantity and rating

14. Sequence timer type, quantity and rating

15. Solenoid valve type, quantity and rating

16. Sprinkler flow, pressure and throw b) PUMPS

Sl. No.

Characteristics Unit Value

1. Make and model no. 2. Type of pump 3. Capacity. m3/hr 4. Total head. m WC

Page 91: Bokaro Steel Plant Specs

STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. Page 0 of 13

Sl. No.

Characteristics Unit Value

5. Quantity Material of construction i) Shaft ii) Impeller

6.

iii) Casing 7. Pump speed rpm 8. Shaft power

Drive details i) Motor make ii) Motor KW iii)Insulation class

9.

iv) Frame size 10. Bearing type & make 11. Type of coupling 12. Vibration level

13. Noise level at 1 m distance for pump set

dB(A)

c) PIPES

Sl. No.

Characteristics Unit Value

1. Material 2. Standard 3. Class 4. Thickness of pipe material 5. Pipe size, length and weight 6. Make

7. Maximum recommended operating temperature

0C

8. Maximum recommended operating pressure

Page 92: Bokaro Steel Plant Specs

STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. Page 0 of 13

Sl. No.

Characteristics Unit Value

9. Type of protective coating

d) PIPE FITTINGS

Sl. No.

Characteristics Unit Value

1. Type of fittings 2. Size (O.D x Thickness) 3. Standard 4. Lengths

5. Maximum recommended operating temperature

6. Maximum recommended operating pressure

7. Type of protective coating 8. Weight of fittings kg

e) VALVES (GATE, GLOBE, CHECK, BUTTERFLY, FLOAT, PRESSURE

RELIEF, AUTO AIR RELEASE)

Sl. No. Characteristics Unit Value

1. Type: 2. Body / Bonnet / Cover: 3. Spindle: 4. Disc: 5. Body seat ring & Disc seat ring 6. End connections: 7. Pressure rating: 8. Flange facing: 9. Manufacturing std.: 10. Hand wheel:

Page 93: Bokaro Steel Plant Specs

STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. Page 0 of 13

Sl. No. Characteristics Unit Value

11. Packing: 12. Companion Flanges 13. Hydrostatic testing: 14. Test certificates:

f) SOLENOID VALVES

Sl. No. Characteristics Unit Value

1. Make and Model 2. Type 3. Power Supply 4. Quantity 5. Solenoid Valve Box size

g) LOAD SENSOR UNIT

Sl. No. Characteristics Unit Value

1. Make and Model 2. Type 3. Quantity

h) MATERIAL SENSOR UNIT

Sl. No. Characteristics Unit Value

1. Make and Model 2. Type 3. Quantity

i) PRESSURE SWITCH

Page 94: Bokaro Steel Plant Specs

STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. Page 0 of 13

Sl. No.

Characteristics Unit Value

1. Make and Model 2. Type 3. Quantity

j) PRESSURE GAUGES

Sl. No.

Characteristics Unit Value

1. Make and Model 2. Type 3. Quantity

k) SEQUENCE TIMER

Sl. No.

Characteristics Unit Value

1. Make and Model 2. Power Supply 3. Quantity

l) HOLDING TANKS

Sl. No.

Characteristics Unit Value

1. Capacity 2. Usage : Water 3. Material of Construction 4. Level indicator 5. Dimensions 6. Quantity 7. Weight 8. Nozzles

Page 95: Bokaro Steel Plant Specs

STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. Page 0 of 13

m) LEVEL INDICATOR

Sl. No.

Characteristics Unit Value

1. Make and Model 2. Type 3. Quantity

n) COMPRESSOR FOR DFDS

Sl. No.

Characteristics Unit Value

1. Make and model 2. Type 3. Quantity

4. Rated capacity Nm3/

min

5. Rated discharge pressure kgf/

cm2

6. Mode of operation 7. Number of stages 8. Speed rpm

9. Power requirement at compressor shaft

10. Drive rating kW 11. Total Cooling water requirement m3/h

12. Noise level at 1 m from compressor at rated capacity

dB(A)

13. Details of lubrication system Compressor capacity control 14.

- Type & No of steps Air intake cum silencer unit 15.

-Type of filter media & no. Moisture separator 16.

-Make, type and model

Page 96: Bokaro Steel Plant Specs

STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. Page 0 of 13

Sl. No.

Characteristics Unit Value

-Overall dimensions Air receiver - Capacity - Design and working pressure

17.

-Overall dimensions

o) MOTOR DATA SHEET

Sl. No.

Characteristics Unit Value

1. Make and type 2. Rated kW at 50 0C kW 3. Rated voltage 4. Frame size 5. Class of insulation 6. Temperature rise 7. Rated speed 8. Rated current 9. Starting current 10. Locked rotor torque 11. Pull up torque 12. Break down torque 13. Max permissible GD2 of load 14. Type of construction 15. Degree of protection of enclosure

Page 97: Bokaro Steel Plant Specs

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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

©2009 MECON Limited. All rights reserved. Page 1 of 16

06.08 AIR CONDITIONING AND VENTILATION SYSTEMS

06.08.01 Scope of work

The scope of work of the Tenderer for air conditioning and ventilation

systems for the various concerned units / areas of “Augmentation of Raw

Material and Handling Facilities” at Bokaro Steel Plant shall include the

design, manufacture / procurement, inspection, shop painting and supply

F.O.R. Bokaro Steel Plant contractor’s site stores, transportation of materials

from above contractor’s site stores to erection site, storage, testing, erection,

commissioning and performance guarantee of the Air Conditioning and

Ventilation Systems.

The air conditioning shall include Package A/C for different dispatcher cum

control rooms and Split type of air conditioning systems for shift manager’s

rooms and office rooms. The MCC / Control rooms and control pulpits of

stackers and reclaimers shall be provided with Split Air Conditioners.

Package air conditioners shall be supplied along with the cooling tower,

condensing water pumps with 100% standby, necessary electrics &

instrumentation, insulation (both thermal and acoustic as required), duct &

pipe work, air supply grills, etc. Split air conditioners shall be supplied along

with necessary accessories.

The ventilation shall include Air washer type of ventilation system for all

electrical switchgear rooms and MCC rooms. The conveyor tunnel ventilation

shall be done with push pull type ventilation systems. Exhaust ventilation

shall be provided for repair shop, maintenance room, store, toilets, battery

rooms, transformer rooms, etc. The air washer type ventilation system shall

comprise centrifugal fan, air washer, pumps with 100% standby, dry panel air

filter, piping & ducting network, electrics & instrumentation, etc as required.

The push-pull ventilation shall be provided with Centrifugal / Tube Axial

Fans, dry panel filters, ducting, etc. as required. The Exhaust fans of suitable

capacities shall be provided with louver shutter / cowl and bird screen.

Page 98: Bokaro Steel Plant Specs

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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

©2009 MECON Limited. All rights reserved. Page 2 of 16

The Tenderer shall clearly specify basis of design being offered along with

back up guarantee on his design. The details of experience and credentials

shall be furnished in the tender.

06.08.02 Design criteria for Air conditioning and Ventilation systems

The following design data shall be considered for selecting and sizing of

various equipment for air conditioning and ventilation systems:

SEASON TEMPERATURE 0C

(DBT)

RELATIVE HUMIDITY

(%)

AIR CONDITIONING

SUMMER 45 24

MONSOON 34 65

WINTER 10 -

VENTILATION

SUMMER 42.2 26

MONSOON 32.2 85

The different air-conditioned rooms shall be maintained at 23±2 ¼C and 55±5

% RH.

The temperature of the ECRs and other electrical premises shall be maintained

at less than 38°C right through the year by the provision of suitable air washer.

The temperature of the areas being exhaust ventilated and with push-pull

ventilation shall not exceed 5 deg. C above the ambient at any part of the year.

The ventilation systems shall be designed based on a minimum of 20 air

changes or the heat loads of the premises whichever is higher.

06.08.03 Applicable standards and norms

Page 99: Bokaro Steel Plant Specs

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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

©2009 MECON Limited. All rights reserved. Page 3 of 16

All equipments, systems and practices shall conform to those contained in the

following publications, norms/guidelines, standards, acts and rules.

Publications of Bureau of Indian standards (BIS)

American Conference of Governmental Industrial Hygienists (ACGIH)

publication USA.

Interplant standard specifications (IPSS) for steel plants.

Publications of International standards organization (ISO).

VDI stipulation of vibration level.

ARI Standard 550-92.

Electrics for the equipments/ units shall be in accordance with the details laid

down in the relevant Indian Electricity Rules (IER) as applicable.

The list furnished for standards and norms may not cover certain aspects or

products. In such cases where norms/standards/guidelines other than those

listed above are followed, the Tenderer shall furnish a copy of such documents

in support for the purchaser’s perusal and acceptance of this project.

Whenever a contradiction is found between the different documents, the

decision of the purchaser shall be final and binding.

06.08.04 Design Requirements

Page 100: Bokaro Steel Plant Specs

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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

©2009 MECON Limited. All rights reserved. Page 4 of 16

The air distribution system shall be sized to have a constant frictional drop

along its length. The maximum air velocity shall be restricted to 6 m/sec for

air conditioning and 10 m/s for ventilation ducts.

All Grills/Diffuser shall be selected to give maximum room, or space,

coverage and low noise characteristics. The noise level within the air-

conditioned area shall be restricted to 65 dB (A) level.

GTS may be referred for further details of equipment, ducting, insulation, etc.

Any other premises not specifically mentioned in the TS but required to be

provided with air conditioning / ventilation within battery limits shall be

provided with suitable air conditioning / ventilation systems to maintain the

required temperature and humidity

Page 101: Bokaro Steel Plant Specs

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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

©2009 MECON Limited. All rights reserved. Page 5 of 16

06.08.05 EQUIPMENT SCHEDULE

SL.

NO.

EQUIPMENT

SPECIFICATIONS

Heat loads, persons

and size of room

QUANTITY

I AIR-CONDITIONING:

1a Package A/Cs for different

dispatcher cum control rooms with

compressors, condenser, cooling

towers, condensing pumps with

100% standby, piping & ducting as

required.

1b Piping, valves & fittings

1c Ducting with necessary insulation,

SA grills / diffusers, return air

grills, etc.

1d Electrics and Instrumentation

1d Supply, laying & termination of

power & control cables as per

scope of work and TS.

2a Split A/Cs for shift manager’s

rooms, office rooms and MCC /

Control rooms and control pulpits

of stackers and reclaimers with

necessary accessories to complete

the system.

To be decided by

Tenderer

To be decided by

Tenderer

Page 102: Bokaro Steel Plant Specs

SAIL

STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

©2009 MECON Limited. All rights reserved. Page 6 of 16

SL.

NO.

EQUIPMENT

SPECIFICATIONS

Heat loads, persons

and size of room

QUANTITY

II VENTILATION SYSTEMS:

1. Air washing plants for all

electrical switchgear rooms and

MCC rooms with air washer, fan,

motor, dry panel air filter, valves,

fittings, pumps, piping, ducting,

supply air grills / diffusers and

other accessories.

2. Push Pull ventilation systems for

conveyor tunnel with fan, motor,

dry panel air filter, valves, fittings,

ducting, supply air grills and other

accessories.

3. Exhaust fans of suitable capacity

with louver shutter / cowl & bird

screen and other accessories for

repair shop, maintenance room,

store, toilets, battery rooms,

transformer rooms, etc.

To be decided by

Tenderer

To be decided by

Tenderer

N. B.: The above list is only tentative. Any other area that needs Air conditioning or

ventilation and not covered above shall also be provided with necessary air conditioning and

ventilation facilities.

Page 103: Bokaro Steel Plant Specs

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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

©2009 MECON Limited. All rights reserved. Page 7 of 16

06.08.06 Data to be furnished by the Tenderer along with the Offer

a) Centrifugal Fan Sl. No. Characteristics Tenderer

1 2 3 1. Make & Model No. 2. Quantity (no.) 3. Type of blade 4. Capacity (m3/h) 5. Static pressure and total pressure (mm

WC)

6. Operating speed (rpm) 7. Critical speed (rpm) 8. Shaft power (kW) 9. Total Efficiency (%) 10. Motor rating, kW/ pole 11. Acoustic lagging / silencer, as included : 12. Material of construction 13. Overall size 14. Velocity at inlet & outlet of fan (m/sec) 15. Static weight & dynamic weight of fan

and motor (kg)

16. Coupling details/V-belt details 17. Vibration level 18. Material of construction & thickness of

scroll, blade, shroud, back plate, shaft diameter

19. Noise level at 1m distance (dB(A)) 20. Bearing details

b) Fan Drive Motor Details Sl. No. Characteristics Tenderer

1 2 3 1. Type & make 2. Voltage, phase & frequency

Page 104: Bokaro Steel Plant Specs

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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

©2009 MECON Limited. All rights reserved. Page 8 of 16

Sl. No. Characteristics Tenderer

1 2 3 3. Rated power (kW) 4. Speed (rpm) 5. Starting/ pull out torque 6. Starter details 7. Line current 8. Starting current 9. Overall efficiency 10. Class of insulation 11. Type of enclosure 12. Any other information

c) VIV & Duct line Damper

Sl. No. Characteristics Tenderer

1 2 3 1. Make, model and type 2. Type of actuator, if applicable 3. Diameter of VIV (mm) 4. Motor (kW/pole) 5. Material of construction and

thickness

d) Dry Panel Air Filter

Sl.

No.

Characteristics Tenderer

1 2 3 1. Make & Model. 2. Capacity (m3/h).

Pressure drop. (mm WC) i ) When clean

3.

ii) When dirty 4. Effective cross sectional free

and face area (m2 )

5. Velocity through filter free and face area (m/sec)

Page 105: Bokaro Steel Plant Specs

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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

©2009 MECON Limited. All rights reserved. Page 9 of 16

Sl.

No.

Characteristics Tenderer

1 2 3 6. Material of filtering panel and

construction details.

7. Cleaning efficiency Vs particle size

8. Overall dimensions & no. of filters.

9. Fixing frame details. 10. Total weight. free and face

area (t & m2)

e) Ducting Sl. No. Characteristics Tenderer

1 2 3 1. M2 of duct work 2. Weight of supports and

flanges (t)

3. Material and thickness of duct work (mm)

f) Connecting Ducting Networks Sl.

No.

Characteristics Tenderer

1 2 3 1. Duct routing showing

diameter and lenght of ducts

2. Weight of ducting (with and without dust)

3. Weight of supports and flanges

4. Material and thickness of duct work

g) Air washing chamber with water tank

Page 106: Bokaro Steel Plant Specs

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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

©2009 MECON Limited. All rights reserved. Page 10 of 16

Sl. No. Characteristics Tenderer

1 2 3 1. Make & Model No. 2. Type of unit (Horizontal/vertical) 3. Overall dimensions (mm) 4. Weight with and without water (kg) 5. Air flow capacity.( m3/h) 6. Air flow velocity 7. Total Pressure drop (kgf/ m2) 8. Material of construction, diameter

and numbers of spray header pipes & nozzles.

9. Make up water requirement 10. Details of make up, over flow,

drainage, supply and return water pipe lines

11. Amount of water and its pressure at the nozzle

12. Material of construction and thickness of casing, tank, air distributor plate

13. Water tank capacity (M3) 14. Mounting supports 15. Details of mist /droplet eliminator:

material of construction, material thickness and depth.

h) Re-circulating water system

Sl. No. Characteristics Tenderer

1 2 3 1. Pump capacity & head, motor KW 2. Re-circulating piping & fitting; 3. Strainer & valve 4. Instruments – pressure gauge,

temperature guage, water flow switch, manometer

Page 107: Bokaro Steel Plant Specs

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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

©2009 MECON Limited. All rights reserved. Page 11 of 16

i) Insulation data sheet

Sl. No. Characteristics Tenderer

1 2 3 1. Make & Type 2. Quantity 3. Density (kg/m3) 4. Thermal conductivity 5. Sound absorption co-efficient 6. Material of construction and

its thickness

7. Cladding material j) Cooling Tower

Sl. No. Characteristics Tenderer

1 2 3 1. Make & Model 2. Type 3. Quantity 4. Overall size of cooling tower 5. Capacity of cooling (TR). 6. Water flow (m3/h) 7. Air flow 8. Design water inlet temperature, outlet

temperature

9. Material of construction and its thickness

10. Speed (rpm) 11. Drive details. 12. Shaft Power consumption. 13. Wheel diameter (mm). 14. Efficiency. 15. Size of fan 16. Static & Dynamic weight of fan &

motor assembly (t)

Page 108: Bokaro Steel Plant Specs

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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

©2009 MECON Limited. All rights reserved. Page 12 of 16

Sl. No. Characteristics Tenderer

1 2 3 17. Bare weight and operating weight of

cooling tower (t)

18. Noise level at 1m distance (dB(A)) 19. Fixing details.

k) Pumps

Sl. No. Characteristics Tenderer

1 2 3 1. Make and model no.

2. Type of pump

3. Capacity (m3/hr.)

4. Total head (m WC)

5. Quantity

Material of Construction

Shaft

Impeller

6.

Casing

7. Pump speed, rpm

8. Shaft power

Drive details

Motor make

Motor kW

Class of insulation

9.

Frame size

10. Bearing type & make

11. Type of coupling

12. Vibration level

13. Noise level at 1 m distance

(dB(A))

Page 109: Bokaro Steel Plant Specs

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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

©2009 MECON Limited. All rights reserved. Page 13 of 16

Sl. No. Characteristics Tenderer

1 2 3 14. Duty

15. Weight of pump & motor

separately (t)

16. Characteristic curves for

pumps

l) Package Air conditioners

Sl. No. Characteristics Tenderer

1 2 3 1. Make and model 2. Quantity 3. Capacity (TR) 4. Overall dimension of Package AC

Unit

5. Air flow capacity of blower (m3/h) 6. Total Pressure (mm WC) 7. Fan Motor kW 8. Fan RPM 9. Compressor type, model 10. Compressor motor (kW) 11. Refrigerant type 12. Condenser type 13. Condenser material of construction 14. Overall size of condenser 15. Material of construction and its

thickness of casing

16. Insulating material of casing 17. Total Power consumption. 18. Noise level at 1m distance (dB(A)) 19. Vibration isolation pad 20. Refrigerant drier and strainer

m) Split Air Conditioner

Page 110: Bokaro Steel Plant Specs

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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

©2009 MECON Limited. All rights reserved. Page 14 of 16

Sl. No. Characteristics Tenderer

1 2 3 1. Make and model no.

2. Quantity

3. Capacity (TR)

4. Air flow (m3/hr.)

5. Flow direction and volume

control grill

6. Material of Construction of

7. Compressor type

8. Drive details and total power consumption

9. Overall dimension

10. Refrigerant type

11. Filter efficiency

12. Weight of unit

13. Noise level at 1 m distance

(dB(A))

14. Accessories included

n) Tube Axial / Propeller fan Sl. No.

Characteristics Tenderer

1 2 3 1. Make & Model 2. Capacity (M3/hr) 3. Quantity 4. Material of construction 5. Total pressure (kgf/m2) 6. Speed (rpm) 7. Size of fan 8. Drive details (kW & power

supply)

9. Efficiency (%)

Page 111: Bokaro Steel Plant Specs

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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

©2009 MECON Limited. All rights reserved. Page 15 of 16

Sl. No. Characteristics Tenderer

1 2 3 10. Weight of fan & motor (t) 11. Details of non-return

damper/louver shutter

12. Fixing frame o) List of spares for two years operation & maintenance Ventilation system

Sl. No. Spare Items Tenderer

1 2 3

1 2 3 4 5 6 7 8 9 10

Air conditioning system

Sl. No. Spare Items Tenderer

1 2 3

1 2 3 4 5 6

Page 112: Bokaro Steel Plant Specs

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STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM

©2009 MECON Limited. All rights reserved. Page 16 of 16

Sl. No. Spare Items Tenderer

1 2 3

7 8 9 10

p) List of Exclusions

Sl. No. Items Tenderer

1 2 3

1 2 3 4 5 6 7 8 9 10

Page 113: Bokaro Steel Plant Specs

STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. Page 1 of 69

06.09.00 ELECTRICS 09.01 SPECIAL INSTRUCTIONS TO THE BIDDER 09.01.01 This specification states the scope of work and requirements as

completely and clearly as possible. However, additional work/ supplies/ requirement not mentioned in this specification but required to make the offered system complete and safe; the same shall also be deemed to be included in the offer. This section of specification describes the technical specification of electrics which have to be supplied and installed by bidder for Material handling system sought to be installed under this package. This shall be read with stipulations made under other chapters of technical specification and General Technical specification. Stipulations made/ requirement specified there in shall be applicable, complimentary and considered as if those are part of stipulations made under this chapter.

The drawings and reference information mentioned in this specification (here or elsewhere) and/or General technical Specification shall be considered to be part of this document. Anything specified in this specification but not clearly shown in the drawings/ GTS or shown in drawings but not mentioned in this specification shall be treated to be indicated in specification and drawings/ GTS and hence binding as though laid down in the Tender specification as a whole. In case of conflict between the stipulations in various documents, the order of Priority shall be as follows: (a) Requirement spelt out in drawings (b) Requirements indicated in technical specification. (c) Requirement indicated in General Technical specification. However, in case - stipulations in drawings/ technical specifications/ GTS, - statutory requirements of Govt. of India/ requirement of state

government - stipulations in relevant standard specifications published by IPSS/

Bureau of Indian standards/ IEC or other standards based on which equipment is designed/ manufactured/ supplied/ erected

are at variance, the most stringent stipulations shall be followed. 09.01.02 The detailed specification and schedule of quantities shall be worked out

based on the detailed engineering to be carried out by the successful bidder, for complete and proper execution of the specified tasks.

Page 114: Bokaro Steel Plant Specs

STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. Page 2 of 69

09.01.03 Before quoting, the Bidders shall satisfy themselves by visit to the site regarding type & extent of work involved, interphasing requirements, details of existing systems etc as required to asses his scope of work and actual site conditions. Failure to do so shall not absolve the successful bidder of his responsibilities regarding supply and installation under his scope of work. Further, no plea of the successful bidder based on unfavorable site conditions or non-availability of information regarding details of existing systems etc required to asses his scope of work shall be considered.

09.01.04 Clause by clause acceptance of technical specification shall be confirmed by the Bidder. Comments and/or deviation if any, of the Bidder on Purchaser/Consultant's technical specification shall be given clause wise. Clauses on which no specific comment or deviation will be indicated in the offer, shall be treated as accepted by the Bidder.

09.01.05 LICENCES AND WORKMEN'S PERMITS .1 The Bidder shall posses himself and/ or engage an agency

having valid electrical contractor's licence for carrying out electrical installation work of the type and magnitude covered in this document and issued by the competent Authority/ licencing board having jurisdiction at the place where the work would be carried out.

.2 The Bidder and/ or agency engaged for carrying out installation work shall have on their rolls/ appoint full time supervisor(s) and depute him/ them at site to supervise the installation work. All work shall be done under direct supervision of these supervisors. The supervisors shall possess valid licence, issued by competent Authority having jurisdiction over the place where the work is to be done, for supervising the type of work being carried out.

.3 The Bidder and/or agency engaged by them for carrying out electrical work shall engage workmen/ electrician possessing valid electrical workmen's permit, issued by competent authority having jurisdiction over the territory where work is being done, for type of work to be assigned to them.

.4 Copy of Electrical Contractors’ Licence, Copies of licences of supervisors deputed for supervising the work and copies of workmen’s permit shall be submitted to Engineer-in-charge at site before taking up work. On demand by supervising engineer of the Owner/Consultant, the above licences/ electrical workmen's permit shall be shown in original.

Page 115: Bokaro Steel Plant Specs

STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. Page 3 of 69

09.01.06 STATUTORY & OTHER RESPONSIBILITIES .1 The successful Bidder shall complete and fulfil all formalities with

the CEA/ Electrical Inspectorate/ licensing board having jurisdiction in the area before commencement of work and for getting approval from competent authority for energisation of installation.

.2 It will be the responsibility of the successful bidder to comply fully with Indian Electricity Act, Indian Electricity Rules, relevant standard specification of Bureau of Indian standards, Regulations of Insurance association of India and Factories Act, while carrying out work as per this specification.

.3 It shall also be the responsibility of the successful Bidder to prepare and submit to the CEA/concerned Electrical Inspectorate all necessary drawings, calculations, test certificate etc. and get their approval for commencing the work.

.4 The successful Bidder shall submit completion report to CEA/concerned Electrical Inspectorate (after completing the particular work) and arrange for inspection of the work completed. Further, he shall also obtain the final approval and safety certificate for the works thus completed and permission for energisation of the same.

.5 Modifications/ alterations suggested by the Statutory bodies either during drawing approval or during inspection of the installation, if any, shall be carried out by the successful bidder without any extra cost to purchaser and without affecting agreed milestones/ project schedules.

.6 All expenses for all the above activities shall be done and borne by the successful Bidder The responsibility of Purchaser shall be limited to the extent of reimbursement of inspection fee charged by the Electrical Inspectorate for inspection of the installation.

09.01.07 CODES & STANDARDS The design, manufacture, performance, (including safety, earthing and other essential provisions) of equipment and accessories covered under this specification shall comply with the recommendations of IEC/ relevant Standard specification of Bureau of Indian Standards/ IPSS. Following statutory regulations shall also be followed for design of electrical system:

• Indian Electricity Act, 1910.

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• Electricity Act, 2003

• Indian Electricity Rules, 1956.

• Indian Factory Act, 1948.

• Electricity regulatory commission Act, 1998 (as amended in 2002) 09.01.08 QUALITY ASSURANCE

.1 All materials, components and equipment covered under the specification shall be procured, manufactured, erected, commissioned and tested as per a comprehensive Quality Assurance Programme (QAP) to be approved by the Owner. Successful Bidder shall submit complete Quality assurance plan for all the equipment/ panels/ motors/ devices etc. under their scope of supply.

.2 The Bidder shall also furnish copies of the reference documents/ plant standards/ acceptance norms/ tests, inspection procedures etc., for the Owner/ Consultant’s review/ approval.

.3 Owner reserves the right to witness any of the tests and verify the documents of the BIDDER, his sub-BIDDER and his vendor. No material/ equipment shall be dispatched from the manufacturer’s works before same is duly cleared for dispatch by the Owner.

.4 All the sub-vendors proposed by the BIDDER for procurement of major bought-out items shall be subject to Purchaser’s approval.

.5 The Bidder shall carry out an inspection and testing Programme during manufacture in his works and/ or that of his vendor’s works to ensure accuracy/ correctness/ completeness of components, compliance with drawings, conformance to functional and / or performance requirements, identify and acceptability of all materials, parts and equipment. He shall carry out all tests/ inspections required to establish that the items/ equipment conform to requirements of the specification and the relevant codes/ standards specified in the specification in addition to carrying out tests as per the approved Quality Plan.

.6 Quality audit/ surveillance/ approval of the results on the test and inspection, approval of drawings will not, however, prejudice the right of the Owner to reject the equipment if it does not comply with the specification when erected or does not give complete satisfaction in service and shall in no way limit the liabilities and responsibilities of the BIDDER in ensuring complete conformance of the materials/ equipment supplied to relevant specification, standard, data sheets, drawings etc.

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.7 Bidders shall supply reports of all requisite factory tests and site tests.

09.01.09 ONSTRUCTION POWER SUPPLY 415 Volt 3 Phase 4 wire construction power supply shall be made

available to bidder at one point in one of the construction power supply sub-stations established by purchaser. Tapping and distribution of construction power supply including supply, erection, testing & termination of cables for at both ends of incoming power cable to construction power distribution board and regular maintenance of the cable shall be in the scope of the BIDDER.

09.01.10 TRAINING OF PURCHASER’S PERSONNEL Bidder shall arrange training of Purchaser’s engineers at manufacturer's works/ training centers for Automation system, UPS system, AC drives, and any other facility included in package, as required.

09.02.00 DRAWINGS & DOCUMENTATION 09.02.01 Following drawings & documents shall be submitted with the offer

.1 Single line distribution diagrams (indicating ratings and other details generally shown in Single Line Diagrams as per best engineering practices) for (a) All HT loads (LTSS, HT Motors and equipment which shall

be fed at HT supply) (b) LT sub-stations proposed by Bidder. (c) All MCCs proposed by Bidder (d) All PDBs proposed by Bidder (e) All MLDBs and Lighting distribution boards etc. proposed

by Bidder. (f) Emergency lighting system proposed by the BIDDER

.2 Tentative equipment layout with limiting dimensions of all panels for all LT sub-stations, MCC Rooms, Electrical Premises showing layout of transformers, Load Break Isolators for transformers, LT switchboards, MCCs, PDBs, MLDBS, LDBs, Emergency lighting DBs, PLC Panels, UPS Panels, Battery chargers, Battery Rooms, Control Rooms, Engineering stations, conference rooms, Cable cellars, cable tunnels, cable trenches, Ventilation Rooms, Air conditioning rooms etc. Plans of various floors and sectional view should be shown.

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.3 Layouts of electrical facilities proposed indicating location of HT Sub-stations, LT sub-stations, MCC Rooms, Electrical Premises, Control rooms, Major cable routes with proposed arrangement for cable routes, cable tunnels/ Overhead Cable Structures/ Bridge etc.

.4 General description of equipment offered specifying the important features, make, technical parameters, materials of construction, etc. to enable the owner to have proper understanding of the equipment offered and its operation. Technical details shall be supported by manufacturers.

.5 Details of equipment with single line diagram, functional diagram, system configuration for automation, Ventilation and Air conditioning system & BOM of Electrics related to all equipment.

.6 Basic power and regulation diagram with ratings of major equipment/ components for (a) VVVF drives for AC drives. (b) Soft starters (c) UPS systems

.7 Details of PLCs and associated equipment being offered for logic control and automation.

.8 System configurations for Automation systems indicating

• List as well as details of hardware/ software

• Details about numbers & locations of I/O panels

• Count of Inputs & outputs of each type loads/ feeders considered.

• Quantity of I/Os of each type with spare I/Os, spare cards and spare slots

Considered in the offer should be indicated. .9 Literature/ catalogues of offered equipment. .10 Lists of equipment considered for supply (Un-priced copy) .11 Equipment/ Drive list indicating Voltage & kW ratings, speed

variation requirement .12 Requirements of 11 kV feeders from purchaser’s HT sub-station

indicating connected load as well as maximum demand of each feeder.

.13 Connected load as well as maximum demand of each LTSS

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.14 Overall maximum demand of the package including future loads/ spares requirement

.15 Lists and requirement of emergency loads and their feeding arrangement

.16 Schemes for general Illumination system and Emergency lighting.

.17 List of commissioning spares included in offer.

.18 List of insurance spares included in offer.

.19 List of special tools, tackles, instruments and calibration equipment & devices included in offer.

.20 List of Testing/ checking instruments/ equipments/ sets/ kits which the bidder considered for making available by them at site.

.21 Lists of spares recommended for 2 years normal operation with specification, manufacturer’s reference number and quantity of each spare.

.22 List of deviations (clause wise), if any, from Technical Specification & G.T.S

.23 List of exclusions.

.24 Reference lists of similar jobs

.25 Time bar chart indicating various activities starting from date of placement of order till commissioning

.26 Any other details which may be felt necessary 09.02.02 Drawings/ Documents to be Submitted For Approval

.1 List of drawings (Basic Engg. / Detailed Engg/ Reference) to be submitted by successful bidder with schedule for submissions

.2 Drawing/ Document numbering system and template for Nameplate for drawings/ documents

Bidder shall note that drawings and/ or documents without approved name plate, drawing/ document number and/ or unauthenticated, shall not be accepted.

.3 Quality assurance plan for all electrical, automations equipment/ panels/ motors/ cables etc under this package/ in this specification

.4 Technical data sheets for all Motors, Brakes, Cables, Sensors, Proximity switches & all field mounted electrics,

.5 Type-II Co-ordination charts as per IS: 13947-1993 for MPCB/ MCCB, Contactor and Overload relay.

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.6 Relay settings with calculations for total network to ensure proper co-ordination

.7 Bus bars sizing calculation with respect to temperature rise & short circuit withstand capacity.

.8 Voltage drop calculations for motor as well as power supply feeders

.9 Calculations for selection of main equipment such as transformers, motors, VVVF drives, soft starters, bus bars, cables, batteries, sizes of earth conductors etc.

.10 Sizing calculations of the UPS and the backup battery

.11 Type tests certificates of all major equipment like transformers, switchgear, MCCs, Control Panels, motors etc.

.12 Shop/ Unit wise Maximum Demand calculations

.13 Single line diagrams with rating of components, cable sizes and details of protection and metering etc. for (a) HT feeders from HT sub-stations (b) Power Control Centers/ Switchboards (c) Motor Control Centers (d) Control Panels, (e) VVVF Drives, Soft Starter etc (f) Power Distribution Boards, (g) Main Lighting Distribution Boards, Lighting Distribution

Boards, Sub-Lighting Distribution Boards, Emergency Lighting Distribution Boards and Panels for automatic/ group control of area lighting/ lighting of conveyor galleries & junction houses.

(h) UPS (i) Emergency lighting. (j) Fire detection and alarm panel etc. (k) Communication systems

.14 Control schemes of DOL, RDOL and other type of feeders for different type of loads indicating control, alarm, indications, interlocking, inputs form /outputs to PLC and field devices

.15 Schematic diagrams for Belt Scale, Belt Weigh feeder, UPS, soft starters, VVVF, magnets, magnetic separators etc

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.16 Scheme for Illumination system & emergency lighting system indicating sizes, ratings & locations of various LDBs & SLDBs.

.17 Detail schemes of FDA system, List of annunciation/ alarm points (location wise) & wiring scheme

.18 Schematic diagrams for communication systems

.19 Power and regulation schemes of AC drives

.20 Layouts of substations, electrical rooms, cable cellars, cable tunnels and control rooms, control cabins including ventilation and air-conditioning rooms, handling facilities etc. indicating: (a) Equipment/ panel layout indicating panel dimensions,

space available for future expansion, minimum clearances among electrical panels/ walls etc

(b) Cable trenches, wall openings, conduit inserts, plate inserts, cable trays, conduits for concealed wiring etc

.21 Layouts of cable trays in cable cellars inside the substation & other electrical premises, cable channels, cable tunnel, overhead cable structures, cable shafts etc

.22 Cable layout drawings in cable tunnel, cable channels, overhead cable structures/ bridge, junction houses, cable galleries, plant buildings etc.

.21 Interplant cable route drawings

.22 Illumination layouts of all the indoor & outdoor premises

.23 Layouts at each floor of Electrical/ Technological building, junction houses, cable galleries etc with details and numbers & locations of light fittings, lighting distribution boards etc.

.24 General arrangement with plan, front view, view with door open & sectional views and foundation plan/ installation details/ dimensional details with load data for all electrical equipment/ panels etc inclusive of following: (a) Transformers (b) HT and LT switchgear equipment (c) MCCs/ Control Panels, ACDBs, PDBs, MLDB, LDBs,

SLDBs, Control desks, local control stations (d) UPS (e) PLC Panels/ Marshalling panels and I/O Panels (f) all electrical equipment/ electronic panels/ controllers

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(g) Main fire detection and alarm panel etc. (h) Erection accessories like cable trays, supporting structures

etc (i) with rating of components, cable sizes and details of

protection and metering etc. .25 Comprehensive bills of materials with description, quantity, rating,

make, model number, type etc. .26 Level-1 automation system configurations .27 Level-1 automation system software .28 I/O listing drive wise as well as I/O card wise in format to be

finalised during engineering. .29 Communication cable (Field bus) routing and procedure for laying

of communication cable. Drawings for graphic displays and menus Formats for reports, alarms, annunciation .30 Earthing schemes with calculations including special electronics

earthing .31 Lightning protection scheme for different buildings/ structures. .32 Layout of earthing and lightning protection network with

calculations .33 Earthing of transformer Neutrals and system earthing .34 Earthing for equi-potential bonding .35 Civil/ Structural engineering design drawings of Electrical

buildings, Electrical rooms, Control rooms, Motor foundations, Cable tunnels, Overhead cable structures/ Bridge etc.

.36 Any other drawing required for equipment/ facilities covered in the package.

09.02.03 Drawings/ documents to be submitted For Reference/Erection purposes .1 Schedule of electrics and their location. .2 HT & LT Motors lists, electric consumer list indicating power

requirement, voltage, rpm, speed variation requirement, type of starting/ control etc

.3 Electrical component list including field mounted electrics/ devices.

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.4 HT/LT feeder requirements with maximum demand of each feeder and control, protection, interlock, metering, alarm, annunciation requirement

.5 Static and dynamic loading of all major equipment

.6 External connection diagrams (panel wise and scheme wise).

.7 Composite drawings showing circuitry of switch-gear remote panels, and other items pertaining to complete circuit for its proper functioning

.8 Power & regulation schemes for AC drive, UPS, soft starter including FCMA type.

.9 Speed-torques, current vs. time, thermal withstands characteristics for motors and characterstics of loads

.10 List of interfaces between successful Bidder’s equipment and Purchaser’s equipment with details.

.11 Cable termination plans with terminal block arrangement and markings.

.12 Interconnection diagrams.

.13 Internal wiring diagrams of equipment

.14 Wiring terminal plan drawings with cable connections

.15 Module wiring diagrams indicating all interlocks, terminal numbers. Wiring terminal plan drawings with cable connections

.16 Power & control cable schedules

.17 UPS panel wiring diagram and circuit diagrams.

.18 Installation drawings of all equipment with layout of equipment, cables

.19 Fire detection systems: layout & cable list.

.20 Consolidated Bills of materials and volume of work for erection

.21 Erection specifications with bill of materials of erection materials, earthing materials, junction box, GI conduits etc. This shall also be furnished in soft copy.

.22 Procedures for testing and commissioning of the entire plant, electrical & automation equipment. This shall also be furnished in soft copy.

.21 Spare part lists and drawings/ catalogue number/ model number/ ordering specification and procedure for ordering spares.

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.22 Instructions manuals for storage /erection, testing & commissioning

.23 Operations and maintenance manual

.24 Detailed technical literature / catalogue of manufacturers.

.25 System grounding/ earthing scheme

.29 List of drawings & spare parts.

.30 Final test & calibration certificates and guarantee certificate / warrantee certificate.

.31 Functional description, control philosophy for the plant indicating start up, shut down, control locations, interlocking and annunciation system, mimic pages, report/ data formats

.32 Application software program listings with detailed documentation

.33 Ladder Logic diagram /Statement Lists and software details

.34 Formats and work sheets for generation and display of overview, groups, loops, graphics, alarms, operator’s guide messages, real time and historical trends Log and shift formats.

.35 As built Control description with Operational instruction use of various commands, instruction for control of plant and equipment from Operator workstation

.36 Following drawings for Automation systems. a) Software including media and documentation. b) Description of all components of the user system with

functional description, overview flow diagram, interface listing, mathematical models, and fault message lists, operator commands, simulation facilities, etc.

c) Source code of the user system. d) Object code of the user system. e) Factory Acceptance Tests & procedures for PLC/DCS

.37 Graphic display sheets, report/data generation, fault listing etc.

.38 Any other drawing required 09.02.04 Drawings/ documents to be submitted with inspection call of

equipment: .1 Type test certificate for identical equipment .2 Sub-supplier’s/vendor’s catalogue/technical literature

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.3 Test reports for internal inspection

.4 Test certificates of components

.5 Technical specification & data sheets of equipment

.6 All drawings as applicable of category ‘Approved’, ‘Approved as Noted’ and ‘For information/ Reference’ including comments thereon.

09.02.05 Erection, testing and commissioning Manuals Manual shall give step by step procedure for: (a) Storage, Handling and Erection (b) Checking/ testing after erection and before energisation. (c) Pre-commissioning tests/ checks and cold trials (d) Commissioning (e) Drawings relevant for erection, operation, maintenance and repair

of the equipment. (f) List of instruments/ testing kits/ sets, measuring instruments etc.

required for testing/ checking with specification, ratings, ranges etc.

(g) Test procedures for site tests/ checks. 09.02.06 Operation & Maintenance Manuals

Successful Bidder shall prepare and submit operation and maintenance manuals for each of the equipment/ system being supplied by him. The maintenance manual shall include the following: (a) Log sheets indicating daily/ hourly recordings of parameters to be

noted down by customer's operating personnel. (b) Procedure for shut down and energisation. (c) Preventive maintenance schedule. (d) Safety procedures for safe operation of equipment and complete

system. (e) Specification of equipment installed. Manufacturer’s catalogues

operation and maintenance manuals for all types of relays/components used.

(f) Test procedures for site tests/ checks. (g) Spares list for each equipment/ system for 2 years operation and

maintenance.

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(h) Relevant calculations and protection relay setting table for the equipment/ system being supplied by him

(i) Instructions for Diagnostic trouble shooting / fault location charts (j) Tests for checking of proper functioning/ Operation. (k) Drawings relevant for operation, maintenance and repair of the

equipment (l) Instructions for Maintenance and Repair (m) List of spare parts with ordering specifications and manufacturer's

catalogues. (n) List of consumables with specifications, brand names and annual

consumption figures. (o) Procedure for ordering spares. (p) All as built drawings.

09.02.07 Other drawings/ Documents After completion of installation and commissioning of equipment/ systems, the successful Bidder shall submit following: .1 ‘As Built Drawings’ after incorporating revisions/ modifications, if

any All the drawings of category ‘Approved’, ‘Approved as Noted’, ‘For Information/ Reference’, manufacturer's drawings, installation drawings etc. are to be included in as-built drawings.

.2 Site test results of all equipment/ systems/ installation/ cables including CTs, PTs, relays, earthing & lightning protection systems in bound volumes. In case site test results vary very widely with factory test results, rectifications carried out during testing and Commissioning Engineer's observations shall be clearly indicated against corresponding equipment, duly identified by manufacturer's serial numbers.

.3 Bound volumes of copies of factory routine and type test certificates for all equipment.

.4 Bound volume indicating list of spares supplied for all equipment The volume shall contain, manufacturer's catalogue, number of

components with description. It shall also indicate precautions to be taken for storing.

09.02.08 Bidder shall ensure that following shall be mentioned in each sheet of drawings/ documents

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(a) Name of the client (M/s BSL). (b) Name of the consultant (c) Name of the contractor (Bidder) (d) Name of the Manufacturer if applicable (e) Name of the Project for which drawings are applicable (f) Drawing/ document number with sheet number and number of

total sheets in the drawing 09.02.09 Bidder shall ensure that in case any model number is mentioned in the

drawing; detailed technical catalogue, literature, explanatory notes to describe the model and its technical details in full, shall also form part of the drawing and should be submitted indicating Drg/ Document Number, Number of sheets in the drawing, Rev number etc (Unique Identification Number). Reference of such drawing/ document number should be mentioned in the drawing.

09.02.10 Bidder shall ensure that all drawings shall be checked by them for compliance with the stipulations of technical specification and authenticated before submission.

09.03.00 DESIGN BASIS FOR EQUIPMENT & INSTALLATIONS 09.03.01 Following ambient temperature shall be considered in different units of

the complex. .1 Shop Floor and Plant areas (Covered) - + 50º C .2 Plant areas (uncovered) - + 55º C .3 Cable basements / tunnels - + 50º C .4 LT Sub-station switchgear rooms - + 50º C

(Pressurized ventilation) .5 Electrical rooms housing - + 35º

VFD panels, Soft starters, UPS, Non-condensing Weigh Feeder/ Belt Scale Panels etc.)

.6 PLC Room, I/O Panels etc, Control rooms, - + 24º Rooms housing intelligent MCCs and Non-condensing Electrical Panels on mobile equipment/ Machines (Air conditioned)

09.03.02 Maximum Relative Humidity - 100% 09.03..03 Altitude - <1000M

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09.03..04 Equipment installed in MCC rooms/ Electrical Rooms/ Control rooms shall be designed for + 50º C so that in case of failure of Air-conditioning/ ventilation facilities, the equipment should not be affected.

09.03..05 Equipment/ cables selected shall be de-rated for (a) higher ambient temperature, (b) restriction in temperature rise (c) variation in voltage, (d) variation in frequency (e) installation conditions viz proximity to heat sources, bunching, layering, separation from others/ laying in conduits etc. with respect to the conditions for which it was designed. Various de-rating factors considered shall be informed with back up documents.

09.03..06 The equipment offered should be suitable for smooth, efficient and trouble free service in the dust laden, corrosive, tropical humid climate prevailing at plant site and under the ambient temperature conditions indicated above for the different shops and areas. In hot areas of higher temperature conditions or in areas of heat radiations, the equipment shall be adequately protected against damage from radiant heat and hot air by providing suitable shields.

09.03..07 The equipment/ panels/ components/ field devices/ mounted electrics shall be designed to work satisfactorily and give required output/ performance when connected to power supply systems indicated in GTS considering most adverse conditions of variation in voltage as well as frequency.

09.03..08 The equipment/ panels/ components/ field devices/ mounted electrics shall be designed to give efficient and reliable performance under steel plant conditions and shall be such that the risks of accidental short-circuit due to animals, rodents and vermin are obviated.

09.03..09 All equipment shall strictly conform to the Technical Specification, except where any deviations, if any, have been explicitly spelt out, specifically discussed and agreed upon between the BIDDER and the purchaser.

09.03..10 The sizes of cables shall be selected such that maximum voltage drop in any feeder shall not exceed:

.1 PCC to motor under steady state condition : 3%

.2 PCC to motor when largest motor starts : 15%

.3 PCC to PDB/ MLDB : 3%

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POWER SUPPLY TO VARIOUS TYPE OF LOADS 09.04.01 All motors, equipment, magnets etc. rated up to 90 kW shall be fed from

intelligent MCCs. 09.04.02 All cranes, hoists, welding socket outlets, 240 V socket outlets and 24

Volt socket outlets shall be fed from PDBs (a) 415V, 100A interlocked switch industrial type welding sockets

shall be provided in all premises, buildings/ junction houses/ conveyor galleries/ areas as per stipulations of TS.

(b) 240V 15A and 24V 5A industrial type receptacles shall also be provided.

(c) Load break isolators for cranes, hoists and other equipment shall be provided which shall be located near the equipment.

09.04.03 Loads in LT sub-stations shall be fed from ACDBs. ACDBs shall be fed from LT breaker Panel (Power Control Centre) of LT sub-station.

09.04.04 All fittings and fixtures for indoor as well as out door/ area lighting shall be fed from MLDBs.

09.04.05 All motors/ loads rated above 90 kW and up to 200 kW shall be fed from intelligent motor control panels (MCPs) which shall be fed from breaker in PCC. Metering and protection components, power contactor(s), auxiliary contactors, indications, interlocks and components for interfacing of the drive with other equipment shall be located in MCPs.

09.04.06 All motors/ loads above 200 kW shall be fed from 11 kV breakers located in HT sub-stations.

09.04.07 Motors of rating above 1000kW and up to 2000kW and any other special application motor fed from 11kV shall have assisted starting.

09.04.08 Motors of rating above 2000kW shall be fed from 33kV with unit transformers and assisted starting devices.

09.04.09 For all mobile equipment/ machines which need to be fed from HT supply (HT Breaker); BIDDERS scope of work for making power supply available on the machine/ equipment shall be inclusive of but not limited to the followings:

• HT load break isolating switch (at ground as well as on the machine) with fuse and Shunt trip facility.

• Power and control junction Boxes at ground as well as on machine.

• Power, control, signal cables from HT sub-station/ associated

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control rooms to power and control junction Boxes.

• Motorized cable reeling drums (power & control) including stalled torque motors with associated controls, slip ring boxes, Cable guide and clamp, power and control Junction boxes etc.

• Flexible power, control, signal cables from power & control Junction boxes on ground to machine with minimum two turns in cable reeling drums in maximum distant position from Junction Boxes. Flexible power cables shall have two cores for earthing of neutral of transformer. Flexible control cables shall have cores for earthing of electronics.

• Dry type Transformer with suitable protection.

• MCC/ Control Panel

09.04.10 Trip supply for breakers feeding motors loads shall be fail safe and

facilities for supervision and annunciation of trip supply shall be provided.

09.04.11 All MCCs, ACDBs, PDBs, MLDBs shall have two incomers and one bus coupler. (a) Each incomer shall be rated in such a manner that total load

(including spare and future loads on full MCC/ PDB/ MLDB/ ACDB) is not more than 80% of rating of incomer when only one incomer is available.

(b) Incomer and bus coupler shall have same rating and rating of main bus-bars shall be 125% of rating of incomer.

(c) Each incomer shall be provided with its own control transformer fed from incoming side of the supply. Control supply for bus-coupler shall be derived from control transformers of both the incomers such that control supply to bus coupler is automatically available whether any one or both incomers are on. Necessary protections shall be provided for safe operation.

09.05.0 DESIGN BASIS FOR ELECTRICAL PREMISES 09.05.01 Stipulations of TS/ IE Rules/ standard specifications published by Bureau

of Indian standards shall be referred for designing of electrical premises & layouts, selection of equipment and installation. In addition to this, stipulations given below shall also be complied.

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09.05.02 LT sub-stations shall be located at load centers. 09.05.03 Motor Control Centre (MCC), RIO stations, PDB, MLDB etc. to be

installed in various MCC rooms, shall be provided near various shop/ technological units.

09.05.04 MCC rooms and LT substation rooms (including rooms for distribution transformers) may be combined considering the location of Substation and shop unit, wherever required.

09.05.05 Rooms housing electrical equipment shall be provided with air tight steel doors and all doors shall open towards exit side. Control Rooms may be provided with glass doors having aluminium frames.

09.05.06 PLC, CPU panels, Operator panel / HMIs, Engg stations, UPS, Battery for UPS shall be located in the air-conditioned rooms in the control room floor.

09.05.07 Structural walkways shall be provided in high rise buildings for maintenance of light fittings.

09.05.08 Cable tunnel/ overhead structures shall be provided for all major & trunk routes for Inter shop cable routing. Covered RCC cable channels are permissible for small branches with few cables

09.05.09 Conveyor galleries shall not be used as thoroughfares or trunk routes. 09.05.10 Cables for one route shall not cross the cables of other route. 09.06.00 SCOPE OF WORK

The scope of work of BIDDER shall cover design, basic and detailed engineering, preparation & submission of drawings/ documents for approval/ reference/ maintenance/ record, manufacture, factory testing, inspection by client / consultant, packing, loading, forwarding, delivery at Plant site, loading/ unloading, storage, handling of material/ equipment to erection site, erection, no-load and load testing, commissioning, PG test, PAT/ AT/ FAT, liquidating the defects and handing over all related electrics, controls, illumination for complete & satisfactory operation of facilities as detailed in NIT specification/ document on turnkey basis.

Any item and/ or equipment not specifically mentioned but essential for process and technological requirement, proper installation, reliable operation, maintenance, completeness and safety of plant/ equipment & personnel will be included by the BIDDER in his scope of work.

The scope of work of BIDDER shall be inclusive of but not limited to: 09.06.01 GENERAL

.1 Design & Engineering (basic as well as detailed engineering)

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.2 Preparation of drawings/ document/ Erection, Testing & Commission Manuals/ Operations & maintenance Manuals/ Reports/ QAP etc. for approval/ reference/ record and/ or for any other requirement to meet Project Schedule.

.3 Submissions of drawings/ documents in time and getting the same approved from concerned authorities before those are required to meet project schedule.

.4 Ensure distributions of drawings/ documents/ Manuals/ Reports in hard as well as soft copies as stipulated and to meet project requirement

.5 Design, manufacture, shop testing of equipment/ cables/ materials and submission of documents with manufacturer’s test reports/ type test reports to Purchaser/ Consultant either with or prior to inspection call.

.6 Arranging inspections by Purchaser/ Consultant as stipulated.

.7 Obtaining dispatch clearance from Purchaser/ Consultant

.8 Packing, loading, forwarding, delivery at site/ store, loading/ unloading, storage as per manufacturer’s recommendation prior to erection, if required; shifting from stores, handling of material/ equipment for erection,

.9 Arranging testing/ checking instruments/ kits/ sets/ apparatus as required to carryout tests as stipulated in specification/ GTS/ other applicable standards with valid calibration certificates issued by duly accredited laboratories/ institutions.

.10 Deployments of electrical contractors, supervisors’ electricians, cable jointers etc. on full time basis (all in possession of valid certificate of competency) for carrying out electrical work.

.11 Installations of equipment/ cables/ materials and conducting per-energisation tests to ensure that installation is fit to be energized Erection shall not be considered complete unless pre-energisation tests are carried out, results are tabulated & submitted to purchaser and are found satisfactory.

.12 Submission of completion certificate for installation completed duly signed by Electrical contractor and Supervisor who has supervised the work.

.13 Preparation of necessary drawings/ documents/ enclosures etc. and applications for obtaining approval of installation from CEA/ Electrical Inspectorate of state/ any other authority as required, lodging applications, coordination with concerned authorities,

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arranging inspections and obtaining approval of the installation. Modifications/ changes suggested by such approval authorities shall be carried out without any extra cost to the purchaser.

.14 Conducting functional/ pre-commissioning checks/ Cold trial runs; no-load & load testing, commissioning

.15 Conducting Performance Guarantee tests and taking corrective steps (inclusive of replacement of equipment/ materials if required) till results are satisfactory/ acceptable.

.16 Conducting Pre-Acceptance Tests/ checks and tabulating the results/ observations

.17 Liquidations of defects/ discrepancies/ observations noted during erection, pre-energisation tests, PAT, AT, commissioning, trial runs, performance guarantee tests etc

.18 Submissions of all final drawings/ documents after incorporation of changes made, if any. (As built)

.19 Conducting Acceptance Tests/ Checks

.20 Conducting Final Acceptance Tests/ Checks

.21 Purchaser’s responsibility shall be limited to making available in HT sub-stations of purchaser 11 kV breakers as required to meet the requirement of electrical loads of Complex and indicated by Bidder in his offer. All facilities down stream of terminals of these breakers shall be planned, designed, supplied, erected, tested and commissioned by Bidder.

09.06.02 POWER DISTRIBUTION .1 This section covers major features of power distribution system

for shop-electrics, drives, control, automation (Level-1), illumination system to be supplied by Bidder under subject package inclusive of illumination, Auxiliary/ support facilities etc.

.2 Normal power supplies shall be made available to BIDDER from the 11 kV switchboards at MSDS IV (HT Sub-station).

.3 Bidders shall include DG supply based/ battery with inverter based emergency lighting. The scope shall include supply of necessary maintenance free battery bank, battery charger and switching ON/ OFF facilities in case of loss/ restoration of normal supply.

.4 The scope of work of the BIDDER shall commence from the outgoing terminals of 11 kV switchboards located at HT sub-stations of purchaser.

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.5 All HT/ LT/ control/ signaling etc. cabling from purchaser’s power supply boards in HT sub-stations shall be in the scope BIDDER.

.6 11 kV Breakers to feed HT loads of the package, as required and as indicated by bidder in his offer, will be made available by Purchaser at HT sub-stations for supplying power to (a) All LT substations (LTSS) which would be planned and

installed by BIDDER for meeting requirement of subject package

(b) All HT motors which would be installed under this package and

(c) All other equipment/ machines etc. which may be installed under this package and which have to be fed at 11 kV supply.

However, in case number of HT motors is more than three (3), bidder shall consider HT MCC in their offer for feeding HT motors. HT MCC shall have two incomers and one bus-coupler and required number of motor feeders including 20% spare feeders (minimum one) of each type in each section. Each incomer shall be rated for total load on HT MCC including requirement of spares. Purchaser shall provide two breakers in his HT sub-station for feeding HT MCC.

.7 FCMA starter panel shall be provided by BIDDER for 11 kV motors. Starters shall be provided with frequent switching duty VCBs and other power/ control equipment/ components needed for assisted starting. Necessary protection and interlocks for motor shall also be provided in starter panel.

.8 FCMA type starters shall either be fed from 11 kV breakers in HT sub-stations of purchaser or be part of HTMCC. In case HTMCC is not considered by bidder in his offer for number of HT motors being 3 or less, 20% (minimum one) spare motor starters of each type (inclusive of HT cable from HT sub-station of purchaser to starter) shall be included in offer. HT breakers provided by purchaser in his sub-station for feeding HT motors shall be feeder breakers and all protection/ control, interfacing/ annunciation/ signaling and other requirements shall be included in FCMA type starter panel.

.9 Quantities, location, rating and control requirement of 11 kV breakers which purchaser would have to make available in his HT sub-stations shall be clearly, unambiguously and specifically indicated by BIDDER in his offer to enable purchaser to fulfill his obligations.

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The BIDDER shall indicate following details (a) Connected load/ Maximum demand for 15 minute duration.

(Feeder wise/ Area wise and total) (b) List of motors having rating above 200kW for deciding

11kV motor feeder requirement. (c) List of distribution transformer (11/0.433kV) feeder for

deciding 11kV transformer feeder requirement. (d) Overall expected maximum demand in 15 min duration for

the entire plant under normal operating conditions. .10 Supply, installation and termination (at both ends) of all HT &

Control Cables, signal, interfacing cables and all other cables from 11 kV switchboards in HT sub-stations of purchaser to (a) All LT substations (LTSS) which would be planned and

installed by BIDDER for meeting requirement of subject package

(b) All HT motors which would be installed under this package and

(c) All equipment/ machines etc. which would be installed under this package and which have to be fed at 11 kV supply.

(d) Control rooms (e) Any other equipment/ facility to meet the requirement of

provisions stipulated in the package. shall be in the scope of work of Bidder. Any signal / communication cable along with automation equipment required for control function/ data transfer for HT switchgear shall be in bidder’s scope. Cabling shall be inclusive of supply of necessary materials, making necessary trenches/ tunnels/ cable supporting structures/ cable trays/ termination kits/ double compression type metallic glands/ crimping type/ copper lugs earthing materials, local control stations, junction boxes, jointing kits etc.

.11 The BIDDER shall plan and install at suitable locations to be decided by the BIDDER based on best engineering practices, adequate number of LT Substations (LTSS) to meet the requirement of LT loads of the package inclusive of future requirements. BIDDER shall ensure to avoid location of LT Substations under Conveyor galleries/ in dust prone areas.

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Each LT sub-station shall consist of but not limited to (a) Two nos. transformers. The transformer rating shall be

worked out on the basis of guidelines given in General Technical Specification. The rating of transformers shall be selected from standard ratings of 630 kVA, 1000 kVA, 1250 kVA, 1600 kVA and 2000 KVA only.

(b) Two load-break Isolator panels with earth switch in the transformer room (one for each transformer). The isolator shall be electrically interlocked with the 11kV circuit breaker. Contacts from this isolator shall be wired such that initiation of opening results in tripping of feeding breaker before contacts of isolator start opening. Isolator Panel shall be provided with transparent door so that the status of the isolator and earth switch may be physically verified without opening the door. The earth switch shall be mechanically interlocked with the isolator. The system shall have three positions viz closed/ open/ earthed. In earthed position feeding HT cable shall be earthed. Further, it shall not be possible to close isolator if feeding breaker is ON. Open/ close status of isolator shall be annunciated on feeding breaker. Connection from isolator panel to transformer shall be through cable.

(c) LT switchboard/ PCC having two sections with bus coupler and each section having one incomer.

(d) MCCs, ACDB, MLDB, PDB, LDBs, Battery, Battery Charger etc. as required.

(e) Transformer room, switchgear room, Ventilation Room/ Air Conditioning room, Battery Room, cable cellar, maintenance area etc.

(f) HT/ LT power & control cables and other necessary items as required for completion and successful operation of the power distribution network, in an integrated manner.

(g) Floor mounted off load isolator panel with earth switch in the transformer room.

.12 All cables (Power, control, signaling, interfacing etc. as required) cable termination glands/ kits, laying and termination (at both ends) of all cables from the Purchaser’s 11 kV switchboard.

.13 The following are to be considered in addition to the equipment

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specification spelt out in TS. a) The vector group for all distribution transformers (LT S/S)

shall be of Dyn11 only to take care of circulation of harmonic currents.

(b) BIDDER shall ensure that supply from existing LT power sources and supply from new transformers is not mixed.

(c) Separate voltmeters (analogue) are provided for measuring line voltages & bus voltages. Ammeter in each of the three phases shall be provided.

(d) All ACBs shall be provided with microprocessor based protection relays and protection settings shall be selectable at site.

(e) Check-synchronizing relay shall be provided wherever sectionalizing is envisaged between two different sources of power supplies.

(f) First fill of all consumables, printers, papers, cartridges, floppy, CDs etc.

(g) Safety items like hand gloves, shock treatment charts, discharge rods, rubber mats (of required voltage classes) in front of all panels, danger/caution boards, shock treatment charts, keys and key boxes, Portable fire extinguishers, sand buckets & other fire fighting equipments as per statutory requirements at each sub-station, MCC Room, Electrical Premise etc.

.14 The detailed specification and schedule of quantities shall be worked out based on the detailed engineering to be carried out by the contractor, for complete and proper execution of the specified tasks.

.15 The quantities of equipment, cables, cable terminations, straight through joints, cable supporting structures, earthing/ protection against lightning, illumination and erection materials, shall be as per actual requirement in accordance with the approved detail engineering drawings.

.16 The final ratings of the circuit breakers, CTs, bus-bars shall be adequate for the actual loads and considering the de-rating factors as substantiated by temperature rise test on the 415 V switchboards. All CT ratios / VA burdens, ranges of meters and instruments, types of relays and relay setting ranges shall be

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submitted for Purchaser’s approval considering the actual demands to be finalized during detail engineering.

.17 The minimum size of 11 kV cable shall be 3 x 185 sq.mm (Al). Minimum size for LT cables shall be 6 sq.mm (Al). The actual sizes shall, however, be higher, if required, to meet the requirements stipulated in TS.

09.06.03 DRIVES & CONTROLS .1 FCMA type starters for HT motors .2 Intelligent types Motor control panels (MCPs) fed from ACBs of

LT switchboard for control of drives of rating from 110 kW to 200 kW.

.3 Indoor type 415 V LT MCC with necessary components, devices, CTs, PTs, metering and protection components/ instruments/ devices etc. as required for control of drives of various technological units of rating up to 90kW. All Motor Control Centers shall be smart, intelligent, non-draw out type, enclosure protection class IP54 with two incomers and bus coupler

.4 MCC/ Control panel mounted on Stacker, Reclaimer and any other major mobile machines shall be conventional non draw-out type.

.5 FCMA type starters, motor control panels and MCCs shall have communication capability/ facility on Profi-bus DP/ Mod-bus/ Device-Net with Plant Automation System.

.6 All FCMA starters, HT MCCs, MCPs and LT MCCs to be provided with current signal converters, which shall be hooked up with PLCs for 3-phase current monitoring and trend charts

.7 Control panel for Tripper car, Cranes, Hoists, Small machines and

Auxiliaries may have conventional non draw-out type control panel.

.8 All panels on the mobile machines shall be mounted on anti vibration pad. Electronic over load relay shall be used in conventional / non-intelligent MCC / Control panels.

.9 Necessary cable reeling drums, cable festoon, cable drag chain, trailing cables for feeding power to mobile machines.

.10 VVVF converters for 415 V motor drive where process requirement calls for variable speed application. All drives shall

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have communication capability on Profi-bus DP/ Mod-bus/ Device-Net with Plant Automation System.

Make of all VVVF drives shall be same and minimum variety of drives should be used for standardization/ interchangeability.

.11 VVVF Converters at medium voltage viz 690 V complete with 3 winding Converter transformer (for 12 pulse configuration) & incoming breakers for higher rated motors.

.12 All HT and LT AC motors, actuators, brakes (all types with associated electrics) etc. as per technological and process requirement. HT motors shall be provided with winding & bearings temperature sensors and vibration sensors. These shall be hooked up with PLC for control & monitoring.

.13 All HT Motors shall have High Voltage Flux Compensated Magnetic Amplifier (FCMA) Soft starter for low starting current. FCMA soft starter shall have suitable by-pass contactors and controls to ensure full voltage running of the motor. FCMA soft starter shall be indoor duty, rugged in construction, user friendly and maintenance free. FCMA starter panles shall have communication capability/ facility on Profi-bus DP/ Mod-bus/ Device-Net with Plant Automation System

.14 Squirrel cage induction motors shall be considered in offer. DOL starter / VFD / Soft Starter shall be provided as required to meet the process requirement/ stipulations of TS/GTS.

.15 Local control stations housing Local-Remote selector switch, push buttons, indication lamps etc. for all drives. LCS for motors directly fed from breakers/ contactors panels shall be provided with close & trip switch with facility of spring return to neutral. LCS of drives with scoop coupling shall be provided with push buttons for coupling and decoupling so that motors need not be switched off for shorter duration. LCS for HT motor shall have Ammeter also. All Local control stations shall have double doors. Stop push button in LCS shall be mushroom head press to lock and turn to release type.

.16 Surge protection devices shall be provided at the incoming side of all MCCs, VFDs, Soft starters, PLCs/ Remote I/O stations, MLDBs, PDBs, other DBs, field devices/ sensors etc. to protect the system/ equipment as applicable.

.17 All field devices, valves, safety switches like Pull chord switches (addressable type) and belt sway switches (addressable type), zero speed switch, chute jamming switches and Proximity

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switches, Warning hooters, photo-electric sensors, level sensors, relays, limit switches, binary encoders, position transducer, isolators, speed sensors etc. as necessary for the process and control of the material handling equipment / system and its all associated / auxiliary equipment / systems.

.18 Belt rupture protection switches shall be provided for all conveyors. Proximity type Limit switches shall be used for shuttle conveyors, tripper car etc.

.19 Completes electrics including motors, control panel, LCS, Brakes, Brake Panels, all equipment/ devices/ controls associated with scoop or any other type of coupling, cables etc. for all types of Conveyors, Screens, Actuators, valves, gates, vibrofeeders, belt feeders etc. as required.

.20 Completes electrics including motors, control panel, LCS, Brakes with panel, cables etc. for Trippers, Cranes, and Hoists etc.

.21 Completes electrics and load cell for Weigh feeder, Weigh hopper, Belt scale etc. as required.

.22 Completes electrics required for Suspended magnet, Magnetic separators, Metal presence detectors, Material Presence Detectors etc.

.23 Complete electrics, controls, instruments, level controller, solenoid valves, Bag filter, Timer controls etc. for the Dust suppression systems, Dust extraction systems, Ventilation systems, Air Conditioning systems.

.24 Display Panel to display the address of safety switches of conveyors shall be provided in control room. Master-cum-display units shall be dual input type. One input shall be used for pull cord switches and another for belt sway switches.

.25 Complete electrics for Air Blaster with solenoids, control panels, cables etc. for bunkers as required.

.26 Complete electrics for sampling systems covering motors, control panels, cables LCS etc.

.27 Sump, slurry and dewatering pumps etc shall be provided in underground floor of technological building/ Junction houses, Tunnels, cellar etc and completes electrics including motors, control panel, LCS, level sensors, cables etc. for sump pump, slurry and dewatering pumps etc shall be included. In addition 415V, 100A Sockets shall be kept near sumps for working of portable submersible pumps.

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09.06.04 UPS SYSTEMS

On line type Dual parallel redundant UPS systems (IGBT based rectifier & inverter) consisting of SMF battery bank for 30 minute back up incase of power failure, Battery charger, UPS Power distribution boards & sub-distribution boards for distribution of UPS power supply to control & Automation equipments, Instrumentation system equipment, FDA system, Weighing system & any other equipment in the Package UPS shall be such that AC to DC converter shall charge the batteries and DC to AC inverter shall be fed from batteries irrespective of the condition whether input power is available or not.

09.06.05 AUTOMATION AND LOGIC CONTROL

1. PLC based Level–1 automation system shall be provided for smooth, safe, efficient, reliable sequential operation, process/ safety logic control, interlocking, monitoring, fault diagnostics, report generation etc. for all the equipment/ facilities included in the package.

.2 Bidder shall provide suitable PLC based automation system including all hardware’s and software’s to run the existing and new material handling plant in an integrated manner. All the instrumentation & automation equipment shall be supplied brand new & from the latest product ranges of reputed manufacturers as per the List of Preferred Makes of purchaser. Purchaser/ Consultant reserve the right of selecting particular make and model of Automation equipment with a view of standardization of the whole plant. Tenderer shall comply with such requirements. Independent PLCs & I/O panels with peripherals shall be provided for all the facilities envisaged in the package. All the field equipment/ facilities shall be interfaced with the respective automation system accordingly for running the new and existing material handling plant in an integrated manner.

.3 PLCs for facilities in subject package and Purchaser’s PLCs of existing plant or being procured through any other package shall be interfaced with each other as per process requirement. All the field equipment shall be generally field bus compatible type and shall be interfaced with PLC systems through field bus & suitable interface modules. However, the signals from the equipment which are not field bus compatible type shall be interfaced through hardware I/O modules of the PLCs.

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.4 Detailed functional requirement of Wagon Tippler, SAC, Paddle feeders etc. as specified would be met. Each machine shall have independent PLC system with necessary interfacing with PLCs at control rooms. All necessary hardware and software shall be provided to achieve the same.

.5 All the necessary controls, interlocks and annunciation as required for smooth, efficient and safe operation of the plant shall be provided.

.6 Remote I/O panel shall be housed in electrical premises located within the Plant at convenient locations (Location shall be decided based on the equipment location which can form a group from process point of view).

.7 For integration of automation system of existing plant and new facilities envisaged in this package, suitable gate ways shall be provided in the automation network for communication with existing PLC. Integration and interfacing shall be done to run the entire plant in an integrated manner. Existing PLCs and remote I/O stations shall be interfaced with PLC systems through field bus & suitable interface modules for integration of units / plants / conveying routes mentioned above.

.8 All HT drives shall be provided with extensive monitoring facilities for fault detection and alarm annunciation. Alarm annunciation shall be provided for over winding temperature, over bearing temperature, overload etc. In case values exceeding pre-decided levels considered to be unsafe (adjustable at site), trip commands shall be initiated.

.9 Alarm annunciation systems shall cover all the equipment of the electrical system.

.10 Plants shall have three modes of control.

• Local de-interlocked mode control shall be carried out by local push button station (LCS) for each individual equipment/ mechanism.

• REMOTE interlocked individual drive control from the HMI at Dispatcher/ Central Control room.

• REMOTE interlocked route wise control from the HMI at Dispatcher/ Central Control room.

.11 The local control operation is meant for testing and maintenance

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facilities only. However, safety interlocks shall be effective in LOCAL mode of operation also. In local control the mechanism is not process interlocked and may be started and stopped from LCS independently after the mechanism selector switch is set to Local operation. The stop P.B. of local control station shall be able to stop the drive mechanism irrespective of selection of mode of control. Starting of any mechanism shall be permissible only after permission is accorded by PLC.

.12 Mechanism selector switch for selection of above modes of operation/ control for each drive motor will be provided in the local control post near the respective motors/ drive. Local selection of any drive will be shown on the HMI screen with some sort of caution.

.13 In Remote interlocked individual mode of control the drives/ mechanisms in the material flow path will be started in succession sequentially opposite to direction of material movement from operating station / HMI. On tripping of any conveyor/ drive/ mechanism, all the mechanisms feeding to the affected (tripped) mechanisms will stop according to material flow diagram. All the mechanism selector switches of the selected material flow path will be set to REMOTE position in this case. Programmable Logic controller will be used for the control, interlocking, operation, and monitoring of the equipment.

.14 In Remote interlocked Group / Route-wise control the setting of the program of operation from HMI as per material flow path to be carried out by the operator before the mechanisms start. This will comprise the following operations:

a) Selection of material flow path including source and destination as per requirement.

b) Selection of mechanisms within the selected material flow path.

c) Selection of switching devices, flap gate etc.

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d) Selection of control mode in REMOTE of master selector switch for each material flow path blocks chain.

On receiving permissive signal from HMI for the selected path/ route the operator will give ON command to start the desired conveying route.

.15 Normal stop and Emergency stop of mechanism for each material flow path, P.B, switches for pre-start warning signal for each material flow path, start & stop P.B. switches of drives with independent operation etc. will also be mounted on desk/ HMI.

.16 A pre-start audio warning signal through motorised hooters will be given in the premises where the mechanisms are to be started before start of the mechanism. For conveyors, hooters shall be installed at head end, tail end and in conveyor gallery so that sound could be heard throughout length of conveyor.

The duration of the pre-start audio signal will be as per requirement. Start of the mechanism will be possible only after the pre-start audio signal is over. Push button shall be provided in LCS for sounding the hooter when starting the movable mechanism in local mode. The push button shall be active only when permission to start from local is accorded.

.17 Stopping of mechanisms:

a) Regular stop

The feeding equipment will be stopped to stop the material flow further in the material flow path. Then after some time delay the last equipment will be stopped ensuring no material will remain in the conveying path.

b) An emergency stop push button (mushroom headed type as press-to-lock and turn-to-release type) switch for each material flow path / loop will be provided in the Control desk for emergency stop of each material flow path/ loop.

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c) When emergency stop of some mechanism takes place for tripping of due to fault, all the mechanisms feeding the material to the effected mechanism will stop. There shall be signaling of the stopped mechanisms by changing colour in the graphic and indication of the operating mechanism continues to glow. This will give an opportunity to find the place of emergency immediately.

The conveying system will be integrated with the associated auxiliary / other system for interlocking, sequencing and monitoring.

.18 Signaling

(a) Status of ON, OFF, Trip/ Fault ,Route selection etc. for all mechanisms including conveying system, dedusting system, dust suppression system, weigh feeders etc. shall be available in the operator work station.

(b) When the drive in the block chain (DE system also) is shifted to local controls, indication will be provided in the HMI.

The annunciation shall be provided on HMI for each drive fault and actuation of safety and limit switches.

• Annunciation for O/L & fault of each drive motor.

• Switching devices, flaps etc failed to close or open.

• Combined fault HT switch gear for Each HT motor including power supply to MPR failure separately.

• Individual annunciation for HT motors bearings and winding temperature high alarm.

• Individual annunciation for following conditions of electrical system:

- 11 kV switchgear trouble

- 415 switchgear trouble

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- Transformer trouble alarm.

- Combined fault/ trouble in bag filter system of D.E

- Unhealthiness of various machines

- Any other failures

(d) Every unplanned stoppage or abnormal condition shall be annunciated/ brought to the notice of operator.

.19 Current readings of all HT and LT motors connected to Intelligent MCC shall be available in HMI at Dispatcher.

.20 Display modules shall be provided for display of status of addressable pull wire switches and addressable belt sway switches in control room. Operation of safety switch shall be annunciated.

.21 Drainage/ sump/ slurry pump shall be provided with Auto/ Local mode of operation. Under automatic mode of operation any one of the pump motors shall start automatically at set level and if the level rises further the second/ reserve pump shall start automatically at second set level and both the pumps shall stop at set low level. If the first pump trips, second pump shall start automatically. Emergency high level annunciation shall be available in the control room.

.22 Under local mode of operation, the pump motors shall start/ stop locally through local control boxes depending on level.

.23 Equipment/ systems/ facilities etc. to be included by bidder shall be inclusive of (but not limited to) following:

(a) PLC systems with redundancy in processors, power supply modules, communication modules, network interface modules, system bus & I/O bus, operator’s and engineering workstations, MIS servers etc. for plants/ units of the proposed Plant including Wagon Tippler, Paddle feeders, Yard Machines etc. All the required facilities & features for interfacing of PLC systems.

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(b) Wireless Ethernet, with fallback option and status indications at central control room, shall be used for interfacing

• Between Control rooms.

• Main PLCs to the PLCs in mobile machines (Stacker cum Reclaimer, Tripper etc.) and

• Engineering Station to PLCs on mobile machines. (c) The required hardware input/ output modules for interfacing of

equipment which are not available with Field Bus compatible features. Suitable local or remote I/O panels for installation of these I/O cards, Field bus interface modules, redundant power supply modules, redundant communication modules, etc.

(d) Required nos. of remote I/O panels with adequate quantity of various types of I/Os, i.e. Digital, Analogue, RTD, Thermocouples, Pulse, power supply cards, Relays for outputs etc. at different locations.

(e) Field bus devices, Field bus interface modules, Field bus cables, terminators, couplers, connectors, power supply modules, power conditioners, surge suppressors, repeaters, Field bus junction boxes, pull boxes, etc., required for completeness of implementation of Field Bus based system.

(f) Preferred Makes of individual equipment i.e. PLC systems, Workstations, Servers, Engineering stations, printers etc., shall be as indicated in this Tender document. All PLCs, work stations, server, printers etc. under proposed Plant Automation system and mobile machines shall be of same make.

(g) All required software i.e. System software, HMI software, Application programmes etc. for PLC, Workstations, Servers, communication interface amongst various automation systems, etc.

(h) VVF Drives, Soft starters and Weighing Systems etc. to be industry standard Field bus.

(i) License to use the application & operating software. (j) All maintenance, diagnostic tools & devices required for

implementation, maintenance & trouble shooting of Field Bus system.

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(k) Specialized Field Programmers (minimum 2 nos.) with suitable provision for connecting to remote I/O stations for trouble shooting and Lap tops.

(l) All Network components like Gateways / interfacing modules, cables, multi-port switches etc., as required for interfacing.

(m)Optical Link Modules, Light Interface Unit, Redundant link modules, Power supply Cards, Converters, and Terminators etc. as per requirements.

(n) Separate PLC systems, if required, for operation of the auxiliary units of the facilities proposed facilities,( other than the PLC systems specified in the configuration diagram, if any) shall also be offered and suitably interfaced with the main automation system. Details shall be indicated in the offer. Suitable interface arrangement shall also be provided for connecting field equipment/ controllers having Profibus DP or equivalent connectivity.

(o) Fully wired cabinets/ panels, etc with MCBs, Fuses, CFL Lamps, Universal type service sockets, Earth strips, etc.

(p) The design to be done in such a manner that cabling and wiring is minimized.

(q) CBM shall be provided for important equipment, interfaced to the automation system.

(r) Control room furniture. (s) Successful Bidder shall arrange tools, tackles and

consumables as may be required for erection, testing, calibration and commissioning activities.

(t) Arrangement of and participation in inspection of Automation equipment by Purchaser/ Consultant is also included in Bidder’s scope. Inspection and Testing shall be carried out in compliance with the Quality Assurance Plans and FAT document, to be approved during detailed engineering stage.

(u) Arranging visits by respective Automation manufacturer’s representatives at site, as & when required, during erection & commissioning.

(v) Testing tools & equipment for automation system shall include all the necessary trouble shooting and maintenance tools, software, analyzers etc. (Tenderer to furnish the list of such items considered by them).

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(w) Providing training to Client’s personnel on the automation system at manufacturer’s works and also at site.

.25 One large screen displays with dedicated PC based control unit shall be provided in each control room.

.27 I/Os to considered for proper operation, safety, control & monitoring shall be as specified/ required and shall be inclusive of but not limited to following:

• Stopped from LCS • L/R selection from LCS • Motor Running (Forward) • Motor Running (Reverse) • Motor OFF • Power ON/ Circuit healthy • Motor Tripped on fault • Pull Cord Switches (Left hand side of conveyor) • Pull Cord Switches (Right hand side of conveyor) • Zero Speed Switch • Belt Sway Switches • Belt Rupture switches • Chute jamming switches • Brake Contactor ON • Brake O/L Trip • Brake engaged from field Limit Switch • Brake disengaged from field Limit Switch • Positions of shuttle conveyor/ movable equipment using

non-contact type sensors • End limits of shuttle conveyor/ movable equipment. • Vibration switches for fans/ sensors for HT motors • Liquid levels in tank • Material level in silos/ bunkers/ hoppers • Dynamic/ regenerative braking contactor ON • Thermistors of actuators • Internal end Limit Switches of Actuators • External end Limit Switches of Actuators • Torque Limit Switches of actuators. • Positions of flap/ rack & pinion/ diverter gates. • Detection of metal • I/Os from weighing, sampling and other systems • Encoder input • I/Os from anti-collision devices • Current drawn by motors/ equipment.

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• Current drawn by Power distribution equipment/ feeders. • Permission from PLC to start from Local • Start/ stop command from PLC (Forward/ open/ left etc) • Start/ stop command from PLC (Reverse/ close/ right etc) • Hooter ON from PLC

.28 List of Drawings & Documents for Automation

Following drawings and documents (in addition to what have been described under electrics elsewhere) shall be submitted by the bidder: (a) ALONGWITH OFFER

• System configuration diagram for the Automation system along with its peripherals. Configuration should indicate nos. of Processors, Nos. of Field bus communication modules, Locations of RI/Os for new and existing plant etc.

• Basic details regarding respective segments of Field Bus devices and a write-up explaining the same.

• Bill of quantities of all hardware & peripherals viz; CPU, I/O units, communication & power supply modules, operator/engineering stations, bus cables & erection accessories etc. offered for the automation system with brief specification.

• Detailed technical catalogues & a write-up explaining the system offered shall also be submitted along with details of software’s being considered.

• Total power requirement & heat load for automation system.

• List of commissioning spares with details.

• List of two years operation & maintenance spares with details & unit rates.

(b) FOR APPROVAL DURING DETAILED ENGINEERING

• Finalised system configuration diagram for the automation system along with its peripherals with list of hardware and write-up on the system.

• Bill of Materials & Data Sheets of all the hardwares i.e. Processors, Communication modules, Power supply

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cards, RLM, OLM, Operator stations, Eng Stations, Servers, Bus cables etc.

• Segment Details for each Field bus shall be provided in separate drawing indicating the Tag nos. of field devices, OLM, RLM, Terminators etc

• Overall General arrangement drawings & sectional views of various cabinets, panels, consoles, etc., showing internal disposition of all components/ units, with dimensional details and bill of materials.

• Interconnecting diagram between existing MCCs & other panels of purchaser and PLC / Remote I/O stations of the tenderer.

• Single line power supply diagram with specification and bill of quantities of electrical accessories.

• Quality assurance plan & Factory Acceptance Test procedures for Automation system.

• Control room layout drawing showing disposition of panels, consoles, desks, etc with dimensional details.

(c) FOR REFERENCE

• Detailed technical literature/ catalogue for Automation system with peripherals, highlighting the model number.

• Input/ Output list.

• Voltage drop & signal attenuation calculation of each segment for Field Bus devices including details of instrumentation items interfaced with each segment.

• Terminal diagram of all the RI/O & Marshalling panels.

• Cable schedule and specification.

• System grounding scheme.

• Formats and work sheets for generation and display of overview, groups, loops, graphics, alarms, operator’s guide messages, real time & historical trends, log & shift formats.

• Detailed listing of application software, system software, HMI software, etc and the number of licenses.

• Application software formats and details in documentation and CDs.

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• Manufacturer’s test, calibration and guarantee certificates for all instruments and automation system.

• Operation and maintenance manuals for Automation system.

• As-built documentation.

• Soft copy of all the above drawings & documents in CDs/DVDs.

09.06.06 CRANES/ HOISTS/ REPAIR NETWORK .1 Power distribution boards (PDB) with two incomers and one bus

coupler for repair network like welding sockets, maintenance cranes and hoists.

.2 415 Volt 100A welding socket outlets (male and female both parts) in each premises at each floor

.3 Single phase 3 pin 240V 15A and 5A switch-socket outlets with interlocked switches (male and female both parts) shall be provided at the following locations: (a) At each floor of building/ junction house/ conveyor gallery

etc so that all facilities are covered using cable length of 30 meters or minimum one for each row/ side.

(b) Two numbers each in switch gear room, cable basement, control room and MCC room.

(c) Near every chute in Junction houses and other technological buildings 240 V and 24V, socket outlets shall be provided for maintenance lighting by hand lamp.

.4 For 15A socket outlet and for lighting circuit minimum size of aluminium cable shall be 6 sq.mm and 4 sq.mm respectively.

.5 Load break isolators for cranes, hoists, tripper car and other equipment shall be provided which shall be located near the equipment.

09.06.07 INTERNAL ILLUMINATION, AREA & ROAD LIGHTING .1 Illumination level and light fittings shall be provided for different

units as indicated below:

SL. NO

UNITS

ILLUMINATION LEVEL (LUX)

TYPE OF LIGHT FITTINGS

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SL. NO

UNITS

ILLUMINATION LEVEL (LUX)

TYPE OF LIGHT FITTINGS

1. Electrical rooms, substations, MCC Rooms etc.

200 Trough type, 2x40W, fluorescent tube light fittings with reflectors.

2 Junction Houses and Conveyor Galleries / tunnels

100 70W/150W, HPSV, well glass fittings and 250W High bay as required.

3 Crusher house, other process and Technological Building

150 70W/150W, HPSV, well glass fittings and 250W High bay fitting as required

4. Office rooms 300 Trough type/Decorative recessed type, 2x40W, fluorescent tube light fittings.

5. Corridors, walkways, staircase

100 Trough type, 2x40W fluorescent tube light fittings with reflectors.

6. Control room, laboratories, and instrumentation rooms.

300 Decorative type, 2x40W fluorescent tube light fittings with mirror optics.

7. Battery room

100 Corrosion/Vapour proof, 2x40W fluorescent tube light fittings.

8. Battery Charger/ UPS room

200 Decorative type, 2x40W fluorescent tube light fittings with mirror optics.

9. Periphery of buildings and cooling towers

50 70W, HPSV, well glass fittings.

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SL. NO

UNITS

ILLUMINATION LEVEL (LUX)

TYPE OF LIGHT FITTINGS

10. Pump Houses 200 70W, HPSV, well glass fittings.

11. Area lighting through flood light towers

20 250/400W, HPSV, flood light fittings

12. Area and road lighting

15 250/400W,HPSV, flood light fittings and 150W, HPSV, street light fittings

For areas other than above, illumination levels as per standard specification of Bureau of Indian Standards shall be followed.

.2 Values of lux levels in TS or in Standard Specification published by Bureau of Indian Standards are not the average values of lux levels to be maintained in a particular area. The illumination levels are those which are to be maintained at all times on the task. These should be considered as levels commonly required. These values may be exceeded provided requirement of freedom from visual discomfort are satisfied.

.3 Lighting systems for total plant shall comprise of the following categories of lighting system.

• Normal 240V AC lighting system.

• 24V AC maintenance lighting system.

• Emergency lighting system. .4 Emergency lighting systems (for evacuation purpose) shall be

provided for all sub-stations (all premises), control rooms, Dispatchers stations, junction houses, conveyor galleries, cellars, lifts, which should switch ON instantly in case of power failure. In normal case emergency lighting system shall remain switched off.

.5 The maintenance factor for design of illumination level shall be considered as 0.6 for all areas.

.6 For arriving at utilization factor, manufacturer's recommendation shall be followed.

.7 All rooms with false ceilings shall be provided with recessed type decorative mirror optics fittings.

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.8 All decorative type fittings shall be mirror optics type.

.9 All buildings shall be provided with peripheral lighting.

.10 The power factor of lighting system shall be improved to 0.9 by providing in built capacitors with individual light fittings

.11 Main Lighting Distribution Boards (MLDB) with two incomers and one bus coupler for Power supply to various Lighting distributions Boards (LDB).

.12 LDBs and Sub Lighting distribution boards as required for providing power to light fittings.

.13 Illumination of the all facilities covered in the package Sub- station rooms, MCC rooms, Control rooms, Ventilation rooms, conveyors, Junction houses, various technological / auxiliary buildings and other installations of the plant by providing Lighting Transformer, Main Lighting Distribution Board, Lighting Distribution Boards, Sub-lighting Distribution Boards, Feeder pillars, Light Fittings, Lighting towers, low voltage switch sockets, conduits, Ceiling fans, Exhaust Fans, all lighting cables etc.

.14 Area, outdoor and peripheral lighting shall be fed from separate LDB/ SLDBs having two modes of control - AUTO and Manual. Under AUTO mode lights shall be automatically switched ON/ OFF through timers where as in Manual mode, lights shall be switched ON/ OFF through local control station located in Dispatcher/ Control room. Selector switch for mode of control shall be located on local control station.

.15 Lighting in conveyor gallery and junction houses (floors above ground) and technological buildings shall be connected to separate lighting circuit and the same shall be switched ON/ OFF by PLC based control from HMI at Dispatcher.

.16 Area lighting, wherever applicable, shall be provided through 400W, HPSV flood light fittings mounted on lighting towers.

.17 Light fittings in sub-station, MCC Rooms, control rooms, offices shall controlled using switches.

.18 All the offices shall be provided with ceiling fans.

.19 For indoor lighting, outgoing feeders in MCB DBs shall be 20A SPN MCBs. Incomer to MCB DB shall be suitably rated heavy duty switch and ELCB shall be provided for detection of leakage current.

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.20 For area and road lighting, 3 phase & neutral feeders may be used and accordingly suitably rated 4 core cables may be provided.

.21 HPSV lamp fittings shall be provided with external electronic igniters and a built in sensor to sense failure of lamp and switch off igniters.

.22 Fittings in Single phase/ three phase circuits shall be connected / distributed in such that total connected load to each phase is equal and phase balancing is achieved.

.23 Stroboscopic effects shall be corrected.

.24 Single phase point wiring shall be done using 3 core cable; third core shall be used as earth connection.

.25 lighting fixtures shall be controlled as follows: (a) Sub-stations, Electrical Rooms, switch gear rooms, control

rooms, offices etc through switches. (b) Technological buildings, junction houses, conveyor

galleries etc through Group/ sectorial control by providing contactor at incoming side of SLDBs.

(c) Area/ outdoor and street/ road lighting through Group/ sectorial control by providing contactor at incoming side of LDBs/ SLDBs.

(d) Local/ remote/ auto selector switch shall be provided for control of lights

(e) In auto mode lights shall be controlled either through 24 hour timer or through lux level control. In remote mode fittings shall be controlled through PLC.

.26 Fixtures shall be wired in such a way so that (a) Loss of any phase does not result in total darkness in an

area. (b) Loss of supply to any SLDB does not result in total

darkness in technological building/ junction house or conveyor gallery.

09.06.08 EARTHING .1 Design Criteria

All parts of all electrical equipment not intended to be alive shall be earthed in accordance with the stipulations of IS: 3043, IE

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Rules and IEC recommendations. The earthing system shall be designed to:

(a) Provide a permanent and continuous path to earth

from circuits, equipment and conductor enclosures for flow of fault current.

(b) Provide sufficient current carrying capacity of the earthing system to conduct safely any current liable to be imposed on it.

(c) Provide sufficient low resistance to earth to limit the potential between metalwork and earth within safe limits.

(d) Provide equal distribution of potential and minimum potential difference for safety of personnel.

(e) Ensure sufficient current in case of fault to facilitate the operation of relays, over current devices, fuses etc. provided in the circuit.

.2 General Requirements (a) All shops, buildings, MCC rooms, control rooms and other

premises housing electrical equipment shall be provided with a ring main earthing system.

(b) All parts of all electrical equipment and machinery not intended to be alive shall be connected to this ring main at two points using two separate and distinct earth connections each of required size. Apparatus rated 240 V and below may, however, have single earth connection.

(c) All individual earth ring main earthing systems shall be connected as a network.

(d) For different floors in a building, localised ground mats shall be formed.

(e) The ring main earthing system or mats for different floors in the building shall be connected to ground earthing ring through vertical risers. Earthing mats may be common to both power and lighting.

(f) The ring earthing system around the plant shall be laid at a distance not less than 1.5 M from the building and at a depth not less than 0.8 M.

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(g) The ring shall be bonded at intervals to the building steel structures.

(h) The earth ring shall further be connected at intervals to deep earthing electrodes to achieve a combined earth resistance as required but not more than one ohm.

(i) All LT power supply cables shall have earth core and/ or armouring having conductivity and current carrying capacity not less than 50 % of the conductivity/ current carrying capacity of phase conductor. The earth core and/ or armouring shall be connected to earth bus using lug, nut and bolts.

(j) Separate and distinct earthing system shall be provided for microprocessor based equipment or any other electronic equipment as recommended by the manufacturer of the equipment for trouble free operation/ working of the equipment supplied. This earthing system shall be isolated & insulated from system/ equipment connected to electrical/ lighting/ lightning earthing system. Insulated earth conductors of copper shall be used.

(k) While crossing railway lines/ roads, wall, floors etc., the earth conductor shall be taken through conduit.

.3 Joints and Connections (a) All joints in earth conductors shall be welded unless

otherwise specifically indicated/ required and protected against corrosion.

(b) The joints shall be welded overlap being not less than width of the conductor or 20 mm whichever is more.

(c) Flexible jumpers of current carrying capacity and conductivity not inferior to the current carrying capacity/ conductivity of earth conductor with lugs at both ends shall be used for connection from earth conductor to equipment earth terminal.

(d) Suitable bimetallic washers shall be provided wherever required.

.4 Erection of Earthing conductors (a) When laid in ground, earth conductor shall be laid at

approximately 1 metre deep.

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(b) Earth conductor shall be painted with bitumen paint, taped with bitumen tape and again painted with bitumen paint before laying in ground.

(c) When laid on wall and/ or structure suitable gap (approx 3-10 mm) shall be maintained between wall/ structure and earth conductor.

(d) Earth conductor shall not be welded either for support or for any purpose other then jointing for extending the length. Suitable saddles, cleats, clamps, brackets etc. (fixed to supports using screws or anchor fasteners or nuts & bolts or by welding) shall be provided for support/ fixing of earth conductor.

(e) Holes shall not be made in earth conductor for any purpose other than at ends for termination. Holes shall be made using drill machine only.

(f) Flat earth conductors shall not be directly terminated on earth terminals on equipment/ machines/ motors. Suitable short jumpers with crimping type lugs shall be used for connection between earth conductor and earth terminals on equipment/ machine/ motors.

(g) When laid on floor, the earth conductor shall be either embedded in floor or top surface will match with the floor level.

(h) At wall/ slab/ road /rail crossings earthing strips shall be laid through conduits /concrete ducts.

.5 Measurement of soil resistivity at site for designing earthing system

.6 Supply and installation of complete earthing system including earth pits, earth grid with GI strips for the substations, neutral earthing of transformers, earthing of all electrical equipments in electrical premises, Junction houses, process / technological building etc.

.7 Special earthing system (including earth pits, earth grid with GI strips, Copper Cables as required) for earthing of PLC, RIO panels, VFD, other Electronics equipment & automation system, TR set panels as per their manufacturer’s recommendation.

.8 Neutral of transformers shall be connected to two separate earth pits using separate and distinct connections. Further, earth conductors from transformer neutral to earth shall be insulated/

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isolated for safety reasons so that they do not come in contact with any other equipment/ structure or personal.

.9 All materials used for earthing and protection against lightning shall be GI.

.10 Bidder shall submit calculations to support size of conductor proposed. Sizes used shall be as indicated below/ sizes as Standard specification of BIS/ sizes required to meet the design criteria as mentioned under .1 above whichever is large/ more:

(a) 6 Sq.mm Stranded GI wire • Motors and starters upto and including 2.2kW, Light

fitting, JBs, etc. • Instruments and miscellaneous small items protected

by fuses of ratings not exceeding 15A.

(b) 16 Sq. mm Stranded wire • Motors and starters above 3.7 kW and upto and

including 15 kW.

(c) 25 x 3 mm GI flat • Motors and starters above 15 kW, and upto and

including 45 kW • Control desks, cabinets, LCB, Welding socket outlet,

Isolators, LDBs. (d) 50 x 6 mm GI flat

• Motors and starters over 45 kW and HT motors • MCC, PDB, MLDB. • Main earthing ring for MCC room, in shop units/ plant

buildings • Bonds to crane gantries • Cable trays all around • LT Switchboards and other equipment protected by

circuit breakers. (e) 75 x 5 mm GI flat

• Main earthing rings • Main LT switch-boards • Transformers • Earthing leads to earth electrodes.

.11 Earthing electrodes

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The earthing electrodes shall be of GI pipes 50 mm dia and about 4 mm thickness in one piece provided with water holes and other filling devices.

,12 Earthing system for computers and microprocessor based equipment/ PCs shall be distinct and separate from the power and lighting equipment earthing system.

.13 Earthing of electrical equipment on cranes and traveling machines

• Each electrical equipment/ panel shall have double earthing.

• A ring earthing system shall be provided within the crane/ machine. Each electrical equipment/ panel shall be connected to this ring at least at two places.

• The earth ring on the crane/ machine shall be connected to the plant earthing system through the gantry rails. Two sets of earth collector brushes shall be provided on each side of crane/ machine to connect its earth ring to the gantry rails.

• Each end of each gantry rail shall be bonded to the plant earthing system.

• In addition, intermediate earthing bond shall also be provided on the rails not exceeding 60 m in case of longer tracks.

• Flexible copper bonds shall be provided across any gap in the running gantry rails.

• For mobile equipment with flexible cables, one separate copper conductor of adequate size shall be provided for earthing.

• In case any power transformer is installed on the machine, two numbers of earth cores shall be provided in power cable for earthing of neutral directly to earth electrodes.

09.06.09 PROTECTION AGAINST LIGHTNING .1 Protection against lightning to Buildings/ Junction Houses/

Structures, Yard machines etc. as per standard specification of Bureau of Indian Standards. Lightning protection system for entire plant including Air termination, separate dedicated earthing stations, conductors, isolation links for testing, interconnections and all other accessories.

.2 All buildings and plant structures vulnerable to lightning strokes owing to their height or exposed situation shall be protected against atmospheric flash-overs and lightning strokes in such a

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manner as to eliminate any danger to the personnel employed therein. Stipulations of IS : 2309 - 1969 shall be followed.

.3 A 'Faraday Cage' made of hot galvanised strip steel connected to all buried pipes and steel structures crossing this cage ring shall be laid around each main building or plant unit as earthing device. This shall be separate from the electrical equipment earthing ring main.

.4 All lightning arrestor earth leads of the buildings and plant units shall be connected to this cage ring.

.5 Air termination network should cover all salient points of the structure. All metallic chimneys, ducts and the like above the roof of the structure shall be bonded to and form part of the air termination network. Vertical air termination points shall project at least 30 cm above the object on which it is fixed.

.6 Down conductors shall follow the most direct path possible between air termination and earth termination avoiding sharp bends. Down conductors shall be insulated from supporting structure till connection to earth electrode.

.7 Down conductor shall have a testing point adjacent to the earth electrode.

.8 Each down conductor shall have an independent earth termination. All earth terminations shall be interconnected.

.9 Earthing electrodes and grid for lightning protection will be distinct separate from the earthing system for earthing of electrical equipment Earth electrodes of both systems may, however, be interconnected.

09.06.10 TESTING OF INSTALLATION AFTER ERECTION

The BIDDER shall carryout tests/ checks after erection of equipment/ cables to check, ensure and demonstrate the conformity of equipment supplied and installation done with the specification and statutory requirement. .1 SCOPE AND RESPONSIBILITY

(a) Prior to starting the test, the contractor shall ensure and satisfy himself that

• The installation is strictly in accordance with the specification, drawings and statutory requirement.

• All equipment is in proper order.

• Any automatic controls that might vitiate the tests have been relaxed.

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• All instruments to be used for testing are suitable for the purpose and have been calibrated by a recognised laboratory within the last 12 months and copy of the same have been submitted to the Owner/ Consultant.

• The installation, testing, commissioning, operation and maintenance manuals are available to the testing engineer and Owner/ Consultant.

• Formats for recording test results have been finalised with the Owner/ Consultant and copies have been distributed to all concerned.

(b) The BIDDER shall provide skilled manpower to test all the equipment, cables, earthing etc. The tests shall be witnessed by the representatives of Owner/ Consultant.

(d) The BIDDER shall compile and tabulate all the test results in agreed formats and submit to Owner/ Consultant for approval prior to acceptance of installation.

(e) Testing and commissioning shall be carried out to demonstrate and record prior to completion, that supply and installation meets the requirement/ performances specified. The installation shall be tested in presence of Owner/ Consultant.

(f) The BIDDER shall give at least 24 hours notice to Owner/ Consultant to enable them to attend the test.

(g) The tender shall submit to Owner/ Consultant test record sheets on daily basis.

(h) No equipment or any part of the installation will be energised unless all pre-energisation tests are completed and test results are approved by Owner/ Consultant.

(i) Failure to submit test results as tests are completed may render the BIDDER for carrying repeat tests.

(j) The BIDDER shall supply six (6) bound and indexed copies of all tests in agreed formats prior to preliminary acceptance and handing over of the equipment/ installation, duly signed by representatives of the Owner/ Consultant who have witnessed the tests.

(k) It will be the responsibility of the BIDDER to supply/ arrange at his own cost all necessary testing equipment and measuring equipment required for conducting the tests as per applicable standards. The testing and measuring instruments need to be

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arranged may be inclusive of but not limited to testing instruments listed under section this specification.

(l) Should any of the tests reveal any discrepancy or non-conformity, the same shall be attended to and retested before proceeding with any other tests.

(m)The BIDDER shall prepare a detailed and comprehensive check list for his use during testing and commissioning.

(n) All tests shall be conducted in accordance with this specification, standard specifications of Bureau of Indian Standards, recommendations of IEC and IE Rules.

.2 TESTS Tests checks to done at site shall be inclusive of but not limited to the following: (a) Physical Check & Verification – All Equipment/Cables etc (b) Tightness of connections – All Equipment/Cables etc (c) Checking for cleanliness – All Equipment/Cables etc (d) Size & No. of Earth connection – All Equipment/Cables etc (e) Erection, alignment, mounting – All Equipment/Cables etc

height and clearances (f) Insulation Resistance test – All Equipment/Cables etc (g) Earth continuity test – All Equipment/Cables etc (h) Earth Resistance test – All Equipment/Cables etc (i) Earth loop impedance test – All Equipment/Cables etc (j) No load & rated load current - All Motors/ Loads (k) No load & rated load P.F. - All Motors/ Loads (l) No load & rated load Power - All Motors/ Loads (m)Functional checks – All Equipment & controls (n) Primary injection test - All switchgear (o) Secondary injection test - All protective relays/ devices (p) Ratio and polarity test - CTs (q) Power frequency HV test - Power & Control circuit (r) Phase sequence checks - I/C & bus couplers (s) Winding resistance test - Motors & Transformers.

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(t) Direction of rotation - All motors (u) Free running for 2 Hrs. - All motors (v) Under voltage tests - All U/V Devices (w) Calibration Checks - All instruments (x) Load and Performance tests - UPS, PLC, & Variable Frequency equipment. (y) Checking of Voltage, current – UPS, PLC, & Variable

and Waveforms at set points frequency equipment. (z) Checking of specific gravity – Battery

and acid level (z) Illumination levels - ALL areas

.3 TESTING EQUIPMENT It is anticipated that following equipment will be necessary to perform testing of the installation. The BIDDER shall, therefore, arrange these as well as any other equipment for testing of the installation. (a) HV Testing Set (b) Primary Injection Set (c) Secondary Injection Set (d) IR Testers (e) Earth Continuity testers (f) Soil resistivity Testers (g) Earth resistance Testers (h) Phase to earth loop impedance testers (i) Mili volt drop testers (j) Micro-ohm meter (k) Phase sequence testers (l) Clip-on ammeters (m)Voltmeters (n) Power factor meter (o) Frequency meter (p) 3 Ph 4 wire unbalance load kWh meter (q) Cable fault location equipment

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(r) Digital multi-meter suitable for testing IC voltage and current levels

(s) Analogue Multi-meters (t) Portable multi-range precision ammeters, voltmeters complete

with CTs, PTs for AC/ DC circuits. (u) Protection relay test plugs (v) Portable earthing equipment (w) Dual beam oscilloscope with storage facility. (x) UV recorder (y) Illumination level meter (z) Thermometers

09.06.11 CABLING .1 All HT/LT Power, control, signal, communication cables (fiber

optic / electrical), special cables, flexible cables, illumination cables etc. as required.

.2 Festoon Cable trolley system and/or Power trolley line conductor (DSL) including rails/ angles, supporting brackets, insulator assembly, junction box etc. for Side Arm Charger, tripper car, shuttle conveyors, cranes, hoists etc.

.3 Motorized/ manual cable reeling drums for power cables, control cables with associated equipment, controls, devices and cables.

.4 Jointing kits, cable termination kits, double compression type metallic glands, compression type copper lugs, protection pipes, cable trays, supporting structures, , etc.

.5 Power and control junction boxes for termination cables as required.

.6 Separate cable tray shall be provided for power, control & lighting cables.

.7 Cables shall be clamped properly on the cable rack in such a way that position and layout of a particular length of cable shall not change throughout the rack so that it can be easily traced during maintenance jobs.

09.06.12 ERECTION TERMINATION MATERIALS AND ACCESSORIES .1 Supply of all erection accessories and materials, all steel

members (angle, channel, plate, steel sheet, etc.) for installation of electrical equipment, GI pipes, GI conduits, bends, clamps, nut,

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bolts, ladder type cable trays, GI cable trays, trays installation materials & trays accessories, cable supporting structures, heat protection materials, flexible metallic hoses, sealing materials for openings/conduits, double compression cable glands, cable lugs, cable tags, cable fasteners, insulating tapes, ferrules, RCC slabs, sand, bricks for under ground cable laying, GI pipes for protection of cables at road crossings and other places, cable markers, cable jointing & termination kits and materials, earthing strips of different sizes, junction boxes, pull boxes, heat resistance paints and all consumable materials for complete laying & termination of cables, erection of electrical equipment and earthing system etc.

.2 For installation work at site, the BIDDER shall be fully responsible for arranging the required tools and tackles, welding sets, pipe bending machine, cable crimping tools, gauges, scaffoldings, ladders, temporary water and power connections.

.3 Arranging construction power supply including PDB, power (both incoming and outgoing) and control cables, cable trays, cable laying etc.

.4 Canopy of all outdoor electrical equipment, if any.

.5 First fill of all consumables, printers, papers, cartridges, floppy, CDs etc.

.6 Safety items like hand gloves, shock treatment charts, discharge rods, rubber mats (of required voltage classes) in front and rear of all panels, danger/caution boards, fire extinguishers, fire sand buckets, nicely framed ‘As built ‘Single Line Diagram of MCCs, PDBs, MLDBs, LDBs, SLDBs keys and key boxes etc.

.7 Supply and installation of GI pipes for protection of cables at road crossings and other places where cables may be subjected to mechanical stress and damage.

.8 Supply and installation of cable supporting structures in the LT substation building, cable cellars, cable tunnel, cable channel or overhead cable bridge for interplant cable routing.

.9 No underground buried cable shall be provided. Cables shall be laid either over ground through structural cable bridge/conveyor gallery or through concrete cable trench covered with pre-cast slabs.

.10 Cables of one area/conveying route shall not cross and shall not be laid through conveyor of other area/conveying route.

.11 Furniture for the control rooms etc.

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.12 For installation work at site, the contractor shall be fully responsible for arranging the required tools and tackles, welding sets, pipe bending machine, cable crimping tools, gauges, scaffoldings, ladders, temporary water and power connections.

.13 All junction boxes and operating switches should be polycarbonate make. MS boxes shall not be used.

09.06.13 CONTROL ROOM AND DISPATCHER ROOMS

.1 The Control Room & Dispatcher room of proposed facilities can be accommodated in the same building and may be called centralized control room. Area Control Rooms/ Local control rooms may be provided for ease of operation & control.

.2 The control room and Dispatchers shall be air-conditioned and provided with false ceiling & false flooring. The respective rooms shall have following suitable aluminum framed glass partitions as listed below: (a) One partition called operator room shall house the operator

workstations, printers and other peripherals of the automation system along with Control desk (for work stations/ printers) & operator chairs.

(b) A separate partition in the control room / Dispatchers shall be used for installation of Engineering Stations, Servers (if applicable) & Software/ Hard-ware related documentation. Minimum four (2) laptops & eight (4) industrial grades PC’s shall be provided for monitoring & planning purpose.

(c) A separate partition shall be used for installation of PLC Panels, I/O panels, Instrumentation panels, weighing panels, & all other electronic panels as per the detail engineering.

All the above partitions shall be accessible directly from a common walkway.

.3 Control room and Dispatcher shall also have facility of Toilet block. Central control room shall have one conference room (with Table & Chairs for 12 persons) & Pantry. However Bidder may accommodate some of these facilities on floor below Control room also, during detail engineering.

.4 Control desks (for installation of HMIs & Engineering Stations etc) shall be of most modern & aesthetic design with Cable Management system.

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09.06.14 LT SUB-STATIONS, MCC ROOMS, ELECTRICAL ROOMS VENTILATIONS ROOMS, AIR CONDITIONING ROOMS, CABLE TUNNELS, CABLE TRENCHES .1 All civil construction work for LT sub-stations, MCC Rooms,

Dispatchers/ Control rooms, Electrical premises, cable basement/cellar, cable tunnel, concrete cable channels, cable supporting structures/ bridges etc. including their associated utility areas like Ventilation rooms, Stairs, Toilet etc.

.2 Excavations, back filling, and leveling of cable trenches

.3 Cable supporting structures in the sub-stations, MCC Rooms, Electrical Premises, dispatchers / control rooms, cable cellars, cable tunnel, cable channel or overhead cable bridge for interplant cabling.

.4 The control room and Dispatchers shall be air-conditioned and provided with false ceiling & false flooring.

09.06.15 VENTILATION/ AIR CONDITIONING OF PREMISES HOUSING ELECTRICAL EQUIPMENT .1 Air conditioning system at 23±20C complete with instruments,

electrics, controls etc. for Control rooms (housing Operator control/ HMIs, Servers, Engg. stations, Instrument panels, UPS etc) and other premises housing those equipment/ materials for which ambient temperature has been specified as 24ºC.

.2 Air conditioning system (at 35 ºC maximum) complete with instruments, electrics, controls etc. for premises housing Intelligent MCCs, MCPs & VVVF panel rooms and other local control rooms/ premises

.3 Ventilation systems complete with instruments, electrics, controls etc. for substation building, Cable tunnels, Cable basement / cellar consisting of suitable capacity fan, Pumps, GI ducting etc. for all other premises housing electrical equipment.

.4 Exhaust ventilation system for toilets, storerooms, Battery rooms etc.

09.04.16 AREA REPAIR SHOP .1 Electrical area repair shop shall be considered with a facility of

rest room, repair area, store(s) to keep tools and tackles, measuring instruments/ testing instrument including megger, clamp tester, hand held tachometer, CRO, multi-meter, vibro-meter etc.

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.2 Bidders shall submit with their offer tentative location, size & layout of each area repair shop. Bidder shall also indicate list of instruments, kits/ sets proposed by them in the Area Repair Shop. The list shall be inclusive of (but not limited to) following: (a) Battery operated 2T capacity Jo truck - 1No. (b) Cable lug crimping tool - 3Nos.

(35 sq mm to 315 sq mm) (c) Chain pulley block of 2T capacity - 2Nos. (d) Hand operated insulation Tester - 3Nos. (e) 3 ½ Digit Multi-meters - 3Nos. (f) Portable vacuum cleaners - 2Nos. (g) Infrared thermometer - 3Nos. (h) Cabinets for drawing/ document cabinets - 2Nos.

(Standard size) (i) 3 phase motor testing panel having - 1Set

Capacity to test motors up to 45 kW 09.06.17 FIRE DETECTION AND ALARM SYSTEM

Intelligent, microprocessor based, addressable type automatic fire detection and alarm system for all HT/ LT sub-stations, MCC Rooms, Transformer Rooms, Electrical Premises, Cable Cellars, Cable Basements, Cable tunnels, Cable galleries, UPS Rooms, PLC Rooms, Battery rooms, Computer Rooms, Rooms Housing Communication equipment, exchange etc.; Control Rooms, Office Rooms using smoke detectors, heat detectors with cross zoning.

09.06.18 PLANT TELEPHONE NETWORK Bidder shall provide telephone network for communication. Handsets shall also be provided by bidder. Network shall 100% spare capacity and minimum 5 pair cables shall be used. The work of bidder shall commence from HT sub-station where telephone cable termination box shall be provided by the bidder. Purchaser’s responsibility shall be limited to providing connection from this box to exchange. Size of termination box shall not be less than sum of pairs of cables (incoming+outgoing) planned to be terminated. Subscribers shall be considered at following locations: .1 Each control room (minimum 2 telephones) .2 Each sub-station .3 Each junction box .4 Each floor of technological building .5 Each junction house

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.6 Each office room

.7 Each control desk

.8 Any other place as per requirement of control and maintenance

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09.06.18 Bidder shall confirm/ submit information with offer

Sl.No. Requirement Confirmation/

information to be given by Bidder

with the offer 1.00 Compliance of Standards in Design/ Engineering/

Installation

1.01 Indian Electricity Rules 1.02 Statutory requirement of Govt. of India and State

Government

1.03 Standard Specification of Bureau of Indian standards 1.04 Inter Plant Standards for Steel Industry 1.05 Recommendations of IEC/ Other International

Standards

2.00 Compliance for Environment Conditions for Design/ Selection of Equiment

2.01 Max. temperature 50 ºC in covered areas and 55ºC in open areas.

2.02 Maximum relative Humidity 100% 2.03 Height - Less than 1000 M from MSL 2.04 Environment - Dust laden & corrosive 2.05 Confirmation that the conditions for which supplies are

designed shall be indicated and equipment/ cables selected shall be derated from their designed conditions for (a) higher ambient temperature, (b) restriction in temperature rise (c) variation in voltage, (d) variation in frequency (e) installation conditions viz proximity to heat sources, bunching, layering, separation from others/ laying in conduits etc. with respect to the conditions for which it was designed. Various derating factors considered shall be informed. supporting documents and calculations shall be submitted.

3.00 Design & Layout of Premises housing Electrical equipment

3.01 All rooms housing intelligent MCCs/ Control Panels, control rooms, PLC rooms, control cabins shall be air conditioned irrespective of the fact whether those are located on shop floor or on mobile machines.

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3.02 All rooms housing switchgears/ non-intelligent LTAC Boards shall be pressurized ventilated using cold air to maintain temperature not exceeding 38ºC.

3.03 All other rooms i.e. battery rooms, pump houses, transformer rooms etc.and rooms generating fumes /heat shall be exhaust ventilated.

3.04 All rooms housing electrical equipment shall be provided with air tight steel doors and all doors shall open towards exit side. Control Rooms may be provided with glass doors having aluminium frames.

3.05 Layout shall be made keeping provisions for future requirement as per best engineering practice (20% approx.).

3.06 Rooms & electrical premises for housing all electrical equipment/ facilities as required including A/C & Ventilation facilities shall be in the scope of Bidder.

3.07 Fire detection and alarm system shall cover all electrical premises.

4.00 POWER SUPPLY 4.01 Confirmation that equipment/ supplies have been

considered in the offer based on following fault withstand capacities

(a) 11 kV - 40 kA for 3 seconds (b) 415 Volt - 50 kA for 1 second

4.02 Standard voltage levels shal be as per of GTS.

4.03 Confirmation to the effect that offer is based on consideration that BSL's scope regarding power supply shall be limited to making 11 kV feeder breakers ( of required rating in desired quantity indicated by bidder in his offer) for meeting requirement of HT as well LT load of subject package available at MSDS IV and everything beyond this shall be arranged/ provided by Bidder without any extra cost to Purchaser.

5.00 FEEDING ARRANGEMENT FOR LOADS 5.01 Motors rated up to 90 kW shall be 3 phase 415 Volt 50

Hz motors and shall be fed from intelligent Motor Control centers (MCCs) located at load centers.

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5.02 Motors rated above 90 kW and up to 200 kW shall be fed directly from breakers of 415 Volt Power Control Center (PCC) and controlled using intelligent motor control panels provided with necessary protection and control equipment.

5.03 All motors rated above 200 kW shall be controlled from High Voltage FCMA starter with by-pass contactor as specified.

5.04 One of each type/ rating spare FCMA starters ( including cabling from HT breaker to starter in case HT MCC is not considered) have also been considered in offer.

5.05 Motors of the drives which require speed variation shall be controlled using VVVF drives.

5.06 All cranes, hoists, welding & maintenance socket outlets shall be fed from Power Distribution Boards.

5.07 All illumination loads shall be fed from Main Lighting Distribution Boards Isolation transformers and lighting Distribution Boards.

5.08 All loads of sub-station shall be fed from ACDB in LT sub-station.

6.00 Power Transformers 6.01 Power transformers shall be 11/0.433 kV, Dyn11 Dry

type

6.02 Each LT sub-station shall have two transformers or integer multiple thereof.

6.03 Rating of each transformer shall be such that it can feed total load of the sub-station plus 20% future load without being overloaded. Number of sub-stations shall be decided accordingly. An electrical premises may be designed to accommodate more than one LT sub-station and other associated equipment.

6.04 Neutral of 11/ 0.415 kV tranformer shall be solidly earthed only at one place i,e at transformer. (TN-S system)

6.05 Neutral of Transformers shall be connected to two separate earth electrodes using two separate and distinct connections each of required size/ rating.

6.06 Load break isolator with earthing switch shall be provided for each Transformer for local isolation/ earthing.

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6.07 Connection from Transformer to 415 Volt incomer shall be through bus-duct.

7.00 415 Volt PCC 7.01 No. of spare Breakers in 415 Volt PCC (20% with

minimum 1 of each type/ rating in each section of bus)

7.02 Automatic bus transfer scheme for bus-coupler 7.03 Breaker handling truck in each sub-station. 7.04 Feeders for MCCs, PDBs, MLDBs, ACDB & spares

feeders shall be provided in each sub-station.

8.00 MOTOR CONTROL CENTERS/ CONTROL PANELS/ PDBs/ MLDBs/ ACDBs

8.01 Type of MCCs - Single front Non-Drawout type Intelligent MCCs

8.02 Intelligent motor controllers for all motors shall be housed in MCCs/ MCPs (for motors above 90 kW and up to 200 kW) and no individual starter panel has been considered/ shall be provided.

8.03 Control transformers in each section of bus for control supply. Each control transformer rated to meet demand of complete MCC individually and with provision to feed either single section or all sections from either of the control transformer.

8.04 Dedicated control transfers in each incomer fed from incoming side of supply and with provision to feed control supply of bus-coupler automatically from either of the control transformers.

8.05 Intelligent starters of all drives viz pumps, fans etc. and control for scoop coupling shall be incorporated in MCC instead of providing separate panel.

8.06 Dynamic braking shall be provided for vibrofeeders. 8.07 All PDBs, MLDBs & ACDBs shall be single front draw-

out type.

9.00 SAFETY SWITCHES FOR CONVEYORS 9.01 Zero speed switches shall be electronic type 9.02 Pull wire switches and belt sway switches shall be

addressable type.

9.03 2 NC contacts of Pull wire switches and belt sway switches shall be separately wired using separate 3 core cables for each, one shall be used for hard wire interlock with MCC and another shall be used for PLC.

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9.04 Contacts of left side and right side Pull wire switches and belt sway switches shall be separately wired and brought to PLC/ MCC.

9.05 Display Panel for addressable switches shall be provided in MCC room.

9.06 Master-cum-display units shall be dual input type. One input shall be used for pull cord switches and another for beltsway switches.

9.06 Belt Rupture switches shall be provided. 9.07 Chute jamming switches shall be provided.. 10.00 AUTOMATION & CONTROL 10.01 One large screen dispay unit with dedicated PC based

control unit shall be provided in each control room.

10.02 Logic & Safety interlocks shall be achieved using PLC. Safety interlocks shall be hard wired.

10.03 Communication with automation system of existing system has been considered.

10.04 All equipment/ hardware and software for control & automation shall be of latest technology/ model.

10.05 Confirmation that software’s shall be windows operating system (latest version) based and all monitors shall be 21” TFT. Further please confirm that latest CD/ DVD reader & writer shall be provided.

10.06 A3/A4 Color Inkjet Printer for Despatcher as well as Engineering station.

10.07 132 column dot Matrix event printer have been considered.

10.08 Interfacing with existing feeding conveyors/ equipment and conveyors/ equipment being fed by/ from equipment/ conveyors under subject package for logic interlock and control including displays.

10.09 All HT/LT MCCs shall be provided with current signal convertors and hooked with PLC

10.10 OFC cable shall be used for communication among vrious premises and necessary media converters/ repeaters have been included.

11.00 UNINTERRUPTED POWER SUPPLY SYSTEMS 11.01 Uninterrupted Power supply Systems for

(a) Automation & Control equipment in control rooms.

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(b) Intelligent MCCs and I/O Racks (c) Instrumentation systems (d) Fire detection & Alarm systems. (e) Communication systems (e) Any other requirement as per TS/GTS

11.02 UPS systems shall be hot redundant with static transfer switch which will have switching time so as not to result in any adverse effect on load side during switching. By-pass switch from normal supply shall also be provided.

11.03 UPS shall be on-line type and provided with isolation transformer on load side.

12.00 Cables 12.01 All 11 kV cables shall be 11 kV (Unearthed) grade

XLPE insulated, armoured PVC sheathed FRLS cables.

12.02 All LT power cables shall be 1.1 kV grade XLPE insulated, armoured PVC sheathed FRLS cables.

12.03 All control cables shall be 1.1 kV grade stranded copper conductor, XLPE insulated, armoured PVC sheathed FRLS cables.

12.04 Heat resistant cables shall be provided wherever required.

13.00 LIGHTING 13.01 Lighting Transformers (Isolation transformers) for

lighting loads

13.02 Group control using 24 hour programmable timers or using photo sensors for outdoor area/ road lighting.Group control through PLC for lighting of conveyors, junction houses and technological buildings. Local/ remote/ auto selector switches and ON/ OFF push buttons for local control have been considered. Fittings in LT sub-stations, electrical rooms, control rooms and office buildings shall be controlled using switches.

13.03 Illumination of offices rooms/ sub-stations/ electrical rooms/ control rooms using fluorescent lamp fittings

13.04 Emergency lighting for evacuation purposes 13.05 Vibration proof fittings shall be used for illumination on

mobile machines and for chutes.

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13.06 Mobile staircase shall be provided for maintenance of light fittings as required.

14.00 EARTHING 14.01 All parts of all electrical equipment in the Complex not

intended to be alive shall be earthed in accordance with the provisions of IS: 3043, Indian Electricity Rules and IEC recommendations.

14.02 For all mobile machines, earth conductors (2 Nos. of required size & rating) shall be taken through power cable reeling drum. In addition to this, equipotential bonding shall be provided through earth brushes on LT wheels and rails.

14.03 Size of earth conductors shall be provided to meet the stipulations under chapter Earthing (Design Criteria) in NIT specification. Minimum size of earth conductor to be provided shall be as per stipulations of GTS.

14.04 Protection against lightning shall be provided as per stipulations of IS 3029.

15.00 MISC. Requirement 15.01 Operation of AC. Ventilation & Pressurisation systems

shall be interlocked with fire detection systems for safe operation.

15.02 All technical drawings/ documents/ test results required for getting approval of installation from CEA and/ or electrical inspectorate of the state as required, shall be prepared and submitted.

15.03 Presence of fire is automatically announced in the affected area by sirens/ hooters or any other methodology and signal/ message is sent to personnel who are expected to attend the emergency

15.04 All electrics required for completion of Project within battery limits shall be deemed to be included in offer and provided whether specifically mentioned in offer or not.

15.05 Make of equipment/ components shall be as per preferred makes of BSL.

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15.06 Additional makes shall not be considered by purchaser at bid stage. During execution stage, in case bidder seeks approval to include additional vendor stating grounds thereof (other than the ground to include vendor of bidder's choice) the same shall be examined by purchaser and decision communicated. This shall, however, not have any adverse effect on the project schedule. In case it is found at any stage of the project that the grounds on which approval of additional vendors was sought are incorrect, the approval accorded shall stand withdrawn.

15.07 Drawings/ documents shall be checked by Bidder themselves for completeness, compliance with the order and authenticated before submission.

15.08 Drawings/ documents having different title shall not be assigned drawing/ document number. Drawing documents bearing same drawing/ document number shall not have same title.

15.09 Drawing documents shall be submitted shall be easily readable and shall be submitted in same size in which those are prepared and not reduced photocopies.

15.10 Bidder shall ensure that drawings 'Approved as Noted' are revised and approval is obtained on revised drawings before equipment manufactured based on approved drawings is despatched form manufacturer's works.

15.11 Engineers of Bidder have visited site, made themselves aware of existing facilities, site conditions, type & extent of work involved to complete the project and have taken care of the same in their offer.

16.00 Bidder shall confirm that following (as per stipulations of TS/ GTS and as applicable) are included in offer.

16.01 LT sub-stations 16.02 Starters for 11 kV Motors 16.03 Intelligent Motor Control Panels for motors rated above

90 kW and up to 200 kW

16.04 Intelligent Motor Control Centers 16.05 PDBs, MLDBs & ACDBs. 16.06 Soft starters 16.07 VVVF drives 16.08 Electrics for Conveyors.

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16.09 Electrics for shuttle conveyors 16.10 Electrics for scoop coupling 16.11 Electrics for display of address of Pull Cord and Belt

Sway Switches in Display Panel in Control Room.

16.12 Electrics for Vibro-feeders 16.13 Electrics for trippers 16.14 Electrics for actuator operated gates 16.15 Magnetic separator panels 16.16 Electrics for suspended/ tramp iron magnets 16.17 Metal Detectors 16.18 Weigh feeder panels 16.19 Belt scale panels 16.20 Weigh Hoppers 16.21 Continuous level monitoring system for silos. 16.22 Electrics for A/c & Ventilation systems 16.23 Electrics for dust suppression/ dust extraction/ fluid

systems

16.24 Electrics for cranes 16.25 Electrics for hoists 16.26 Electrics for Repair Network 16.27 Electrics for any and all other equipment/ systems/

facilities included in the scope of work under the package.

16.28 Area repair shop (s) 16.29 Erection, laying, termination Materials 16.30 Testing & Commissioning of installation & post

commissioning services shall be provided as required/ as per stipulations of NIT document.

17.00 Cabling from MDF or cable termination box in control room building to subscribers for Plant telephone network.

18.00 Bidder has submitted/ mentioned/ indicated in his offer

18.01 Number and rating of 11 kV feeders required by Bidder to meet requirement of subject package indicating maximum demand of each feeder.

18.02 Maximum demand for subject package (inclusive of future requirement) with details.

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18.03 Complete load list (MCC/ PDB/ MLDB wise) indicating details viz. fed from, description of load, number of drives (working & standby), voltage, rpm, type of motor, duty class, speed variation requirement (fixed/ variable), Type of starter considered and method of speed control.

18.04 Over all single line diagram for complete electrics included in offer from battery limit of supply by purchaser to incomers, bus-coupler & bus-bars of MCCs, PDBs, MLDBs, ACDBs, Motor control Panels, motors above 90 kW inclusive of HT Panels, transformers, PCCs etc.

18.05 Layout of plant showing tentative locations of sub-stations, Electrical Rooms/ MCC Rooms/ Control Rooms/ I/O Rack Rooms/ Battery Rooms etc. and Major cable routes proposed by Bidder.

18.06 Single Line Diagram showing details of Emergency lighting included in offer

18.07 System configuration drawing for Automation with specification of equipment considered in offer.

18.08 Basic scheme drawing for fire detection, alarm and control system giving detais of equipment/ system

18.09 Commissioning spares 18.10 Insurance Spares 18.11 Special tools & tackles, instruments & calibration

equipment/ devices

18.12 List of spares recommended for 2 years normal operation

18.13 Clause wise deviations, if any, from NIT specification have been indicated in the offer.

18.14 Clauses on which deviations have not been indicated are acceptable to bidder.

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6.10 INSTRUMENTATION & CONTROL

6.10.01 GENERAL

01. This specification is intended to define the basic requirements for instrumentation and control system for raw material handling complex coming under the 5.77 MTPA expansion of Bokaro Steel Plant (BSL) with a view to achieve smooth, efficient, safe and reliable operation of the process.

02. This specification, read together with the Instrumentation &

Automation part of the General Technical Specification (No.GS-03), General Conditions of Contract (GCC) and other commercial terms & conditions, shall form the Tender document, against which selected vendors (here-in-after called Tenderer) shall submit their complete & most competitive techno-commercial offers.

03. Measurement and control equipment offered for the process shall

be complete in all respect in line with this specification. Any equipment / accessories not explicitly indicated in this specification, but considered essential for proper functioning of technological equipment and process shall be included by Tenderer in their scope of work and supply.

04. Monitoring, Control & Alarm functions for the process parameters

& equipment of the raw material handling complex shall be achieved through PLC based automation system & electronic instrumentation equipment. The sequential operation and interlock functions of the process & equipment related to Electrical facilities shall be achieved through PLC based automation system. The requirement regarding automation system has been separately described under ‘Automation system (level-1)’ chapter of this Technical Specification.

05. Instrumentation equipment & system of the plant shall be in

general 4-20 mA DC compatible type and shall be interfaced with the PLC based automation system through signal conditioning / isolator modules ( as applicable). Signals from these instruments shall be interfaced through hardware input/ output modules of PLC system.

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06. Other features of the instrumentation facilities shall be as indicated in the Instrumentation part of General Technical Specification (No.GS-03) attached with this Tender.

07. The raw material handling complex shall be provided with

dispatcher Control Room in various areas which will house the automation system. The dispatcher control room shall be air-conditioned.

08. The field signals which are to be interfaced with the I/O system of

PLC shall be brought to respective dispatcher control rooms of raw material handling plants through Junction Boxes at field and terminated into the respective PLC panel, as per the finalised cable schedule and wiring & termination drawings of the successful Tenderer. To avoid long distance signal wiring, remote I/O system shall be employed.

09. All the instrumentation & control equipment shall be brand new &

supplied from the latest product ranges of reputed manufacturers as per the List of Preferred Makes, furnished in this TS. Purchaser/ Consultant reserve the right of selecting particular make and model of instrumentation equipment with a view of standardisation of the whole plant. Tenderer shall comply with such requirements. All equipment envisaged shall be suitable for round the clock operation throughout the year.

10. All field-mounted level transmitters shall be radar type. Control

room instrumentation equipment shall be the PLC based, automation system with visualization system, working on 240 V AC, 50 Hz power supply system. Auxiliary relays shall be envisaged for process and safety interlock functions. Interlocking contacts & other important signals from these areas will be connected through signal isolator/ distributors to PLC based control & automation system of respective technological units for integrated plant operation and management information functions.

11. Tenderer shall execute complete instrumentation package on

turnkey basis to the satisfaction of Purchaser/ Consultant. Tenderer shall comply with all the requirements indicated under General; Scope of Work and Supply; List of Measurement,

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control, alarm & interlock; Submission of Drawings & Documents and other related clauses/ annexure included in this specification.

12. All correspondences / documents shall be in English language

and for all the data, drawings & documentation metric or SI units shall be followed.

6.10.02 SCOPE OF WORK AND SUPPLY

Tenderer’s scope of work and supply shall include design; engineering; manufacture/ procurement; assembly; calibration; shop testing; inspection at works & at site; painting; packing; transportation to site including loading, unloading, storage & handling of all instrumentation & control equipment including electrical accessories, cables, pipes, erection accessories, panels/ cabinets and all associated hardware, as required for completeness of instrumentation system in all respect along with site fabrication, erection, testing, commissioning of the complete instrumentation system for completeness & satisfactory stable operation of raw material handling plants. The scope of work shall also include liquidation of defect points, participation in tests for establishment of plant performance guarantee (PG) and post commissioning activities till issue of final acceptance certificate (FAC) by BSL. The scope of work and supply shall also include, but not limited to, the following:

- Instrumentation equipment as per the measurement list covered

elsewhere in this TS.

- All electrical accessories for instrumentation system including UPS and other instrument power supply equipment as applicable.

- All types of control, signal, LT power & special cables, as

required for this package. - Fully wired cabinets / panels, junction boxes, pull boxes,

transmitter cabinets, etc

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- Galvanized trays, protection pipes, fittings, steel structures & frames, erection hardware & accessories, as required for this package.

- Submission of drawings and documents described elsewhere in

this TS. - Erection, testing, calibration and commissioning of the total

equipment included in this specification. Successful Tenderer shall arrange tools, tackles and consumables as may be required for erection, testing, calibration and commissioning activities.

- 1(One) no. hand held universal type calibrator having sufficient

memory capacity and with battery & battery charger as required for calibration of all level transmitters. All the necessary software shall be loaded in the calibrator.

- Preparation of earthing pit, supply of earthing materials including

cables and installation of separate earthing system for case earthing, power and instrument signal earthing.

- Arrangement of and participation in inspection of

Instrumentation equipment by Purchaser/ Consultant. Inspection and Testing shall be carried out in compliance with the Quality Assurance Plans, to be approved during detailed engineering stage.

- Scope includes arranging visits by respective instrumentation

equipment manufacturer’s representatives at site, as & when required, during erection & commissioning.

- Providing training to Client’s personnel on instrumentation

equipment at manufacturer’s works and also at site. - Two years maintenance spares and consumables. - Commissioning spares and three months consumables. - Supply of all instrumentation equipment from “List Of Preferred

Makes” ( GS-13) as attached with this Tender.

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- Compliance with Instrumentation part of ‘General Technical

Specification’ (GS-03) as attached with this Tender. 6.10.03. Measurements & Controls:

Following are the indicative list of measurements, controls, alarms & interlocks for raw materials handling complex and Tenderer shall comply with the same. However, Tenderer shall offer equipment for all the measurements, controls, alarms & interlocks as may be required for stable, efficient & satisfactory operation of the offered system, and indicate detailed list of the same in their offer. Unless otherwise stated, all monitoring & control of the process parameters shall be achieved in PLC based automation system and displayed in HMI stations. The field instrumentation equipment shall be offered accordingly. Bunkers as mentioned below have been indicated in the enclosed drawings for reference.

The measurements & Controls for raw material handling plants shall include, but not limited to, the following: 1. Measurement & signaling (high) of level of materials ( lump iron

ore) in bunkers (4 nos.) with high level alarm in nearby dispatcher control room.

2. Chute jamming detectors in all the transfer chutes.

6.10. 04. LIST OF DRAWINGS & DOCUMENTS

Following drawings and documents shall be submitted by the Tenderer for Instrumentation system:

A) TO BE SUBMITTED ALONGWITH OFFER

01 Process and instrumentation (P & I) diagram indicating all local & remote measurements, controls, alarms and interlock functions, using ISA symbols and using suitable tag numbers against each instrumentation equipment.

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02 List of measurements, controls, alarms & interlocks, along with BOQ and brief specification of each instrumentation item.

03 Detailed technical literature of the instruments offered. 04 Total power requirement for instrumentation & control system. 05 List of commissioning spares as included in the offer with details. 06 List of recommended spares for two years operation &

maintenance with details & unit rates.

B) TO BE SUBMITTED BY THE SUCCESSFUL TENDERER DURING DETAILED ENGINEERING

I) For Approval : 01. Finalised process and instrumentation (P & I) diagram indicating all

local & remote measurements, controls, alarms and interlock functions, using ISA symbols and using suitable tag numbers against each instrumentation equipment.

02. Finalised list of measurements, alarms & interlocks, along with BOQ and specification of each instrumentation item indicating make, model number, scale range, quantity, application and tag number (as per P&I diagram).

03. Detailed specification datasheet for each instrumentation item, filled in as per the format finalized for this plant.

04. Overall general arrangement drawings & sectional views of various cabinets, panels, consoles, etc., showing internal disposition of all components/ units, with dimensional details and bill of materials.

05. Single line power supply diagram with specification and bill of quantities of electrical accessories along with that of UPS.

06. Quality assurance plan for each instrument & control system.

II) FOR SCRUTINY AND REFERENCE

01. Detailed technical literature/ catalogue for each instrumentation item.

02. Instrument Installation/ Hook up diagrams with bill of materials. 03. Instrumentation layout drawings showing location of instruments

and route of cables from these upto control room. 04. Wiring and termination diagrams with details of termination of field

signals to local JBs/ panels and from JBs to panels/ marshalling racks/ cabinets including internal wiring drawings.

05. Loop schematic diagrams.

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06. Cable schedule and specification. 07. Control room layout drawing showing disposition of panels,

consoles, desks, etc. 08. System grounding scheme. 09. Manufacturer’s test, calibration and guarantee certificates for all

instruments. 10. Operation and maintenance manuals for instruments. 11. ‘As-built’ documentation. 12. Soft copy of all the above drawings & documents in CD-ROMs/

DVDs.

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BSL

STEEL AUTHORITY OF INDIA LIMITED BOKARO STEEL PLANT, BOKARO

TECHNICAL SPECIFICATION FOR RAW MATERIAL HANDLING SYSTEM.

PACKAGE – 066.

© 2009. MECON Limited. All Rights Reserved. TELECOMMUNICATION Page 1 of 2

06.11 TELECOMMUNICATION & V.H.F SYSTEM.

06.11.01 General

This section covers major features of Telecommunication & V.H.F system. to be supplied by Bidder for Augmentation of Raw Material Handling System. under 5.77 Mt Expansion Project.

The Bidder shall refer to General Technical Specification for Telecommunication, V.H.F system for detailed specification of equipment / components. This Technical Specification (TS), General technical Specification (GTS) including Preferred Makes for Equipment and supplies and other attached documents considered, as a whole shall comprise the complete Tender Specification. These are complementary and anything laid down in one and not in other will be deemed as binding, as though laid down in the Tender specification as a whole. In case of conflict between the Technical specification and GTS, the Technical specification (TS) shall prevail.

06.11.02 Scope of Work

The scope of work of Bidder shall cover design, basic and detailed engineering, supply, submission of drawings for approval, manufacture, testing, inspection by Purchaser/Consultant, packing, loading, forwarding, delivery at Plant site, loading/unloading, storage, handling of material / equipment for erection testing, commissioning, PG test, PAT/FAT and liquidating the all defects related to Communication & V.H.F equipment for complete & satisfactory operation of the system on Turnkey basis.

Any item or equipment not specifically mentioned but essential for proper

installation, operation, maintenance and safety of plant, equipment and personnel shall be included by the Bidder in his scope of work

The scope of work for this package shall include but not limited to the following: -

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PACKAGE – 066.

© 2009. MECON Limited. All Rights Reserved. TELECOMMUNICATION Page 2 of 2

a) LOUDSPEAKER TALK BACK (LSTB) SYSTEM

Loudspeaker talk back system shall be provided for facilitating reliable two-way intercommunication between various strategic points of the plant complex i.e. Junction houses, Conveyor galleries, tunnels, Wagon tippler building, Control room, Storage yard etc. The subscriber stations shall be provided at locations having very high ambient noise level. List of subscribers with type of station shall be prepared by the successful Tenderer. For other technical details of system, equipment and cables refer GTS.

b) VHF COMMUNICATION SYSTEM:

V.H.F. Communication system with the required number of Trans-receiver sets shall be provided. Each trans-receiver set shall be complete with transmitter, receiver, suitable antenna units, masts for antenna (as required),cables, connectors, power supply equipment, earthing of system, mounting accessories and all other erection accessories as required for the completeness of system. In addition to the above hand held trans-receiver sets shall be provided with DTMF dial pad to interface with telephone exchange of the Steel plant. Telephone interface equipment shall also be provided. The frequency allocation for operating V.H.F system shall be obtained by the Tenderer, a separate frequency preferably 149.75 M.Hz., from the Wireless Planning Commission, ministry of communication. The purchaser shall provide the necessary help to the Tenderer, if so needed for obtaining the same, without financial implication to the Purchaser. For other technical details of system and equipment refer GTS.

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07.00 SPARES, CONSUMABLES, TOOLS & TACKLES AND CONSTRUCTION EQUIPMENT

07.01 Commissioning Spares

Supply of commissioning spares as required shall be in the scope of supply of the Tenderer along with the equipment. The list of commissioning spares as per the format as given in SBD shall be furnished along with the tender. It shall cover requirements of erection, cold tests, startup and initial operation of the plant till integrated testing & successful commissioning and commencement of commercial production up to a period of six months. Any leftover commissioning spares shall be the property of the Purchaser. Any commissioning spares required over and above the list given by the Tenderer shall have to be provided by the Tenderer free of cost up to the successful commissioning & commencement of commercial production of the plant and equipment.

07.02 Consumables

The Tenderer shall supply all consumables such as initial fill of lubricants, oils, grease, chemicals, refractories, resins etc. as required to complete the plant till commissioning and shall have a shelf life of minimum one year. The scope of consumables shall include electrodes, shims, packing, bolts, nuts, gaskets, rivets, washers etc. The Tenderer shall fulfill the requirement given in SBD.

The Tenderer shall also furnish Indian equivalent of oils, lubricants, refractories and other consumables along with necessary specifications, drawings, catalogues etc. to enable the Purchaser to procure them from indigenous sources.

The Tenderer shall indicate the annual requirement of all such consumables.

07.03 Operating, Maintenance and Two Years’ Spares

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07.03.01 The Tenderer shall ensure the interchangeability of the parts wherever

possible. The Tenderer shall furnish an itemized list of interchangeable spares as given in SBD.

07.03.02 The list of spares as necessary and recommended by the respective

manufacturer for two years’ of reliable and trouble free operation and maintenance of all equipment under this package shall be in the scope of the Tenderer. The same shall be quoted separately. In the event of order the successful Tenderer shall furnish complete specification of the same.

07.03.03 Spares list giving complete list of the replaceable parts, fully illustrated,

shall be quoted separately. The list shall include the following information.

• Item designation

• Reference drawings

• Quantity installed

• Quantity recommended for two years’ normal operating including

the insurance spares

• Weight of each spare part

• Supplier or sub-supplier’s catalogue number

• Recommended minimum stock

• Expected replacement time

• Installation instruction in detail shall be supplied both for original

installation and future, for replacement of major electrical

equipment, circuit wiring diagram shall be provided

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07.04 Special Erection/ Maintenance Tools and Tackles 07.04.01 The Tenderer shall supply a complete and unused set of all the special

tools and tackles including required number of toolboxes as required for erection, maintenance, overhaul or complete replacement of the equipment and components required for the plant. The Tenderer shall submit a list of such special erection and maintenance tools and tackles.

07.04.02 All the tools shall be supplied in separate containers clearly marked with

the name of the equipment for which they are intended. 07.04.03 The Successful Tenderer shall indicate list of construction machineries,

handling equipment and other facilities including tower crane or equivalent for erection at high elevation required for the execution of work based on their previous experience, considering site conditions and other considerations of work and furnish resource deployment plan. The successful Tenderer shall mobilize these equipment at site for the execution of work and this is an important requirement of the project. The availability of required facilities shall be ensured for completeness of the project in time.

07.04.04 For any fabrication/ control assembly (necessary for erection) work to be

done in the plant premises the plan shall be indicated by the Tenderer. The necessary equipment such as plate bending machines, special purpose welding machines, fixtures, tools & tackles and other equipment required for fabrication shall be arranged by the successful Tenderer.

07.04.05 The successful Tenderer shall carry out the testing of welded joints by

radiographic and ultrasonic methods. They must have only qualified/certified welders with them for completing all the welding jobs.

07.04.06 All the measuring instruments shall be calibrated having reference to

NPL (National Physics Laboratory).

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07.04.07 All tools and tackles, apparatus, special instruments required for erection, testing, commissioning and establishment of the Performance Guarantee Test, measurements required for establishing the pollution control norms and such other instruments, as required, shall be arranged by the successful Tenderer. After commissioning, the successful Tenderer shall handover all the special tools & tackles to the Purchaser as per the requirement given in SBD.

07.04.08 The successful Tenderer shall supply all required consumables, initial

fill, oil, lubricants, construction and erection materials including but not limited to shims, packing plates, joining compounds, kerosene, solvents, sealing compounds, tapes, connectors, brazing and soldering materials, welding and brazing gases and rods, electrodes and wires, erection bolts, nuts, rivets, piano wire, packing sheet and packing compounds, temporary supports, spacer templates, jute and cotton waste cloth, sand and emery paper etc. for the commissioning of the plant.

07.04.09 For load testing of handling equipment, loads shall have to be arranged

by the successful Tenderer. Electrical/ operation tests, as per standard practice, shall also be arranged and completed by them.

07.04.10 All materials, equipment, tools, tackles etc. brought at site by the

successful Tenderer within the plant area shall not be removed without the written permission of the Purchaser. Similarly, all enabling works built/erected and/or acquired by them within the plant premises shall not be dismantled and removed without the written permission of the Purchaser.

07.05 General tools and tackles

A list of general tool and tackles to be supplied shall be indicated as per the format given in schedule at chapter 12.

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07.06 Information/ Data on Spares and Consumables

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

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08.00 PERFORMANCE GUARANTEE

08.01 General On completion of erection of the plant units along with utilities and auxiliaries by respective package contractors as per approved drawings / documents as well as detailed drawings, the successful tenderer shall undertake preliminary Acceptance Test (PAT) i.e. cold test, to prove that the unit has been supplied as per agreement and after erection the unit is fit to be started up and commissioned. The PAT shall be followed by commissioning (hot trials) to demonstrate that the unit is fit for commercial production.

08.01.01 Preliminary Acceptance Test (PAT)

001 Cold tests shall be performed on the individual sub-assemblies of the

unit and shall be designed to conduct the systematic check of the components and of the functional operation thereof.

002 Cold tests shall comprise idle, no-load tests. Cold tests shall be

conducted by the successful tenderer under his sole responsibility. The purchaser will provide skilled operating personnel during the cold test.

003 A detailed programme of cold tests shall be drawn up by the successful

tenderer and shall be subject to the approval of the purchaser / consultant. Such programme may be revised and adjusted as may be required by the purchaser during the test run.

004 Results of cold tests shall be recorded jointly by the successful tenderer

and the purchaser. 005 On successful completion of preliminary acceptance tests, and

liquidation of the defects list, preliminary acceptance certificates shall be issued by the purchaser.

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08.01.02 Successful Commissioning (Hot Trials) 001 Within 60 (sixty) days from the date of issue of preliminary acceptance

certificates, the successful tenderer shall start-up and commission the unit in an integrated manner under his sole responsibility.

002 During the start-up and commissioning, the successful tenderer shall

perform the required adaptation, adjustment and hot run the Plant & Equipment to demonstrate its production capacity.

003 The purchaser shall, for the purpose of start-up and commissioning,

provide operating personnel as may be available with him for normal operation, who shall work under the instructions and guidance of the successful tenderer.

004 Start-up and commissioning of the unit shall be taken up only when

material handling system, electrical power system, inter-plant fluid system and auxiliaries serving the unit as well as the preceding / succeeding plant units are under normal operation and / or feed material is available. The successful tenderer shall rectify the defects observed during commissioning.

005 The quantities of starting material and facilities necessary for conducting

the commissioning shall be mutually determined by the successful tenderer and purchaser.

006 Commissioning of the unit shall be deemed to be successfully

completed, when the total commercial production of about 10,000 tonnes of material – or- ten(10) days of rated material is successfully transported, for the particular circuit.

007 Results of start-up tests and commissioning shall be recorded jointly by

the successful tenderer and the purchaser. 008 On successful completion of commissioning of the unit and its

commencement of commercial production as per clause 08.01.02.006, commissioning certificate shall be issued by the purchaser within 15 days.

009 The unit shall be taken over by the purchaser when:

a) Commissioning certificate as per clause 08.01.02.008 has been

issued by the purchaser.

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b) The successful tenderer has submitted all final documents in

compliance with the provisions of this specification.

c) The successful tenderer has supplied all consumables, change parts, special tools and tackles and commissioning spares.

d) The successful tenderer has met, to the satisfaction of the

purchaser, all the observation, if any, contained in the Preliminary Acceptance certificate.

08.02 Performance Guarantee Tests (PG)

001 After successful commissioning of the plant & equipment, the tenderer shall offer the plant for conducting performance guarantee tests as mutually agreed upon between the purchaser and tenderer.

002. The tenderer shall supervise and carry out the operation under their instruction and guidance during performance guarantee tests and shall take full responsibility of the operation. The purchaser will make available necessary operating and maintenance personnel as per the agreed manning schedule as well as the raw materials, utilities and services etc, as specified.

003 The tenderer shall submit the scope, general preconditions, test procedures, guaranteed values and test evaluation methods which shall be finalised during tender discussion.

004 The performance tests for all plant equipment shall be carried out to satisfy all operating parameters as per the relevant clauses of the Technical specification for the equipment under consideration.

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Performance Guarantee Test

Sl. No. Description Acceptable Acceptable

with penalty Liquidated Damages Rejected

1 Wagon Tippler

20 tippling per hour

Nil Not applicable Less than 20 wagons per hour

2 Side Arm Charger

6600t rake pulling and placement of 20 wagons per hour

Nil Not applicable Below TS values

3 Conveying capacity

As per rated capacity

Nil Not applicable Less than acceptable limits

4 Environment Norms

As specified in TS

- - Less than acceptable limits

The performance guarantee test shall be performed for each sub section continuously for 10 days. Continuity of operation however, be limited by availability of raw materials for unloading and stacking and availability of storing capacity on delivering end. Wherever equipment in the sub section is of stand by nature, each such equipment shall operate for at least 10 hours on load in the period. The performance guarantee test shall also be performed for the complete system for 5 days on round the clock basis. In case the test is disrupted due to equipment or facilities supplied by others, the performance is to be repeated for two more times after rectification of fault of the equipment or facilities supplied by others. Repair / Rectification of fault shall be done by others. If the test is disrupted even after that, the performance test shall be on the basis of total hours of un interrupted operation of the system 200 hours for sub section and 100 hours for total system. However, there should not be any failure of the equipment supplied by Contractor between starts and finish of this time counting. If the operation stops due to failure of any item supplied by contractor, the operating hours prior to such failure will not be counted. In case some equipment can not be tested within the period of testing because of failure of equipment or facility provided by others, the same will be accepted on the basis of load test result for the limited period or no – load test result where load test could not be performed at all.

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The contractor shall prepare and submit a draft performance test procedure for each equipment and system within 12 months of order. The final performance test procedure will be prepared jointly by the purchaser / consulting engineers and the contractor based on the draft performance test prepared by the contractor and various requirement indicated in the contract specification and the order.

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Page 1 of 4

09.00 PROJECT SCHEDULE & PROGRESS MONITORING 09.01 The project envisages augmentation of Raw Material Receipt and

Handling System for Bokaro Steel Plant (BSL), Bokaro. Augmentation of Raw Material Handling System, including design and engineering, manufacturing of equipment, delivery, civil work, structural fabrication and erection including technological structures, erection of equipment, testing and commissioning, shall be completed within the overall schedule of 24 months from Zero date which shall be reckoned as Effective date of contract for the package. Zero date and commissioning mentioned above and as shown in the schedule shall be same as defined in the technical and commercial part of the specification. The project will be executed on turnkey basis, including civil and structural work. However, feed–back data for utilities and services for preparation of technical specification by Purchaser / Consultant for items not included in tenderer’s scope shall be furnished by the successful tenderer.

An indicative Implementation Schedule, in line with the total time period and indicating the major activities, is shown in drg. no. MEC/S/E24F/11/PY/0/00/00/066.01-R0 for reference.

09.02 Project Schedule 09.02.01 The Tenderer shall submit the following along with the offer:

i) Overall bar-chart schedule

The heads to be covered in the schedules shall broadly be as follows: • Basic engineering and approval • Preparation and issue of ordering / technical specifications

for sub-vendors • Placement of orders on sub-vendors • Detailed design, engineering and approval • Manufacture and supply of equipment/ piping/ cables, etc

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Page 2 of 4

• Civil work • Fabrication and erection of all structures including

technological structures • Submission and approval of erection drawings and

manuals • Erection of equipment, piping, cables, etc. • Testing, trial runs and commissioning

The major milestones for the project are to be highlighted in the schedule.

ii) The tenderer shall submit an overall erection plan for the plant

and equipment under his scope of supply along with the tender. The plan shall include the following :

• Requirement of construction water • Requirement of construction power • Requirement of equipment storage area • The Off-site & On-site organization chart for execution of

the project

09.02.02 The Tenderer shall submit the following before finalization of contract:

i) Deployment of man power for construction / erection

ii) Special erection techniques to be employed, if any

iii) The list of construction / erection equipment and machinery, tools & tackles, etc, and details of deployment of the same

If simultaneous erection work is carried out along with civil and structural works, the movement of men, machine and materials at site shall be planned suitably

09.02.03 The Successful Tenderer shall have to submit the following: i) The detailed project network schedule both in hard and editable

soft copy (in MS Project / Primavera) covering further details of project and erection activities, area-wise, shall be submitted

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Page 3 of 4

within 2 months from zero date for approval and finalisation by the Purchaser / Consultant.

ii) The format of progress report shall be discussed and finalised

within 1 month from zero date.

iii) The progress report (in approved format) shall be submitted every month.

iv) Updated detailed project network schedule (in hard and soft

copies) shall be submitted every month along with progress report.

v) The erection micro-schedule during execution stage is to be

submitted 2 months before start of erection at site. However, the micro-schedule shall cover only the critical areas.

09.03 Progress Monitoring 09.03.01 An effective system of progress monitoring is to be evolved to ensure

timely completion of all project activities. In general, progress of the following major activities is to be reported.

• Issue of ordering / technical specifications and placement of

orders on sub-vendors for bought out items / components. • Detailed design and engineering including submission of

drawings and their approval. • Manufacturing activities at the works of the Contractors /

associates / sub-vendors. • The progress report on inspection status. • Dispatch of equipment to site. • Site activities including receipt of material / equipment at site, civil

work, structural fabrication and erection including technological structures, equipment erection, testing and commissioning.

A monthly progress report showing current status of various activities including status of ordered / yet to be ordered items shall be submitted to the Purchaser / or his consultants by the contractor. The monthly

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progress report shall also indicate progress of activities against targeted dates and targeted quantities. Reasons for shortfalls, if any, shall be clearly brought out and proposed remedial measures to arrest the delays shall be indicated by the contractor in the progress report, wherever applicable. The contractor shall submit a schedule for site-execution, along with quantitative program in terms of month-wise physical targets for various disciplines of work, two months before start of site activities. After the site activities are started, the contractor shall furnish information on site activities viz: daily, weekly and monthly progress reports for construction / erection, receipt of equipment, monthly construction / erection plan, etc. The contractor shall also indicate resource deployment at site, highlights of critical areas and constraints in the site progress reports. Other information related to site activities as may be required by the Purchaser / Consultant, shall also be submitted by the contractor. In the interest of timely completion of the project, the area of monitoring may be altered in consultation with the Purchaser / Consultant, if required.

09.03.02 The Purchaser/Consultant shall also have the Right to:

• Invite the Contractor for monthly / fortnightly meetings to review the progress of each activity.

• Depute Purchaser’s authorised representatives for ascertaining /

expediting progress at contractor’s works. • Suggest remedial actions to bridge-up time gap between planned

progress & observed progress.

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ID Task Name Dur (w)1 BSL Expansion - Raw Material Handling

System104 w

2 Effective Date of Contract (Zero-date) 0 w

3 Basic Engineering & Approval 22 w

4 Tendering & Ordering on Sub-vendors 30 w

5 Detailed Engineering & Approval 56 w

6 Civil Work 65 w

7 Fabrication & Erection of Structures (incl.Tech. Str)

69 w

8 Delivery of Equipment 52 w

9 Erection of Equipment 56 w

10 Testing & Commissioning - Utilities &Services

9 w

11 Testing & Commissioning - RMHS 13 w

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

Task Milestone Summary

STEEL AUTHORITY OF INDIA LIMITEDEXPANSION OF BOKARO STEEL PLANT TO 7.0 MT

AUGMENTATION OF RAW MATERIAL RECEIPT & HANDLING SYSTEMINDICATIVE IMPLEMENTATION SCHEDULE

'© 2007 MECON limited. All rights reserved’ 1 of 1 DRG. NO. MEC/S/E24F/11/PY/0/00/00/066.01-R0

File: BSL_Exp_RMHS_TS_sch_Pkg-066.

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© 2009. MECON Limited. All Rights Reserved. CHAP-10 DRGS_DOC SUBMSN Page 1 of 1

10.0 DRAWINGS AND DOCUMENT TO BE SUBMITTED

All Drawings and document to be submitted by the Tenderer and the

successful Tenderer are indicated in the respective Technical

Specifications of the various equipment covered in the GTS or in

Chapter 06.01 of this Technical Specification.

The Tenderer shall go through the list of Drawings and document and

submit all relevant drawings/ document as stipulated.

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© 2009. MECON Limited. All Rights Reserved. CHAP-11 LIST OF DRGS Page 1 of 1

11.00 LIST OF DRAWINGS

List of drawings enclosed with this Technical Specification is furnished below:

Sl. No.

TS Drawing Number REV Description of Drawing

1 MEC/S/E24F/11/17/K/01/55/02102 2 LAYOUT OF RAW MATERIAL HANDLING SYSTEM

2 MEC/S/E24F/11/17/K/01/55/02101 2 FLOW DIAGRAM OF RAW MATERIAL HANDLING SYSTEM

3 MEC/S/E24F/11/17/K/01/55/02105 0 AREA REPAIR SHOP 4 MEC/S/E24F/11/14/0/00/00/001.01 0 GENERAL LAYOUT OF

BOKARO STEEL PLANT 5 MEC/S/E24F/11/PY/0/00/00/066.01 0 INDICATIVE

IMPLEMENTATION SCHEDULE

Sl. No. 5 included in Chapter 09

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© 2009. MECON Limited. All Rights Reserved. CHAP-12 SCHEDULE Page 1 of 48

12.00 SCHEDULES

The following schedules are to be filled-up and submitted by the Tenderer along with the offer. Schedule 01 – Technical information of Belt Conveyor, Belt Feeder, Shuttle Conveyor

and Reversible Shuttle Conveyor System Schedule 02 – Technical information of Vibratory Feeder Schedule 03 – Technical information of All Types of Gates Schedule 04 – Technical information of Belt Weigh Scale (BWS) Schedule 04A – Technical information of MD and Suspended Magnet Schedule 05 – Technical information of Travelling Tripper and Bunker Sealing

Arrangement Schedule 06 – Technical information of Cranes and Hoist Schedule 07 – Technical information of Vulcanising Machine and Mobile Belt

Changing unit Schedule 08 – Technical information of Wagon Tippler Schedule 09 – Technical information of Side Arm Charger Schedule 10 – Technical information of Dual fluid dust suppression system (DFDS) Schedule 11– Technical information of Air conditioning & Ventilation system (ACVS) Schedule 12 – Technical information of Civil Works Schedule 13 – Electrical Schedule 14– List of special tools & tackles Schedule 15 – List of Commissioning Spares Schedule 16 – List of Insurance Spares Schedule 17 – List of 2 Years Spares for Maintenance & Operation Schedule 18 – List of exclusions Schedule 19 – List of deviations

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Schedule 01

12.01 Technical Information Of Belt Conveyor, Belt Feeder, Shuttle Conveyor and Reversible Shuttle Conveyor System

01. Questionnaire (General) - Necessary particulars to establish the possession - Yes/ No of technical know-how and facilities available furnished

- Reference list for supply of similar equipment - Yes/ No along with users certificate furnished - Write up of testing facilities available at works - Yes/ No furnished? - Copy of Tender drg. signed and submitted ? - Yes/ No - Delivery schedule - Yes/ No. - Bought out items conforms to T.S.? - Yes / No. - List of tools furnished - Yes/ No. - List of commissioning spares furnished - Yes / No. - List of spares for two years operation along with - Yes/ No item wise prices furnished - List of insurance spares with price furnished - Yes / No. - Erection plans furnished - Yes/ No. 02. Questionnaire The Tenderer shall fill in this questionnaire and submit with his offer. This data shall form a

part of the contract with Successful Tenderer. General .01 Name and address of the Tenderer : .02 List of drgs. literatures enclosed with : the offer.

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.06 Is it the Tenderer's intention, if awarded : the contract, to comply fully in all respects with owner's specifications covering the work? If not, he shall state specific exception in details. 03. Questionnaire .01 Belt conveyor/ shuttle conveyor i) Conveyor no. : ii) Carrying capacity (t/h) : iii) Centre to centre horizontal : distance (m) iv) Lift (m) : v) Belt width (mm) : vi) Belt speed (m/s) : vii) Pulley details : Followings to be indicated for head, bend, snub, tail, take-up pulleys separately: a) Pulley diameter (mm) : b) Face width (mm) : viii) Idlers : a) Type (in-line / off set) : b) Diameter (mm) : c) Troughing angle : ix) Motors a) KW rating : b) RPM : c) Type : x) Gear Boxes a) Make : b) Type : c) Reduction ratio : d) Torque rating (kg-m) : e) Overall efficiency : f) Wt. of Gear box : xi) Couplings

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© 2009. MECON Limited. All Rights Reserved. CHAP-12 SCHEDULE Page 4 of 48

a) Make and type of high : speed couplings b) Make & type of low speed : couplings xii) Take-up type : xiii) Belt cleaners – type : xiv) Pull chord switches : (no. of pairs ) xv) Belt sway switches : (no. of pairs ) xvi) Brakes a) No and location : b) Brake drum diameter (mm) : c) Torque rating (kg-m) : xvii) Hold Back a) No. and location : xix) Take-up Winch a) Capacity : b) Rope dia : c) Operating effort : The detail information of individual components as asked for in the following

questionnaire shall be indicated for each conveyor separately wherever the details are not identical.

A. IDLERS i) Make : ii) Roll diameter (mm) : iii) Roll thickness (mm) : iv) Tube specification : ( ERW / Seamless ) v) Max. Roll eccentricity (mm): vi) Bearings : a) Make : b) Number : c) Expected life (hrs) : B. BRAKE

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i) Type : ii) Make : C. HOLD BACKS i) Type : ii) Make : iii) Lubrication arrangement : D. CONVEYOR FRAMES / STRUCTURES i) Size of supporting posts : ii) Size of stringers :

iii) Spacing of supporting posts : iv) Deck plate thickness (mm) : v) Deck plate arrangement : - furnish typical drgs. vi) Intermediate frame details : vii) Wt. of frame for running : meter (kg)

E. SKIRT BOARD i) Arrangement | furnish typ. drgs. for ii) Cross section | various conv. widths -- F. TRAVELLING TRIPPER i) Conveyor no. : ii) Carrying capacity : iii) Track Centre : iv) Rail size : v) Overall dimension : vi) Slope of tripper conveyor table : vii) Pulley details | - As per belt conveyor viii) Brakes | except item no (xii) * ix) Wheel dia and hardness : x) Travel Speed : xi) Power supply arrangement : xii) Estimated weight. :

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© 2009. MECON Limited. All Rights Reserved. CHAP-12 SCHEDULE Page 6 of 48

Schedule – 02

12.02 Technical Information of Vibrating Feeder The Tenderer shall furnish the following questionnaire and submit with his offer. This data shall form a part of the contract with Successful Tenderer.

01. Name and address of the Tenderer : 02. Previous experience of the Tenderer : 03. List of similar equipment supplied : along with user’s certificate 04. Is it the Tenderer's intention, if awarded : The contract, to comply fully in all respects with Purchaser’s specifications covering the work? If not, he shall state specific exception in details. 05. Location / Nos. off : 06. Type of feeder & Designation : 07. Capacity through : 08. Material of construction of different parts : 09. Total weight and weight of individuals parts : 10. Type of liner and thickness : 11. Motors a) KW rating : b) RPM : c) Type : d) Bearing : e) Make : f) Expected life (hrs) : 12. Gear Boxes a) Make : b) Type : c) Reduction ratio : d) Torque rating (kg-m) : e) Overall efficiency : f) Wt. of Gear box (kg) : 13. Couplings a) Make and type of high : speed couplings

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© 2009. MECON Limited. All Rights Reserved. CHAP-12 SCHEDULE Page 7 of 48

b) Make and type of low : speed couplings c) Weight (kg) :

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Schedule – 03

12.03 Technical Information of All Types of Gates like Rod Gate, Sector Gate, Motorised flap Gate, Rack & Pinion Gate, Motorised Rack & Pinion Gate

The Tenderer shall also furnish the following questionnaire for each type of gates required

and submit with his offer. This data shall form a part of the contract with Successful Tenderer.

General 01 Name and address of the Tenderer : 02 Previous experience of the Tenderer : 03 List of similar equipment supplied : 04 List of drgs./ literatures enclosed with : the offer. 05 List of gates with details : 06 List of users of similar type of :

gates with satisfactory service certificate

Questionnaire

01. Make : 02. Type of gate : 03. No. of gates offered :

04. Gross wt. Of gate (kg) :

05. Weight of heaviest part (kg) : 06. Capacity and designation of the equipment :

07. Materials of construction of different parts :

08. Type of liner and thickness :

09. Type of actuator and thrust in kg of each actuator :

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© 2009. MECON Limited. All Rights Reserved. CHAP-12 SCHEDULE Page 9 of 48

10. Stroke in mm of each actuator :

11. Velocity in mm of each actuator :

12. Motor at ------- type, rating, power supply, class

of duty, insulation, make number of starts/ hours :

13. Make, ratings, type of limit switches :

14. Effort required for manual operator, kgf :

15. Type of limit switches :

16. IS : standards/specification : Pin : Pinion : Liner (type and thickness) : Lip plate :

17. Special features, if any : 18. Any other information :

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© 2009. MECON Limited. All Rights Reserved. CHAP-12 SCHEDULE Page 10 of 48

Schedule – 04 12.04 Technical Information of Belt Weigh Scale The Tenderer shall submit the following details along with the quotation of the equipment.

01. Type :

02. Operation : 03. No. of floating idlers : 04. Load Cells Details : 05. Overload protection : 06. Capacity : 07. Flow Rate Indicator : 08. Flow totalizer : 09. Accuracy : 10. Calibration :

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Schedule – 4A 12.04A Technical Information of MD and Suspended Magnet

1. Type and Make : (Attach G.A.drg & Catalogue)

2. Principle of operation : 3. Capacity and Designation : 4. Operating height : 5. Gauss strength : 6. Force index at centre of Magnet : 7. Operating voltage : 8. Power consumption : 9. Minimum and maximum size

of tramp iron can be separated/detected :

10. Material of construction of different parts : 11. Nos. and type of non-metallic Idlers to be provided. :

12. Mounting details :

13. Wiring diagram of the system : 14. Total weight of the equipment :

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Schedule – 5 12.05 Technical Information of Travelling Tripper and Bunker Sealing Arrangement

The Tenderer shall also furnish the following questionnaire and submit with his offer. This data shall form a part of the contract with Successful Tenderer.

01 Name and address of the Tenderer : 02 Previous experience of the Tenderer : 03 List of similar equipment supplied : 04 Tripper Details : 05 Sealing belt details : 06 List of drgs./ literatures enclosed with : the offer.

07 Drive details : 08 Motors

a) KW rating : b) RPM : c) Type : d) Bearing : e) Make : f) Expected life (hrs) :

09 Gear Box a) Make : b) Type : c) Reduction ratio : d) Torque rating (kg-m) : e) Overall efficiency : f) Wt. of Gear box (kg) :

10 Couplings a) Make and type of high : speed couplings b) Make and type of low speed : couplings c) Weight (kg) :

11 Belt cleaners – type : - Weight (kg) :

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Schedule – 6 12.06 Technical Information of Cranes and Hoist

01 Double Girder EOT Cranes

1. DPR/TPR/ Crane No. 2. No. Off 3. Type of Crane 4. Supplier/ Make 5. Capacity (t) 6. Span (m) 7. Duty Class 8. Speeds (normal & Creep ) m/ min

a) Main hoist & creep b) Aux. Hoist & creep b) Cross travel c) Long travel

9. Height of lift (m) a) Main hook Above floor Below floor b) Aux hook Above floor Below floor

10. Crane rail height above floor (m) 11. Max wheel load (t) (without impact) 12. Type of cabin 13. Type of hook:

a) Main hook b) Aux hook

14. Location (Indoor/ Outdoor) 15. Hook approaches (m)

a) Main hook b) Aux hook

16. No of rope falls, dia, construction, & breaking strength for a) Main hoist b) Aux hoist

17. Gantry rail size 18. Crab rail size 19. Over buffer dimension (m) 20. Wheel base 21. Wheel diameter for

a) LT wheel b) CT wheel

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22. Handling attachments 23. Special features (weighing device etc) 24. Motor: (Type, kW, rpm starts/ hr enclosure etc)

a) Main hoist b) Aux hoist c) Cross travel d) Long travel

25. Type of control for each motion with corresponding characteristic curve :

26. Method of obtaining creep speed: 27. Power supply

- Power supply S.L.D: - Electric equipment specification

28. Control voltage 29. Ambient temp/ Environment 30. Total weight of the crane (t) 31. Break up of crane weight (t)

a) Structural b) Mechanical c) Electrical

32. Total weight of the crab (t) 33. Code of design 34. General arrangement drawing, incorporating the front and side elevations,

plan, hook approaches, location of cabin/ pendant, down shop lead, clearance dimension, handling attachments and other relevant characteristics of the crane.

35. Details of swiveling / rotating arrangement, if any, along with scheme. 36. Any other information

02 Single Girder EOT/US Cranes

1. Crane No. : 2. Nos. off : 3. Type of crane : 4. Capacity (t) : 5. Span (m) : 6. Duty class : 7. Location : 8. Hoists

a) Speed with safe working load, m/min : b) No. of rope falls supporting the load : and specification of rope : c) Lift of hook above floor, m : d) Drop of hook below floor, m :

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© 2009. MECON Limited. All Rights Reserved. CHAP-12 SCHEDULE Page 15 of 48

e) kW of motor at specified rating : f) RPM of motor : g) Make, type and size of brake :

9. Cross - travel a) Speed with working load, m/min : b) Wheel base, mm : c) No. of wheels : d) kW of motor at specified speed : e) RPM of motor : f) Make, type and size of brake :

10. Bridge a) Speed with safe working load, m/min : b) Wheel base, mm : c) No. of wheel on each end-carriage : d) Diameter of wheel, mm : e) Maximum wheel load, kg : f) No. of motors : g) kW of motor at specified rating : h) RPM of motor : i) Make, type and size of brake :

11. Power supply : 12. Control voltage : 13. Made and type of control : 14. Total weight of crane, t : 15. Total weight of hoist, t : 16. Break-up of crane weight, t :

a) Structural : b) Mechanical : c) Electrical :

17. General arrangement drawing showing details as enumerated :

18. List of deviations from the Purchaser’s Specification. :

03 Electric Hoists

General

1. Item number : 2. Location : 3. Capacity : 4. Duty classification : 5. Total weight of hoist : 6. Make :

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© 2009. MECON Limited. All Rights Reserved. CHAP-12 SCHEDULE Page 16 of 48

Hoist

7. Speeds with safe working load : Lifting height : a) Above floor level : b) Below floor level :

8. Wire ropes a) Type of construction : b) Size : c) Number of falls : d) Factor of safety :

9. Rope drum :

a) Materials : b) Diameter :

10. Drives

a) Type & material of gear box : b) Gear & pinion :

c) Material & hardness :

11. Motors a) Type & number : b) Kw rating : c) Synchronous speed : d) Class of insulation : e) Pull out torque : f) Frame size :

12. Brakes :

a) Type : b) Size : c) Torque rating :

13. Type & details of limit switches : 14. Type of couplings : 15. Type of bearings :

16. Lifting hook

a) Type : b) Material :

17. Type & details of control :

Trolley

18. Speed with safe working load : 19. Wheels

a) Numbers :

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b) Diameter : c) Material & hardness : d) Max. wheel load : e) Wheel base :

20. Drive a) Type & material of gear box : b) Gears & pinions : c) Material & hardness : d) Kw rating : e) Synchronous speed : f) Class of insulation : g) Pull out torque : i) Frame size :

21. Brakes

a) Type : b) Size : c) Torque rating :

22. Type & details of limit switches : 23. Type of coupling : 24. Type of bearings : 25. Type & details of controls : 26. Clearance diagram indicating the basic :

dimensions 27. Type & lubrication provided : 28. Type & size of cables : 29. Location & control details of hoist :

block power feeding arrangement

03 Manual Hoists

1. Equipment No. : 2. Capacity : 3. Quantity : 4. Height of Lift : 5. Class of Duty : 6. Make :

7. Minm . Radius of Curvature Of Track beam size: :

8. Max. Tractive effort (Kgs) • Hoist : • Travel :

9. Movement in ‘m’ corresponding to operating chain movement of 30m. Hoist : Travel :

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Schedule – 7

12.07 Technical Information of Belt Vulcanising Machine & Mobile Belt Changing Unit

1. Type & Name of Supplier

2. Technical Parameters:

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Schedule – 8

12.08 Technical Information of Wagon Tippler

1. Wagon Tippler

- Make and type - Material of construction of main parts/units in the part list. - Type of wagons that can be handled at a time. - Mode of placement of wagons. - Capacity of wagons that can be handled at a time. - Type of speed arrestors Provided. - Rail gauge - Load capacity - No. of tipplings/hour - Average Cycle time with break up. - Angle of rotation. - Speed of rotation - during tippling & on return. - Power consumption - Drive details (KW, frame size, speed etc.) - Type of motor, brake etc. - Power transmission arrangement - Characteristics of main units like cradle, rail table, top and side clamping

device, locking gear, spill plate, liner plates (if any). - Mode of control - Safety features as envisaged - Type of lubrication arrangement provided - Gross weight and weight of the single heaviest part. - Special feature (if any). - Track gauge - Vibrator for wagons provided? - Yes/ No - Type of clamping & No of clamps provided. - Load data for Civil/Structural/Electrical works.

2. Dust Suppression System Pump : (a) Make (b) Type of pumps (c) Capacity, m3/h (d) Total head, mWC (e) Material of Construction

(i) Shaft

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(ii) Impeller (iii) Casing

(f) NPSH required, m (g) Speed, rpm (h) Impeller dia, mm (i) Shaft power (j) Efficiency (k) Drive detail (l) Bearing type & make (m) Noise level at 1 m distance (n) Static weight and dynamic weight (p) Accessories (q) Weight (r) Performance curve Nozzle :

(a) Make (b) Dia, (c) Water spraying cap., and pressure required (d) Material of construction (e) Weight

Valve : (a) Make & type (b) Material of Construction (c) Weight (d) Dia Pipe :

(a) Make (b) Material (c) Dia (d) Thickness (e) Weight, kg/m

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Schedule – 9

12.09 Technical Information of Side Arm Charger

- Make and type - Material of construction of main parts/units in the part list. - Type of wagons that can be handled at a time. - Capacity of wagons that can be handled at a time. - Rail gauge - Load capacity - Speed – with rake & without rake. - Power consumption - Drive details (KW, frame size, speed etc.) - Type of motor, brake etc. - Power transmission arrangement - Mode of control - Safety features as envisaged - Type of lubrication arrangement provided - Gross weight and weight of the single heaviest part. - Special feature (if any). - Track gauge

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Schedule – 10 12.10 Technical Information of Dual Fluid Dust Suppression System (DFDS)

a) GENERAL

Sl. No.

Characteristics Unit Value

1. Make of equipment 2. Design water flow quantity 3. Design compressed flow requirement 4. Work zone dust concentration 5. Total power requirement 6. Total water requirement 7. Any specific design consideration

8. Noise level at 1m distance from the dust suppression equipment

dB(A)

9. Support / Structure / Weathering shed DS system

10. List of drive 11. Spray nozzle make rating, quantity 12. Spray nozzle material of construction

13. Load monitoring switch type, quantity and rating

14. Sequence timer type, quantity and rating 15. Solenoid valve type, quantity and rating

b) PUMPS FOR DFDS

Sl. No.

Characteristics Unit Value

1. Make and model no. 2. Type of pump 3. Capacity. m3/hr 4. Total head. m WC 5. Quantity

Material of construction i) Shaft ii) Impeller

6.

iii) Casing 7. Pump speed rpm 8. Shaft power

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Sl. No.

Characteristics Unit Value

Drive details i) Motor make ii) Motor KW iii)Insulation class

9.

iv) Frame size 10. Bearing type & make 11. Type of coupling 12. Vibration level 13. Noise level at 1 m distance for pump set dB(A)

c) PIPES FOR DFDS

Sl No

Characteristics Unit

Value

1. Material 2. Standard 3. Class 4. Thickness of pipe material 5. Pipe size, length and weight 6. Make

7. Maximum recommended operating temperature

0C

8. Maximum recommended operating pressure

9. Type of protective coating

d) PIPE FITTINGS FOR DFDS

Sl. No.

Characteristics Unit Value

1. Type of fittings 2. Size (O.D x Thickness) 3. Standard 4. Lengths

5. Maximum recommended operating temperature

6. Maximum recommended operating

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Sl. No.

Characteristics Unit Value

pressure 7. Type of protective coating 8. Weight of fittings kg

e) VALVES (GATE, GLOBE, CHECK, BUTTERFLY, FLOAT,

PRESSURE RELIEF) FOR DFDS

Sl. No. Characteristics Unit

Value

1. Type: 2. Body / Bonnet / Cover: 3. Spindle: 4. Disc: 5. Body seat ring & Disc seat ring 6. End connections: 7. Pressure rating: 8. Flange facing: 9. Manufacturing std.: 10. Hand wheel: 11. Packing: 12. Companion Flanges 13. Hydrostatic testing: 14. Test certificates:

f) SOLENOID VALVES FOR DFDS

Sl. No. Characteristics Unit

Value

1. Make and Model 2. Type 3. Power Supply 4. Quantity 5. Solenoid Valve Box size

g) LOAD SENSOR UNIT FOR DFDS

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Sl. No. Characteristics Unit

Value

1. Make and Model 2. Type 3. Quantity

h) MATERIAL SENSOR UNIT FOR DFDS

Sl. No. Characteristics Unit Value

1. Make and Model 2. Type 3. Quantity

i) PRESSURE SWITCH FOR DFDS

Sl. No.

Characteristics Unit Value

1. Make and Model 2. Type 3. Quantity

j) PRESSURE GAUGES FOR DFDS

Sl. No.

Characteristics Unit Value

1. Make and Model 2. Type 3. Quantity

k) SEQUENCE TIMER FOR DFDS

Sl. No.

Characteristics Unit Value

1. Make and Model 2. Power Supply 3. Quantity

l) TANKS FOR DFDS

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Sl. No.

Characteristics Unit Value

1. Capacity 2. Usage : Water 3. Material of Construction 4. Level indicator 5. Dimensions 6. Quantity 7. Weight 8. Nozzles

m) LEVEL INDICATOR FOR DFDS

Sl. No.

Characteristics Unit Value

1. Make and Model 2. Type 3. Quantity

n) COMPRESSOR FOR DFDS

Sl. No.

Characteristics Unit Value

1. Make and model 2. Type 3. Quantity

4. Rated capacity Nm3/min

5. Rated discharge pressure kgf/ cm2

6. Mode of operation 7. Number of stages 8. Speed rpm 9. Power requirement at compressor shaft 10. Drive rating kW 11. Total Cooling water requirement m3/h

12. Noise level at 1 m from compressor at rated capacity

dB(A)

13. Details of lubrication system 14. Compressor capacity control

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Sl. No.

Characteristics Unit Value

- Type & No of steps Air intake cum silencer unit 15. -Type of filter media & no. Moisture separator -Make, type and model

16.

-Overall dimensions Air receiver - Capacity - Design and working pressure

17.

-Overall dimensions

o) MOTOR DATA SHEET OF MOTORS FOR DFDS

Sl. No.

Characteristics Unit Value

1. Make and type 2. Rated kW at 50 0C kW 3. Rated voltage 4. Frame size 5. Class of insulation 6. Temperature rise 7. Rated speed 8. Rated current 9. Starting current 10. Locked rotor torque 11. Pull up torque 12. Break down torque 13. Max permissible GD2 of load 14. Type of construction 15. Degree of protection of enclosure

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Schedule – 11

12.11 Technical Information of Air Conditioning and Ventilation System (ACVS) a) Centrifugal Fan

Value Sl. No.

Characteristics Unit As per TS As per Tenderer

1. Make & Model No. 2. Quantity no. 3. Type of blade 4. Capacity m3/h 5. Static pressure and total

pressure mm WC

6. Operating speed rpm 7. Critical speed rpm 8. Shaft power kW 9. Total Efficiency % 10. Motor rating, kW/ pole kW/ pole 11. Acoustic lagging / silencer, as

included :

12. Material of construction 13. Overall size 14. Velocity at inlet & outlet of fan m/sec 15. Static weight & dynamic weight

of fan and motor kg

16. Coupling details/V-belt details 17. Vibration level 18. Material of construction &

thickness of scroll, blade, shroud,

19. back plate, shaft diameter mm 20. Noise level at 1m distance dB(A) 21. Bearing details

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b) Fan Drive Motor Details Value Sl.

No. Characteristics Unit

As per TS As per Tenderer 1. Type & make 2. Voltage, phase & frequency 3. Rated power kW 4. Speed rpm 5. Starting/ pull out torque 6. Starter details 7. Line current 8. Starting current 9. Overall efficiency 10. Class of insulation 11. Type of enclosure 12. Any other information

c) VIV & Duct line Damper

Value Sl. No.

Characteristics Unit As per TS As per Tenderer

1. Make, model and type 2. Type of actuator, if applicable 3. Diameter of VIV mm 4. Motor kW/pole 5. Material of construction and

thickness

d) Dry Panel Air Filter

Value Sl. No.

Characteristics Unit As per TS As per Tenderer

1. Make & Model. 2. Capacity. m3/h

Pressure drop. Mm WC i ) When clean

3.

ii) When dirty 4. Effective cross sectional free

and face area m2

5. Velocity through filter free and face area.

m/sec

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Value Sl. No.

Characteristics Unit As per TS As per Tenderer

6. Material of filtering panel and construction details.

7. Cleaning efficiency Vs particle size

8. Overall dimensions & no. of filters.

9. Fixing frame details. 10. Total weight. free and face area t & m2

e) Ducting

Value Sl. No.

Characteristics Unit As per TS As per Tenderer

1. M2 of duct work m2 2. Weight of supports and flanges t 3. Material and thickness of duct

work mm

f) Connecting Ducting Networks

Value Sl. No.

Characteristics Unit As per TS As per Tenderer

1. Duct routing showing diameter and lenght of ducts

2. Weight of ducting (with and without dust)

3. Weight of supports and flanges 4. Material and thickness of duct

work

g) Air washing chamber with water tank

Value Sl. No.

Characteristics Unit As per TS As per Tenderer

1. Make & Model No. 2. Type of unit (Horizontal/vertical) 3. Overall dimensions mm 4. Weight with and without water kg 5. Air flow capacity. m3/h 6. Air flow velocity 7. Total Pressure drop kgf/ m2

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Value Sl. No.

Characteristics Unit As per TS As per Tenderer

8. Material of construction, diameter and numbers of spray header pipes & nozzles.

9. Make up water requirement 10. Details of make up, over flow,

drainage, supply and return water pipe lines

11. Amount of water and its pressure at the nozzle

12. Material of construction and thickness of casing, tank, air distributor plate

13. Water tank capacity M3 14. Mounting supports 15. Details of mist /droplet

eliminator: material of construction, material thickness and depth.

h) Re-circulating water system Value Sl.

No. Characteristics Unit

As per TS As per Tenderer 1. Pump capacity & head, motor

KW

2. Re-circulating piping & fitting; 3. Strainer & valve 4. Instruments – pressure gauge,

temperature gauge, water flow switch, manometer

i) Package Air conditioners

Value Sl. No.

Characteristics Unit As per TS As per Tenderer

1. Make and model 2. Quantity 3. Capacity TR

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Value Sl. No.

Characteristics Unit As per TS As per Tenderer

4. Overall dimension of Package AC Unit

5. Air flow capacity of blower m3/h 6. Total Pressure mm WC 7. Fan Motor kW kW 8. Fan RPM rpm 9. Compressor type, model 10. Compressor motor kW 11. Refrigerant type 12. Condenser type 13. Condenser material of

construction

14. Overall size of condenser 15. Material of construction and its

thickness of casing

16. Insulating material of casing 17. Total Power consumption. 18. Noise level at 1m distance dB(A) 19. Vibration isolation pad 20. Refrigerant drier and strainer

j) Split Air Conditioner

Value Sl. No.

Characteristics Unit

As per TS As per Tenderer

1. Make and model no.

2. Quantity

3. Capacity TR

4. Air flow m3/hr.

5. Flow direction and volume

control grill

6. Material of Construction of

7. Compressor type

8. Drive details and total power consumption

9. Overall dimension

10. Refrigerant type

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Value Sl. No.

Characteristics Unit

As per TS As per Tenderer

11. Filter efficiency

12. Weight of unit

13. Noise level at 1 m distance dB(A)

14. Accessories included

k) Pumps

Value Sl. No.

Characteristics Unit

As per TS As per Tenderer

1. Make and model no.

2. Type of pump

3. Capacity m3/hr.

4. Total head m WC

5. Quantity

6. Material of Construction of

Shaft

Impeller

Casing

7. Pump speed rpm

8. Shaft power

9. Drive details

Motor make

Motor kW kW

Class of insulation

Frame size

10. Bearing type & make

11. Type of coupling

12. Vibration level

13. Noise level at 1 m distance dB(A)

14. Duty

15. Weight of pump & motor

separately

t

16. Characteristic curves for pumps

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l) Cooling Tower

Value Sl. No.

Characteristics Unit As per TS As per Tenderer

1. Make & Model 2. Type 3. Quantity 4. Overall size of cooling tower 5. Capacity of cooling. TR 6. Water flow m3/h 7. Air flow 8. Design water inlet temperature,

outlet temperature

9. Material of construction and its thickness

10. Speed. rpm 11. Drive details. 12. Shaft Power consumption. 13. Wheel diameter. mm 14. Efficiency. 15. Size of fan 16. Static & Dynamic weight of fan

& motor assembly t

17. Bare weight and operating weight of cooling tower

t

18. Noise level at 1m distance dB(A) 19. Fixing details.

m) Insulation data sheet

Value Sl. No.

Characteristics Unit As per TS As per Tenderer

1. Make & Type 2. Quantity 3. Density kg/m3 4. Thermal conductivity 5. Sound absorption co-efficient 6. Material of construction and its

thickness

7. Cladding material

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n) Propeller fan

Value Sl. No.

Characteristics Unit As per TS s per Tenderer

1. Make & Model 2. Capacity M3/hr 3. Quantity 4. Material of construction 5. Total pressure kgf/m2 6. Speed rpm 7. Size of fan 8. Drive details (kW & power

supply)

9. Efficiency 10. Weight of fan & motor t 11. Details of non-return

damper/louver shutter

12. Fixing frame

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Schedule – 12 12.12 Technical Information of Civil Works

1. Excavation

2. Piling

3. RCC

4. PCC

5. Shuttering

6. Reinforcement Steel

7. PCC Flooring

8. Finishing

9. Inserts/ Bolts

10. Any miscellaneous items deemed necessary for successful completion of civil

works of the proposed plant.

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Schedule-13

12.13 Questionnaire for Electrical Equipment

Sl.No. Questionnaire Tenderer’s reply 1.0 General 1.1 Confirm to have fully complied with the

Technical specification (TS) and General Technical specification.

1.2 Name and address of the tenderer’s Electrical Contractor who shall supply complete Electrics.

1.3 Name and address of the tenderer’s Automation Contractor who shall supply complete Automation equipment.

2.0 Specific energy consumption 3.0 Total connected load 3.1 30 minute maximum demand (MD) 3.2 1 minute maximum demand 3.3 Total connected load & 30 minute MD of each

LT substation

4.0 List of emergency load and their feeding arrangement

5.0 Power factor 5.1 Uncorrected Power factor 5.2 Power factor after correction 6.0 Construction power requirement 7.0 List of major equipment and source of supply

(imported/indigenous)

8.0 List of minimum commissioning spares 9.0 List of 2 years maintenance spare

10.0 List of exclusions/deviations from TS & GTS (if any)

11.0 Reference list of similar Automation system supplied and installed

12.0 Layout drawing showing location of HT/LT substation building, MCC rooms, Control rooms enclosed or not

13.0 Confirm inclusion of following:- 13.1 First filling like transformer oil (including 10%

extra oil in non-returnable containers), grease, lubricants as required.

13.2 Carrying out soil resistivity test at site 13.3 Arranging construction power supply and

temperary lighting during storage, erection, testing and commissioning

14.0 AC Motors 14.1 Furnish complete motor and component list 14.2 AC Motors

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Make Standards followed Class of insulation Temperature rise Degree of protection Cooling system

14.3 Actuators Make Standards followed Class of insulation Temperature rise Degree of protection

15.0 MCC/Control Panel/PDB/MLDB 15.1 List of MCC/Control Panel/PDB/MLDB 15.2 Make 15.3 Draw out or non-draw out type 15.4 Single front or double front design 15.5 Degree of Protection 15.6 Type of Power isolating device considered for

incomers & Bus coupler (ACB/MCCB)

15.7 Type of Power isolating device considered for out going motor feeders & power supply feeders (MCCB/SFU)

16.0 VVVF converter/Thyristor converter 16.1 List of equipment 16.2 Make 16.3 Digital control system 16.4 Type of enclosure 16.5 Isolation transformer considered at incoming

side or not

16.6 Communication with Level-1 automation provided or not

16.7 Type of speed feedback considered 17.0 UPS 17.1 Estimated rating in KVA 17.2 Make 17.3 Dual parallel redundant 17.4 Type of enclosure 17.5 Isolation transformer considered at incoming

side or not

17.6 Communication with Level-1 automation provided or not

17.7 Type of battery (NI-Cd) or SMF 17.8 Battery back up time 17.9 Make of battery 18.0 Cables 18.1 Type of HT Cables 18.2 Type of LT Power Cables 18.3 Type of LT Control Cables

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18.4 Type of Flexible cables 18.5 All type of cables considered in the scope of

supply or not

19.0 Field switches Limit switches, safety switches, Encoder,

Level sensor, Anemometer, Hooter etc.

20.0 Type of Light Fittings 21.0 CRD 22.0 Trolley line/DSL

The tenderers to note / confirm the following questionnaire:

Description Unit Requirement Vendor to fill Confirm suitability of equipment for permissible voltage and frequency variation and fault level

voltage kV 6.6,+6% -9% To confirm fault level kA 40 duration sec 3 voltage V 415, +10% -15% To confirm fault level kA 50 duration sec 1 frequency Hz 50 ,+3% -3% To confirm AC control voltage V 240, +10%-15% To confirm DC control voltage V 220 / 110 To confirm

Ambient temperature: Indoor Deg. C 45 (maximum

daily average) To note

Outdoor Deg. C 50 To note System earthing:

6.6 kV system Resistance earthed

To note

415V system Solidly earthed To note Load details area wise: Battery proper, water supply system,, utility system, etc.

connected load kW To indicate working load kW To indicate 30 min. maximum demand kW To indicate

(HT & LT load to be indicated separately)

Total connected load: HT consumer LT consumer Lighting load

kW kW kW

To indicate To indicate To indicate

Working load: HT consumer LT consumer Lighting load

kW kW kW

To indicate To indicate To indicate

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Maximum Demand: HT consumer LT consumer

kVA kVA

To indicate To indicate

Specific energy consumption

kWh/T To indicate

Emergency load requirement kW To indicate Power will be made available at outgoing terminals of the circuit breakers of Purchaser’s 6.6 kV switchboard at LBDS-2. Further distribution of 6.6 kV and 415 V is under bidder’s scope

To note

The location of proposed substation and control rooms on the layout drawing

To indicate

Overall single line diagram To furnish 6.6/0.433kV Distribution Transformer Primary Delta connected and secondary star connected with neutral brought out with Dyn11 configuration

To confirm

Preferred rating of Transformers and its impedance voltage

To confirm

1600 KVA - 6.25% 2000 KVA - 6.25% Off circuit tap changer with +2.5% and +-5% taps provided on HV side

To confirm

Emergency Push Button shall be provided in transformer cell

To confirm

Load Centre Substation (LCSS) (i) 415V LCSS will be double ended type

To confirm

(ii) For double ended load centre, the maximum demand on each LCSS will not exceed 90% of the rated capacity of one transformer. The rating of each transformer will be such that each can carry load of the substation with a provision for 20% additional load in future.

To confirm

(iii) Number of distribution transformers envisaged along with number of load centres considered

To furnish

ONAN transformer To confirm Winding temperature indicator with alarm and trip contact

Accessories as per IS : 2026 To confirm LT Switchboard (PCC) (i) Number of switchboards offered, location of switchboards and tentative dimension.

To furnish

(ii) Incoming and bus coupler air circuit To confirm

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breaker will be electrically operated and outgoing air circuit breaker will be manually operated .No MCCB will be used in switchboard. (iii) Inclusion of breaker handling truck To confirm (iv) Automatic bus transfer (ABT) scheme for bus coupler breaker will be considered

To confirm

(v) Momentary paralleling will be considered through trip selector switch. Restoration of power will be in manual mode only.

To confirm

(vi) Continuous current rating at 45 deg C ambient while installed in switchboard :

Main Busbars A Tappings A Short time current rating and duration kA,

Sec

Circuit Breaker Type Continuous rating at 45 deg C ambient while installed in switchboard

A

Short time current rating and duration kA, Sec

Rated symmetrical breaking capacity kA Type of operating mechanisms (whether motor operated spring charging)

415 V Bus Duct 3 phase non segregated aluminium busbars for connection between 415 V PCC and transformer

To confirm

2 mm thick enclosure with IP50 enclosure protection for indoor application and IP54 for outdoor application

To confirm

Phase changeover box To confirm Continuous aluminium earth busbar To confirm Space heater with current monitoring To confirm Cables ,Earthing and Lightning Protection

6.6 KV cables XLPE, aluminium armoured with ST2 outer sheath

To confirm

1.1 KV grade cables XLPE, aluminium armoured

To confirm

1.1 KV grade control cables XLPE, copper armoured

To confirm

All electrical equipment will be earthed To confirm

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at two points as per Indian Electricity Rules Normal earthing electrode Metre 3 m The resistance value of substation earth grid

ohm <1 To confirm

separate electronic earthing will be provided

To confirm

Lightning protection will be considered for all building.

Miscellaneous All points covered under ‘General Requirement’ will be complied with. All electrical equipment will comply with the statutory requirement wherever required by regulation. The successful tenderer will have to obtain the approval of the competent authorities. Any change required by the authorities shall be to the account of successful tenderer.

To confirm

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Schedule -14 12.14

LIST OF TOOLS & TACKLES (To be filled in by the tenderer)

Tenderer shall clearly indicate the list of tools & tackles for each equipment.

Sl. No.

List of Tools Equipment for which

required Remarks

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Schedule – 15 12.15

LIST OF COMMISSIONING SPARES (To be filled in by the tenderer)

Tenderer shall clearly indicate the list of commissioning spares for each equipment.

Sl. No.

Spares Details Remarks

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BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-12 SCHEDULE Page 45 of 48

Schedule – 16 12.16

LIST OF INSURANCE SPARES (To be filled in by the tenderer)

Tenderer shall clearly indicate the list of insurance spares.

Sl. No.

Insurance Spares Details Remarks

Page 253: Bokaro Steel Plant Specs

STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-12 SCHEDULE Page 46 of 48

Schedule – 17 12.17

LIST OF 2 YEARS SPARES FOR MAINTENANCE & OPERATION (To be filled in by the tenderer)

Tenderer shall clearly indicate the list of 2 years spares for maintenance & operation of each equipment.

Sl. No.

Spares Details Remarks

Page 254: Bokaro Steel Plant Specs

STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-12 SCHEDULE Page 47 of 48

Schedule – 18 12.18

LIST OF EXCLUSIONS (To be filled in by the tenderer)

Tenderer shall clearly indicate the exclusions from the tender specification.

Sl. No.

Exclusions Clause reference & Details Remarks

The Tenderer hereby certifies that the above mentioned are the complete list of exclusions from the tender document.

Page 255: Bokaro Steel Plant Specs

STEEL AUTHORITY OF INDIA LIMITED

BOKARO STEEL PLANT, BOKARO TECHNICAL SPECIFICATION FOR

RAW MATERIAL HANDLING SYSTEM

© 2009. MECON Limited. All Rights Reserved. CHAP-12 SCHEDULE Page 48 of 48

Schedule – 19 12.19

LIST OF DEVIATIONS (To be filled in by the Tenderer)

Tenderer shall clearly indicate the deviations from the tender specification.

Sl. No.

Deviations Clause reference & Details Remarks

The Tenderer hereby certifies that the above mentioned are the complete list of deviations from the tender document.

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