TENDER DOCUMENT

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

FOR

Tender for ‘Design, Engineering, Supply, installation,

testing and commissioning of DUST SUPPRESSION
PACKAGE AND ASSOCIATED WORKS’ for the project of
“Augmentation of Raw Material Handling Receipt and
Handling facilities with new OHP Part– B (Package- 061)
of Bhilai Steel Plant, (SAIL)”.

VOLUME – 2B

TECHNICAL SPECIFICATION

ENGINEERING PROJECTS (INDIA) LIMITED

(A GOVT. OF INDIA ENTERPRISE)
Core-3, Scope Complex, 7, Institutional Area,
Lodhi Road, New Delhi-110003
TEL NO: 011-24361666 FAX NO. 011- 24363426
 VOLUME - 2B

CONTENTS

Sl. No. DESCRIPTION

1. Documents/information to be furnished alongwith offer

2. Scope of Supply

3. Brief System Description

4. Technical Specifications –Dust Suppression Package

5. Spares

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

 GENERAL

The following Technical Specification shall be read in conjunction with General

Technical Specification (GTS) of Bhilai Steel Plant, SAIL and General Specification.
If there are any provisions in this Technical Specification, which are at variance
with the provisions of General Technical Specification (GTS) of Bhilai Steel Plant,
SAIL and General Specification, the provisions in this Technical Specification shall
take precedence.

1.0 DOCUMENTS/ INFORMATION TO BE FURNISHED

ALONGWITH OFFER.

(i) Clear Scope of supply.

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

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

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

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

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

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

(viii) Weight of the equipment in Kgs.

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

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

(xi) Unpriced Copy

2.0 SCOPE OF SUPPLY
The scope of the supply includes Design, engineering, manufacture, shop
fabrication. assembly, testing and inspection at manufacturer’s works, packing ,
dispatch, transportation, delivery to site, receipt, required fabrication at site,
installation, testing & commissioning completion of facilities, performance
guarantee testing, final painting at site and handing over to Bhilai Steel Plant,
SAIL / EPI of COMPLETE DUST SUPPRESSION PACKAGE and ASSOCIATED
WORKS as per specifications and scope defined in tender documents complete
with all accessories and drive, which are not mentioned specifically but are
required for the efficient and trouble free operation of the equipment/system.

2.1 Following items are also included in bidder’s scope.

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

(ii) Consumables like first fill of lubricating oils etc. for the initial operation of
the equipment till handing over.
(iii) Commissioning spares and start-up spare parts.
(iv) Special tools & tackles, if any required.
(v) Recommended spare parts for (3) three years trouble free operation and
maintenance.
(vi) Painting of complete equipment (including final painting before handing
over to the Employer).
(vii) Installation, testing & commissioning at site.
(viii) All drawings/documents along with operation and maintenance manuals as
per requirement mentioned elsewhere in the tender document.
(ix) Getting approval of design/drawings and any other design calculation
related to the equipment from BSP/MECON/EPI.
(x) 3 Ph, 415V +10% & -15%, 50Hz +4% & -6% power supply shall be
provided at Power cum Control Panel of Ventilation at one point only
through power cables. Other voltage levels, if required shall be arranged
by the bidder itself. Installation, testing & commissioning of panel shall be
in Bidder’s scope.
(xi) Carrying out any modifications/deletions/additions/alteration in
design/drawings/documents as required by client & Client’s consultant and
EPI for proper execution of works at site till completion and handing over
of the project to the client.
(xii) Drinking Water & Construction Power shall be provided free of cost to the
bidder at one point. However, further distribution shall be in the bidder’s
scope. Bidder has to ensure the optimum and effective utilization of
Construction Water & Construction Power.
(xiii) Construction Water shall be arranged by the bidder themselves.

Exclusions:

(i) Civil works including grouting.

2.2 Bidder to note the following:

1) BSP approved preferred make list shall be followed for Hydraulics & Pneumatics.
2) All HT and LT AC/DC motors, actuators, brakes etc. as per technological and
process requirement.

3) Generally Squirrel Cage Induction Motor with DOL starter / Soft Starter will be
provided. Use of Slip ring motor in general will be avoided. Suitable Rotor
contactor panels and SS-grid Resistance Boxes will be provided for slip ring
motors if inevitable.
4) Soft starter will be provided for LT motors of rating more than 75kW.
5) All LT motors for conveyors will be S6 duty and will have class F insulation with
temperature rise limited to class B.
6) Equipment selection and dating will generally be based on ambient temperature
of+50 Deg.C. For specific areas and shops, the ambient temperature conditions
indicated above will be taken into consideration and equipment suitably derated
wherever necessary.
7) The equipment should be suitable for smooth, efficient and trouble free service
in the tropical humid climate prevailing at plant site and under the ambient
temperature conditions indicated above for the different shops and areas. In
hot areas of higher temperature conditions, the equipment will be adequately
protected against damage from radiant heat and hot air.
8) Roller bearings will be provided at DE end for motor of rating 30KW and above.
3.0 BRIEF SYSTEM DESCRIPTION

The turnkey package of this Contract Document comprises of the following sub-
systems:
1) New Ore Handling Plant (OHP-II) including receiving, unloading, Stacking &
Reclaiming and finally transporting of Raw Material required for Blast Furnace
#8, Sinter Plant-III.
2) New conveyor line for New Lime Dolomite plant RMP3 and for proposed SMS-
III.
3) Modifications/ up-gradations of existing equipment, including:
• An additional series of conveyor from OHP I to JH-20 and JH-
42(Exst’g) parallel to existing route.
• Up gradation of capacity of existing shuttle conveyors J9BRSC1.

3.1 New Ore Handling Plant (OHP-II)

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

(i) Design Considerations

The Ore Handling Plant (OHP-II) has been planned based on the following
assumption:
A. Size of Raw Material
1. Lump Iron Ore : -40 mm
2. Iron ore fines : - 8 mm
3. Lime Stone (BF/SP grade) : -60 mm
4. Dolomite (BF/SP grade) : -60 mm
5. Quartzite : -50 mm
6. Lime Stone (SMS grade) : -25 mm
7. Dolomite (SMS grade) : -25 mm
8. Pellets : -18 mm
9. Manganese Ore : -25 mm
10. Coke Breeze : -25 mm

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

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

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

One number Wagon tippler WT no.B1 along with a Track Hopper TH-B1 with two
parallel tracks on it have been envisaged for unloading Iron ore (lump and fines),
Limestone & Dolomite (both BF grade and Sinter Plant grade), Mn-ore, Quartzite etc.
The Wagon Tippler shall be of Rota-side type capable of unloading BOXN and
proposed BOXNHA ,BOXNHS, BOBS, BOY wagons as per IS:10095-1982, reaffirmed
2001. The rated unloading capacity shall be rated 20 Tips/hour. Adequate system of
handling sticky rakes such as vibrator/ air blaster shall be provided.
25t wagon axle load and 110t gross weight of wagons (BOX, BOXN, BOXN HA, BOXN
HS, BOXN EL, BOYEL) to be considered for design of Wagon Tippler and track
hopper. 2 nos. Weighbridges included in contractor's scope. The location of Weigh
Bridge shall presently be considered at entry of pre hopper yard. However as the
total railway track is being engineered by RITES, the location of Weigh Bridge may
undergo change in detailed engineering stage. The drawings of wagon tippler/track
hopper shall be subjected to approval by RITES /SECR/RDSO as applicable.
The placement of rakes shall be done by Side arm chargers capable of handling a full
rake BOXN, BOXNHA, BOBS, BOY, BOXN EL, BOYEL wagons.
Two nos. of track hopper each of length 210 m excluding maintenance bay and
holding capacity of 6000 t each considering material of bulk density of 1.6 t/ cu.m.
shall be included in contractor's scope. The side angle of hopper with vertical shall be
minimum 60 deg. Each hopper shall have four compartments. Track hopper
envisaged to accommodate minimum 18 BOBS wagons. Contractor to maintain
sufficient height of the track hopper superstructure to take care of OHE.
Total 4 nos. Electric hoist of 5 t capacity shall be provided for maintenance of Paddle
Feeder at both ends of Track Hopper building. Two nos. double door pressurized
cabin shall be provided for paddle feeder inside the track hopper tunnel. Anti-
derailment device/ check rail shall be provided in the track hopper subject to
approval of RITES. Supply / Laying of 60 kg/ m rail with continuous MS insert plate
within track hopper building only are in scope of contractor.
In addition to the above, one dedicated compressor station at track hopper TH-B1for
unloading of BOBRN wagons is to be provided. Compressed air connection to BOBRN
wagons to be provided at 15 mts interval. The details of requirement of compressed
air, the pressure and type shall be obtained from RDSO. Other points as applicable
for compressed air station shall be considered as per CS for compressed air facilities
indicated elsewhere.
Provision of adequate illumination should be there on both pre & post tippler as well
as on Merry Go Round circuit.
Two belt feeders below Wagon Tippler shall discharge the raw material on either of
two conveyors i.e. Z1-C1 or Z1-C2 which, in turn will discharge the material at Jn
House JH-Z1. From Jn House JH-Z1, conveyors Z3-C1 & Z3-C2 will carry the material
and discharge at JH-Z3. There will be three incoming conveyors in Junction House
JH-Z3. The tail end of two conveyors Z3-C1 & Z3-C2 will start from JH-Z1 and Belt
conveyor Z3-C3 from JH-Z2. Junction house JH-Z2 shall be located in between the
JH-Z1 & JH-Z3.
The track hopper with four nos. paddle feeders of 1500 tph each, two on conveyors
Z2-C1 and two on conv Z2-C2 has been envisaged. From Jn. House JH- Z2, either of
three conveyors Z3-C1, Z3-C2 (coming from JH-Z1) & Z3-C3 (begin from JH-Z2)
shall carry the material upto Jn house JH -Z3. Reversible shuttle conveyors
Z2RSC1/2 at JH-Z2 will facilitate to discharge the material on either of any three
conveyors. Therefore, JH-Z2 shall be designed suitably so as to receive material from
any of the conveyors coming from Track Hoppers. Non sticky liners/ polymer liners
are to be fixed in the track hoppers to improve flowability.
Suitable interchangeability shall be provided below Wagon Tipplers and Track
Hoppers for the conveyors by providing Diverter gates.
In Jn House Z3, three nos. Reversible Shuttle conveyors no. Z3-RSC1,2&3 can feed
any one of conveyor no. Z6C1, Z6C2 and Z6C3. Contractor to provide jumbo gallery
suitable for three nos. mobile trippers up to JH-Z5 from JH Z4 over conveyors Z6C1,
Z6C2 and Z6C3. Out of three trippers, two nos. (Over conv. Z6C2 and Z6C3) shall
extend upto JH-Z6 and one no. shall have provision of extension up to junction house
coming in future. Maintenance hoist of minimum 5t cap shall be provided for the
trippers. Each of the three conveyors Z6C1, Z6C2 and Z6C3 shall be capable of
feeding the stacking conv. Z4BC1 as well as itself in JH Z4 and stacking conv. Z5BC1
as well as itself in JH Z5. Each of the two conveyors Z6C2 and Z6C3 shall be capable
of feeding the stacking conv. Z6BC1 as well as future conveyor in Junction House –
JH-Z6.
The raw material can be either transported via. Jn House Z4, Z5 or Z6 to the
respective stacking conveyors Z4B-C1, Z5B-C1 & Z6B-C1 for stockpiling or can be
fed directly to the reclaiming conveyors Z7-C1/ Z7-C2 which means convey material
directly from the WT/ Track Hopper to:
(a) To the Blast Furnace#8 Stock House
(b) To the Fuel & Flux crushing circuit of Sinter Plant-III.
Suitable interchangeability shall be provided at Junction house JH-Z4, 5 & 6 for the
conveyors by providing 2-way chutes in mobile tripper. 5T Electric hoist each shall be
provided at JH-Z5 & JH-Z6. Whereas, JH-Z4 shall be designed only as a transfer
point.
The Stacking conveyors Z4B-C1, Z5B-C1 & Z6B-C1 can form a stockpile 30m wide,
350m long and 10.5 m (maximum) high with the help of Twin boom stackers.
Suitable number of electrically operated Under-Slung Cranes, Hoists etc. shall be
provided in all floors of Junction Houses and building for maintenance of equipment.
Electro-Magnetic Separators, In-Line Magnetic Separators, Metal Detectors, Belt-
Weigh-Scales, Air-Blasters/ Bin Vibrators shall be provided to make the system
complete and the operation/ maintenance smooth.
(iii) STORAGE AND RECLAMATION OF ORE
From the Wagon Tipplers WT-B1 and the Track Hopper TH-B1, the raw material may
sometimes be fed directly to the consuming plant in case of emergency. However,
this shall not happen under normal circumstances, when the three Twin-boom
stackers over conveyors Z4B-C1, Z5B-C1 & Z6B-C1 store the raw material in the
designated place of the yard in bed nos. 1 to 6. Flexibility shall be in built in the Jn
Houses Z4, Z5, & Z6 to ensure stacking is trouble free.
Bed blending system shall be possible with the stacker running to and fro on the
length of the pile -or- on a length between two defined position in case more than
one material is stored in a bed marked by travel limit switches, which through a relay
sequencing circuit, with time control-reverses the traveling gear after the travel in
each direction covering the desired length of the pile. After a layer of some pre -
determined amount is deposited in one traveling direction of the stacker, probes
fitted on the stacker boom gives it a “raise” signal as soon as a net height of material
is formed. The next layer is then formed.
Iron ore may require stockpile formation as described above for blending and
uniformity. However, the emphasis on blending shall be for iron ore fines which shall
be blended while stacking.
Four nos Bucket-wheel reclaimers have been envisaged for bed no. 1 to 6.
All stacking line conveyors feeders and stackers etc. shall have a rated capacity of
1500 tph & a designed capacity of 1800 tph.
All reclaim line equipment shall have a rated capacity of 1500 tph and a designed
capacity of 1800 tph in the ore handling area.
Reclamation takes place by the conveyors Z7-C3 (Bed no. 1), Z4A-C1 (Bed 2or 3),
Z5A-C1 (Bed no.4 or 5) and Z6A-C1 (Bed no. 6) and the reclaimed material via Jn
House Z4A, B, Z5A, B, Z6A and Z6B shall reach Jn House Z7. Two reclaim conveyors
Z7-C1 and Z7-C2 between Z6A to Z7 will receive all the materials from yard for
further transportation.
Reclamation from OHP takes place for the following circumstances:-
• Feeding of iron ore lump, dolomite, limestone, manganese, quartzite, pellet
etc. to BF#8 stock house.
• Transporting Limestone/ Dolomite (SP grade) and iron-ore fines to fuel & flux
crushing area for Sinter Plant-III.
Two streams of belt conveyors shall reclaim the material from new OHP-B yard to
above places. Belt conveyor Z7-C1 & C2 shall carry the material and transport thru
Z8-C1, C2, Z9-C1, C2, Z10-C1, C2 to Z11-C1& C2 to Junction house JH-Z11.
Junction House-Z11 can discharge the material either to existing conveyors R103/
R104 of Sinter Plant-III or proposed conveyor Z12-C1/ C2 of BF#8, with the help of
reversible conveyors. To receive the material from Z11-C1 & C2, suitable
modification in existing gallery of R103 & R104 is required. Also a junction house JH-
Z11 with two reversible conveyors & tail end of belt conveyors Z12-C1 & C2 shall be
erected above these conveyors. Further, conveyor Z12-C1 & C2 and then Z13-C1 &
C2 shall move towards stock house of BF#8 and discharge at JH-Z15 onto reversible
shuttle conveyors J15RSC1/2. The gallery from JH-Z14 to JH-Z15 shall have
provision for installation of three identical conveyors i.e. Z15-C1, Z15-C2 and future
conveyor Z15-C3. Suitable insert plate/ foundation bolts shall be provided for future
conveyor Z15-C3. However, future conveyor Z15-C3 is not in scope of contractor.
 Specification of future conveyor:
Length - ~ 35 m: Lift 0.0 m: Capacity 1200 tph: Belt width – 1400mm
Centre to centre distance from Z15C2 – 3010 mm
A junction house JH-Z14 shall be provided in between the junction houses JH-Z13 &
JH-Z15. Two series of belt conveyors shall discharge the Sinter at the Junction House
Z14 over belt conveyor Z15-C1 & C2. Junction House JH-Z14 and conveyors Z14-
C1/C2 shall be in the scope of Employer i.e. BSP.
Suitable Junction houses with RCC floors, diverter gates & galleries shall be provided
to transfer the material from one conveyor to another. The scope of contractor shall
finish at JH-Z15 with complete drive and discharge (including reversible shuttle
conveyor) facilities. The receiving belt conveyor below Z15-C1 & C2 shall be in the
scope of Employer i.e. BSP. However, JH-Z15 shall have a provision (inserts/
foundation bolts) to erect outgoing conveyors to Stock House.

3.2 OTHER ADDITIONS/ MODIFICATIONS AND UPGRADATION IN EXISTING

OHP (REF. DRG. NO. MEC/S/9101/11/17/0/00/00/061.B01)

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

Another proposed conveyor No J9-C1 parallel to J9-C3/J9-C4, besides conveyors R-
102, shall start from Jn. House JH-9B and shall discharge the material in a proposed
conveyor J9H-C1 in existing JH-9, which in turn feeds to conveyor J10-C2 in new
Junction house JH-9H . Conv J10-C2 can feed proposed conveyor J11-C3, J11-RC2,
J14-C2/J12-C2 (Exst’g) , J15-C2. Conv J15-C2 shall feed new reversible conv. J15-
RC1 in junction house JH-15, which in turn can feed either existing SMS-II feeding
conv. J15A-C1 or new conv. J15B-C1. Conv. J15B-C1 or another new conv. J15B-C2
which shall receive sinter from existing conv. SS-10 shall feed new conveyor J16-C3
in new junction house JH-15B which in turn shall discharge onto new conv. J16-C3A
in new junction house JH-16A. Conv. J16-C3A shall discharge onto new conv. J17-C3
in JH-16A which shall convey material to conveyor J17A-C1 in JH-17(exst’g).
Conveyor J17A C1 (Capacity 1500tph) shall discharge to either of the two conveyors
J20C3 or J17B-C1 through a adjustable flap gate in junction house J17A. further
J17B-C1 shall discharge the material over J42-C2 in JH-17B. The capacity of the
outgoing conveyors J20C3 and J17B-C1/J42C2 shall be 500tph and 1000tph
respectively. Conveyor J20-C3 shall be provided with one no. belt weigh scale and
have provision of discharging onto existing sinter carrying conveyor J27-C5 (Exst’g)
in junction house JH-20 (Exst’g). Conveyor J42-C2 shall have provision of discharging
onto existing conveyor J44-C5 in junction house J42 (Exst’g). Necessary
modification/strengthening shall be carried out in junction house J42 to take care of
additional loads by new conveyor. Suitable electrical interlock shall be provided
between the conveyors J27-C5 & J20-C3 in junction house JH-20 to trip all the
incoming conveyors in case feed rate exceeds capacity (500tph) of the corresponding
downstream conveyor J27-C5. Similar interlock shall also be provided between J44-
C5 & J44-C2 in junction house JH-42 to avoid any spillage/chute blockage.
These additional conveyors with gate will facilitate a new additional route for BF #
7.
All above conveyor shall run adjacent to the existing conveyor/ galleries at same
elevation. Junction houses JH-9H, JH-10A, JH-15B, JH-16A ,JH 17A and JH- 17B shall
 be new Junction houses. For conveyor no. J11-C3, J11-RC2,J14-C2, J15-C2, J15-
RC1, J15B-C1, J15B-C2 , J17-C3, J17A-C1, J20-C3 & J42-C2, the existing junction
houses (JH-10, JH-11, JH-14, JH-15, JH- 17, JH-20 and JH-42) shall be suitably
modified to suit proposed conveyor transfer points/crossing over.
(ii) Up gradation of Reclaiming conveyors
The capacity up-gradation and utilization of reclaim conveyors are of utmost
importance to ensure smooth operation in the OHP.
The list of conveyors in the reclaiming circuit that shall be upgraded to 1500 tph
are given in table 03.01.
Table 03.01
EXISTING PROPOSED
SL CONVEYOR
BELT WIDTH BELT WIDTH
No NO CAP CAP tph
mm mm

1 J9B-RSC1 1400 500 1400 1500

m3/hr

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

3.3 NEW LIME DOLO PLANT (RMP III) AND SMS III CIRCUIT
Existing conveyor R-101/R-102 shall be utilized to convey raw material required for
Lime/Dolo Calcination plant RMP III and of SMS-III by tapping the conveyor from Jn
house JH-N102 (With suitable modification in the Jn House) and taking a new route
to the proposed Lime/Dolo calcination plant/SMSIII. Any civil work related to
installation of new conveyors in existing junction house JN#102 shall be contractor’s
scope.
The SMS grade limestone, dolomite and iron ore in existing OHP-I shall be reclaimed
via. Jn House N101, N102. Existing Belt Conveyors R101/102 coming from OHP-I
shall now mostly carry Lime stone and dolomite. In JH-N102, two existing reversible
conveyor R103A & R104A are having a provision for taking material to Sinter plant
III as well as proposed Lime Plant. A discharge chute below R103A & R104A to feed
at the tail end of proposed belt conveyor L1C1 shall be provided at Junction house J-
N102. Belt conveyor L1C1 shall discharge the material on L2C1 in junction house JH-
L2. Conv L2C1 discharges onto conveyor L3C1 which discharges onto L4C1 in JH
L3.Conv L3C1 in turn discharge material at Junction House JH-L4 to any of the two
conveyors i.e. L5C1 & L7C1 with the help of diverter Gate.
Thereafter, conveyor L7C1 will carry the material and transfer onto conveyor L9C1.
Conveyor L9C1 will carry the material up to Surge Bin building JHL9 through
reversible shuttle conv. JL9RSC1. Surge bin building JHL9 shall have 3 nos. bunkers
of minimum geometric capacity 190 cub m each for storing iron ore lump/limestone
/bauxite. Suitable rod gate and motorized rack and pinion gates shall be fitted at the
bottom of bunkers. Three (3) nos. VVF controlled vibro feeders of 420 tph capacity
each shall withdraw material from bunker and discharge it onto conveyor L10C1
which shall convey up to Junction house JH L10 for onward transportation to Surge
Bin Building for SMS-III (Surge bins with Vibro-feeder as shown in flow diagram at
JH-L9 are in contractor’s scope.) through SMS feeding conveyor. Conveyor L10C1
complete with discharge facilities and junction house JH L10 shall be in the scope of
contractor and SMS feeding conveyor shall be in the scope of employer.
The other conveyor L5C1 shall receive material from conveyor L4C1 and discharge at
JH-L5 on to conv. L6C1 which shall convey up to junction house JH-L6 and discharge
onto lime plant feeding conveyor for onward transport to Lime & Dolomite calcination
plant RMP III. Conveyor L6C1 complete with discharge facilities and junction house
JH L6 shall be in the scope of contractor .However lime plant feeding conveyor shall
be in the scope of employer i.e. BSP.
Calcined lime/dolomite is received from the day bins of lime/dolo product storage
building of RMP III onto conveyor L8C1.Conv. L8C1 discharges onto conv. L9C2 in JH
L8 which in turn discharges onto conveyor L10C1 in Surge Bin building JH L9. This
finished product of RMP III is transported to the junction house JH L10 by conveyors
L10C1 which shall also carry limestone, bauxite, iron ore received directly from OHP I
yard to SMS III. The scope of contractor starts from tail end on conveyor L8C1
including skirt boards.
A fixed hopper of 8 cub m capacity on conveyor L10C1 near JH L9 with VVF
controlled vibro feeder of 420 tph capacity shall also be used to transport coke fines
as and when required in the storage bins of the bulk material charging system of
SMS III. Any other material e.g limestone/ DRI can also be transported under
emergency conditions through fixed hopper. Suitable ramp shall be provided to
unload the material over hopper.
4.0 Technical Specifications of DUST SUPPRESSION PACKAGE

The scope of work of Dust Suppression package includes;

4.1 Dust Suppression System

4.2 Compressed Air System
4.3 Water Supply System

4.1.0 Dust Suppression System

4.1.1 Scope of work of Dust Suppression System
The scope of work of dust suppression system include
(i) Plain water dust suppression (DS) system of track hopper & stock piles.
(ii) Plain water dust suppression system for paddle feeders of track hoppers. The
dust suppression system will be integral part of the paddle feeders and will
be captive unit of these mobile equipment.

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

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

feeders, dust suppression system for paddle feeders shall not be in
the scope of bidder. However, the bidder has to provide Ring Header
for DS of Paddle Feeders of the Track Hopper. The water requirement
of paddle feeders shall be met out by the water pumps installed for
dust suppression of Track Hopper Periphery)

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

New OHP area:

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

Existing OHP area

DFDS systems will be provided at all the new and upgraded conveyors at
junction houses JH-9B, JH-9, JH-9H, JH-10A, JH-11, JH-14, JH-15, JH-15B,
JH-16A, JH-17, JH-17A, JH-17B, JH-20, JH-42, JH-N102, JH-L1,JH-L2, JH-
L3, JH-L4, JH-L5, JH-L6, JH-L7, JH-L8, JH-L9, JH-L10
 DFDS system will be divided in zones and each zone will have pumping station
and consist of two pumps (1W+1S).

4.1.2 APPLICABLE CODES AND STANDARDS

The execution of the work covered under this specification will conform to the
latest Indian Standards specification where the same are available or the reputed
standards acceptable to the owner / consultant. In case such specifications are not
available, the work will be according to good engineering practice and norms
acceptable to owner / consultant.

4.1.3 DESIGN CRITERIA

(1) DS/DFDS system will be provided in all the new and upgraded areas
(1a) Work zone dust concentration will be less than 5 mg/Nm3 (at 5m to 7 m
distance from source) above ambient level.
(2) Water line velocity will be maintained less than 1.5 m/sec. Water pipe line
will be supported at regular interval. Make-up water, quick fill, drains and
overflow connection will be included at each pump station tank. Duplex
strainer will be included at inlet to dust suppression system pumps. IS-1239
heavy class, ERW, G.I pipe line (for size up to 150 NB) will be used in the
water line. The pipes above 150 NB will be MS, spirally welded, 6 mm thick &
conforming to IS: 3589. Water pipe line will be preferably be laid over
ground along conveyor gallery. In case of non-availability of same suitable
supporting scheme will be provided to suit site. Underground pipeline
(wherever provided) will have wrapping and coating as per IS – 10221
(preferably wrapping coating will be coal tar based). Hume pipe protection
will be laid at road crossing area.
(3) IS-1239 heavy class, ERW, G.I pipe line will be used in the compressed air
line. Compressed air pipeline network over ground laying will be preferred
with a minimum slope of 10 mm in 1m (1: 100) along flow and moisture trap
with drain provision at regular interval. Compressed air pipeline will be
preferably laid along conveyor gallery or can be supported from building
supporting structure. In case of non-availability of same suitable supporting
scheme to be developed by the Contractor to suit site.
(4) Dust suppression system for stockpiles are to suppress the generated dust due
to wind blowing. Sprinkler post of approx. 2m height will be installed on the
spray header along both sides of the stockpile. Before each sprinkler ball
valve & solenoid valve will be provided for manual control and automatic
control respectively. The sprinklers should be swiveling type. Water spray
quantity will be minimum 1.6 litre/hr/m2 of area. Sprinklers will be sized and
spaced to ensure complete coverage of stock pile. Sequence timer will control
solenoid valve open/ close operation & water spray. Sprinkler will be
operated for a predefined time period at different location of stockpile.
A bypass line (with pressure relief valve) from pump discharge line to water
tank will be provided. In addition to above a bypass line with ball valve will
also be provided.
There will be three water pumps (two working and one reserve).
(5) Spray Nozzles/Spray bar for DFDS systems at transfer points will be selected
so as to ensure complete coverage. Solenoid valves will be mounted on each
spray nozzle header at material transfer points. Solenoid valves will be
interlocked with under belt switch and conveyor drives so that spray of water
& compressed air take place when conveyor running with material. At
reversible shuttle conveyor spray nozzles will be provided at both side.
The DFDS system nozzles will have air driven acoustic oscillator capable of
producing super fine atomization of water droplets of size as that of dust
particles & blanket of extremely fine fog. The approximate water addition will
not be more than 0.2% of the weight of material being handled.

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

(7) Compressed air receiver and water tank at different pumping station will be
provided with connecting valve, pipe fitting, and instruments for quality
checking.
(8) In track hopper, spray nozzles will be arranged in a no. of groups to cover the
entire track hopper. Water spray in each group of nozzles will be through
solenoid valve. The operation (open/ close) of solenoid valves may be by local
push buttons. There will be two water pumps (one working and one
reserve).
(9) In wagon tippler, spray nozzles will be arranged in three rows, at both side of
hopper and top of hopper to cover the entire hopper. Water spray in each
 group of nozzles will be through solenoid valve. The operation (open/ close)
of solenoid valves will be linked with the wagon tippler rotation, i.e wagon
tippler position switches and timers rotation.
There will be two water pumps (one working and one reserve).
(10) Compressed air station will be provided for DFDS systems. Standby
compressor will be provided.
(11) At each pump station air receiver capacity will be considered @ 16% of the
compressed air consumption in m3/min or 2 m3 capacity, whichever is higher.
(12) Adjacent to pump station of stock piles & track hopper, RCC water tank will
be provided with minimum 30 minutes water storage capacity. For all other
pump stations of DFDS system & wagon tippler dust suppression system, MS
tank of 5 mm thick with stiffener for 1-hour storage capacity will be provided
by the Contractor. The inside surface of MS tank will be epoxy painted.

(13) The Contractor will provide platform, walkway, stair case adequate for the
necessary approach to the equipment for operation & maintenance point of
view.
(14) Duplex strainer with SS filter element will be provided at inlet to dust
suppression system pumps to remove all suspended particles exceeding 100
micron
(15) Monorail with chain pulley block will be provided for handling of equipment of
weight more than 300 Kg
(16) The Contractor will provide the following minimum instruments
• High level and low level switch in water tank. Low level switch interlocked with
pump operation.
• Spring loaded operated pressure release valve (adjustable) at pump discharge
line for by passing water line to tank to avoid shut-off condition.
• Pressure gauge at all pump discharge line .
• Pressure gauge at air-receivers, safety valve and drain provision
• At consumer application points following instruments will be provided :

-- Independent pressure gauge & control valve (Ball valves) will be provided
for pressure regulation .This unit will housed in a steel cabinet of IP-55
construction.
 -- For flow activation, solenoid operated valves will be provided in water and
airline.
-- Belt conveyor load monitoring switch will be provided for sensing conveyor
running with material.
-- Pressure switch in compressed air line to prevent spray operation at low
pressure.
-- Indication lamp in FAS to show ON/OFF operation of spray.
-- Individual valve will have selection mode to run in Auto/Manual mode.
-- Sprinkler operation will be regulating by sequence timer.

4.1.4 EQUIPMENT SPECIFICATIONS

The equipment for "DFDS" dust control system is grouped into two main categories.
Main Equipment
The main equipment will include spray bar assemblies fitted with dual-fluid air driven
acoustic oscillator atomizing nozzles, pressure regulating units, and flow activation
stations for ON-OFF control of the system and instrumentation for auto operation.

Auxiliary Equipment
The auxiliary equipment will include water storage and pumping unit with duplex
water filter and associate electrical works, air and water piping, enclosures,
necessary hoods and skirt boards on belt conveyors / equipment to suit spray nozzle
operation.

Starter cum control panel will be provided at pumping station and local control panel
will be provided at different application points.

Brief Specifications of various components of the system are given below

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

Pressure regulating units (PRU)

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

The number of pressure regulating units will depend upon the position / elevation of
spray bars. Generally independent pressure regulating units will be provided when
the elevation of spray bars exceeds 3 m. Further the number of nozzles operating
from one PRU should not exceed 6 ~ 8.

Flow activation stations (FAS)

The flow activation station will consist of solenoid valves in air & water line,
pressure switch in the airline, selector switch, and indication lamps. Isolation ball
valves will be provided in the air & water line. All the equipment will be installed in
a metallic enclosure with inspection door with rubber sealing arrangement. Flexible
hoses will be provided with each FAS for connection to air and water pipeline.
The "ON - OFF" control of the fogging system will be through the flow activation
stations with facility for both manual and auto mode. A three-position selector switch
will be provided to select the mode of operation. The switch when energized will
open the electric solenoid valves, which will permit compressed air and water to
enter into the pressure regulating units and spray bars.

In addition, a pressure switch will be installed in the airline to ensure that air and
water solenoid valves are energized only when sufficient air pressure is available in
the line. This will ensure that the system cannot operate without sufficient air
pressure to the nozzles and reduces the chance of un-atomized water to pour into
the dust source. Flow activation will have indication for: -
- System ON
- System OFF due to lower air pressure

Auto operation

The flow activation stations will have provision for both manual and automatic
operation. For manual operation, the system will become operational with selector
switch in manual mode and in auto mode, the fogging operation starts on receiving a
signal either from a speed switch cum belt load monitor or limit switches installed at
a strategic location in the material conveying line or potential free Contract from the
drive motor of equipment as per requirements.
Each dust suppression system location will be provided with requisite number of
spray bar assemblies with DFDS atomizing nozzles. Pressure regulating units will be
provided at each location to regulate the pressure of compressed air and water.
The dust suppression system will be divided into independent circuits taking into
account the flow diagram, operational requirements, distances between dust
suppression locations etc. Flow activation stations with instruments for auto
operation are provided for each circuit for ON/OFF control of the dust suppression
system.

Centrifugal Pump :

Horizontal back pull out pump will be provided. Pump casing will be vertically
split type. Impeller rpm will generally not exceed 1450. However, for pumps with
low capacity & high head may be provided with 2900 rpm. Pump will be coupled to
motor with flexible coupling. Spacer type coupling will be provided. Pump will
conform to IS : 1520.
Pump will give satisfactory performance at any point on the H-Q curve over a range
of 40% of rated flow to 120% of the rated flow. The maximum efficiency will
preferably be within ± 10% of the rated design flow. The total head -capacity curve
will be continuous rising towards the shut off without any zone of instability and
with a minimum shut-off head of 15% more than the design head.
Pumps will have shaft seal by gland packing. Pump will be fitted with double wearing
rings, one is fitted in the front of the impeller on the casing and the other is fitted in
the back of the impeller on the impeller itself.

Impeller will be dynamically balanced. The magnitude of peak to peak vibration will
be limited to 75 micron. Pump impeller will be non overloading type. Impeller will
be made in one piece & keyed to the shaft.

Material of construction
Casing - C.I
Impeller - Bronze
Bearing Bracket - C.I
Shaft protection sleeve - Bronze
Wearing ring - Bronze
Shaft - EN-8
Common base frame for pump & motor - M.S

Common base plate for pump & motor will be in one piece & made of welded steel
construction. Adequate space will be provided between pump drain connection
and base plate for installation of minimum 15 mm drain piping. Pumps will be
supplied with suitable drain pans or drain rim type base plates with tapped drain
connections.

Critical speed of the shaft will be at least 30 percent above the operating speed.

Water Piping and Fittings

Water piping up to 150 mm NB size will be GI, ERW, heavy class and conforming to
IS-1239 Part- 1. The pipes above 150 NB will be MS, spirally welded, 6 mm thick
and conforming to IS:3589. Pipe ends will be beveled. Pipe fittings will be as per
IS 1239, Part -2 for pipes of size up to 150 NB. Fabricated fittings manufactured
from the pipes may be provided for pipes of sizes 200 NB & above.

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

Pipes will be of welded joints. Welding (manual metal arc welding) will be as per
relevant IS code and only certified welders will be employed.

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

Auto air venting valves will be provided at highest point of the pipe lines & drain
valves will be provided at lowest points of the pipelines in different segments.

Pipe supports comprising pipe shoes, saddles, base plate, clamps & structural
members like channels, angles etc. will be provided

Valves
Butterfly Valves will be provided in water line of size 65 NB and above and ball
valve will be provided for pipe size below 65 NB. However, ball valve will be
provided in the pipe line (irrespective of sizes) when flow control is required.

Butterfly valve
Type : Wafer design, flange less
Body : SG iron with nitrile rubber/ EPDM lining
Disc : SG Iron with teflon (PTFE) coating
Stem : High tensile stainless steel

The valves will be provided with integrally moulded & bonded body liner to provide
perfect seating and complete isolation of body material from fluid. The body liner will
provide the seating to valve disc, primary seal to the stem & gasket joint with mating
pipe flanges. Valves will be provided with self locking lever operation from open to
fully closed position with intermediate positions marked on the indicator plate
mounted on the top flange. The valves will conform to BS : 5155 / IS : 13095.
Extended valve shaft will be provided so that the lever can be operated without any
obstruction on the insulated pipes. Gear operated valves will be provided for sizes
more than 250 NB.

Ball Valve

Body : Cast steel

Body liner : Nitrile rubber/ EPDM
Ball : ASTM A351 Gr CF8
3 piece design
Socket welded type

Ball valves will be with 200 mm length welded joint pipes from manufacturer works.

Check valve

Type : Dual plate check valve with two springs hinged on a central hinge rod
Body : SG iron
Body liner : Nitrile rubber/ EPDM
Disc : ASTM A351 Gr CF8
Wafer design
4.2.0 Compressed Air System

4.2.1 Instruction to Contractor

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

compressed air. Also, compressed air will be required for track hopper poking. To
meet these air requirements, one common compressed air station along with
interconnecting inter-shop and in-shop piping facilities upto the individual consumers
will be provided in the RMH area on turnkey basis. The compressed air station will be
located suitably to ensure proper distribution of air to all the consumer points.
The Compressed Air shall be supplied to the following Areas;
A) Track Hopper Building
B) Wagon Tippler Building
C) Area Repair Shop
D) All Water Pump Houses (5 Nos., PH-1 to PH-5)
E) All Material Transfer Points where DFDS (Dry Fog Dust Suppression) system is to
be installed in various buildings, Junction Houses, Trippers etc.

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

New OHP area:

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

Existing OHP area

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

All Compressor Cooling Water Pumps, Cooling Towers, Make-up Water

Pumps, Piping, Valves & Fittings, Instrumentation, Controls etc. are in the
scope of Bidder.

4.2.2 The Contractor will furnish all the drawings, documents, data like fault diagnosis,
operation and maintenance manuals, general details and layout drawings, design
calculations and equipment specification of plant and equipment, together with `as
built' drawings for all mechanical, electrical, civil, structural and instrument & control.

4.2.3 Meteorological data

The following meteorological data will be taken into account for design of plant and
equipment. Site conditions will be assumed to be as follows:
 Temperature : 500C (Max)
50C (Min)
Humidity
Maximum : 100%
Minimum : 25%

Altitude above MSL : 307m

4.2.4 Selection Criteria

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

b) Performance guarantee tests will be demonstrated at 350C temperature and

60% RH, 330C cooling water temp., 50 Hz frequency.

c) Motor will be selected at 50C temperature and 100% RH, 50 Hz frequency.

d) Design ambient temperature for Electrics will be considered as 500 C.

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

4.2.5 Delivery Schedule

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

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

4.2.7 Scope of Work

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

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

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

i) Five (5) sets (3W + 1S + 1MS) each of 36 Nm3/min (@ 8 kgf/cm2(g)

discharge pressure after aftercooler) oil free, water cooled rotary screw
packaged type air compressors with electric motor and all its accessories &
auxiliaries including the following:
 a) Intercooler, after cooler, moisture separator with trap station,

b) Suction air filter cum silencer,

c) Lube oil system.

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

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

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

(a) Continuous Variable Load /unload regulation

(b) Automatic Start-Stop Regulation.

ii) 2 no. of Air Receivers of 12 m3 water holding capacity at 8 kgf/cm2(g)

operating pressure, complete with all fittings such as safety valves, drain
connection with auto condensate trap and bypass valve, vent connections and
all inlet and outlet connections with companion flanges, supporting
arrangement, access platforms, instruments etc. The material of construction
will be as per IS – 2002 – Gr. – 2A . The air receiver will be designed,
manufactured and tested according to IS – 7938, 1976 (RA 1991).
iii) All necessary interconnecting pipes (from compressors outlet upto the
consumer points including dedusting system and track hopper poking),
valves, fittings including supports and supporting structures.

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

v) Miscellaneous structures, access platforms for operation and maintenance of

equipment parts, valves, instruments, etc. forming part of the equipment.

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

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

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

ix) All anchor bolts & nuts, washers, foundation bolts, shear lugs, counter flanges
for inlet and outlet of each compressor, receivers and connected piping & base
frame for equipment. Miscellaneous materials and services, if not otherwise
specifically mentioned will be included, but not limited to nuts, bolts, washers,
gaskets, necessary connections for hook up with employer’s pipe network and
equipment.

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

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

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

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

xiv) Complete civil & structural works.

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

4.2.8 PLANT ELECTRICS

The Contractor will supply complete electrical equipment for compressors.

All the technical specifications of the electrical equipment/system including LT
switchgear, MCC, Metering and protection, cables, etc., shall be as per GTS/TS.

The scope of supply for electrics shall include the following:

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

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

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

iv. For compressor motor bearing and winding temperature detection,

monitoring, interlocking, signalling & annunciation, micro processor based
temperature controller shall be provided for each motor by the Contractor.
The scanner will be housed in an independent control panel.

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

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

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

vii. Power and control cables from the control cabinets, for interlocking & inter
connection to all motors, instruments, consumers etc.
 viii. Junction boxes with required number of terminals including 20% spare
terminals.

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

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

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

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

xiii. HT compressor motor shall be provided with Flux compensated magnetic

amplifier (FCMA) type soft starter enclosed herewith. The HT soft starter to be
designed considering the incoming feeder line distance from the supply feeder
end. Motor soft starter to be connected in line side of motor.

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

xv. Local push button stations

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

xvii. LDBs / Junction Boxes etc(as per the requirement).

xviii. Earthing for all equipment within the scope of supply.

xix. Cable trestle, supporting structures, conduits, prefabricated GI cable trays,

cable racks, other associated accessories like cable glands, lugs,
termination/jointing kits, ferrules, clamps including trefoil clamps for single
core cables, cable markers, cable identification tags, and all other hardware
material as per requirement.

xx. Fire sealing materials for laying termination and sealing of cables.

xxi. Complete electrics of material handling equipment like cranes, lifts, hoists, etc
(if any).

xxii. Complete electrics of ventilation systems for area under battery limit.

xxiii. Water drainage pumps in required numbers with complete electrics including
source feeders, pumps/motors, cable laying, etc.

xxiv. Fire protection system including Fire Detection and Alarm System for the
complete plant, etc.
 xxv. Welding sockets, 240 V power sockets and 24 volts AC sockets with
transformers.

xxvi. Illumination for the entire plant and boundaries.

xxvii. Installation, erection accessories.

xxviii. Safety items.

SPECIFICATIONS OF MOTOR SOFT STARTER

To avoid impact on electrical system due to heavy motor starting current, a soft start
system limiting motor current to 2 to 2.5 times shall be provided to ensure voltage
drop at motor terminals limited to 15% with a provision of DOL starting . Contractor
to submit the voltage drop calculation, considering adequate fault level at 6.6 kV
board.

The soft start system shall be based on principle of flux compensated non-saturated
magnetic amplifiers for control of motor starting current. Also, the starter should not
introduce any harmonics into the system.

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

The enclosure class shall be IP54.

The Sheet steel thickness shall be 1.6 mm.

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

Lamp indication shall be provided using LED type lamps.

Ammeter shall be provided on front door.

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

Bypass device used shall be 6.6kV contactor.

4.2.9 CONTROL & INSTRUMENTATION

General

Electronic type instruments generally working on 4- 20 mA DC signal system will be

used. The instrument panel will be suitably installed in the compressor room. All
instrumentation items will be selected to function satisfactorily in shop floor
environment.
 List of measurements & controls

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

i) Equipment/ local panel mounted measurements

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

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

compressor.

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

compressor.

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

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

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

vii. Indication of differential pressure across lube oil filter.

viii. Indication of temperature at the inlet & outlet of common header of

compressor cooling water circuit.

ix. Indication of pressure at the outlet of common header of compressor cooling

water circuit.

x. Indication of flow of compressed air.

ii) Alarms and interlocks

01 Following audiovisual alarms and interlocks will be provided for each compressor:

1) Differential pressure of air across suction air filter high Alarm only.

2) Temperature of air after air compressor high- Alarm only.

3) Temperature of air after air compressor too high Alarm and trip.

4) Pressure of air after after-cooler high - Alarm only.

5) Pressure of air after after- cooler too high- Alarm & trip.

6) Differential pressure across lube oil filter high - Alarm only.

7) Pressure of lube oil to compressor low - Alarm only.

8) Pressure of lube oil to compressor too low- Alarm & trip.
 9) Temperature of lube oil to compressor high- Alarm only.

10) Cooling water supply pressure low - Alarm only.

11) Cooling water supply pressure too low - Alarm & trip.

12) Motor over load - Alarm & trip.

13) Manual tripping- Alarm only

4.2.10 COMPRESSED AIR PIPES, FITTINGS & VALVES

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

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

Specification of Pipes & Fittings

Sl. Service Size Pipes Fittings Flanges Gaskets End
Type
1.0 Compressed <50NB A53 Gr.B ASTM A105 ASTM Teflon Plain
Air System or Or A105 End
IS 1239,
IS 1239,
Part-II
Heavy
Grade
>65NB A53 GR.B ASTM A234 ASTM Teflon Welded/
or Gr.WPB A105 Flanged
IS 1239,
Heavy
Grade

Specification of valves
Sl. Service Size Body/ Disc Stem Hand Valve
Bonnet Wheel ends

1.0 Compressed >65NB ASTM A ASTM A ASTM A479 ASTM A47 Flanged
Air System 216 Gr. 216 Gr. Type 410-2 Gr. 32510 Raised
WCB WCB Face

>25 & ASTM A ASTM A ASTM A ASTM A47 Flanged

< 50 105 479,Type 479,Type Gr 32510 Flat Face
NB 410-2 410-2
< 25 ASTM A ASTM A ASTM A ASTM A47 Socket
NB 105 479,Type 479,Type Gr. 32510 Welded
410-2 410-2

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

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

Recommended tests on Air Compressors are listed hereunder. Compressors may be

tested using a suitable shop motor.

i) Volumetric and overall efficiency (type test)

ii) Capacity (Routine test)

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

iv) Speed (Routine Test)

v) Testing of unloader (Routine test)

vi) Safety valve test (Routine test)

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

4.2.12 STANDARDS AND CODES

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

4.2.13 GUARANTEE AND PENALTIES

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

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

Air Compressor:

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

frequency

* Rated discharge pressure : 8 kgf/cm2 (g)

at the outlet of after cooler
* Discharge temperature after : <390 C
after cooler at rated capacity
and pressure

* Oil content in the air at the : Oil free

outlet of air compressor

* Specific Power consumption : 6.17

of the compressor at the rated
condition mentioned above
(kwh/Nm3) (at motor input)

* Noise Level : 80 dB(A)

* Volumetric efficiency of each : 87.4 %

the compressor

* Inter cooler/ After cooler : 0.2 kgf/cm2 (max)

pressure drop
4.2.14 LIST OF PREFERRED MAKES

- Compressor

M/s Atlas Copco, M/s ELGI, M/s Ingersoll Rand, M/s Kirloskar
Pneumatics.

- Electrics

1. Motors

Alstom Ltd. , Asea Brown Boveri Ltd. , BHEL, CGL, NGEF, Kirloskar
Electric Co.

2. Cables

Cables Corporation of India,

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

3. Control Stations Weather Proof

Baliga Lighting equipment Ltd., Bhartia Industries Ltd.

Electrical Equipment Corporation, Ex-Protecta,
Shrenik & Company.

4. Light fittings & Accessories

CGL, Philips, Bajaj.

5. Actuators - MOV

Auma India Ltd.,

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

- Instrumentation

TRANSMITTERS (PRESSURE, FLOW & LEVEL) :

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

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

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

RTDs & THERMOCOUPLES :

GENERAL INSTRUMENTS, INDUSTRIAL INSTRUMENTATION,
INSTRUMENTATION LTD, NAGMAN SENSORS, TOSHNIWAL BROTHERS.

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

DIGITAL SCANNER:
JYOTI, LECTROTEK, PROCON, MASIBUS.

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

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

LEVEL SWITCH / SENSORS:

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

SOLID STATE ALARM ANNUNCIATOR :

APPLIED ELECTRONICS LTD. (APLAB), PROCON INSTRUMENTATION
PVT. LTD., PIRI SYSTEMS PVT LTD., IIC, MINILEC, MASIBUS.

POWER CABLES :
CABLE CORPORATION OF INDIA LTD., UNIVERSAL CABLES LTD., FORT
GLOSTER INDUSTRIES LTD., ASIAN CABLES LTD, FINOLEX CABLES
LTD., KEI.

INSTRUMENTATION SCREENED CABLES :

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

COMPENSATING CABLES :
TOSHNIWAL CABLES, GENERAL INSTRUMENTS, UDAY RAJ, KEI.
4.2.15 Water System Facilities for Air Compressor Unit

a) Cooling Water System

i) The cooling water system will generally comprise the following main
units:-
Open Indirect Industrial water (clean) cycle:

a. Pumpsets
b. Cooling tower
c. Strainers (simplex with manual backwash through valves’
operation)
d. Interconnecting piping
e. Chemical conditioning system
f. Electrics, instrumentation & control system.

ii) For cooling of plant and equipment of the air-compressor unit there shall
be a separate cooling water re-circulation system for each unit / sub-
system with pumps, cooling towers and piping network. Contractor shall
provide a separate pump house to house compatible group of pumps.
Separate group of pumps and separate piping shall be provided for each
sub-system to enable flexibility in operation.
iii) The cooling water system shall be supplied in line with the GTS with
regard to design norms (including no. of standby pumps, type of pumps,
valves and piping design) and subject to Purchaser’s approval.
iv) The total cooling water to the units shall be filtered through simplex
strainers. For this simplex strainers (1W+1S) of 500 microns filtration
grade shall be installed on each of the two supply headers complete with
isolation valves. Strainers shall be backwash type.
v) The cooling water circuits shall be provided with chemical conditioning
system to control corrosion and scaling and prevent bio-fouling. To reduce
blow-down higher cycle of concentration shall be targeted.
vi) Pump houses shall be provided with air-washer based air-conditioning and
ventilation system.
 vii) With a view to conserve and save upon fresh water requirement the
Contractor will plan to utilize/ reuse/ recycle the reject/blow-down from
the cooling water systems in the plant with necessary treatment etc. as
specified by the Purchaser.
viii) Make-up water for cooling water re-circulation system for the
compressor will be tapped from the Purchaser’s existing industrial water
network as mentioned under the clause for Battery Limits and will be
conveyed to the various consumers through a pipe network.

b) Make- up Water System

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

minor leakages including service water requirement, etc. shall be
replenished by a separate common make-up water system to be provided
by the Contractor.
ii) Make up water system will include extension of pipelines from the battery
limit with isolation valve to the recirculation cooling water system for
equipment cooling, water circulation system for ACVS facilities as well as
service and process needs.
iii) Make-up water will be tapped from the Purchaser’s existing industrial
water network as mentioned above under the clause for Battery Limits and
will be conveyed to the various consumers through a pipe network.
iv) Tapping of industrial make-up water shall be based on two points feeding
and shall conform to provisions of TS/GTS. Contractor shall extend the
industrial water line with an isolation valve alongwith flow meter to his
proposed systems for service/make-up water requirement for the entire
plant area.
v) Quality of industrial make-up water is furnished in the GTS. This water will
be supplied as make-up water to Package 061 for process & cooling needs
at only one point for the entire needs of the Package 061 at battery limit
as specified. The Contractor shall provide necessary treatment facility,
wherever required, to make the water suitable for cooling and other
purposes.
vi) Drinking water & Feed water for DM Plant-Maroda-II water quality as per
GTS shall be followed,
 vii) Industrial make-up water – Maroda-I water quality as per GTS shall be
followed.
viii) All make up tapings should have flow meters with by-pass arrangement
with isolation facility.
ix) Online boosting of the make-up water is not permitted. A makeup water
sump with pumps and piping (pump house and sump are to be provided
by the Contractor), if required, shall be provided.

c) Water Conditioning System

i) To protect the circulation water system from corrosion and scale formation
and to bring the make up water to the condition suitable for the cooling
water requirement of air-compressor unit there shall be a water
conditioning facility as per system requirement and inline with the details
given in GTS.
ii) It shall consist of dosing tanks, pumps, valves, pipes, fitting, pipe supports
and associated civil, structural, technological structures, electrical,
instrumentation, material handling, air-conditioning & ventilation etc. The
scope of work for all these remains the same as specified for cooling water
system.
iii) These pumps may also be housed in the same pump-house for cooling
water system or separately.
iv) The Contractor shall furnish the details of chemical dosing proposed for
the system.
v) The Contractor shall include in the scope of supply three months chemicals
requirement for the chemical conditioning system from the date of
commissioning.
4.2.16 COOLING TOWER

Type : Induced draft counter flow

Casing/ Basin : FRP
Frame Work : MS hot dip galvanized
Fills : PVC
Nozzles : Brass
Bolts, nuts, miscellaneous hardware : MS electro galvanized
Fan hub & blades : Cast Aluminium
Fan type : Axial flow, direct drive
Fan speed : 720 rpm
Degree of protection of motor : IP 55 (temperature rise limited to class B)
Ladder : Galvanised steel ladder with safety cage & hand railing up to the top
of tower. Inclined to 300 to the vertical
Eliminators : No. of deflector to be arranged to reduce drift loss < 0.2% of
water circulation.

Cooling Tower Accessories:

(i) Level switch at cooling tower basin (to be interlocked with pump)
(ii) Make up connection with float valve (float made of copper) & back up
ball valve
(iii) Quick fill connection with ball valve
(iv) Overflow connection
(v) Drain connection with ball valve
(vi) GI wire mesh 18 gauge strainer
(vii) Equalizing line of cooling towers with isolation valves

4.2.17 WATER PUMPS

Mono block pump will be provided for capacity 15 m3/hr & less. Pump will
conform to IS: 9079-1989. Pump casing will be of C.I & impeller will be of
bronze & will have stuffing box arrangement for gland packing. IP-55
protection motor will be provided.
 Horizontal back pull out pump will be provided for capacity more than 15
m3/hr.

Centrifugal Pump :

Horizontal back pull out pump will be provided. Pump casing will be
vertically split type. Impeller rpm will generally not exceed 1450. However,
for pumps with low capacity & high head may be provided with 2900 rpm.
Pump will be coupled to motor with flexible coupling. Spacer type coupling
will be provided. Pump will conform to IS : 1520.

Pump will give satisfactory performance at any point on the H-Q curve over
a range of 40% of rated flow to 120% of the rated flow. The maximum
efficiency will preferably be within ± 10% of the rated design flow. The total
head -capacity curve will be continuous rising towards the shut off without
any zone of instability and with a minimum shut-off head of 15% more than
the design head.

Pumps will have shaft seal by gland packing. Pump will be fitted with double
wearing rings, one is fitted in the front of the impeller on the casing and the
other is fitted in the back of the impeller on the impeller itself.

Impeller will be dynamically balanced. The magnitude of peak to peak

vibration will be limited to 75 micron. Pump impeller will be non
overloading type. Impeller will be made in one piece & keyed to the shaft.

Material of construction

Casing - C.I
Impeller - Bronze
Bearing Bracket - C.I
Shaft protection sleeve - Bronze
Wearing ring - Bronze
Shaft - EN-8
Common base frame for pump & motor - M.S
 Common base plate for pump & motor will be in one piece & made of
welded steel construction. Adequate space will be provided between pump
drain connection and base plate for installation of minimum 15 mm drain
piping. Pumps will be supplied with suitable drain pans or drain rim type
base plates with tapped drain connections.

Critical speed of the shaft will be at least 30 percent above the operating
speed.
4.2.18 Water Piping and Fittings

Water piping up to 150 mm NB size will be GI, ERW, heavy class and
conforming to IS-1239 Part- 1. The pipes above 150 NB will be MS, spirally
welded , 6 mm thick and conforming to IS:3589. Pipe ends will be beveled.
Pipe fittings will be as per IS 1239, Part -2 for pipes of size up to 150 NB.
Fabricated fittings manufactured from the pipes may be provided for pipes of
sizes 200 NB & above.

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

Pipes will be of welded joints. Welding (manual metal arc welding) will be
as per relevant IS code and only certified welders will be employed.

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

Auto air venting valves will be provided at highest point of the pipe lines &
drain valves will be provided at lowest points of the pipelines in different
segments.

Pipe supports comprising pipe shoes, saddles, base plate, clamps & structural
members like channels, angles etc. will be provided

Valves

Butterfly Valves will be provided in water line of size 65 NB and above and
ball valve will be provided for pipe size below 65 NB. However, ball valve
will be provided in the pipe line (irrespective of sizes) when flow control is
required.

Butterfly valve
Type : Wafer design, flange less
Body : SG iron with nitrile rubber/ EPDM lining
Disc : SG Iron with teflon (PTFE) coating
Stem : High tensile stainless steel
The valves will be provided with integrally moulded & bonded body liner to
provide perfect seating and complete isolation of body material from fluid. The
body liner will provide the seating to valve disc, primary seal to the stem &
gasket joint with mating pipe flanges. Valves will be provided with self
locking lever operation from open to fully closed position with intermediate
positions marked on the indicator plate mounted on the top flange. The valves
will conform to BS : 5155 / IS : 13095. Extended valve shaft will be
provided so that the lever can be operated without any obstruction on the
insulated pipes. Gear operated valves will be provided for sizes more than
250 NB.

Ball Valve

Body : Cast steel

Body liner : Nitrile rubber/ EPDM
Ball : ASTM A351 Gr CF8
3 piece design
Socket welded type

Ball valves will be with 200 mm length welded joint pipes from manufacturer
works.
Check valve
Type : Dual plate check valve with two springs hinged on a central hinge rod
Body : SG iron
Body liner : Nitrile rubber/ EPDM
Disc : ASTM A351 Gr CF8
Wafer design
Pressure Gauge

Manufacturing Standard : IS 3624

Range : 0 – 6 Kg/ cm2 or 0-10 Kg/ cm2
Range (at pump suction) : (-)2 to (+) 2 Kg/ cm2
Dial Diameter : 100 mm
Accuracy : + 1% of FSD
Degree of protection : IP 65
Sensing element : Bourdon tube
Bourdon tube material : AISI SS316
Connection : Screwed
“
Connection size : ½ BSP (M)
Mounting : Direct with bottom entry
Case : Die cast Al stove enamelled black finish
Bezel (screwed) : Die cast Al stove enamelled black finish
Dial window : Shatter proof glass
Pointer : Al anodised black
Dial : Al white with black letters
Movement assembly : AISI 304SS
Shank : AISI 3166SS
Adjustable pulsation damper : Yes

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

4.3.0 Water Supply System

4.3.1 Scope of work of Water Supply System

The scope of work of water supply system include

(i) Drinking water system,

(ii) Service water system,

(iii) Dewatering system for underground premises (Track Hopper building, Wagon
Tippler building & Junction House JH-Z1) and Drainage system for Pump
Houses (6 Nos.),

4.3.2 Battery Limit

All water tappings shall be made by the Contractor through two points (~10-15m
apart) from the Purchaser’s network through isolation valves; make-up water
tappings shall be through flow meter with requisite isolation valves on either side and
by-pass arrangement.

a) Industrial water / Service Water

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

available to the Contractor at one point within 100 m from the proposed Package
061 area at a pressure of approximately 1.0 kgf/ cm2.

b) Drinking water

Drinking water will be made available to the Contractor at one point within 100 m
from the proposed Package 061 area at a pressure of 1.5-2.0 kgf/ cm2.

4.3.3 Specification and Description of Work

Water System Facilities:

Water system shall in general include the following facilities:-
a) Drinking Water System

i) The drinking water shall be made available at one point near Package 061
within battery limit as specified. The Contractor shall extend the pipeline
from battery limit with an isolation valve in a valve pit up to various
drinking water consumers under the subject package.
ii) Tapping of drinking water shall be based on two points feeding and shall
conform to provisions of TS/GTS. Contractor shall extend the drinking
water line with an isolation valve in a valve-pit to his proposed units for
drinking water requirement for the entire plant area.
iii) On-line boosting of the drinking water is not permitted. If the pressure,
as indicated in battery limit parameters, is felt inadequate for the area
under the scope of the Contractor, Contractor shall provide separate sump
and drinking water pumps along with piping and electrics etc. to meet the
requirement.
iv) The details and specification of pumps, valves, pipes, fitting, pipe supports
and associated civil, structural, electrical, instrumentation, material
handling, air-conditioning & ventilation etc. for cooling water system is
applicable for this system also.
v) Drinking water to be supplied to the entire junction houses, Control
Rooms, Area Repair Shop, Stores (sub-store), Welfare Buildings; except
for the Welfare Buildings the drinking water tappings shall be one for each
no. and type of premise. Drinking water shall be supplied through
continuous pumping.

b) Service Water System

For Service Water, pipeline network shall start from common pump house
to all the transfer points of each floor and conveyor gallery. In each floor,
1 no. tapping point will be provided and for the conveyor gallery the
tapping point shall be provided at every 50metre interval. For each
tapping point 1 no. gate valve, hose (DN25) and quick fix connection shall
be provided.
 For service water line each tapping point discharge rate will be 2m³/hr.
and maximum 6 Nos. points can be operated at a time. Pumping system
shall be conforming to GTS for design norms including no. of standby
units, pump rpm, piping etc.

c) Dewatering system for underground premises and Drainage system for

Pump Houses

Dewatering system for underground sumps (Track Hopper building,

Wagon Tippler building & Junction House JH-Z1) and Drainage system for
Pump Houses (5 Nos.) shall be provided as required. The water from the
sumps will be pumped to the nearest surface drainage system through
pumping arrangement to be provided as per GTS and subject to
Purchaser’s approval.

The details of Sump Pumps are given below;

1. Track Hopper building - 4 Nos. (2W+2S), (2 Nos. each side).
2. Wagon Tippler building - 2 Nos.(1W+1S)
3. Junction House JH-Z1 - 2 Nos.(1W+1S)
All Sump Pumps shall have Cap. – 50 CBM /Hr. & Head - 15 Mtr.

The details of Drainage Pumps are given below;

1. Pump House (5 Nos.) - 10 Nos. (5W+5S)
All Drainage Pumps shall have Cap. – 25 CBM /Hr. & Head - 15 Mtr.

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

All the water lines including Drinking water, Service Water, Dust
Suppression Water, Dewatering, Make-up water lines will generally be laid
over-ground.
d) Water Pollution Control and Conservation

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

Quality of circulating water will be maintained through dosing of conditioning
chemicals for controlling corrosion, scale deposit and microbial growth.

Through cascaded reuse of blow down, the water scheme will ensure
minimization of waste water discharge from the industrial water circuits. Any
discharge/reject into the Purchaser’s system shall conform to the local
pollution control norms.

Design Criteria

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

guiding criteria of the design of the water system for the proposed plant.
Water system shall be designed as per TS/GTS and subject to Purchaser’s
approval.
The followings are the guiding factors for designing the water system:

i. The water system shall be designed & supplied generally as per the
contract document, GTS and subject to Purchaser’s approval.
ii. Design norms including no. of standby units, pump rpm, piping shall
conform to GTS as applicable for this package.
iii. Following MOC to be considered:
Gate valve:
Body & Cover: CS ASTM A216 Gr WCB, Disc: ASTM A216 Gr WCB Face
ring 13% Cr steel, Body seat ring: 13% Cr. Steel, Stem: SS 410, Gaskets:
Neoprene rubber, Gland packing: Rubber, End connections: Flanged to be
drilled as per IS: 6392-1971 (RA 1998) T-17.
Butterfly valve:
Body: ASTM A216 Gr WCB, Disc: CF8, Seat: EPDM (integral with the
body), shaft: AISI 410 self-lubricated PTFE lined bearings for both drive
end and non-drive end, hand lever /hand wheel: pressed/forged steel, end
connection: Flanged to IS6392, T-17.
 iv. Pipe thickness shall be as per GTS (numerical values indicated for each of
the pipe sizes).
v. Tapping of Industrial water / Service water, Make up water & Drinking
water will be based on two points feeding and will conform to provisions of
TS & GTS.
vi. Isolation gate valves shall be provided in suction and delivery side of
pumps as per GTS.
vii. The drainage pumps shall be split casing; self priming and horizontal
centrifugal pumps type with common base frame with drive motors, there
will be one reserve pump for one working pump. The pumps shall not be
of mono-block design.
viii. Each pump shall have independent suction. The delivery line of each pump
shall be connected to the main header with isolating header gate valves
for isolating delivery valves.
ix. Suitable number of header valves shall be such that delivery valve of
pump can be isolated for maintenance without affecting other stand-by
pump’s availability.
x. Motorized gate valves shall be provided in automated pumping system for
pumps’ suction & delivery.
xi. Commissioning spares & consumables as required for the successful
commissioning are included in the scope of the Contractor.

4.3.4 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.
2. The welding work should be carried out as per the approved WPS and PQR.
3. The successful Contractor shall supply all required manpower, tools and
related equipment, all hoisting equipment, all necessary scaffoldings, all
necessary transporting equipment, consumables. Construction and erection
materials, petrol, diesel oil, kerosene, solvents, sealing compound, tapes,
brazing and soldering materials, welding and brazing gases, erection bolts,
nuts and packing sheets/compounds, temporary supports, wooden blocks,
 spacers, templates, jute and cotton wastes, sand/emery paper etc. as
required for the satisfactory completion of work.
4. After erection, all equipment having moving part, subject to pressures or
voltages shall be given trial operation. The trial operation shall consist of 72
hours of continuous operation. All modifications and rectifications required
during the trial operation or required for proper operation shall be done at his
own cost by the Contractor as accepted by the Purchaser.
5. Rotating equipment shall be checked for proper direction of rotation and shaft
alignment. Equipment subject to pressures shall be carefully examined for
leakage. All equipment, such as pressure taps, temperature measurement
connections, flow measurement devices etc. shall be provided by the
Contractor.
6. On completion of the work, the Contractor shall remove and dispose off all
rubbish and other unsightly materials caused by his working to a distance of
five kilometer from the Package 061 or as directed by the Purchaser and
thereby leaving the premises in good, clean, safe and operable condition.
7. 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 Contractor shall be made available to the final inspecting
authority. However, approval and final inspection at the manufacturing works
shall not relieve the Contractor of responsibility of replacing at his cost any
defective part/material which may be detected by the purchaser during
erection and commissioning or guarantee period.
8. All materials required for fabrication, construction, testing and inspection shall
be supplied by the successful Contractor. No material shall be free issue to
the Contractor.
9. No equipment or part item shall be dispatched without final inspection and
issuance of inspection certificate.
10. All equipment, assemblies, sub-assemblies shall be shop tested as per
relevant standards and the test certificates shall be submitted by the supplier.
11. Erection, testing & commissioning of various equipments and piping etc shall
be done also inline with details given in various chapters of GTS.

4.3.5 Painting
The Contractor shall follow the painting procedure as mentioned in GTS.
4.3.6 Preferred Makes

The Contractor shall follow the list of preferred makes indicated hereinafter.

4.3.7 Drawings/documents to be furnished by the Contractor for approval:

1. Scheme of the complete water supply system with descriptive and illustrative
literature.
2. Process flow diagram indicating the water consumption figures complete with
temperature, pressure and quality requirements.
3. P&IDs 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. Write -up detailing the control logic for the entire water system.
5. All equipment and piping sizing calculations,
6. Data sheets for various pumps, strainers, filters, valves and other equipment
as applicable in line with in the GTS.
7. Pipeline materials and specifications considered for various systems.
8. Layout drawing showing the battery limits of service water, make –up water,
drinking water and the pipeline route to various consumers including
requirement of service water, make-up water and drinking water at battery
limits.
9. General arrangement drawings of pump houses showing tentative dispositions
of various equipment and piping.
10. Layout of piping system indicating pipe routing, location of supports, valves
and other fittings as required.
11. Data sheets and technical details of all the equipments, valves and piping.
12. Catalogues, literatures and GA drawings of all equipments and valves.
13. List of special tools and tackles.
14. Test procedures for preliminary and final acceptance tests.
15. Quality Assurance Plan.
16. Test certificates for the following:
ƒ Material test certificate for all major equipment and their components.
ƒ Hydraulic test of equipment, pipe fittings & valves.
ƒ Static and dynamic balancing of all rotary parts/ equipments
 17. List of commissioning spares.
18. List of spares for two years of normal operation and maintenance with item
wise prices.
19. Specification and capacity of all equipment, valves etc. offered by the
Contractor.
20. Details of various drives, instruments, handling & hoisting facilities, air
conditioning & ventilation facilities, etc.
21. Bill of Quantities covering all equipments, valves, strainers, pipelines, etc.
22. Any other drawing/ documents as required by the Purchaser.

4.3.8 Drawings / Documents to be furnished by the Contractor for reference and

record

1. The Contractor shall submit required sets of all the approved / received for
reference drawings, documents and manuals for Purchaser’s record and use.
Further, after erection of plant and equipment, the Contractor shall submit
one set of linen tracings/ reproducible in required number of prints along with
soft copies in CD (in AutoCAD format) of each “As built drawings”.
2. Operating and maintenance manual.
3. Spare parts recommendation and price list.
4. Instruction for erection, testing and commissioning.
5. Manufacturer’s test certificates.
6. Various equipment assembly drawings and bill of material.
7. Welding procedure.
8. Hydraulic test logs.
9. Equipment GA drawings and bill of materials.
10. Operation and maintenance manuals for all equipments, valves and complete
water system along with soft copies.
11. Test and calibration certificates.
12. Warranty/ guarantee certificates.
13. Technical literature, catalogues and manufacturer’s drawings for all brought
out equipment, valves and other items.
14. All inspection/ test report/ certificates.
15. Any other drawing/ documents as required by the Purchaser/Consultant.
4.3.9 Preferred makes

List of vendors for Water System

Sl Item Description : Manufactures

No.
1. Horizontal centrifugal : Kirloskar Brothers, KSB, Beacon Weir, Voltas,
Pumps Mather & Platt, Jyoti, WPIL (Worthington).

2. Submersible pumps : KSB, SU Motors, Kirloskar Brothers.

3. Dosing Pump : Shapo Tools, Asia LMI (Madras), Toshniwal,
Milton Roy India.
4. Cooling Towers : Paharpur, Shriram Tower Tech, Gammon,
Southern Cooling Tower.
5. Sluice Gates : Jash, IVPL.
6. Basket Strainers : Filteration Engineers, Superflo.
7. Rubber expansion : BDK, CORI Engineers.
joints
8. CS Valves (gate, NRV) : Audco, Fouress, BHEL, KSB, BDK, Kirloskar,
Leader, Chemtech.
9. Plug Valves : Audco, Xomox, BDK, Tufiln, Chemtrol Samit,
KSB.
10. Ball Valves : Audco, Xomox, BDK, KSB.
11. Butterfly Valves : AUDCO, Fouress, Intervalves.
(manually & electrically
operated)
12. Float Valve : Leader, IVPL, Levcon.
13. Control Valve : Audco, Fouress, IL, Xomox, Fluid Line.
14. Solenoid Valve : Rotex, INDFOS, AVCON.
15. Air Release Valve : IVPL,
16. Check Valve (Zip type) L&T, Leader, BDK, Fouress, Chemtech
17. Electric Actuators : Beacon Rotork, Auma, Limitorque, IL, Palghat,
EI-O-Matic
18. Pneumatic Actuators : AL Saunders, Xomox, EL-O-Matic, AUMA
Sl Item Description : Manufactures
No.
19. Hoses : Senior Flexonics, Hydrocrimp
20. Pipe a) MS/GI : SAIL, TATA, Jindal, MAN, SAW, Welspun,
Prakash, PSL, MSL,
21. MS/GI Pipe Fittings : Tube bends, Stewards & Lloyds, BST, Jindal.
22. Chemical Dosing : GE India Industrial Private Limited, Ion
System Exchange, Chembond Drewtreat.
4.4 LEVEL OF VARIOUS BUILDINGS AND JUNCTION HOUSES

(A) Z-LINE

Sr. Name of Building Ground No. of Floor Levels (Mtr.)

No. / Junction House Level Floors I II III IV V
(Mtr.)
Wagon Tippler
1 Building 307.250 5 307.250 304.982 298.500 295.000 291.100
2 Pump House-2 307.250 --- --- --- --- --- ---
3 LTSS-1 307.250 --- --- --- --- --- ---
4 JH-Z1 306.000 3 303.750 300.050 296.050 --- ---
5 JH-Z2 307.000 3 309.000 313.000 316.900 --- ---
Track Hopper
6 Building 308.358 2 308.358 299.158 --- --- ---
7 JH-Z3 306.000 3 306.000 310.100 314.100 --- ---
8 JH-Z4A 303.000 4 303.000 307.100 310.600 315.800
9 JH-Z5A 303.000 3 303.000 307.100 310.600 --- ---
10 JH-Z6A 303.000 3 303.000 307.100 310.600 --- ---
11 JH-Z7A 303.000 3 303.000 307.100 310.600 --- ---
12 JH-Z4 303.000 2 309.000 312.600 --- --- ---
13 JH-Z4B 303.000 2 303.000 309.000 --- --- ---
14 JH-Z5B 303.000 2 303.000 309.000 --- --- ---
15 JH-Z6B 303.000 2 303.000 308.700 --- --- ---
16 JH-Z7 303.000 2 303.000 308.300 --- --- ---
17 Main Pump House-1 303.000 --- --- --- --- --- ---
18 Compressor House 303.000 --- --- --- --- --- ---
19 LTSS-2 303.000 --- --- --- --- --- ---
20 JH-Z8 303.000 2 316.600 321.600 --- --- ---
21 FTH-1 311.000 2 318.000 322.500 --- --- ---
22 JH-Z9 308.000 2 313.900 317.500 --- --- ---
23 JH-Z10 310.500 3 317.000 320.600 324.100 --- ---
24 JH-Z11 310.000 3 320.000 323.700 327.300 --- ---
25 Pump House-3 310.000 --- --- --- --- --- ---
26 LTSS-3 310.000 --- --- --- --- --- ---
27 JH-Z12 310.000 2 316.500 320.000 --- --- ---
28 JH-Z13 310.000 2 322.900 328.000 --- --- ---
29 JH-Z15 308.500 3 343.800 347.400 350.400 --- ---
(B) L-LINE

Sr. Name of Ground No. of Floor Levels (Mtr.)

No. Building / Level Floors I II III IV V
Junction House (Mtr.)
1 JH-J102 310.000 1 317.100 --- --- --- ---
2 JH-L1 310.900 2 314.525 318.525 --- --- ---
3 JH-L2 310.100 2 325.625 328.225 --- --- ---
4 JH-L3 310.500 2 317.800 324.325 --- --- ---
5 JH-L4 310.000 3 316.800 320.400 324.000 --- ---
6 LTSS-4 310.000 --- --- --- --- --- ---
7 JH-L5 310.000 2 315.332 320.150 --- --- ---
8 JH-L6 308.500 2 322.670 327.670 --- --- ---
9 JH-L7 306.000 2 312.900 316.500 --- --- ---
10 Pump House-4 306.000 --- --- --- --- --- ---
11 JH-L8 304.000 2 304.000 309.300 --- --- ---
12 JH-L9 312.000 3 312.000 328.000 332.000 --- ---
13 JH-L10 307.000 1 352.600 --- --- --- ---

(C) J -LINE

Sr. Name of Ground No. of Floor Levels (Mtr.)

No. Building / Level Floors I II III IV V
Junction House (Mtr.)
1 JH-J9B 308.500 1 308.500 --- --- --- ---
2 JH-J9H 309.200 3 312.120 316.000 320.000 --- ---
3 JH-J10A 310.000 2 324.000 327.800 --- --- ---
4 JH-11 310.000 3 312.400 319.600 323.800 --- ---
5 Pump House-5 310.000 --- --- --- --- --- ---
6 JH-J14A 310.000 2 317.578 321.100 --- --- ---
7 JH-J15B 309.500 4 314.650 318.650 322.150 325.650 ---
8 LTSS-5 309.500 --- --- --- --- --- ---
9 JH-J17A 307.300 2 313.700 317.700 --- --- ---
10 JH-J17B 307.300 3 323.300 327.100 330.800 --- ---
11 JH-J20 307.300 1 330.850 --- --- --- ---
5.0 SPARES
(A) Commissioning Spares and Insurance Spares

Supply of commissioning spares and insurance spares as required shall be in

scope of supply of the Bidder alongwith the equipment. The list of commissioning
spares and the insurance spares as per the format as given in SBD shall be
furnished alongwith 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 Bidder shall have to be provided by the Bidder free of cost up to the
successful commissioning & commencement of commercial production of the
plant and equipment. The Bidder shall supply adequate insurance spares to
ensure smooth operation and maintenance of the plant.

(B) Consumables

The Bidder 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, packings, bolts, nuts, gaskets,
rivets, washers etc. The Bidder shall fulfill the requirement given in SBD.

The Bidder 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 Bidder shall indicate the annual requirement of all such consumables.

(C) Operating, Maintenance and Two Years’ Spares:

(1) The Bidder shall ensure the interchangeability of the parts wherever possible.
The Bidder shall furnish an itemized list of interchangeable spares as given in
SBD.

(2) 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
Bidder. The same shall be quoted separately. In the event of order the
successful Bidder shall furnish complete specification of the same.

(3) Spares list giving complete list of the replaceable parts, fully illustrated, shall be
supplied. The list shall include the following information.

• Item designation
• Reference drawings
• Quantity installed
 • Quantity recommended for two years’ normal operation 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.

(D) Special Erection / Maintenance Tools and Tackles:

(1) The Bidder shall supply a complete and unused wet of all the special tools and
tackles including required number of tool boxes as required for erection,
maintenance, overhaul or complete replacement of the equipment and
components required for the plant. The Bidder shall submit a list of such
special erection and maintenance tools and tackles.

(2) All the tools shall be supplied in separate containers clearly marked with the
name of the equipment for which they are intended.

(3) The Successful Bidder 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 Bidder 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.

(4) For any fabrication / control assembly (necessary for erection) work to be done
in the plant premises the plan shall be indicated by the Bidder. 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 Bidder.

(5) The successful Bidder 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.

(6) All the measuring instruments shall be calibrated having reference to NPL
(National Physics Laboratory).

(7) 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 Bidder. After
 commissioning, the successful Bidder shall handover all the special tools &
tackles to the Purchaser as per the requirement given in SBD.

(8) The successful Bidder 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.

(9) For load testing of handling equipment, loads shall have to be arranged by the
successful Bidder. Electrical/ operation tests, as per standard practice, shall also
be arranged and completed by them.

(10) All materials, equipment, tools, tackles etc. brought at site by the successful
Bidder 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.

(E) Information/ Data on Spares and Consumables

The list of Spares & consumables shall be furnished by the successful Bidder as
required in SBD. However, the successful Bidder shall furnish various information
regarding spares, consumables, tools & tackles etc. as per the schedules
indicated in chapter 12 of this Technical Specification.
DATA SHEETS
6.0 TECHNICAL DATA SHEET (To be filled by the vendor)

6.1 DUST SUPPRESSION SYSTEM (To be furnished separately for all the
systems)

1. Type of dust suppression system :

2. Total capacity of dust suppression system :

3. Make of equipment :

4. Design water flow quantity :

5. Work zone dust concentration :

6. Total power requirement :

7. Total water requirement :

8. Any specific design consideration :

9. Noise level at 1m distance from the

dust suppression equipment

10. Space requirement (L x B x H) :

11. Support / Structure / Weathering

shed DS system

12. List of drive :

13. Spray nozzle make rating, quantity :

14. Spray nozzle material of construction :

15. Sprinkler make, rating, quantity :

16. Sprinkler material of construction :

17. Load monitoring switch type,

quantity and rating

18. Sequence timer type, quantity and rating :

19. Solenoid valve type, quantity and rating :

6.2 Technical Information of Dry Fluid Dust Suppression System (DFDS)

The Bidder shall also fill up the following questionnaire and submit with his offer.
This data shall form a part of the contract with Successful Bidder.

a) GENERAL

Sl.
Characteristics Unit Value
No
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 dB(A)
dust suppression equipment
9. Support / Structure / Weathering
shed DS
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
15. Solenoid valve type, quantity and

b) PUMPS FOR DFDS

Sl.
Characteristics Unit Value
No
1. Make and model no.
2. Type of pump
3. Capacity. m3/hr
4. Total head. m WC
5. Quantity
6. Material of construction
 Sl.
Characteristics Unit Value
No
i) Shaft
ii) Impeller
iii) Casing
7. Pump speed rpm
8. Shaft power
9. Drive details
i) Motor make
ii) Motor KW
iii)Insulation class
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
Characteristics Unit Value
No
1. Material
2. Standard
3. Class
4. Thickness of pipe material
5. Pipe size, length and weight
6. Make
0C
Maximum recommended
7.
operating temperature
Maximum recommended
8.
operating pressure
9. Type of protective coating

d) PIPE FITTINGS FOR DFDS

Sl.
Characteristics Unit Value
No
1. Type of fittings
2. Size (O.D x Thickness)
 Sl.
Characteristics Unit Value
No
3. Standard
4. Lengths
Maximum recommended
5.
operating temperature
Maximum recommended
6.
operating pressure
7. Type of protective coating
8. Weight of fittings kg

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

PRESSURE RELIEF) FOR DFDS

Sl.
Characteristics Unit Value
No
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.
Characteristics Unit Value
No
1. Make and Model
2. Type
3. Power Supply
4. Quantity
5. Solenoid Valve Box size
 Enquiry Specification for Dust Suppression, Compressed Air & Water Supply Package

g) LOAD SENSOR UNIT FOR DFDS

Sl.
Characteristics Unit Value
No
1. Make and Model
2. Type
3. Quantity

h) MATERIAL SENSOR UNIT FOR DFDS

Sl.
Characteristics Unit Value
No
1. Make and Model
2. Type
3. Quantity

i) PRESSURE SWITCH FOR DFDS

Sl.
Characteristics Unit Value
No
1. Make and Model
2. Type
3. Quantity

j) PRESSURE GAUGES FOR DFDS

Sl.
Characteristics Unit Value
No
1. Make and Model
2. Type
3. Quantity

k) SEQUENCE TIMER FOR DFDS

Sl.
Characteristics Unit Value
No
1. Make and Model
2. Power Supply
3. Quantity

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 Enquiry Specification for Dust Suppression, Compressed Air & Water Supply Package

6.3 TECHNICAL DATA SHEET (To be filled by the vendor)

A. AIR COMPRESSORS

01. Manufacturer's Name & address :

Model No. :

Type :

No. provided :

Rated capacity Nm3/min :

Rated discharge pressure :

kgf/cm2g

kW input at motor terminal :

Motor rating :

Air temp. at delivery after :

after-cooler at rated capacity
and pressure, deg.C.

Screw Speed, rpm

1st stage (male & female) :
2nd stage (male & female) :

Oil content in the air at outlet :

of air compressor, ppm.

Noise level at source when the :

compressor running at rated
capacity, dB (A).

Cooling water requirement :

Pressure drop across compressor :

Temp. rise :

02. Inter cooler & after cooler Inter cooler Aftercooler

No. per compressor :

Design standard/code :

Make :

Max. working pressure, kgf/cm2g :

i) Water side :

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 Enquiry Specification for Dust Suppression, Compressed Air & Water Supply Package

ii) Air side :

Tube material, size and thickness :

Shell material and thickness, mm :

Moisture content in air after :

aftercooler, ppm

Space required for pulling out :

tube assembly of intercooler :
& aftercooler

03. Moisture separator

Make :

Type :

Model :

Number :

Design standard/code for :

pressure vessel

Shell material and thickness :

Design pressure,kgf/cm2 (g) :

Moisture content after separator :

B. Motor

Type :

Make :

Rated kW at 50 deg.C :

Rated kW at 40 deg.C :

Rated voltage & system condition :

Frame size :

Class of insulation :

Rated speed & direction :

of rotation

Starting system :

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 Enquiry Specification for Dust Suppression, Compressed Air & Water Supply Package

C. AIR RECEIVER

Number :

Design Standard/ Code :

Capacity :

Overall dimensions :

Wall plate thickness :

Plate material :

Design Pressure :

Working Pressure :

D. COOLING TOWER for Water Line

Make & Model :

Type :
Quantity :
Overall size of cooling tower :
Capacity of cooling in TR. :
Water flow m3/h :
Air flow :
Design water inlet temperature, :
outlet temperature

Material of construction and :

its thickness

Speed in rpm :
Drive details :
Shaft Power consumption :
Wheel diameter :
Efficiency :
Size of fan :
Static & Dynamic weight of fan :
& motor assembly

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 Enquiry Specification for Dust Suppression, Compressed Air & Water Supply Package

Bare weight and operating :

weight of cooling tower

Noise level at 1m distance in dB(A) :

Fixing details :
Vibration level :
Water spray nozzle type :

6.4 CENTRIFUGAL PUMP for Water Supply System (To be furnished

separately for all the systems)

1. Make and model no. :

2. Type of pump :

3. Capacity in m3/hr. :

4. Total head in m WC :

5. Quantity :

6. Material of Construction of

• Shaft :

• Impeller :

• Casing :

7. Pump speed (rpm) :

8. Shaft power :

9. Drive details

• Motor make :

• Motor kW :

• Class of insulation :

• Frame size :

10. Bearing type & make :

11. Type of coupling :

12. Vibration level :

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 Enquiry Specification for Dust Suppression, Compressed Air & Water Supply Package

13. Noise level at 1 m distance :

14. Duty :

15. Weight of pump & motor separately:

16. Characteristic curves for pumps :

17. Type of liquid to be handled :

6.5 WATER LINE VALVES for Water Supply System

1. Make & Model :

2. Type :

3. Quantity :

4. Size :

5. Pressure rating :

6. Material of construction :

7. Operating system :

8. Drive details :

9. Gland packing :

10. End connections :

11. Service :

12. Test pressure :

6.6 WATER LINE PIPES for Water Supply System

1. Material :
2. Standard :
3 Class :

4. Thickness of pipe material :

5. Pipe size, length and weight :
6. Make :

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 Enquiry Specification for Dust Suppression, Compressed Air & Water Supply Package

7. Maximum
recommended 0C :
operating temperature :
8. Maximum
recommended :
operating pressure :
9. Type of protective coating :

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