Tender Doc NALCO Agon Tipper Part II

NATIONAL ALUMINIUM COMPANY LIMITED
BID DOCUMENT No. : WT/01/2011/RITES/NALCO-ANGUL
PACKAGE - I
TENDER DOCUMENT FOR DESIGN, MANUFACTURE, SUPPLY, ERECTION, TESTING AND COMMISSIONING OF WAGON TIPPLER AND CONVEYOR SYSTEM FOR M/S. NALCO AT ANGUL.
PART II
CONTENTS 1. GENERAL 2. INTENT OF SPECIFICATIONS 3. INSTRUCTION TO BIDDERS 4. SYSTEM PARAMETERS, OPERATION AND CONTROL PHILOSOPHY 5. GENERAL TECHNICAL REQUIREMENTS 6. ELECTRICAL 7. CONDITION OF CONTRACT FOR FIELD SERVICES 8. ANNEXURES
(A GOVERNMENT OF INDIA ENTERPRISE) PROJECT OFFICE BHAGWAN TOWER, 1ST FLOOR CUTTACK ROAD, BHUBANESWAR 751006
INDEX
SECTION 1 2 3 4 5 6 7 8 GENERAL
DESCRIPTION
PAGE NO 1-5 1-18 1-12 1-66 1-29 1-77 1-26 1-62
INTENT OF SPECIFICATIONS INSTRUCTION TO BIDDERS SYSTEM PARAMETERS, OPERATION AND CONTROL PHILOSOPHY GENERAL TECHNICAL REQUIREMENTS ELECTRICAL CONDITIONS OF CONTRACT FOR FIELD SERVICES ANNEXURES
SECTION 1
1.0 GENERAL M/S. National Aluminium Company Ltd. (NALCO), Angul have undergone 2nd phase expansion of their Captive Power Plant (CPP).The 9th & 10th units are added in 2nd phase expansion of the Existing Captive Power Plant (CPP) by increasing the station capacity to 1200MW. Facility for Storage and Handling of about 90,000 t additional uncrushed Coal has been envisaged to be added in 2nd phase expansion of Captive Power Plant. The new uncrushed coal storage yard shall be equipped with stacker and reclaimer machines and shall have uncrushed coal supply connectivity to old and new coal bunkers through respective crusher house. 2.0 Basic Data Material to be handled Feed size Specific gravity of coal Moisture (%) No of working days / yr No of working shift / day 3.0 DESCRIPTION OF EXISTING SYSTEM The salient features of existing coal handling facilities consist of following: 3.1 ROM Coal of (-) 250 mm size is brought from coalfields in Bottom Discharge Captive Railway Wagons. Coal from coalfield is received through a Merry Go-round (MGR) system between the CHP and coalfield. There are two (2) nos. of existing Track Hopper Buildings with underground RCC hopper. Each Track Hopper Building has four (4) nos. of paddle feeders of travelling type at its bottom to scoop coal from the track hopper. Two paddle feeders are mounted on individual conveyor. Uncrushed coal (Grade E / F / G) (-) 300 mm 0.8 t/m3 for volume calculation 1.1 t/m3 for strength calculation 6% to 10% 330 3 shift of 8 hrs per day
3.2
3.3
3.4
Technical Specification: General
Page 1 of 5
3.5
There are two (2) underground conveyors at bottom of each track hopper. Both conveyors are running parallel at the bottom of the track hopper1. The parallel conveyor installed at the bottom of track hopper2 run in opposite direction. There are two (2) Bunker Bays. The old Bunker Bay meets the crushed coal requirement for Unit 1 6 whereas the new Bunker Bay meets the crushed coal requirement for unit 7 to 10. Thus, there are two separate conveyor paths. Each path has two conveyor streams running in parallel. Rated & designed capacity of each conveyor stream is 800 TPH & 960 TPH respectively. Two parallel conveyors with moving tripper are installed on the top of each Bunker Bay. One moving tripper is provided on each conveyor installed on the top of Bunker Bay. Moving trippers feed the crushed coal in desired bunkers as per requirement. The CHP has two (2) Crusher Houses. The old crusher house is provided on conveyor path that is feeding crushed coal to Units 1- 6. The new crusher house is provided on conveyor path that is conveying crushed coal to Unit 7 to 10. Each crusher house has two (2) crushers & associated equipment installed on parallel conveyor series. Thus, each crusher series has been provided with dedicated crusher and associated equipment. There are three uncrushed coal storage yards with stacker cum reclaimer machine (SCR) in present CHP. One SCR machine is provided on each storage yard. Storage yard 1 & 2 receive uncrushed coal from track hopper 1 & 2. Storage yard 3 receives uncrushed coal from track hopper 2 only. Scooped uncrushed coal from track hopper 1 is conveyed to old crusher house and then to coal bunker bay of Units 1-6 through conveyor path that is conveying crushed coal to coal bunkers Bay of Units 1-6. OR, Uncrushed coal is conveyed to storage yard 1 & 2. Preparation of coal Stock Pile is carried out by installed Stacker-cum-Reclaimer (SCR) machine. Uncrushed coal is reclaimed by SCR machine and conveyed to either of boiler bunkers through dedicated conveyor paths which is operating for these two boiler bunker bays. OR, It is conveyed to boiler bunker Bay of Units 7 to 10 through new crusher house by conveyor path that is feeding crushed coal in boiler bunkers of Unit 7 & 8. SCR machine is positioned in by-pass mode while conveying coal from track hopper 1.
3.6
3.7 3.8
3.9
3.10
3.11
3.12
3.13
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3.14
Scooped coal from track hopper 2 is conveyed to crusher house and then to coal bunker bay of Units 7 to 10 through conveyor path that is conveying crushed coal to coal bunkers Bay of Units 7 to 10. OR, It is conveyed to boiler bunker Bay of Units 1- 6 through conveyor path linked with track hopper 1. OR, It is conveyed to storage yard 3. Preparation of stockpile is made with the help of SCR machine. Coal from the Stock Pile is reclaimed by SCR machine and is fed on to yard conveyor. The yard conveyor discharges the coal on to the conveyor path linked with boiler bunker bay of Units 7 to 10. OR, It is conveyed to the storage Yard 1&2 through the conveyor paths linked with track hopper 1.
4.0
Additions to existing system currently under development:
Presently an additional coal storage and handling system is being implemented under a separate contract to augment the coal handling system. The salient features of the new scheme are:
4.1 The terminal points for Additional Coal Storage & Handling System of CHP in 2nd Phase Expansion commences from and consist of: Modification and shifting of discharge end of existing belt conveyor BC-115 in Junction House JH-7 with a provision of two way chute and flap gate to feed uncrushed coal received from Track Hopper No. 2 to either the existing conveyor BC-116 or to new conveyor BC-118A under implementation. Modification of existing Junction House JH-7 to accommodate tail end of new conveyor BC-118A for receiving & conveying uncrushed coal to the proposed Additional Coal Storage Yard. Provision of new Junction House JH-7A adjacent to existing Junction House JH-7 to accommodate discharge / head end of new belt conveyor BC-122 from the proposed Additional Coal Storage Yard and extended tail end of conveyor BC-116 to receive uncrushed coal from new conveyor BC-122. Extension of tail end of existing conveyor BC-116 from existing Junction House JH-7 to new Junction House JH-7A to receive reclaimed uncrushed coal from the Additional Coal Storage Yard through a new conveyor BC-122. Uncrushed coal received on
4.2
4.3
4.4
4.5
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conveyor BC-116 will be conveyed to the new crusher house through existing belt conveyor system for supplying the crushed coal to bunkers of unit 7-10. 4.6 Extension of tail end of existing conveyor BC - 104 from existing Junction House JH-2 to new Junction House JH-13 to receive reclaimed uncrushed coal from the Additional Coal Storage Yard through a new conveyor BC-120 and BC-121.Uncrushed coal received on the extended conveyor BC-104 shall be Conveyed to the old crusher house through the existing belt conveyor system for supplying crushed coal to the bunkers of unit # 1-6. For Receipt of uncrushed coal for the proposed Additional Coal Storage and Handling System, uncrushed coal conveyed to JH-7 by existing conveyor BC-115 from Track Hopper No.2 can be diverted either to existing conveyor BC-116 or to new conveyor BC-118A at Junction House JH-7. The new conveyor BC-118A will convey material to the proposed Additional Coal Storage Yard through a new conveyor system under development. For this, the existing Junction House JH-7, shall be modified to accommodate the tail end of new conveyor BC-118A. The discharge chute of the existing conveyor BC-115 shall be replaced with new chute arrangement having a two way chute with a flap gate. Two-way chute with flap gate will divert the material discharged from conveyor BC - 115 either to existing conveyor BC-116 or to the new conveyor BC-118A depending on position of the gate. The discharge pulley of existing conveyor BC-115 will be relocated suitably to ensure the flow of uncrushed coal, either to conveyor BC-116 or to the new conveyor BC-118A is smooth through the new flap gate and chute arrangement. The rated capacity of conveying system is 800 t/hr. 4.8 For storage of uncrushed coal in the Additional Coal Storage Yard under development, the coal received through conveyor BC-118A will be conveyed to the Yard through conveyors BC-119 & BC-120 and new Junction Houses JH-10 & JH-11. The conveyor BC120 will be equipped with a Slew Stacker Machine. The Slew Stacker Machine will be capable of forming two identical stock piles of uncrushed coal on either side of its track. The length of each stock pile will be 275 m. The storage capacity of each Stock Pile will be 45,000 t of uncrushed coal. The rated capacity of stacking system is 800 t/hr For Reclaiming the uncrushed coal from Additional Coal Storage Yard, a Bucket Wheel Reclaimer will be provided. The Bucket Wheel Reclaimer will be installed on conveyor BC -120 such that its discharge is collected on the yard conveyor BC-120. The BWR will be operating on the same track as that of the Slew Stacker Machine. Simultaneous operation of stacking and reclaiming is also proposed on the yard conveyor BC-120. Uncrushed coal reclaimed on conveyor BC-120 will be conveyed to new Junction House JH-12. The rated capacity of the reclaiming system shall be 800 t/hr.
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4.7
4.9
4.10
Conveyor BC-120 will convey reclaimed material to new Junction House JH-12. Head/ discharge end of conveyor BC-120 will be provided with two way chute with flap gate arrangement. Depending on position of flap gate in the discharge chute, uncrushed coal reclaimed from the Additional Coal Storage Yard will be diverted either to conveyor BC-121 or to conveyor BC-122 at new Junction House JH-12. Conveyor BC121 will transport the material to new JH-13 and transfer material to the tail end of existing and extended conveyor BC-104, Conveyor BC-122 will convey the material to new Junction House JH-7A and transfer the material to tail end of existing and extended conveyor BC-116. The rated capacity of conveying system is 800 t/hr. Conveying of uncrushed coal to new crusher house. Uncrushed coal received on conveyor BC-122 will be conveyed to new Junction House JH-7A, located adjacent to existing JH-7. At Junction House JH-7A, conveyor BC-122 shall discharge the uncrushed coal at the extended tail end of existing conveyor BC-116. Uncrushed coal received on conveyor BC-116 will be conveyed to the new crusher house through the existing coal flow path. The rated capacity of conveying system is 800 t/hr. For Conveying the uncrushed coal to the old crusher house, uncrushed coal received on conveyor BC-121 shall be conveyed to new Junction House JH-13. At this new Junction House JH-13, conveyor BC-121 will discharge the material to the extended tail end of the existing conveyor BC-104. Coal received on conveyor BC-104 will be conveyed to the old crusher house through existing coal flow path. The tail end of existing conveyor BC-104 at JH-2 will be extended up to the new Junction House JH-13 and a new conveyor gallery between existing Junction House JH2 and the new Junction House JH-13 will be provided to house the extended length of existing conveyor BC-104. The system rated capacity is 800 t/hr.
4.11
4.12
4.13
Dust Suppression System will be provided at all transfer points at various Junction Houses and uncrushed coal storage yard. Suitable ventilation and air conditioning facilities will be provided in Switch gear cum MCC room, Battery room, Transformer rooms. PLC based operation & control system is being provided for additional coal storage & handling system. Controls are being suitably interfaced with existing conveyor system through limit switches.
4.14
4.15
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SECTION 2
1.0 1.1 INTENT OF SPECIFICATIONS This specification is intended to cover the following activities and services in respect of all the equipment of Wagon Tippler and Conveyor System Package to be installed for National Aluminium Company Limited (NALCO), Captive Power Project located in Angul of Orissa State in India. (a.) The broad scope of work covers the following: i. Detailed design and engineering of all the equipment and equipment system(s). ii. Complete manufacture including shop testing/ type testing. iii. Providing engineering data, drawings, Commissioning procedures and O & M manuals, etc. for the Owners review, approval and records. iv. Packing and transportation from the manufacturers works to site. v. Receipt, unloading, storage, preservation and conservation of equipment at site. vi. Fabrication, pre-assembly, (if any), erection, testing and satisfactory operation of all the equipment including successful completion of facilities. vii. All associated civil, structural and electrical works. viii. Commissioning and completion of facilities and Performance Guarantee Tests. ix. Furnishing of spares and handing over to NALCO stores. x. Reconciliation (if any) with custom authorities. xi. Satisfactory conclusion of the contract. (b.) The equipment and services to be furnished and installed as required in this Technical Specification shall also meet all the requirements as stated in other sections of bid documents which shall be considered as a part of this technical specification as bound herewith. (c.) The Contractor shall be responsible for providing all materials, equipment and services, specified or otherwise (unless specifically excluded) which are required to fulfill the intent of ensuring operability and the reliability of the complete system covered under this specification. (d.) It is not the intent to specify completely herein, all aspects of design and construction of equipment. Nevertheless, the equipment shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation.
Technical Specification: Intent of Specifications
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(e.) Whenever a material or article is specified or described by the name of a particular brand, manufacturer or trade mark, the specific item shall be understood as establishing type, function and quality desired. Other manufacturers products may also be considered provided sufficient information is furnished so as to enable the Owner to determine that the products are equivalent or superior to those named. (f.) Bidder is requested to carefully examine and understand the specifications and seek clarifications, if required, to ensure that they have understood the specifications. Such clarifications should reach Owner at least 15 days before the scheduled date of the opening of the bids. The Bidders offer should not carry any sections like clarifications, interpretations and/or assumptions. (g.) If the Bidder feels that, in his opinion, certain features brought out in his offer are superior to what has been specified, those may be highlighted separately. The Bidder may also make alternative offers provided such offers are superior in his opinion. In which case, adequate technical information, operating feed back, etc. shall be enclosed with the offer, to enable the Owner to assess the superiority and reliability of the alternatives offered. In case of each alternative offer, its implications on the performance, guaranteed efficiency, auxiliary power consumption etc. shall be clearly brought out for the Owner to make an overall assessment. In any case, the base offer shall necessarily be in line with the bidding documents/ specifications. Under no circumstances the equipment / system specification in Technical Specification shall be brought out as alternative offer. (h.) Any deviation or variation from the scope, requirement and/or intent of this specification shall be clearly defined by the Bidder in Deviation Schedules of "Bid Proposal Sheets" irrespective of the fact that such deviations/ variations may be standard practice or a possible interpretation of the specification by the Bidder. Except for those deviations/ variations covered under Deviation Schedules, which are accepted by the Owner before the award of the Contract, it will be the responsibility of the Bidder to fully meet the intent and the requirements of the specification within the quoted price. No other deviation whatsoever from this specification, except for the declared deviations submitted by the Bidder with his proposal under Deviations shall be considered. Bids not complying with this requirement shall be treated as non-responsive and hence liable for rejection. The interpretation of the Owner in respect of the scope, details and services to be performed by the Bidder shall be binding unless specifically clarified otherwise by the Owner in writing before the Award of the Contract. (i.) Before submitting his bid, the Bidder should inspect and examine the site and its surroundings and should satisfy himself as to the nature of the ground and subsoil, the quantities and nature of work, materials necessary for completion of the work and their availability, means of access to site and in general shall himself obtain all necessary information as to risks, contingencies and other circumstances which may influence or affect his offer. No consequent extra claims on any misunderstanding or otherwise shall be allowed by the Owner. The contractor shall,
Technical Specification: Intent of Specifications Page 2 of 18
prior to commencement of design work, carry out the Geo-technical investigation in the area proposed for development of wagon tippler and conveyor system package. The number of bore holes shall be decided by the contractor to ensure adequate data to carry out the design and guaranteeing the installation. The cost of such Geo-technical investigation is deemed to be included in the bid submitted by the contractor. (j.) The sizes of various buildings/conveyor galleries indicated in the tender drawings and the parameters of equipment indicated in various sections of technical specifications are the minimum requirements of the Owner. Any increase in these sizes or the parameters, if required to meet the system/maintenance/operational requirement shall be supplied by the contractor without any extra cost implication to the Owner. (k.) The works under the scope of this contract are to be executed in an operating power station. The contractor shall take all necessary precautions to protect all the existing equipment, structures, facilities and buildings etc. from damage. In case any damage occurs due to the activities of the contractor on account of negligence, ignorance, accidental or any other reason whatsoever, the damage shall be immediately made good by the contractor at his own cost to the satisfaction of the Owner. The contractor shall also take all necessary safety measures, at his own cost, to avoid any harm or injury to his workers and staff from the equipment and facilities of the power plant. (l.) Contractor should note that the existing rail lines within the plant area are operational with rail traffic of coal and liquid fuel rakes. Contractor shall take all precautions to ensure the safety of existing rail tracks and other associated facilities as well as the safety of his men, material and equipment from the operating rail traffic. The contractor shall plan and make all arrangements to ensure that disruption to the existing rail traffic is minimum and shall follow the instructions of the Owner in this regard. Further, contractor shall plan and coordinate all his activities considering restrictions, if any, on free access to his work areas due to the rail traffic. (m.) After award of work and , before finalising his layout especially the layout / levels of conveyors, cable / pipe routes and other services, the contractor shall carry out a site survey to identify the location & details of existing facilities that may interfere with his proposed facilities. The contractor shall suitably modify his layout / levels to prevent dislocation of existing facilities and any cost / time implication arising out of such modifications shall be to his account. Contractor shall also be responsible to determine and obtain the necessary details at site as required for interfacing and interconnection with the existing system / facilities. (n) If during the execution of works it is found that there is interference with the existing facilities / structures, the contractor shall revise his design / detailed drawings to clear the interference and shall provide all necessary measures for the safety of existing structures. No claim in terms of cost or relaxation in time shall be entertained for any redesign, rework and for safety measures provided. If at any stage of work, any dismantling or modification or relocation of
any existing facility is required to be done to complete the work in contractors scope and which has been agreed by the Owner, the same shall be done by the contractor at no extra cost or time implication to the Owner. All such changes will be as per drawings and work plan approved by the Owner. Equipment and services covered under WAGON TIPPLER AND CONVEYOR SYSTEM PACKAGE are described in the subsequent sections: 1.2 In addition to the specifications of equipment / system indicated in various sections as above and General Technical Requirement and Erection Conditions of Contract attached of the Specification shall also form part of this Technical specification. TENDER DRAWINGS The drawings listed elsewhere, form part of the specification and shall supplement the requirements specified herein. The scope and terminal points for the equipment to be furnished under this package shall be as identified in these drawings and read in conjunction with the text of these specifications. These drawings are preliminary drawings for bidding purpose only and subject to changes that may be necessary during the detailed engineering. In case of any conflicts / contradiction among various volumes / sections / annexures / chapters / appendices / tender drawings of bid documents, the same shall be referred to the Owner for clarifications whose decision shall be final and binding. No extra claims shall be allowed on this account. BRIEF DESCRIPTION OF PROJECT NALCO intends to augment the coal handling facilities at its Captive Power Plant by an additional annual volume of 2.0 Million tonnes. For this purpose, it intends to install a wagon tippler and connecting conveyor System to receive the above quantum of coal through rail mode. The wagon tippler system shall be suitable for handling all prevailing wagons in coal circuits such as BOX / BOX-N / BOXNHA / BOX N.MKDII. The facility provided shall be suitable to accommodate locomotives of maximum 150 T weight passing through the platform at a maximum speed of 8kmph. The Wagon Tippler System shall have an in built weighing mechanism (load cell type) below the platform for weighment of wagons prior to and after each tippling cycle to record the exact quantity of coal unloaded from each wagon. A sizer unit is proposed to be installed between the Apron feeder and the receiving conveyor to reduce the lumpsum size of coal from (-) 300 mm to (-) 100 mm.
1.3 1.3.1
1.3.2
2.0
Coal received at the tippler hopper would be transported by belt conveyors and integrated to existing system for feeding the existing and the new stockpiles under development. 2.1 BRIEF DESCRIPTION OF PROPOSED WAGON TIPPLER AND CONVEYOR PACKAGE (i) Indian Railway rakes consisting of Box-N wagons shall transport coal to the power plant. These Box-N wagons are proposed to be unloaded in underground RCC hopper by means of a Rota side Wagon Tippler. Wagon tippler hopper shall have a holding capacity of minimum 2 wagons loads of coal i.e. 120 Tonnes. One Rota side wagon tippler (WT-1) is to be utilised for unloading of IR coal rake. A Side arm charger is envisaged for placement of loaded wagon on the tippler table & retrieval of empty wagon from the tippler table after tippling. Clear access shall be provided for movement of pay loaders on the hopper side of both Wagon tippler. Wagon tippler hopper grating is to be positioned and designed accordingly. (ii) Apron feeder is proposed under the Wagon tippler for extracting coal from the Wagon tippler hopper and feed into the sizer which in turn discharges crushed coal on to the proposed receiving conveyor RC-1. Conveyor RC-1 will transfer the coal to conveyor RC-2 at the new transfer tower TP-1. Conveyor RC-2 shall feed coal on to existing Conveyor BC-103/BC-115 at the existing junction house (JH-1). The rated capacity of all the conveyors in this package shall be 1200 TPH. (iii) The existing CHP control and monitoring system is PLC based. It is proposed to provide an independent PLC based control for smooth, efficient & trouble free operations of Wagon Tippler, sizer and conveyor system package. The control and monitoring system for belt conveyors covered under this Package shall be integrated with the existing control system such that the operation of existing CHP is not hampered. Necessary interlocks and software changes in the existing PLC logic are also envisaged in this package. 3.0 3.1.1 SCOPE OF WORK The scope of Wagon Tippler and Conveyor System Package to be furnished, erected and commissioned under this specification shall be as detailed hereinafter. The Contractor shall be fully responsible for system and detailed design, engineering, manufacture, shop fabrication, assembly, testing and inspection at manufacturers works, packing, dispatch, transportation, transit insurance, custom clearance etc. as applicable, delivery to site, unloading, handling and storage at site, insurance during storage, construction, erection, including erection supervision, testing, inspection, commissioning and handing over to Owner and Guarantee testing including all associated electrical, civil & structural works as specified, unless specifically excluded as per Section-Terminal Points & Exclusions. The scope of the contractor shall be deemed to include all such items which although are not specifically mentioned in the bid documents and/or in Contractors proposal but are needed to
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3.1.2
make the system complete in all respects for its safe, reliable, efficient and trouble free operation and the same shall be furnished and erected unless otherwise specifically excluded in this document. The general description of the proposed system and the broad scope of work under the specification shall include but not be limited to as detailed below. 3.1.3 An underground RCC Wagon Tippler Hopper, machinery hatches with wagon tippler hopper, associated underground tunnel, transfer point and pent house complete with civil, structural and electrical works for Wagon Tippler hopper and machinery hatches, steel grating over hopper portion, removable chequered plate covers over openings in machinery hatches for handling underground equipment, equipment handling facilities for apron feeder and sizer unit inside below wagon tippler hopper including the structural steel shed with E.O.T crane over the WT-1 and other equipment/systems such as Dust Suppression system, ventilation system, drainage system etc. as specified elsewhere in the specification. However, the track work is excluded from Contractors scope however rails over tippler table and the track for Side Arm Charger are included in Contractors scope. One (1) no. Rotaside Wagon Tippler complete with clamping arrangements, all structural members, tippler platform, tippling mechanism, tippler drive along with necessary controls, associated electricals, civil / structural works and accessories. Side arm charger associated with the Wagon Tippler complete with travel rails, drive equipment along with necessary controls, associated electricals, civil/structural works & accessories. One (1) no. Apron feeder complete with drives, all mechanical, electrical accessories & supporting structure etc. One sizer unit complete with drives and all mechanical electrical system and concluding the supporting structure etc. Receiving Belt Conveyors RC-1 complete with conveyor supporting structures, short supports, stringers, deck plate, seal plate, conveyor foundations, drive motors, drive units, pulleys, idlers, gravity take ups, take up structure upto ground level, take-up platforms at intermediate level, internal and external belt cleaners, pull chord switches, belt sway and zero speed switches, electro-hydraulic thruster brakes, all electricals etc. including RCC tunnel for receiving Conveyor RC-1 and underground tunnel portion upto pent house of Conveyor RC-1 with all civil, structural and architectural works for conveyor gallery, gallery supporting trestles and their associated foundations. A new pent house along with over ground structures, for conveyor Rc-1 complete with all civil structural, architectural and electrical works including chutes, monorails, hoists/chain pulley blocks, hoist maintenance platforms, RCC/steel floors, external staircases, hand rails etc.
3.1.4
3.1.5
3.1.6
3.1.7
3.1.8
3.1.9
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3.1.10 A transfer point TP-1 complete with civil, structural and electrical works and associated foundations for transfer of coal from conveyor RC-1 to conveyor RC-2. 3.1.11 Complete chute work along with chute plug switches and actuator operated flap gates in all Transfer points, maintenance platforms along with suitable approach. 3.1.12 Adequate number of ventilation equipment for ventilating the wagon tippler hopper, underground conv. RC-1 upto Pent House, complete with all mechanical, electrical, civil and structural works. 3.1.13 Pressurised Ventilation system for all Switchgear rooms, MCC rooms complete with all mechanical, electrical, accessories, civil and structural works. 3.1.14 Air conditioning of Wagon Tippler control room and PLC room, complete with all electrical, civil & structural works etc. 3.1.15 Exhaust fans for battery rooms, all toilets complete with electrical, civil & structural works etc. Exhaust fans along with required ducting shall also be provided for all underground structures/Transfer Points. 3.1.16 Minimum of four (4) Nos. sump pumps in Wagon Tippler house complete with motors, local control panel, level switches, individual discharge piping with fittings and valves to nearest plant drain etc. 3.1.17 A complete dust suppression system for control of fugitive dust at Wagon tippler, apron feeder, sizer unit, transfer points, complete with enclosed pump houses, water tanks, pumps, drives, hoisting arrangements, piping, valves etc. electrical, accessories, civil and structural works as briefly specified below: a) Plain water dust suppression through fogging nozzles for control of dust during Wagon Tippler operation. b) Dry fog type dust suppression system at all Transfer Points both at discharge and loading points including all electrical and accessories. c) Compressor units, Pump houses & water tanks for dust suppression, service water and cooling water system. 3.1.18 Cooling water system for scoop coupling, Service water system for Wagon Tippler Package System shall be taken from nearest header located at new track hopper area. 3.1.19 An E.O.T crane for installation & maintenance of equipment in wagon tippler complex complete with all electrical and control including the covered structural steel shed.
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3.1.20 Monorails and electrically operated hoist blocks as well as hand operated chain pulley blocks for servicing/installation/easy replacement of drive machinery, different types of pulleys for all conveyors, GTU and other equipment. 3.1.21 All buildings in contractors scope shall be complete with all electrical, civil, structural, architectural works, cable trenches, fire safety walls, foundation / fencing / earthing for transformers. All cables / duct banks, trenches, cable trestles shall be complete with associated civil/ structural work and necessary civil foundations. 3.1.22 Drainage of Wagon Tippler hoppers, tunnels, conveyor galleries, TPs, upto nearest existing CHP drain all civil & structural works. 3.1.23 All equipment/fittings, supporting structure, along with insert plates, bolts, accessories, MS sleeves, base plates, grouting as may be required and proper alignment etc. 3.1.24 A complete set of all special tools and tackles, which are necessary or convenient for erection, commissioning and overhauling of any equipment, covered under the scope. 3.1.25 First fill of all consumables e.g.; oils and lubricants for one year toppings requirements. 3.1.26 Preservative shop coating, final painting of all structures and equipment under the scope. 3.1.27 Fire hydrant system along with FDA system should also be the scope of the tenderer. 3.2 3.2.1 Electrical System / Equipment Unless specifically excluded, contractors scope of work shall include all electrical works as required for putting into successful operation of the Wagon Tipplers & Associated Conveyors covered under this specification. LT SWITCHGEAR 415V Switchgear/motor control centers distribution boards, AC & DC fuse boards, local emergency stop push button stations for all drives and local motor starters as required for plant and equipment. MOTORS Motors along with couplings and coupling guards for all rotating auxiliaries are covered under this package. All motors shall be with cable glands & lugs. CABLES HT & LT Power cables, control cables, Instrumentation cables and any special cables required for connection between equipment / devices in Contractors scope and also cables between Owners equipment and Contractor's equipment.
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3.2.2
3.2.3
3.2.4
3.2.5
CABLING, EARTHING AND LIGHTNING PROTECTION (a) All cabling with cable accessories, cable trays with supporting structure, terminations and jointing kits, trenches, overhead trestle, duct banks etc. as required for the cables to be supplied by the Contractor. (b) Grounding and lightning protection for the plant and equipment under Contractors scope along with its interconnection to the nearest Owners earth grid at two points.
3.2.6
ILLUMINATION SYSTEM Complete illumination system as required for complete internal and external lighting of associated plant, equipment and buildings covered under Contractors scope including 2 Nos. of Lighting Masts for area lighting in W.T. area.
3.2.7
CONTROL SYSTEM An independent Control desk, PLC panels, I/O racks, UPS, battery & battery chargers etc. for the control of Wagon Tipplers and other equipment. One (1) No. control building to be located near WT-1 . This building shall have two floors i.e. ground & first floors. The first floor of control room shall house PLC panels, control desks for operation of WT-1. One office room (5m x 5m) at the first floor. There shall be a projected viewing balcony at a suitable location to have clear view of the Wagon Tipplers during operation. The ground floor shall house the MCC, DBS, Battery DBS etc.
3.3 3.3.1
CIVIL WORKS The work to be performed under this specification consists of providing all labor, materials, construction equipment, tools and plant, scaffolding, supplies, transportation, all incidental items not shown or specified, but reasonably implied or necessary for successful completion of the work including Contractors supervision and in strict accordance with the drawings and specifications. The nature of work shall generally involve earthwork in excavation including very deep underground excavation, de-watering, shoring and strutting, sheet piling, back filling around completed structures and plinth protection, area paving, disposal of surplus excavated materials, piling, concreting including reinforcement and form work, brick work, fabrication and erection of structural / miscellaneous steel works, inserts, architectural items & finishes such as plastering, painting, flooring, doors, windows & ventilators, glass and glazing, rolling shutters etc., permanently colour coated profiled steel sheeting, anchor bolts, R. C. C. trenches with covers, drainage, damp proofing, water proofing and other ancillary items. The work shall have to be carried out both below and above ground level and shall be involving, basements, equipment foundations, grounding, slabs, beams, columns, footings, rafts, walls,
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3.3.2
steel frames, brick walls, stairs, trenches, pits, access roads, culverts, conveyer galleries, trestles, penthouses, Wagon tippler hopper, underground tunnels, transfer points, finishes, complete architectural aspects, drainage and all other civil, architectural and structural works associated with the complete Wagon Tippler and conveyor system Package. 3.3.3 Scope of work shall also include dismantling and modifications of the existing structures/facilities, which may be required to facilitate, inter connection between the existing and the new structures or facilities and making good the dismantled/modified structures. TERMINAL POINTS Terminal point for Wagon Tippler and conveyor system commences from wagon tippler complex upto feeding points at conveyors BC-103 & BC-115, in Junction House (JH-1) including the modification necessary to the Junction House. Within these terminal points, all equipment and services, civil, structural and architectural works, electrical distribution, piping network etc. as required for wagon tippler and conveyor system package will be furnished and erected by the contractor unless specifically excluded. Contractor's Scope responsibilities shall include but not be limited to the following: Wherever Contractor is permitted by Owner to take support from any of the Owners Structures, the Contractor shall ensure that no damage is done, to the Owners Structures including Painting thereof. In case of any damage to the Owners Structure and/or Painting, then the Contractor shall rectify the same to the complete satisfaction of the Owner. The contractor shall carry out the redesign of JH-1 and shall ensure that the proposed modifications are adequate to support the discharge point of the conveyor RC-2 as well. Regarding erection of transfer point on existing junction house-1, contractor shall ensure that opening on existing building and erection of conveyor chutes/skirts & platform are done in a manner to minimize shut down of existing conv. BC-103 & BC-115. As work is to be executed in operating project, extra care must be taken by the Contractor. Water supply connections for dust suppression, service water system & cooling water shall be provided by the Owner, details of which are given elsewhere in the specification. Further network of piping including all compressors, pumps, tanks, necessary accessories, supports and fittings etc. for distribution of water for dust suppression and service water system in all transfer points, control rooms, MCC rooms, toilets, Machinery hatches of the Wagon tippler etc. shall be under the scope of the contractor. Road lighting in wagon tippler area, for the roads, is included in the scope of Contractor.
4.0
4.1 4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
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4.2 4.2.1
EXCLUSIONS Supply, laying and fixing of rail track for the inhaul and out haul siding is excluded for the scope of this Contract. However, supply, laying and fixing of rail over Wagon Tippler table and for side arm charger is included in the scope of this Contract. Site leveling and access roads are excluded from the scope of this Contract. However site clearance i.e. removal of vegetation including bushes and trees etc. shall be the responsibility of the Contractor. SYSTEM DESIGN BASIS The rated capacity of the Conveyors shall be 1200 TPH. The design capacity of the conveyors shall be 1320 TPH. The mechanical and structural / civil system shall be designed for 1320 TPH capacity and round the clock operation with both the streams operating simultaneously. Following shall be considered while designing the Conveyors : a. The Coal delivered to the power station shall be of size 300 mm & below. However occasionally coal of higher lump size may also be encountered. b. HGI of the Coal shall be between 44 to 65. Normally moisture content in coal will vary between 6% to 10%. However for design purposes, moisture content of 10% shall be considered.
4.2.2
5.0 5.1
5.2
c. The coal as received shall contain varying percentage of fines. Coal with such fines may tend to form adhesive lumps, particularly during monsoon when surface moisture is at its maximum value. d. The sizing and selection of the vital equipment viz. apron feeder and sizer covered under the system shall be based on the above characteristic of coal and operating conditions. Contractor shall ensure that equipment/ system efficiency shall not be effected particularly during monsoon when surface moisture is at its maximum value. 5.3 For the purpose of volumetric computation, the bulk density of the coal shall be taken as 800 kg/m3. Therefore for calculation of belt conveyor capacity, for their drives & drive motors kW requirement, and sizing (volume calculations) of chute, hoppers etc. the above bulk density shall be considered. For all other purposes viz. for stresses/ load on structures, loading on sizer and Apron Feeder tables, sizing of actuators for flap gates, calculations of plugged chute/ hopper loads etc. the bulk density of the coal shall be taken as 1100 kg/ m3. 5.4 5.4.1 Coal Flow paths For the purpose of conducting guarantee test coal, the following flow path would be assessed.
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5.4.2 5.4.3 6.0 6.1
Apron feeder will feed coal unloaded at WT-1 to sizer and sizer will discharge to Conveyor RC-1. Coal on RC-1 will be transferred to RC-2 through Transfer point feeding on to existing Conveyors (either BC-103 or BC-115) in JH-1. Contractor shall also demonstrate that all intermediate equipments can perform as per specification and design requirement during PG Test. Performance and Guarantee tests have been elaborated elsewhere in the specification. ENGINEERING SCHEDULES Within one month of acceptance of Award Letter, Contractor shall submit, for review and approval, detailed engineering schedules, based on Master Network (as per requirement of bid documents), to the Owner / Consultant, showing the logic & duration of activities in the following areas : a) Detailed engineering, including submission and approval of quality plans and PG test procedure. b) Inputs required from Owner for smooth and timely execution of contract. The Contractor shall submit within 30 days of letter of award a master list of drawings incorporating the scheduled dates of submissions. The schedule date of submissions should match with the manufacturing and erection programme submitted in the detailed Master Network Schedule. The list shall be updated every month reflecting the additions / deletions during the period. The network schedule shall be updated at a frequency mutually agreed upon for the purposes of progress monitoring. However, for the purpose of identification of Contractor's Contractual Liability the agreed Master Network shall only be applicable. GUARANTEE AND LIQUIDATED DAMAGES Guarantee The Bidder shall guarantee that equipment offered shall meet the rating, performance and functional requirement stipulated for various equipment covered in this specification. The Bidder shall also furnish a declaration in the manner prescribed and included in the Bid Proposal Sheets and other Schedules of Volume II for certain guaranteed parameters which shall attract levy of liquidated damages for shortfall in performance.
6.2
6.3
7.0 7.1
7.2
Performance Requirement Guaranteed parameters of the major equipments shall be as follows:
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7.2.1
Flow Path Capacity Flow path capacity including the intermediate equipment for conveyor streams to be tested for 1200 TPH
7.2.2
Equipment Capacity Capacity of individual equipment shall be tested separately: (i) Each Wagon Tippler : 20 tips/hour (Guaranteed) (ii) Each Apron feeder : 1200 TPH (Guaranteed) (iii) Sizer unit : 1200 TPH (Guaranteed)
7.2.3 7.2.4
Contractor shall also demonstrate that all intermediate equipments viz. Gates, Dust suppression, Ventilation System etc. can perform as per specification and design requirement. Performance and guarantee requirement of various other equipments have been elaborated elsewhere. PERFORMANCE & GUARANTEE TEST PROCEDURE In accordance with GTR the plant shall be subjected to performance and Guarantee Tests on successful completion of trial operations. Further, the performance and Guarantee Tests shall be conducted as per the guideline procedure indicated elsewhere. However, detailed procedure shall be submitted by vendor as per the guidelines for Owner's approval. The P&G Test procedure shall be submitted as per format attached in the specification.
8.0
8.1
Liquidated Damages for Shortfall in Performance Should the results of the performance and guarantee tests show that the equipments / system have failed to meet the guaranteed parameters, the Contractor shall carry out modifications, if considered necessary, within 90 days of the notification by Owner. If the equipment fails to meet the guarantee parameters at the end of the above specified period of 90 days, Owner may at his discretion, reject the equipment or accept it after assessing the liquidated damages at rates specified herein, to be payable by the Contractor.
8.2
The following equipments/streams shall be subjected to performance and guarantee test in line with the specification to prove the performance guarantee for all intermediate equipment. Liquidated Damages towards shortfall in guaranteed performance shall be imposed @ 1% of the order value limiting to 10% against following parameters.
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Sl. No. 1
Equipment Wagon Tippler
Guaranteed parameter 20 Tips /Hour
Short fall By One tip per hour By two tips per Hour Beyond two tips per hour By 0.5% By 1.0% Beyond 1.0% By 0.5% By 1.0% Beyond 1.0% By 0.5% By 1.0% Beyond 1.0%
Apron Feeder
1200TPH
Sizer
1200TPH
Conveyors (R1 & R2)
1200TPH
LD amount to imposed 1% of order value 2% of order value Rejected 1% of order value 2% of order value Rejected 1% of order value 2% of order value Rejected 1% of order value 2% of order value Rejected
be
The LD shall be assessed on the basis of conveyor equipment having the poorest performance. 9.0 COMMISSIONING (SYSTEM TRIAL OPERATION) Duration of the trial operation of the complete equipment shall be (14) days with minimum operation of 12 hrs daily. For successful trial operation, the trial shall necessarily include steady operation of the plant at its rated flow path capacity for atleast one hour duration per day on an average. TYPE TESTS AND TYPE TEST CHARGES All equipment / systems to be supplied shall conform to type tests as per relevant standards and proven type. The Bidder / Contractor shall furnish the reports of all the type tests carried out within five years of the date of bid opening as per specification and relevant standards for all components / equipments / systems. These reports should be for the tests conducted on identical / similar components / equipments / systems to those offered / proposed to be supplied under this contract. In case contractor is not able to submit report of type test(s) conducted in last five years, or in case type test report(s) are not found to be meeting the specification / relevant standard requirements, then all such tests shall be conducted under this contract by the Contractor free of cost to Owner, and reports shall be submitted for approval. All acceptance and routine tests as per relevant standard and specification shall be carried out. Charges for these shall be deemed to be included in the bid price.
10.0 10.1
10.2
10.3
10.4
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11.0 11.1
SPARES GENERAL The Contractor shall include in his scope of supply all the necessary Mandatory spares, start up and commissioning spares and recommended spares and indicates these in the relevant schedules of the Bid Form and Price Schedules. The general requirements pertaining to the supply of these spares have been described in the following paras.
11.2
MANDATORY SPARES
11.2.1 The list of mandatory spares considered essential by the Owner is included in this specification. The Bidder shall indicate the prices for each and every item (except for items not applicable to the Bidders design) in the Schedule of mandatory Spares whether or not he considers it necessary for the Owner to have such spares. If the Bidder fails to comply with the above or fails to quote the price of any spare item, the cost of such spares shall be deemed to be included in the bid price unless the bidder specifies "not applicable" for the type of equipment/system offered by him. However during execution if such spares are found to be applicable, the Contractor shall supply them without extra cost to the Owner. The Bidder shall furnish the population per unit of each item in the relevant Schedules. Whenever the quantity is mentioned in sets the Bidder has to give the item details and prices of each item. 11.2.2 Whenever the quantity is indicated as a percentage, it shall mean percentage of total population of that item in the Package, unless specified otherwise, and the fraction will be rounded off to the next higher whole number. Wherever the requirement has been specified as a set it will include the total requirement of the item for a unit, module or the station or as specified. Where it is not specified a set it will include the total requirement of the item for a unit, module or the station or as specified. Where it is not specified a set would mean the requirement for the single equipment/system as the case may be. Also one set for the particular equipment. e.g. set of bearings for a pump would include the total number of bearings in a pump. Also the set would include all components required to replace the item; for example, a set of bearings shall include all hardware normally required while replacing the bearings. 11.2.3 The Owner reserves the right to buy any or all the mandatory spare parts. 11.2.4 The prices of mandatory spares indicated by the Bidder in the Price Schedules shall be used for bid evaluation purposes. 11.2.5 All mandatory spares shall be delivered at site at least two months before scheduled date of initial operation. However, spares shall not be dispatched before dispatch of corresponding main equipments.
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11.2.6 Wherever quantity is specified both as a percentage and a value, the Contractor has to supply the higher quantity until and unless specified otherwise. 12.0 12.1 RECOMMENDED SPARES In addition to the spare parts mentioned above, the contractor shall also provide a list of recommended spares for 2 years of normal operation of the plant and indicate the list and total prices in relevant schedule of the Bid Form and Price Schedules. This list shall take into consideration the mandatory spares specified in this Volume-II, and should be independent of the list of the mandatory spares. The Owner reserves the right to buy any or all of the recommended spares. The recommended spares shall be delivered at project site at least two months before the scheduled date of initial operation. However, the spares shall not be dispatched before the dispatch of the main equipment. Price of recommended spares will not be used for evaluation of the bids. The price of these spares will remain valid upto 6 months after placement of Notification of Award for the main equipment during which the Contractor shall provide necessary justification for the quoted prices for these spares. However, if the Contractor fails to provide the aforesaid justification of the quoted prices, the prices of recommended spare shall remain valid for 2 months from the last date of providing such justification to the satisfaction of the Owner. START-UP & COMMISSIONING SPARES Start-up and commissioning spares are those spares which may be required during the start-up and commissioning of the equipment/system. All spares used till the plant is handed over to the Owner shall come under this category. The Contractor shall provide for an adequate stock of such start up and commissioning spares to be brought by him to the site for the plant erection and commissioning. They must be available at site before the equipments are energized. The unused spares, if any, should be removed from there only after the issue of Taking Over certificate. All start up spares which remain unused at the time shall remain the property of the Contractor. COMMON REQUIREMENTS: The Contractor shall include in his scope of supply all the necessary Mandatory spares, start up and commissioning spares and recommended spares and indicate these in the relevant schedules of the Bid Form and Price Schedules. The general requirements pertaining to the supply of these spares is given below. The Contractor shall indicate the service expectancy period for the spares parts (both mandatory and recommended) under normal operating conditions before replacement is necessary.
12.2
13.0
14.0 14.1
14.2
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14.3
All spares supplied under this contract shall be strictly inter changeable with the parts for which they are intended for replacements. The spares shall be treated and packed for long storage under the climatic conditions prevailing at the site e.g. small items shall be packed in sealed transparent plastic with desecrator packs as necessary. All the spares (both recommended and mandatory) shall be manufactured along with the main equipment components as a continuous operation as per same specification and quality plan. The contractor will provide Owner with cross-sectional drawings, catalogues, assembly drawings and other relevant documents so as to enable the Owner to identify and finalise order for recommended spares. Each spare part shall be clearly marked or labeled on the outside of the packing with its description. When more than one spares part is packed in a single case, a general description of the content shall be shown on the outside of such case and a detailed list enclosed. All cases, containers and other packages must be suitably marked and numbered for the purposes of identification. All cases, containers or other packages are to be opened for such examination as may be considered necessary by the Owner. The contractor will provide the Owner with all the addresses and particulars of his sub suppliers while placing the order on vendors for items/components/equipments covered under the contract and will further ensure with his vendors that the Owner, if so desires, will have the right to place order for spares directly on them on mutually agreed terms based on offers of such Contractors. The Contractor shall warrant that all spares supplied will be new and in accordance with the contract Documents and will be free from defects in design, material and workmanship.
14.4
14.5
14.6
14.7
14.8
14.9
14.10 In addition to the recommended spares listed by the contractor, if the Owner further identifies certain particular items of spares, the contractor shall submit the prices and delivery quotation for such spares within 30 days of receipt of such request with a validity period of 6 months for consideration by the Owner and placement of order for additional spares if the Owner so desires. 14.11 The Contractor shall guarantee the long term availability of spares to the Owner for the full life of the equipment covered under the contract. The Contractor shall guarantee that before going out of production of spares parts of the equipment covered under the Contract, he shall give the Owner atleast 2 years advance notice so that the latter may order his bulk requirement of spares, if he so desires. The same provision will also be applicable to sub-contractors. Further, in case of discontinuance of manufacture of any spares by the Contractor and/or his sub
contractors, Contractor will provide the Owner, two years in advance, with full manufacturing drawings, material specifications and technical information including information on alternative equivalent makes required by the Owner for the purpose of manufacture/procurement of such items. 14.12 In case of equipment supplied with grease/lubricants from imported origin, the supplier shall clearly indicate the indigenous equivalent of the grease/lubricant and source of supply so as to enable the Owner to procure these items from indigenous sources.
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SECTION 3
1.1. 1.1.1 GENERAL This Technical Specification (Volume-II:-Technical) shall be read in conjunction with Volume-I: Commercial, General Condition of Contract and other project requirement mentioned in this specification. The Bidder shall quote for complete scope of work as covered in this specification. This Technical Specification is for turnkey supply of the plant & equipment and related structures including execution of structural steel works and civil works as specified in subsequent chapters, along with necessary modification, as detailed in the Scope of Work and Technical Specification. Instructions to Bidders / Special Instruction specified in other chapters shall be read in conjunction with stipulation stated in this chapter. The Bidder shall submit the drawings / documents, technical data / information as mentioned in various sections and annexures without which the Bid shall be considered as incomplete and may not be considered further. The Bidder shall submit along with the bid a work schedule in the form of a bar chart indicating the commencement and completion dates of each activity such as preparation of design, approval of design & drawings, preparation & approval of fabrication drawings, procurement of steel and other material, ordering of bought out items, their delivery to shop, major shop activities like fabrication of structures/ manufacture of equipment, assembly, shop testing, inspection, shop painting & despatch to the site, schedule of erection, final painting after erection at site, testing and commissioning of Plant and Equipment, without which the bid may not be considered. The Bidder shall clearly indicate the clause wise compliance to the specification. Non compliance with this and generalized statements like. "The equipment shall be manufactured as per IS standard / our specification etc" may result in rejection of the Bid. The deviation, if any, shall be clearly specified clause-wise in the format enclosed with this technical specification. In absence of deviation indicated, it will be presumed that the Bidder has no deviations. One copy of the Tender document and drawings shall be duly signed by the Bidder as a token of acceptance of all clauses / parameters / data mentioned therein and returned along with the Bid without which the Bid is liable to be rejected. In case the Bidder intends to change any data /
Page 1 of 12
1.1.2 1.1.3
1.1.4
1.1.5
1.1.6
1.1.7
1.1.8
Technical Specification: Instructions To The Bidders
parameter given in Technical Specifications the same shall be clearly mentioned in the deviation list, with reasons thereof. 1.1.9 If the Bidder feels that any information/ data described in the technical specification needs to be modified, he shall indicate the same specifically and submit an alternative proposal, on the basis of the design data, that he considers suitable and capable of meeting the requirement of this specification.
1.1.10 All the materials used and equipment supplied shall be new and the best of heir kind and shall comply with the statutory requirements of the Govt. of Orissa, Govt. of India and the latest revision of the Indian Standards/ Indian Electricity Rules. Where the equipment/ material supplied is not according to Indian Standards or regulations to which the equipment / material conform, the Bidder shall submit relevant document along with the Bid. 1.1.11 The Bidder shall visit the plant / site, and satisfy himself fully about the existing plant /site conditions etc. The successful Bidder shall bear full responsibility for inferences and conclusions as to the nature and conditions under which the work is to be executed, including effect of climate, rainfall etc. Failure to do so shall not absolve the Bidder of his responsibilities about the proper execution of the job. No claim for extra payments due to any special site conditions and ignorance about the site conditions shall be considered after acceptance of his Bid. For the site visit, the Bidder shall contact the Purchaser and take prior appointment from them. 1.1.12 The drawings of the existing coal handling plant, available with the Purchaser, can be made available to the successful Bidder for reference. However, for the areas of the plant for which drawings are not available, the Bidder shall make site measurements and work accordingly. 1.1.13 The Bidder as far as practicable ensure that major equipments are brought to site in pre assembled condition to minimize site work and to achieve an early commissioning of the equipment after delivery. Site welding shall be avoided as far as possible. The Successful Bidder before proceeding with design details shall satisfy himself about the site condition so as to avoid any difficulty in erection arising out of design. 1.1.14 The equipment shall be inspected during different stages of its manufacture (starting from raw material till the completion of manufacture) by the Purchaser / his authorized representative at the Bidder's or his sub Successful Bidder's works as per the inspection procedure mutually agreed between the Purchaser or his authorized representative and the successful Bidder. Inspection shall be regarded as a check up and shall be in no way binding on the Purchaser. However, general terms and conditions of inspection and testing is indicated in the subsequent chapter of this specification.
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1.1.15 Documents of all electrical and mechanical equipment supplied with equipment shall be put up for inspection along with the equipment. After inspection, an endorsement would be made in the inspection certificate about the availability of the documents. 1.1.16 The offer shall be complete in all respects and any additional equipment, accessories, auxiliaries, services, work etc. which are not specifically mentioned in the specification but are required for smooth and trouble free operation and to achieve performance required to be guaranteed in terms of the Bid Document, shall be included by the Bidder in the offer. 1.1.17 The make of all bought out items shall be as per List of preferred makes of supplies and equipment mentioned in Annexure-VI. 1.1.18 Metric systems & English language shall only be used throughout the Bid and in the drawings. 1.1.19 The Bidder shall satisfy himself about his ability for completing the work as per the time schedule before submitting his offer. Additional weightage may be given to the Bidder in case of improvement in the indicated completion schedule. In case the Bidder is unable to adhere to the schedule indicated in this specification, the Bidder need not submit their offer against this Bid. 1.1.20 A complete list of exclusions from Bidder's scope of work shall be clearly indicated in the Bid. 1.1.21 In case of any contradiction between Instructions to Bidder and Technical Specifications, stipulation in the Technical Specification shall prevail. 1.1.22 The Bidder has to carry out the work is such a manner that it does not affect the plant operations. If other Contractors are also engaged at the same work site for other jobs, the Bidder shall work in co-ordination with them such that the work of other Contractor is not affected. For integration of new facilities & the existing one, shutdowns period in phases, as per the schedule mutually agreed between Purchaser and successful Bidder would be provided. Hence, Bidder shall indicate in their offer, the stages at which the shut downs are required and their respective duration. 1.1.23 All parts of equipment requiring replacement or inspection or lubrication shall be so arranged/ assembled that they are easily accessible without the need of dismantling of other equipment or structures. All electrical cables shall be so laid that they are not liable to be damaged and can be easily inspected and maintained and when necessary any damaged cable can be accessed & replaced individually. 1.1.24 All equipment shall be complete with adequate safety devices wherever a potential hazard to personnel exists. Provision for safe access of personnel working to and around equipment for operation and maintenance, shall be provided.
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1.1.25 The Bidder shall train the Purchasers personnel in all disciplines of the operation & maintenance of the plant & equipment being provided by them under the contract. 1.1.26 Standardization of components and assemblies shall be carried out to the maximum possible extent to ensure interchangeability/as well as to minimize inventory levels. 1.1.27 Bidders shall furnish drive ratings of all equipments including conveyors along with the offer. Conveyor profiles enclosed with this specification are indicative only. However, after the placement of order and at the time of detailing, if there is any change of conveyor profile by the Purchaser, the following shall be adopted: (i) For changes up to +/-5% of conveyor length without change in drive kW rating there will not be any price variation. For changes beyond +/- 5% of conveyor length the Bidder shall indicate Per meter cost of conveyor. Per kW rate for change in the drive rating.
(ii)
1.1.28 The Bidder shall include in his scope of supply, a complete set of new and unused special tools and tackles required for operation and maintenance of the plant and equipment. The list of tools & tackles considered in the bid shall also be submitted. 1.1.29 The Bidder shall include in his scope, the requirement of initial fill of oils, lubricants, grease, and all other consumables required for start- up, testing, commissioning and performance guarantee tests of the unit/equipment. A list of such consumables shall also be furnished by the successful Bidder for Purchasers use. 1.1.30 The Bidder shall include in his scope the supply of spares required for successful commissioning of plant & equipment. The list of commissioning spares considered in the bid shall also be furnished along with the bid. 1.1.31 The Bidder shall quote separately for the spares required for the normal operation and maintenance of the plant and equipment for a period of 24 months to be reckoned from the date of taking over of the plant and equipment. A list (as per Annexure-II) of the spare parts shall also be furnished along with item wise price. 1.1.32 The successful Bidder shall not offload the contract or part thereof to any subcontractor without written permission of the purchaser. In the event of subletting of any part of the work with due permission by the purchaser, the fact that such permission has been accorded shall not absolve the successful Bidder from any of his obligations and liabilities under the contract.
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1.1.33 Subject to availability and at the request of the successful Bidder, water for construction purpose will be made available by the Purchaser at one mutually agreed point at site. The successful Bidder shall make his own arrangement for any further distribution at his own cost. Water supply shall be free of cost and shall be provided as specified under clause no. 54.13 b) of the GCC. 1.1.34 Power Supply Subject to availability and at the request of the successful Bidder, Electric Power will be made available at one point only at a distance not more than 500 meters away from the Contractors premises. The power will be supplied at 400/440 Volt and shall be metered and charged at the rate as specified in the GCC. The successful Bidder should have sufficient number & capacity of DG sets to meet the emergency power requirements in the event of failure in power supply. 1.1.35 Civil and structural steel works The supply of conveyor galleries, trestles, Junction towers, buildings & civil work are in the scope of this tender, including the design of Civil & Structural, shall be within the scope of successful bidder. 1.1.36 Fire hydrant system The Bidder shall include in his scope extension & rerouting of fire hydrant system to the wagon tippler & conveyor system. The hydrant line should be laid as per IS specification. 1.1.37 Exclusions: Following items are excluded from the scope of work 1. Railway track system. ERECTION The successful Bidder shall be responsible and perform the following with respect to the erection of the Plant and supplies. The scope of work of the successful Bidder shall be complete erection of the Plant and Equipment etc. as specified in the Technical Specification. The Bidder shall make all arrangements to deliver the equipment at Purchasers stores / site by wagons / truck / trailers, build his own stores (covered, uncovered and air-conditioned, if necessary) for the proper storage of equipment, maintain the stores and all related documents and records, transport the equipment to site for erection purpose and take an Erection- cum- Storage insurance policy covering all the risks including third party liability for all supplies as well as human life. All security arrangements also
1.2 1.2.1
1.2.2
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1.2.3
shall be made by the successful Bidder. Space only for stores and site office shall be made available to the Bidder by the Purchaser. The successful Bidder shall take the equipment from stores and transport the same to erection site. The successful Bidder shall unpack and do visual checking against physical damages to the equipment / cases, cleaning of equipment before start of erection. Damage / shortage if any, will be reported to the Purchaser / consultant and shall be rectified / replaced expeditiously, free of charge to Purchaser so as not to upset the erection and commissioning schedule. Delay on account of settlement of insurance claims by the successful Bidder shall not be considered an excuse for delay in completion. The successful Bidder shall lay and maintain properly all the temporary supply lines in the erection site for temporary power and water required for storage and erection purposes from a single point to be provided by the Purchaser. Drinking water shall also be made available at one central point at site. The successful Bidder shall make his own arrangement for any further distribution. The successful Bidder shall arrange all necessary construction machinery/ equipment, tools & tackles, instruments, compressors, small hand tools, welding equipment, all commissioning instruments, erection & service bolts, nuts, jigs and fixtures, winches, alignment tools, precision levels etc., Crane/ hoists and other equipment which may be required for carrying out the erection work efficiently within the time schedule provided herein the specification. Unless otherwise specified, the above construction materials shall be the property of the successful Bidder. However Purchaser's prior permission shall be required for removal of these construction materials from the site. Successful Bidder shall ensure that proper documentation is maintained for such items, which are required to be carried back by successful Bidder after the completion of work. The successful Bidder shall provide all temporary ladders, scaffolding materials, platforms, supports and other necessary facilities required for handling, erection, testing and visual inspection of supplies at the point of installation and shall also provide necessary packing plates, wedges, shims, levelling screws etc. required for erection of equipment and technological structures. The successful Bidder shall provide erection consumables like oxygen and acetylene gas, welding rods, solder lugs, oil, grease, kerosene, cotton waste, etc. required for erection of equipment and technological structures.
1.2.4
1.2.5
1.2.6
1.2.7
1.2.8
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1.2.9
The successful Bidder shall erect and maintain his own site offices, main stores and site temporary stores as required for the work and arrange for maintaining in neat manner of the area placed at the Successful Bidder's disposal.
1.2.10 The successful Bidder shall provide sufficient fencing, notice boards and lights to protect and warn others as may be considered necessary by the purchaser / consultant. All materials used for providing these facilities shall be properties of the successful Bidder. 1.2.11 The equipment and technological structures will be erected as per the instructions of the suppliers & under the supervision of the supervisory staffs to be deployed by the successful Bidder at site and only with the approval of Purchaser / Consultant. The successful Bidder shall use pre-assembly and mechanisation to the maximum extent in order to fulfill erection & construction targets. 1.2.12 The Successful Bidder shall align, level, couple and securely fix all equipment, appurtenances and accessories in accordance with drawings and / or instructions of Purchaser/ Consultant. 1.2.13 Laying and termination of cables, bus bars, bus ducts, lightening protection and earthing shall be done by the Successful Bidder. 1.2.14 The successful Bidder shall be responsible for protection and / or diversion of all existing underground and over ground services, wherever required. The terms and conditions for protection / diversion of services not shown on drawing / indicated in the specifications shall be mutually agreed. 1.2.15 Installation and connection of all piping and fittings within the scope of work shall be responsibility of the successful Bidder. 1.2.16 The successful Bidder shall be responsible for checking the correctness of erection of mechanical equipment, technological structures and auxiliary systems, electrical equipment etc. as per the specification. 1.2.17 The successful bidder has to carry out the work in such a manner that it does not affect the operation of other plant/ shop. If other Contractors are also engaged in the same work site for other jobs the bidder shall work with them in a co-ordinated manner. 1.2.18 The successful Bidder shall be responsible for the management of erection work with proper and adequate supervision for ensuring progress of erection work and quality of workmanship. 1.2.19 The successful Bidder shall deploy required number of supervisory, skilled, unskilled and auxiliary labour as required for the erection work: as per detail mobilisation schedule (to be furnished with
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Bid by successful Bidder) and comply with such reasonable instructions of the Purchaser / Consultant in the interest of satisfactory progress and completion of the work according to the schedule. The successful Bidder shall work in 3 shifts per day basis for meeting the completion target, if required within the contract price. 1.2.20 The successful Bidder shall organise the work in a manner that other work at site is not impeded and the workmen therein not endangered and shall arrange temporary access at site, if required for the erection work. 1.2.21 Successful Bidder shall return to the Purchaser all crates, packing cases and packing materials excess commissioning spares, oil and lubricants at a place designated by the Purchaser. 1.2.22 The successful Bidder shall conduct all necessary tests / checks during erection. 1.2.23 The successful Bidder shall attend to the rectification of erection defects, if any, expeditiously. The successful Bidder shall arrange all testing instruments for such testing at site. 1.2.24 The successful Bidder shall carry out final painting of the Plant & Equipment and technological Structures etc. erected as per the instructions stipulated in the Technical Specification. 1.2.25 The successful Bidder shall be responsible for total commissioning of the Plant and equipment including cold trial run and demonstration of Performance Guarantee Test. The Purchaser's supervisory and skilled operating personnel shall, however, be available to work under the guidance and supervision of the Bidder. Necessary raw materials, auxiliaries, utilities, electricity and operating personnel shall be made available by the Purchaser covering 3 shifts operation as per the programme agreed to in advance. 1.2.26 The Successful Bidder shall supervise running of the Plant for satisfactory, reliable and regular operation and performance after its successful commissioning for establishing performance guarantees. 1.2.27 Electrical energy and construction water shall be supplied by Purchaser to the successful Bidder during erection, at one point. 1.2.28 All safety measures required to be adopted as per the Statutory Regulations & the Safety Rules of the Plant shall be strictly followed by the successful Bidder during the execution of the Contract. The successful Bidder shall depute safety engineers for strictly compliance of safety rules & regulations. 1.2.29 The successful Bidder shall intimate the Plant authorities in writing well in advance about the requirement of shut down of any of the existing units / facilities for inter connection / incorporation of additional facilities. The shut down period shall be mutually discussed and
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finalised. The work to be undertaken during the shutdown period shall be planned meticulously to reduce the shut down period to the minimum. 1.2.30 The successful Bidder shall comply with all statutory Rules, Regulations with respect to the employment of labour at site. 1.2.31 The successful Bidder shall carry out any and all such works, as may be required, to build a Plant complete in all respect as per the Technical Specification and achieve the Performance Guarantees and other parameters as given in the subsequent chapter of this specification. 1.2.32 Any loss of plant and equipment due to imprudence, negligence and / or inequitable treatment and handling shall be replaced by the Successful Bidder / his sub-contractor at his own cost. 1.3 PAINTING All parts of the equipment shall be thoroughly cleaned of loose mill scales, rust or foreign matters. All parts excepting motors, resistors, gears etc. shall be painted at shop and at site with two coats of epoxy zinc based on zinc dust. Interior of all gear housing shall be painted with oil resistant paint. All machine pads, bearings surface or structures or housing shall be painted with white lead. All parts, inaccessible after assembly, shall be painted and assembled while the paint is wet. After erection, the damaged portion of the painted surface shall be retouched and an intermediate coat / final coat of PVC copolymer alkyd resin with micaceaus iron oxide (MIO) shall be applied. The colour shall be as per the choice of the Purchaser. The subsequent one final coat of paint of PVC copolymer alkyd with weather resistant pigment (approved by the Purchaser) and glossy finish shall be applied. The details of the dry film thickness (DFT) of the different coats shall be as follows: a) b) c) Primary coat Intermediate coat Final coat : : : 30 40 micron per coat 70 80 micron per coat 40 50 micron per coat
The painting scheme & colour code shall be approved by the Purchaser. The successful Bidder shall refer to Annexure-I for further detail of painting scheme & colour codes.
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1.4
OPERATING / PERFORMANCE PARAMETERS All the equipment covered in this specification shall fulfill the operating and performance requirement covered under this Technical Specification and indicated in the approved drawings. The successful Bidder shall study the specification and satisfy himself thoroughly regarding the workability and suitability of the equipment offered by him. He shall take full responsibility for the guaranteed and satisfactory operation of the equipment as regards to its performance and smooth and reliable working.
1.5
PRELIMINARY ACCEPTANCE After completing the erection of a unit or agreed portion thereof, the successful Bidder shall give a notice in writing stating that the job is complete in all respects and ready for preliminary acceptance. The job shall be visually inspected by representatives of the Successful Bidder and Purchaser / Consultant to ascertain whether supply, fabrication and erection are as per contract drawings and Technical Specification. All observed defects, deficiencies and omissions shall be noted down. If the defects, deficiencies and omissions are not major in the opinion of the Purchaser / Consultant, the successful Bidder shall be issued a preliminary acceptance certificate mentioning the defects, deficiencies and omissions. The noted defects, deficiencies and omissions shall be made good by the successful Bidder within a period of 3 to 4 weeks.
1.6
FINAL ACCEPTANCE Before commencement of final acceptance test of the building or unit, the successful Bidder shall make available required numbers of complete sets of ordinary prints of drawings, required numbers of set of DOD list for the drawings and one set of reproducible film of all drawings, all representing As-Built condition (i.e. all additions and alterations done during fabrication and erection shall be incorporated in the drawings). The successful Bidder shall attend to all defects, deficiencies and omissions noted down during preliminary acceptance and after rectifying or making good the above in all respects, shall inform 10 days in advance the Purchaser / Consultant for conducting final acceptance. During Final Acceptance all defects, deficiencies and omissions noted earlier shall be checked. The successful Bidder shall also make good any defect, deficiency or omission not notified during earlier preliminary acceptance, but pointed out during final acceptance. Final Acceptance certificate shall be issued by the Purchaser after all defects, deficiencies and omissions noted under preliminary or final acceptance have been rectified.
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1.7 1.7.1
SCOPE OF WORK The broad turnkey scope of work shall be as per the following: Design, manufacture, inspection, shop & primary coat of paint & supply of complete plant & equipment, fabrication (shop & site) of building structures & technological structures, civil construction materials, power distribution, electrics, instrumentation & automation, illumination, all utilities & services, in-plant road networks, drainage systems, landscaping, fire detection & alarm system, fire fighting pump house, as required, for complete & trouble free operation of Coal Handling System in an integrated manner. Basic engineering, detail engineering and reference category of drawings, operating software and documents, in requisite copies, for approval of NALCO/ RITES. Further, the Tenderer will furnish final basic & detail engineering drawings, manufacturing drawings of fast wearing items and non-standard items, as built drawings, erection drawings/documents, operating software, operation and maintenance manuals in soft editable format. Receipt of material, loading / unloading, storage, civil construction, complete erection, testing, commissioning, handing over of Wagon Tippler Complex to Purchaser, demonstration of performance guarantee and post commissioning services for a period of six months after commissioning. Preparation and approval of erection survey / alignment schemes, grouting clearances, painting clearances, testing of welds, pressure testing protocols and other related site protocols. Deputation of representatives of equipment suppliers and technology suppliers to site for supervision of erection, testing and commissioning. Applying final finish coat of paint as per approved procedure & shades before handing over, first fill of lubricant & oil, special tools & tackles, mobile equipment, handling & hoisting equipment etc. Supply of all commissioning spares. A list of such commissioning spares shall be indicated separately. Tenderer shall quote separately for two years spares and insurance spares along with the main offer. Progress reporting as per agreed formats, providing documentary evidence of purchase orders on sub vendors with addresses of contact persons, attending all site progress review / engineering review meetings at NALCO, Angul or at RITES, Gurgaon / Bhubaneswar, opening an equipped site office with coordinator overseeing all activities.
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Arrangement of all erection equipment viz. cranes, hoists, winches, etc, and safety appliances as required for erection of plant & equipment. Appointment of safety officer by the contractor shall be included. Specialized training of Purchasers personnel for operation, maintenance, for smooth handing over the plant. Testing and cold trial run of systems/ sub - systems and integrated testing shall be carried out by the successful Tenderer on continuous basis for complete Coal Handling System along with associated facilities followed by commissioning. On successful commissioning of the various sub-systems of the Wagon Tippler complex, PG test of the entire Tippler House shall be carried out as elaborated in the relevant chapter. Receiving delivery of items at site, their proper storage, and handling at site, watch and ward services, removal of debris to a location specified by the Purchaser etc. Site shall be handed over to the Purchaser in clean and orderly manner to the satisfaction of the site engineers after commissioning of the project. Getting Purchasers/ consultants approval for the drawings prepared by the successful Tenderer, obtaining required approval from statutory authorities, providing adequate personnel, equipment, tools & tackles for timely completion of the project. For detailed scope of work and design parameters on various subsystems & facilities, the Tender Specification shall be referred to.
1.7.2
This is a turnkey project for Installation of Wagon Tippler and conveyor system and all the facilities required for proper functioning of the wagon tippler and achieving the rated capacity shall be deemed to be covered in the tender specification, unless specifically excluded from the Tenderers scope. DELIVERY The project is schedule up to handing over to Purchaser shall be within 12 months from the date of placement of LOI on successful contractor to handing over. The delivery of plant & equipment shall be FOR, NALCO-Angul site.
1.8
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SECTION 4
1.0 1.1 SYSTEM PARAMETERS, OPERATION & CONTROL PHILOSOPHY The specifications as brought out in various Sub-sections for mechanical equipment shall be applicable for the proposed wagon tippler and conveyor system and specifically to all mechanical including their operation & control philosophy. However, some specific parameters of the entire system as a whole and the major equipment are brought out as under. PARAMETERS Conveyor System i. Rated Capacity (Guaranteed) : 1200 TPH ii. Design capacity : 1320 TPH iii. Belt width : 1200 MM iv. Belt speed : 3.5 m/sec. (approx.) Belting and Pulleys (a) Belt ratings with appropriate ratings shall be selected. (b) Minimum number of plies for belting shall be four (4) if possible, can be standardized with the type of belting available with NALCO. (c) For Pulley, following minimum parameters shall be adopted: (1.) Shell thickness : 16 mm (Min.) (2.) End disc plate thickness : 24 mm(Min.) (3.) Maximum allowable deflection of shaft at hubs : 5 Minutes (4.) Diameter for all drive pulleys shall be minimum 800 mm. Diameter of all other pulleys shall be minimum 630 mm The contractor shall obtain confirmation from belt manufacturers regarding the adequacy of the pulley diameters. Wagon Tipplers (a) No. required: 1 (One) (b) Guaranteed tips per hour per tippler: 20 Side Arm charger (a) Nos. required :1 (one) (b) Guaranteed haulage : 60 fully loaded coal wagons (Box N) Apron Feeder (a) No. required : One (1) (b) Guaranteed (rated) capacity: 1200 TPH Apron Feeder
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2.0 2. 1
2.1.1
2.1.2
2.1.3
2.1.4
Technical Specification: System Parameters, Operation & Control Philosophy
2.1.5
Sizer (a) No. required : One (1) (b) Guaranteed (rated) capacity: 1200 TPH E.O.T Crane (a) No. of unit : One (1) (b) Guaranteed (rated) capacity (Main/Aux.) Dust Control System The parameters for the dust control system specified hereinafter are intended for Contractors guidance only. Contractor shall provide adequately sized and effective dust control system, the performance of which shall be guaranteed by the Contractor as required in the Technical specifications. The performance guarantee test procedure is to be submitted by the Contractor. However, the capacity of the offered system shall not be less than that specified below. (a.) Area Dust Suppression System at Wagon Tippler (1) Location : Wagon Tippler Top (2) Capacity of each nozzle : 2.0 lpm at 2.5 kg/ cm2 (3) Nozzle spacing. : 500 mm All nozzles to operate simultaneously in each wagon tippler area. (b) Dust Suppression System for other areas (1) Operation : Water sprayed with fogging nozzle (2) Location of spray : All coal loading and discharge point on the conveyor (3) Capacity / Pressure : 2.0 lpm / 2.5 kg/cm2 inlet of spray head
2.1.6
: 25 T/5T
2.1.7
2.1.8
Service Water System Service water connections are to be provided in conveyor galleries & tunnels at 50 meter interval and one (1) no. on each floor of Transfer Point. (a.) Flow at each valve : 5 cub . m/hr (b.) Minimum discharge Pressure at tap point : 2 kg/sq.cm (c.) No of pumps : 2 nos. (d) No. of valves operated : 6 nos. simultaneously
2.1.9
Ventilation System A Mechanical Ventilation System For Underground Areas a Minimum of 15 supply air changes and minimum 7 exhaust air changes per hour. For other Areas a Minimum of 10 supply air changes per hour. B. Pressurized Ventilation System: Minimum 15 supply air changes per hour C. Air Conditioning System : Adequate number of air changes to Maintain uniform temp. & humidity.
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2.1.10 Chutes Minimum clear cross section of chute shall be 1200 mm x 1000 mm (inside both ways). 2.1.11 Hoists Suitable hoists as specified elsewhere shall be provided for erection & servicing of all major equipment. The equipment to be covered shall include (but not limit to) all conveyor drive units, all pulleys, Apron feeder, sizer, sump pumps, various DS/service water/potable water pumps, gravity take up units, removal of equipment from tunnels, lifting of belt drum at all transfer houses. 2.1.12 All other equipment under the scope shall be suitable to the system capacities parameters as specified above. 3.0 3.1 OPERATION AND CONTROLS This section is intended to cover design, engineering manufacture, supply, erection, testing and commissioning of the complete control and instrument panel/desk with annunciation panel, etc. as specified hereinafter complete in all respects, required for the system. General Requirements The instruments and controls to be furnished and erected under this specification are as required for safe and satisfactory operation of the plant & equipment under Wagon Tippler and Conveyor System Package, as outlined under mechanical section and as specified elsewhere in the specification. For the equipment and materials procured by the Contractor from his sub-vendors, the Contractor shall study the specification, safety requirements, interface drawings for such equipment and material in detail and shall coordinate his work with his subvendors and supply instrumentation and control to ensure suitability of the system. Standards / Codes All construction, installation, workmanship, design & equipment shall conform to acts, rules & regulations of the jurisdiction within which the project is to be located, and to the current edition of the following or equivalent standards or codes, in so far as they apply: American Iron & Steel Institute (AISI) American Society for Mech. Engineers (ASME) American Society for Testing & Materials (ASTM) American Wire Gauge (AWG) Institute of Electrical & Electronic Engineers (IEEE) Instrument society of America (ISA) National Electrical Code (NEC) National Electrical Manufacturers Association (NEMA) Bureau of Indian Standards (BIS) Conveyor Equipment Manufacturers Association (CEMA)
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3.2
3.2.1
Guideline for wagon tipplers issued by RDSO G33 (Rev. 1) of May 2010 with latest amendments if any.
3.2.2 3.3 3.3.1
This Sub-section shall be read in conjunction with Electrical Sub-sections. Construction and Design Construction Control desks/panels and annunciation system shall be provided as per the requirement of electrical Section. Annunciations, indications, electrical meters and instrumentation shall be provided as specified. Ammeters shall be provided on control desk for all motors rated 30 kW and above and for all equipment. Design The Contractor shall provide a comprehensive control indication and annunciation scheme for the plant & equipment under wagon tippler and conveyor system package and integrate the same with the existing control & monitoring scheme of the CHP. Contractor shall furnish a block diagram and write-up on the scheme proposed. The final scheme will be approved by the Owner and the Contractor shall be required to execute the approved scheme. In general, interlocking shall be achieved through feed-back signals from field equipment. A comprehensive Annunciation and Indication scheme shall be provided such that, it will be possible for the operator to locate and identify the fault from the display ace of Control desk. The scheme shall include the basic remote control instrumentation, indication and annunciation requirements as per various technical specification requirements. However, the Contractor may offer any alternative proposal which he considers to be equal, superior to the scheme as described in subsequent clauses below for achieving reliable and trouble free operation of the plant, for consideration of the Owner. OPERATION AND CONTROL PHILOSOPHY The Wagon Tippler control room shall be located by the side of Wagon Tippler to accommodate control & monitoring equipment of wagon tipplers. It shall also have a battery room. The existing coal handling system is being controlled from the following control points. The existing control philosophy of the coal handling plant is being described below for the contractor to understand the existing system and suitably plan integration of the controls and interlocks of the proposed control system of the wagon tippler package with the existing system. Owners Existing Coal Handling Plant Control Room Operation of the CHP equipment is being controlled from the Owners CHP control room. (a.) Conveyors, feeders, flap gates, hydraulic couplings etc. (b.) Complete Dust Suppression system & service water system. (c.) Ventilation system (group/individual control as required). (d.) In line Magnetic separators and Suspended Magnet (ON/OFF control with indication). (e.) Metal Detectors (ON/OFF control with indication).
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3.3.2
4.0 4.1
4.2
4.2.1
(f.) Belt weigher (ON/OFF control with indication) 4.2.2 Local Control Panels Local control stations for following equipment shall be provided for (a) All conveyors (b) All gates (c) Electric hoist - wall mounted control box with pendent push button controls. (d) Wagon Tippler (e) Apron feeder (f) Double roll Sizer (g) Sump Pump (h) Dust suppression system for wagon unloading (i) Hydraulic scoop coupling, if any. All the above local control panels shall be accessible and located near their respective equipment and shall be complete with all the required controls, interlocks, annunciations etc. Necessary controls, indications and annunciations for all the above equipment shall also be provided at main CHP Control Room. 4.2.3 In addition to the remote control of various equipments, local stop push button stations shall be provided for all equipment. SYSTEM OPERATION Typical Operation philosophy of the plant, in general, as elaborated below is for the information of the contractor to facilitate development of the control & monitoring scheme of wagon tippler and conveyor system package and integration with the existing control & monitoring system of existing CHP.
4.3 4.3.1
(a.) Coal flow path selection shall be done from Owners existing control desk to select conveying paths. (b.) The coal handling system operator will select any one of the paths from the main control desk. The flow stream path is then selected by positioning different flap gates at desired positions. Once the system is in the operation, the gates can not be moved from their positions and path. Flap gates which do not from the stream in which coal flow is taking place, can be operated at any time. (c.) The Control system will be designed for both Auto & Manual operation of the conveyors in the selected path. Auto/Manual Selection shall be done from Owners existing control desk. Auto Mode : In the Auto mode, the conveyors and related equipment will start sequentially when the System Start is activated. During stopping, when the System Stop is activated, all
Technical Specification: System Parameters, Operation & Control Philosophy Page 5 of 66
conveyors will also stop sequentially (in the reverse sequence) allowing time delays for clearing the belts. Manual Mode : In Manual Mode, the operator will start the conveyor system, in the same sequence as in Auto mode from control desk. The operator will also stop the conveyor system, by pressing "System stop" or individual Stop push buttons/command from control desk in the reverse sequence. System Start and System Stop PBs and located on the Owners Control Desk. 4.3.2 Conveyor System
(a) Normally the operation of the apron feeder, sizer and the reclaim conveyor shall be controlled from main control room for evacuating coal from tippler hopper. (b) The approach of a Railway wagon rake to the plant shall be signaled (visual and audible) in the wagon tippler Control room as well as to the main coal handling plant control room, as soon as the rake come within 100 meters distances from the wagon tippler. (c) Each conveyor shall be protected against damage to the edge of the belt due to excessive sideways movement by providing adequate number of belt sway switches. In addition, each conveyor shall be provided with one (1) No. speed detection device (zero speed switch). The zero speed switches shall be designed to sense belt speed. (d) All the conveyors shall be protected from roll back due to power failure by providing mechanical / or electrical locking system. (e) The starting sequence of the conveyors shall follow a direction opposite to that of flow of material. The details of Coal flow diagram of the existing stage-I CHP shall be furnished to the successful bidder. (f) Any individual equipment (belt conveyor etc.) should not be allowed to start unless the equipment immediately following the same in the direction of flow of material is already in operation. (g) Pull-cord switches shall be provided along the length of each belt conveyor, which shall enable the respective conveyor to be stopped immediately. Each pull operated chord switch and belt sway switch shall be tagged and shall be identifiable in the main control room. (h) Siren shall be provided to fore-warn personnel working nearby when starting any conveyor. (i) Interlocking of various conveyors shall be achieved with Flap Gate, limit switches and zero speed switches. (j) Motors shall start only when the brake/rail clamp if-provided, is in open condition. This signal shall be obtained from limit switch provided for that purpose.
(k) Once a conveyor trips, flap gate directing coal from this conveyor shall change over its position with a time delay and shall come back to the original position again, to prevent jamming of gate. (l) Where ever scoop type coupling provided for HT motors, the coasting time of respective conveyor, thruster brake, actuator selection and the chute size shall be so selected such that there is no spillage of coal from any downstream conveyors. 4.3.3 Interlocking a) The following conveyors / equipment are considered under interlock scheme :(1.) All conveyors (2.) All gates (3.) Wagon tippler (4.) Apron Feeder (5.) Double roll Sizer b) The following equipment will not come under interlock of the conveyor scheme. (1.) All dust suppression systems & service water system. (2.) Ventilation systems c) All conveyors and equipment have local push button stations each consist of : (1.) Pos - I, Pos - II & stop button for flap gate (2.) Emergency stop push button (Red) for other equipment d) Belt scale is started when relevant conveyors are started. e) The dust suppression systems will be energized as soon as the conveyors are energized. f) Coal Handling plant shall be tripped in case of detection of fire. Necessary input contact shall be made available to the Contractor in the Owners main control room. g) Interlock for H.T. Motor : H.T. motors used will continue to run on no load by disengaging the fluid coupling in case of failure of any process interlock. The H.T. motors will however be tripped in case of any motor fault like O/L, high motor winding temperature etc. In addition, in case of normal stop command, after running of the system, motors will stop. h) The following are the various safety interlocks for the conveyors and other equipment. This list is indicative only and the Contractor shall develop a comprehensive interlocking scheme. Conveyors a). Pull - Chord switch - not operated b). Belt sway switch - not operated c). Underspeed switch - closed at 90% speed of the conveyor within designed accelerating time. d). Motor protection - not tripped e). Local stop PB reset f). Chute Block switch - not operated. g). Brakes for conveyor not operated. h). Trip circuits healthy. i). Temp. of fluid coupling oil - not high
Wagon Tippler a). Motor O/L - not tripped b). Local E-Stop PB - reset c). Stop PB in main CHP control room - reset d). All Limit Switches reset e). All limit switches not tripped Apron Feeder & Sizer a). Motor O/L - not tripped. b). Local stop PB - reset. Flap Gates a). End of travel limit switches - reset. b). Torque limit switches - reset. c). Local stop - reset. 4.3.4 The lists of indications and audio-visual annunciation given in subsequent clauses are indicative only and the same shall be finalised during detail engineering. Status indications in Mimic. Following individual status indications shall be provided in mimic with individual ON/ OFF /TRIP indications on HMI of PLC. (a.) Conveyor 'ON' (b.) Flap Gate/Rack and Pinion position. (c.) Belt scale flow rate indication and totalizer. (d.) Belt sway switch operated for each conveyor (individual switch indication on CRT). (e.) Pull cord switch operated for each conveyor (Individual switches indication on CRT). (f.) Zero speed switch operated for each conveyor (g.) Wagon Tippler ON' (h.) Apron Feeder ON' (i.) Sizer ON (j.) DS/ SW/ Vent ON (System wise) Further Mimic lamps and Controls for HT and LT Breakers shall be provided on the control desk. 4.3.6 Annunication System: The Control desk shall be provided with adequate number of facia type annunciation windows for the following audio-visual fault annunciation purposes. Wherever group annunciation is provided, alarm status of individual equipment shall be provided on mimic. All audio visual annunciation of following parameters should be incorporated in the HMI of PLC. (a) 6.6 kV Breaker Trip (Group wise for each board)
4.3.5
(b) 415 V MCC Breaker Trip (MCC wise) (c) Bus under voltage for each LT MCC (d) Following group wise annunciation shall be provided for transformers : (i) Buchholz alarm (ii) Winding/oil temperature high alarm (iii) Oil level low alarm (iv) Buchholz trip (v) Winding/oil temperature high trip (e) A.C Control Supply failure. (f) D.C. Control Supply failure. (g) Annunciation supply failure. (h) Both CPU fail (i) Stand by CPU in service (j) H.T. motor overload alarm (individual) (k) HT motor bearing/ winding temp. high alarm (group) and trip (group) (l) HT motor trip on electrical fault (Group) (m) LT motor overload tripped (Group). (n) Belt sway switch operated (Group) (o) Pull cord switch operated (Group) (p) Zero speed switch operated. (Group) (q) Chute plugged (Group) (r) Wagon rake arrival. (s) Wagon Tippler tripped (group) (t) Apron feeder. (u) Sizer (v) Dust suppression/service water system faults and trips (system wise) (w) Water level low in tanks (group) (x) Oil temperature of fluid coupling high (y) 20% spare windows For identification of the fault for a particular conveyor or equipment, status indication against that conveyor / equipment in the mimic will start fast flickering and the annunciation window will be blinking against that particular fault. In addition, a buzzer (alarm) will also start sounding. After acknowledgement of the fault, the buzzer will stop, but the fast flickering on the mimic and the steady glow on the annunciation window will continue until the fault is cleared and the Reset push button is pressed. When the fault is cleared and the Reset push button is pressed, the status indication of that conveyor / equipment on the mimic will start slow blinking if it is on selected path otherwise it will go off and the steady glow in the annunciation window will go off. However, pressing of the Reset push button before clearance of the fault, will have no effect on the lamps. At the time of a fault, the faulty conveyor / equipment, as well as the preceding conveyors / equipment in the interlock sequence, will stop except H.T. motors for which only scoop coupling will be disengaged and motor will continue to run for process fault. In case of motor fault, H.T.
motor will trip but the succeeding conveyors / equipment will continue to run. The status indication against the preceding conveyors / equipment will start slow blinking while the faulty conveyor / equipment will be fast blinking. Start command shall not be initiated unless reset button in pressed after clearance offault. The sequence of operation of the annunciation system shall be as follows:Condition Normal : Status : Off. : Steady glow : Off. : Blinking. : Fast blinking : Sounding.
Fault :
Ann. Window Status indication Buzzer Ann. Window Status indication Buzzer
Press Accept PB. Ann. Window Status indication Buzzer
: Steady glow. : Fast blinking : Off.
4.3.7 (a.)
Press Reset PB (When fault is cleared): Ann. Window : Off. Status indication : i) Steady blinking (if on selected path) ii) Off (if not on selected path) Buzzer. : Off. Dust Suppression System Conveyors / Equipment
1. It shall be possible to spray the water on to coal stream only when corresponding conveyors/equipments are running with material at spray application points. 2. If a running pump trips stand-by pump shall start automatically. It shall be possible to select any of the pumps as auto standby from main CHP control room. 3. Pump/pumps shall trip with a time delay, if discharge valves fail to open. Suitable pressure/flow switch shall be provided to sense this condition. 4. Pumps shall trip in case of low level of water in tank. 5. All feeding pumps to tank shall trip in case of high-high level in tank. 6. All the controls shall be through control desk. (b.) Wagon unloading 1. System shall be operated from local control panel. 2. Dust suppression system shall be provided to cover the WT Hopper. 3. Pumps shall be started manually or from. If any of the pump/pumps trips, stand-by pump/pumps shall start automatically. It shall be possible to select any of the pumps as auto stand - by.
4. Pumps shall trip in case of low level of water in tank. 5. Following annunciations shall be provided at local control panel. (i) Motor electrical protection operated (Group) (ii) Discharge water pressure low (Group) (iii) Water level low in tank (Individual) 6. Following individual indications shall be provided at local control panel. (i.) Motor ON/OFF/TRIP (ii.) Discharge pressure healthy (iii.) Water level high in tank. 4.3.8 Sump Pumps (a) Sump Pumps shall start and stop by the level switches in the sump automatically. Further manual override start / stop push button shall be provided locally on ground level. (b) Any of the pumps can be selected as auto-standby. (c) If the sump level continues to be high even after the first pump is under operation second pump shall start automatically. (d) The following indications for sump pumps shall be provided on local Control Panel. (1.) Water level high (2.) Motor ON/OFF/TRIP. 4.3.9 Wagon Tippler Wagon Tippler shall be controlled from the local control panel suitably placed. Requirement of operation as described elsewhere in the specification shall be complied with. Following indications shall also be provided on the local control panel: (a.) Motor ON/OFF (b.) Motor O/L protection operated (c.) Brakes applied (if provided) (d.) Hydraulic power pack indications as applicable. 4.3.10 Flap Gates All flap gates shall be motorised and remote controlled from the main control desk. Their position shall be indicated on the mimic of main control room. 4.3.11 Service water and Cooling Water (a) These pumps shall be started from main CHP control room (b) Pump shall trip in case of low water level in tank. (c) Following individual inputs shall also be provided to PLC system for alarms/indications : (1.) Motor ON/OFF/TRIP (2.) Discharge water pressure low (3.) Water level low in tank (4.) Water level high in tank
5.0
5.1 5.1.1
WAGON TIPPLER GENERAL Rotaside / Rotary wagon tippler shall be furnished complete with all structural members, tippler platform, tipping mechanism, tippler drive motors, brakes, couplings, shafting and all automatic controls for positioning, tipping and discharging the entire contents of the wagons into the hopper. Wagon Unloading System The rake comprising of specified maximum 58 number of wagons shall be pushed into the reach of in-haul equipment by a locomotive. Further placing of wagons over tippler platforms and carrying away the empty wagons shall be accomplished with the help of a side arm charger under scope of bidder. Wagon unloading equipment shall be suitable to handle any type of wagons being used by Indian Railways for transportation of coal. Thus side arm charger and wagon tippler shall be suitable to handle all standard broad gauge (1676 mm) wagons of RDSO design used by Indian Railways conforming to latest revision of IS: 10095. Maximum moving dimensions of locomotive & wagon as per Indian Railway norms shall be adopted for providing clearances with respect to structures, equipment and tippler arrangement. Complete wagon tippler and accessories shall have the approval of concerned Indian Railway Authorities and RDSO. Further, the contractor shall submit to the Owner detailed drawings of wagon tippler and accessories including civil and structural drawing only after getting the same approved from the concerned Railway authorities. The bidder shall obtain all statutory approvals from the relevant Railway authorities, before the wagon tippler complex is put into operation. Any statutory payment charges, to be made to the concerned authorities shall be to Bidders account. It is the responsibility of the Contractor to carry out any modifications as required by the Railway authorities, at no extra cost to the Owner. Wagon Tippler Hopper The wagon tippler hopper shall be of RCC construction and adequately sized to accommodate the coal load for atleast two (2) nos. 8 wheeled wagons of RDSO design used by Indian Railways. For effective volumetric capacity computation of the hopper, the angle of repose of coal shall be considered as 37. The minimum valley angle of the hopper shall be considered as 60. The hopper shall have opening below which apron feeders shall be provided to evacuate coal from the hopper and feed onto associated belt conveyors below. Complete inside surfaces of the hopper shall be provided with 50 mm thick guniting. Further it shall be possible to empty out all the coal, without any dead stock from the hopper.
5.1.2
5.1.3
5.1.4
5.1.5
5.2 5.2.1
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5.2.2
Steel gratings of mesh size 350 mm x 350 mm over wagon tippler hopper shall be provided. The gratings shall be built of minimum 200 mm x 36 mm thick flats. The hopper and gratings shall be designed for movement of front end loader/bulldozer over them. Bull-dozer weight shall be considered as about 35 T. CODES AND STANDRDS The design, manufacture, inspection and testing of Wagon Tippler shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Wagon Tippler shall conform to the latest edition of the standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be constructed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision so the Engineer shall be final and binding.
5.3
5.4
DESIGN REQUIREMENT Keeping in view Technical guideline issued by RDSO ( Research & design services organization )G 33 Rev.01 issued on May10 & effective from Dec10, the specification of wagon tippler along with apron feeder & sizer to be designed as under: a) Wagon tippler capacity : 25 Tips per Hour b) Load handling capacity of wagon tippler : 140 Ton
5.4.1
The wagon tippler shall be suitable to unload a coal wagon by lifting and rotating it sideways. The angle of tip shall be at least 160 giving 60 angle to the side of the wagon for emptying the coal contents into the hopper below. During each cycle of operation, the tippler shall be capable of holding, completely unloading and replacing the wagon to its original position without damage to the tippler or the wagon or the track. The tippler shall be suitable for continuous operation, 24 hours a day, round the clock. The wagon tippler structure shall be designed to conform to the requirements of Indian Railways Research, Design and Standards Organisation, (RDSO) - G 33 Rev.1 with regard to the nature of loading, impact factor and allowable stresses. It shall be the sole responsibility of the contractor to ensure that each and every component of the wagon tippler is adequate in rigidity, strength and of heavy duty construction of first class quality to guarantee against failure or major damage, assuming proper maintenance and usage. The tippler shall be designed to allow passage of all standard broad gauge (1676 mm) Indian Railways diesel locomotives over tippler table at restricted speed. The wagon tippler shall be suitably counter balanced at each stage of operation so as to require minimum driving power.
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5.4.2
5.4.3 5.4.4
5.4.5
5.5 5.5.1
WAGON TIPPLER WEIGHING SYSTEM This specification calls for an electronic static weighing system to measure / record the quantum of coal, wagon wise on the wagon tippler table before & after tippling. The weighbridge with adequate no. of load cells shall be provided beneath the wagon tippler platform with a minimum accuracy of 1% of the gross weight of the wagon. The platform shall be freely supported on the weigh bridge before and after tipping for accurate weighing. The wagon tippler weighbridge shall be designed to statically weigh the wagons in an uncoupled condition. The system shall comprise of a weighbridge, a tippler table, load cells, weight digitizer and an intelligent terminal with printer with the facility for computerized printed output of data gross weight, tare weight, wagon no., time, date etc. the weighbridge shall be chosen to accommodate all types of wagons as per RDSO guidelines to move coal. The weighbridge shall be supported on minimum 4 nos. compression type load cells mounted on free motion structural unit assembly. Alternatively, in-motion weigh scales in both in-haul and out-haul tracks shall be provided for the purpose. The load cells shall be suitable for dusty environmental conditions. The calibration of the weigh bridge shall be the scope of the bidder. The bidder shall co-ordinate with statutory authority to get the necessary stamping & other requirements.
6.0 6.1 6.1.1
CONSTRUCTION REQUIREMENT Cradle The cradle shall consist of a pair of heavy welded steel plate sections reinforced with stiffeners and connected by side bearer beams pivotally attached, each section being fitted with a massive trunion shaft carried in bronze bushed cast steel bearings on each side, bolted to steel pedestal carried on concrete pedestals. Circumferential driving rack shall be rigidly bolted to the peripheries of the sectors. The sectors shall be made of cast steel. Necessary features of safety against coming down of wagon tippler in the event of failure of one of the drive pinions and / or gear racks shall be provided and the same shall be clearly indicated in the bid. Rail Table The rail table shall be constructed of rolled steel joints with standard steel rails (52 kg/metre) mounted on it. The table shall be pivoted from arms extended from the sectors. The table shall be covered with chequered plates between the rails. Feeders and Clamps The wagon shall be clamped automatically by hydraulic system and firmly on the cradle during the tipping without any damage or undue pressure on any part of the wagon and no hand adjustment of any sort shall be necessary. Sliding side stop pads shall be of resilient material to prevent damage to either the wagon or the stops.
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6.2 6.2.1
6.3 6.3.1
6.4 6.4.1
Spill Plate Fixed to the cradle of the tippler shall be a plain steel spill plate for deflecting material into the tippler hopper. Driving Gear Multiple pinions meshing with cast steel racks bolted to the end sectors shall impart drive through hydraulic drive with each pinion drive through slow speed high torque hydraulic motors using gear boxes as applicable. Suitable oil coolers shall be provided for hydraulic power pack. Suitable dust protective cover shall be provided. Brake An automatic electro hydraulic brake shall be furnished to hold the tippler in any position with the load and against any movement except that provided by drive. Limit Switches Limit switches of suitable type which can be readily adjusted to give the desired tippling angle shall be provided. An emergency over tip limit switch operated by a striker on the tippler trunnion shaft shall be furnished. Ballast Ballast necessary for counter weight and balancing the tippler shall be provided as per the requirement. Lubrication All bearings shall be properly lubricated. Grease nipples and reservoirs shall be furnished where necessary. Guards
6.5 6.5.1
6.6 6.6.1
6.7 6.7.1
6.8 6.8.1
6.9 6.9.1
6.10
6.10.1 All gears inside machinery pits and other moving parts shall be securely guarded. 6.10.2 All necessary base plates, guide plates, chequered plate covering for drive pit and any other pits, all required fixing materials, inserts and sleeves shall be furnished. 7.0 7.1 DATA SHEET GENERAL Wagon Type : All types of wagons in coal transport used by Indian Railways to move coal (as per latest RDSO guidelines)
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Moving Profile No. of tips (guaranteed) Designed Rail Gauge Weigh bridge Duty 7.2 DESIGN & CONSTRUCTION A. Wagon Tippler Hopper Construction Size No. of openings
: : : : : :
As per IR norms. 20 per hour. 25 Tips per Hour 1676 mm. Load cell type Continuous 24 hrs.
: RCC Construction. : To accommodate atleast 2 nos. 8 wheeled wagons. : One (1)
Angle of repose of coal for wagon tippler hopper sizing Lining Steel Grating (i) Mesh size (ii) Grating Section B Wagon Tippler Type Tipping angle Duty Requirement Counter balancing Cradle Driving Gear (i) Racks (ii) Pinion Rail Table Drive Brake Clamping Top & side stops 8.0 8.1 8.1.1 SIDE ARM CHARGER GENERAL
: 37 : 50 mm thick guniting. : 350 mm x 350 mm : 200 mm x 36 mm thick flats.
: Rotaside / Rotary type (As per latest RDSO guidelines) : Atleast 160 : Continuous operation : Suitable to keep power requirement at minimum. : Heavy welded steel plate construction trunion mounted. : Cast steel rack sections bolted to end sectors. : Multiple pinions meshing with rack. : Rolled steel joists with steel rails mounted on it. : Hydraulic motors. : Electro hydraulic thruster operated. : Hydraulically operated : Self aligning type made of resilient material.
Side Arm Charger shall be furnished complete with travel rails, drive equipments and associated accessories.
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8.1.2
The rake comprising of specified maximum number of wagons shall be pushed into the reach of inhaul equipment by a locomotive. Further placing of wagons over tippler platform and moving out the empty wagons shall be accomplished with the help of side arm charger. CODES & STANDARDS The design, manufacture, inspection and testing of Side Arm Charger shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed and all norms stipulated by RDSO- G 33 Rev.1. The Side Arm Charger shall conform to the latest edition of the standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Engineer shall be final and binding.
8.2
8.3 8.3.1
DESIGN REQUIREMENT A single module of side arm charger shall be used for inhaul and outhaul operations. Thus, side arm charger shall be used for indexing forward the rake of 58 nos loaded wagons, placing decoupled wagons on the tippler table and out hauling the empty wagons. The rake of 58 loaded wagons will be brought by locomotive and placed on the retipping line such that the leading wagon will be within the reach of the side arm charger. Now the side arm charger will be coupled to the leading wagon, pull the rake of 58 nos. loaded wagons towards tippler table. The first wagon will be decoupled manually from the rake and signal will be given to the side arm charger operator that the wagon is de-coupled. Now the leading wagon will be placed centrally onto the tippler table by side arm charger, (simultaneously ejecting the empty wagon from the tippler table). After the loaded wagon is placed on the tippler table, the arm is de-coupled from the loaded wagon. Adequate clearance between tippler table and empty wagon shall be ensured. The side arm charger will stop at the end of its strokes, the arm will be swung vertically-up and the machine will move towards in-haul direction and occupies the initial position. In the meantime, the tippler will tip the loaded wagon placed on the tippler table and return to its original position. Before tippling operation of wagon tippler is completed, the arm of the side arm charger will be swung to horizontal position and will be coupled to the rake of remaining loaded wagons at waiting position just before the tippler table and is now ready for the next cycle to start. After the tippling operation of wagon tippler is completed the cycle will be repeated. TECHNICAL REQUIREMENTS CONSTRUCTION REQUIREMENT The Side Arm Charger shall be suitable to handle 58 number of loaded wagons. The pusher arm shall be vertically rotatable arm mounted on a carriage running back and forth parallel to the train track.
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8.3.2
8.4 8.4.0 8.4.1
8.4.2
The arm shall be raised to clear the movement of wagons and locomotives during reversing back of positioner carriage and shall be lowered for engaging the head of the arm with the wagon coupler for index strokes. The arm shall be raised and lowered by means of hydraulic cylinder mounted on the carriage. Suitable means shall be provided to prevent damage to the arms should the arm be accidentally lowered into the side of wagon. The arm shall be of robust construction either of cast steel or of heavy duty fabricated steel for the required duty. The construction of the head assembly of the push arm shall be such that no damage is suffered by the couplers of wagons and engagement of arm over the coupling assembly as well as transmittance of indexing forces to accelerate, run and decelerate the train during the positioning cycle shall be very smooth. The carriage frame shall be a suitable fabrication assembly of large proportions massive enough in strength and rigidity for the required duty. Travel Carriage Drive System The travel carriage with push arm shall be propelled to and fro, parallel to train track through hydraulic motor driving through a gear box and EHT brake. The rating of the drive equipment and its characteristics shall match with indexing forces required to be exerted in varying amounts depending upon train dynamics and to suit haulage of 58 wagon loaded rake. The travel carriage shall ride on vertical bearing wheels and will be guided by horizontal bearing wheels by suitably transmitting the thrust load from the positioned arm to the foundation. The wheels/rollers shall be of forged steel and shall run on the rails supported over the RCC pedestal. Cushioned emergency bumpers (buffers) shall be provided at the forward and return end of carriage travel run for protection. These shall be designed to arrest the machine without undue shock in case the machine exceeds its extremities because of any mal-operation. DATA SHEETS GENERAL Quantity No. of wagons to be handled By each side arm charger at a time : 1 (One) no : 58
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8.4.3
8.4.4
8.4.5
8.4.6
8.5 8.5.1
8.5.2
8.5.3
8.5.4
9.0 9.1
No. of tips by wagon tippler
: 20 (min.) per hour (guaranteed) : 25 per Hour (designed)
9.2
DESIGN & CONSTRUCTION REQUIREMENTS Arm Arm Drive Carriage Frame Travel Carriage drive Motor Travel brake Bearings for sheaves : Robust construction either of cast steel or heavy duty fabricated steel. : Hydraulic cylinder : Single fabrication assembly. : Hydraulic : Integral part of hydraulic motor : Anti friction bearings.
10.0 10.1
APRON FEEDER GENERAL Apron feeders complete with all accessories shall be furnished for wagon tippler hoppers as specified.
10.2
CODES & STANDARDS The design, manufacture, inspection and testing of apron feeders shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The apron feeders shall conform to the latest edition of the standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be constructed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Engineer shall be final and binding.
10.3
DESIGN REQUIRMENTS Apron feeders shall be of robust construction & designed for handling ROM coal as specified and without any choking particularly during rainy season when coal is sticking. A drible conveyor shall be provided for proper clean up. The pan and chain shall be of proven design and shall be with adequate factor of safety.
10.4
CONSTRUCTION REQUIREMENT The frame shall be manufactured from rolled steel section welded and bolted together to form a rigid structure. The roller shall be life time lubricated and shall be manufactured from alloy steel. The chain Link shall be forged steel. Pins and rollers shall be of hardened steel. The chain link shall be bolted to the pans. Apron/pan shall be of suitable thickness which shall be constructed out of fabricated MS with wear resistant liner plate or special alloy steel without any liner plate for the duty requirement. The pan would be fitted directly to the chain attachment. The head and tail
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end shall be of sturdy steel construction suitably stiffened. The sprocket shall be made of cast alloy steel with case hardened teeth or forged steel. The traction wheel shall be made of cast steel with case hardened surface. Tensioning arrangement with sufficient travel shall be provided for the tensioning of the chain. Complete dribble belt system consisting of head pulley, tail pulley, drive, motor, stringers, deck plates etc. shall be provided. 10.5 DATA SHEET Capacity (TPH) Angle of Installation Chain Link Apron pan Traction wheel Rollers 11.0 SIZER GENERAL A Sizer complete with all accessories shall be furnished in wagon tippler complex as specified. 11.1 CODES & STANDARDS The design, manufacture, inspection and testing of a Sizer unit shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Sizer shall conform to the latest edition of the standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be constructed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Engineer shall be final and binding. DESIGN REQUIRMENTS The facility shall be provided with a twin shaft coal low head room sizer unit. The sizer unit shall be capable of handling up to 300mm size material from the apron feeder discharge chute. The rated capacity of sizer shall be 1200 TPH minimum. The sizer shall reduce over size material without causing undue degradation of quality from (-)300 mm to (-) 100 mm production size. The equipment shall be suitable for continuous operation and shall be able to handle wet material. The shaft Sizer shall have two contra-rotating shafts having attached with the appropriate sizing teeth with scroll arrangement. The sizer shall be of extremely robust construction and of adequate strength to withstand heavy duty operation with generation of minimum fines and oversize. The teeth of the Sizer shall be able to continuously agitate scroll in feed material to
: 1500 MTPH ( Design) 1200 MTPH ( Rated ) : Horizontal : Forged alloy Steel : MS fabricated with wear resistant plate or special alloy steel . : Cast Steel : Forged Alloy Steel
avoid jamming of Sizer due to wedging. The Sizer shall be able to handle oversize material without any pre-screening. Undersize material shall pass through the Sizer without further degradation. The sizer shall be designed to contain the breaking forces within its own framework, and transfers none of these forces to the supporting structure. The sizer shall be of low height, compact dimension and shall be of lighter weight for easy & quick installation with minimum support and avoid heavy civil foundation. It shall also ensure less lifting height for discharge from dumpers/tipping trucks for primary sizing. It shall be able to handle sticky coal or hard coal or combination of both maintaining peak throughput capacity. The machine shall stall under pre-set overloading situation and shall be saved from breakdown of machine. In the event of stalled situations resulting from fouling by unbreakable foreign object, recovery should be achieved simply by rotor reversal without need to physically dig out material from the machine. The entire mechanism shall be protected by adequate safety measures. Lubrication of shaft bearing assemblies shall be via an automatic greasing system to prevent contamination. The sizer shall be driven by electric motor through hydraulic fluid couplings and reduction gearbox. The design and selection of sizer shall be such that it can guarantee the specified output of (-) 100mm product size. The inlet of the sizer shall be suitable sized to accommodate occasionally over size lumps. DATA SHEET
(i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x) Capacity Type Material Specifications Hard Grove Index Moisture Content Lump Size Product Size Bull Density Max Temperature Relative Humidity : 1500TPH ( Design) : 1200TPH ( Rated) : Low Head room twin shaft sizer : ROM Coal : 56-65 : 6 to 18% : (-) 300mm : (-) 100mm : 0.8t/m : 50 o C : 75%
3
12.0
DRIVE EQUIPMENT GENERAL Suitable Drive Chain Equipments like electric motors, gearboxes (where applicable), fluid couplings (where applicable), flexible couplings and other accessories shall be provided for all the
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belt conveyor systems, wagon tippler, side arm charger, apron feeders, various pumps of dust suppression system, fans for ventilation system, monorail electrical hoists and other equipments specified in this specifications. Various requirements as spelt out in the Technical Specifications for individual equipments shall be taken into consideration while designing the associated drive chain equipments. 12.1 CODES AND STANDARDS The design, manufacture, inspection and testing of Drive Equipment shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment in to be installed. The Drive Equipments shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those, specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Owner shall be final and binding. IS:3688 : Dimensions for shaft ends IS:3681: General plan for spur & helical gears IS:7403 : Code of practice for selection of standard worm and helical gear boxes 12.2 DESIGN AND CONSTRUCTION REQUIREMENTS 12.2.1 GEAR BOXES 12.2.2 Gear Boxes shall be of sealed type and mounted on machined or ground surfaces. 12.2.3 The gearboxes shall be designed for 24 hours continuous duty and gear boxes shall have appropriate thermal rating. 12.2.4 The gears used shall be helical conforming to IS:3681 (latest revision) or worm reduction units or spiral bevel speed reduction units conforming to suitable Indian Standards. The dimensions of the shaft end shall conform to IS:3688 or its latest revision. Above 40 kW drive rating, all gearboxes shall be helical or bevel helical type only. 12.2.5 Recommended oil grade shall be compatible with gear internals like material of bearing, cages. Further, all gearboxes shall have suitable breather plugs, dipstick, drain plug etc. 12.3 COUPLINGS 12.3.1 Flexible / Rigid Couplings Approved type of couplings shall be used for power transmission depending upon duty requirements. The design of the coupling shall be such that it can take shock and misalignment without sacrificing its efficiency. Geared type flexible coupling shall be used on low speed side for all conveyors and other drive chains where gear box is provided. Other couplings in the drive
chains shall be either rigid or flexible type, depending upon the requirement of equipment design and shall be finalized during detailed engineering. 12.3.2 Fluid Couplings Fluid couplings shall be provided in all the drive machinery for wagon tipplers & associated belt conveyor systems if the actual power requirement at motor output shaft is more than 40 kW. The fluid coupling for LT motors shall be of traction type. Cooling water coils for traction type fluid coupling shall not be accepted. Scoop tube type fluid coupling shall be provided for conveyors with HT motors. Suitable electrically operated actuators shall be provided for scoop tube operation from local as well as remote. Suitable provision for alternate manual operation shall also be kept. Separate pump with motor shall necessarily be provided for circulating the fluid coupling oil through oil cooler. Independent arrangement for forced cooling water supply using 2X100% capacity pumps to oil cooler shall be provided by Contractor. Suitable interlock using flow switches shall be provided in both oil as well as water lines to trip the drive motor in the event of flow in either lines falling below/ acceptable levels. Suitable pressure indicators and flow indicators shall be provided in the cooling water lines along with all-relevant valves, strainers and accessories. Necessary isolation valves shall be provided in the oil / water line for maintenance of any equipment in the line. Necessary interlock shall also be provided so that the HT motor cannot be started from remote / local unless position of scoop tube permits no load start of the motor. Tripping of downstream equipment while the system is under normal operation shall result in scoop tube re-positioning to permit no load run of the concerned HT motor. Temperature switch shall be provided in the oil circuit and shall trip the system in case of high oil temperature. Selection of rating & speed of actuator for scoop type fluid coupling shall be made taking into consideration the coasting time of downstream and upstream conveyors and the engagement/disengagement time achievable. The scoop tube operation must be such so to ensure quick draining out of oil from the operating circuit, by providing a double speed motor. 12.4 DATA SHEET: DRIVE EQUIPMENT GENERAL
12.4.1 Continuous Motor Rating (Name Plate Rating) at 50 Degree Centigrade Ambient temp. for Electric Motors a) For conveyors of belt conveyor systems and belt for In line magnetic separator: *120% of actual power at drive motor output shaft at specified design capacity b) WT, SAC, apron feeders: *110% of actual power requirement at drive motor output shaft at guaranteed (rated) capacity. c) Mono-rail hoists (travel and hoisting), various pumps of DS systems, service water systems, cooling water system, potable water system and sump pumps: *110% of actual power requirement at drive motor output shaft at guaranteed (rated) capacity. d) Ventilation Fans: *110% of actual power requirement at drive motor output shaft at guaranteed (rated) capacity. In case of belt drive, the efficiency of transmission shall be considered as 95%.
*The actual power at drive motor output shaft shall be calculated after considering all the losses of down the line equipments of the drive train. 1.0 Drive Equipment Rating a) For Conveyors : 120% of actual design requirement b) Other Equipment 1 x 100 % duty: 120% of actual design requirement c) Other Equipment 2 x 50 % duty: 110 % of actual design requirement
2.0 DESIGN & CONSTRUCTION REQUIREMENT 2.1.0 Gear Box 2.1.1 Type (a) Below 40 KW: Helical, worm, bevel as per requirement without cooling coil (b) Above 40 KW: Helical / bevel helical without cooling coil 2.1.2 Service Factor: As per accepted engineering practice / manufacturer's recommendations 2.1.3 Ambient temperature for Thermal rating: 50o C Minimum 2.1.4 Mounting: On Machined/Ground Surfaces 2.1.5 Output Rating: a) For belt conveyor systems @ Service factor X {1.2 times the actual power requirement at drive pulley shaft at design capacity} b) For other equipment @ Service factor X {1.2 times the actual power requirement of the driven equipment } @ Service factor shall include all the components considered by the supplier and should be clearly indicated in manufacturers gear box selection catalogues. 2.1.6 Duty: 24 Hrs. Continuous 2.2.0 Flexible Couplings: 2.2.1 Type: Geared capacity. 2.2.2 Rating: Not less than motor rating. 2.3.0 Fluid Couplings: For all motors having rating more than 40 KW. 2.3.1 Type (a) L.T. Motors: Traction type (b) H.T. motors: Scoop tube type. 2.3.2 Rating: Not less than motor rating 13.0 13.1 EOT CRANE GENERAL An E. O. T. crane complete with all accessories shall be furnished for maintenance at wagon tippler house. The design, manufacture, supply erection and commissioning of EOT crane complying with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is
to be installed. The EOT crane shall conform to the latest edition of the standards and codes. Other internationally acceptable standards/codes, which insure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Engineer shall be final and binding. 13.2 DESIGN REQUIREMENTS AND CONSTRUCTION REQUIREMENTS The crane shall be generally of box type double girder construction and shall designed for appropriate class of duty in accordance with BSS: 466/1960 and or IS:3177 to meet the installation and maintenance of wagon tippler and the associated equipment. The bridge should comprise of two main girders with two out riggers and the end carriage built up from mild steel channel with adequate diaphragms or stiffing plates. Each bridge girder shall be fabricated and dispatched without any spliced joints. Box Girder & End carriage joints shall preferably have fit bolts. For all bolted joints the holes are to be drilled and reamed and bolts are to be force fitted. Hand railing shall be fitted on both sides of the end carriages and throughout the length of the platform (height of 1.1m) parallel to girder. Size of the hand rail shall be not less than 25 mm bore heavy gauge steel pipe. The vertical pipes shall have flanges at the bottom for proper support. Suitable hand railing should be provided on Cross Travel Trolley also. All Rotating parts & Overhang parts shall be provided with suitable guard. The end carriages shall be of approved design, with L type Brackets of substantial construction and ample stiffness built up of mild steel sections securely welded. The end carriages of the crane are to be mounted on double flanged wheels of approved diameter in accordance with IS: 3177. Number of wheels on each side of the crane shall be 2 Nos (Total 4 Nos in the Crane for Long Travel motion) The Wheel shall be of forged steel having composition as Cr 55 Mn 75 (EN 9) hardened to 300-350 BHN with minimum depth 10mm confirming SAE 1055 / IS 1570 & shall be fitted with roller bearings with dust proof seals. For lubrication, Grease nipples shall be provided at convenient points. Twin drive system to be adopted for Long Travel of E. O. T. in the bay. One wheel in each carriage is to be driven by forged steel gears through a motor mounted on or adjacent to the carriage. Long travel mechanism shall be provided with, a thruster brake on each individual drive of the track wheels. These brakes shall be such that it can be operated from both the control desk as well as remote control. The brakes shall be of post type with hinged shoes, lined with good quality reinforced bonded brake lining and suitable for easy of adjustment of the wear on lining.
An independent additional mech. / electrical operating brake are to be provided with LT motion to stop the crane immediately in case of power failure. 13.3 DATA SHEET 13.3.0 13.3.1 13.3.2 13.3.3 13.3.4 CAPACITY AND LEADING DIMENSION Safe Working Load: Main Hoist - 25T Safe Working Load: Aux. Hoist - 5T Duty as per I.S.3177 (Latest Amendment) SPEED OF MECHANISMS: - 6 M/Min - 8 M/Min - 10 M/Min - 30 M/Min
(a) Main hoist Hoisting / Lowering (b) Aux. Hoist Hoisting / Lowering (c) Cross Traverse (CT) Forward/ reverse (d) Long Travel (LT) Left / Right
13.3.5 (a) Normal Span: Actual span & other dimensions as required as per structural steel shed of wagon tippler shall be evaluated by the bidder and confirmed in the bid. 13.3.6 (b) Rail Center to Center: Bidder to confirm 13.3.7 Gantry Rail heights above floor level: Bidder to confirm 13.3.8 Hook lift above floor level to be provided: Bidder to confirm depending upon actual site condition 13.3.9 Type of Hook - Shank type 13.3.10 Available head height above rail top: to be confirmed by Bidder 13.3.11 Available side clearance from gantry rail center: Bidder to confirm 13.3.12 Location Wagon tippler shed, Bay Length & Width: Bidder to confirm 13.3.13 Electric power supply - 415 Volt, 3 Phase, 50 HZ A.C. Supply 13.3.14 Gantry rail size - Bidder to confirm. 14.0 14.1 MONORAILS AND HOISTS GENERAL Suitable handling arrangements shall be provided for all equipments included in Contractors scope to transfer the equipment to maintenance area within the building and/or to transfer the equipment outside the building upto ground level for further transportation by the Owner. For this purpose Contractor shall provide monorails and hoist blocks with cross travel facility. 14.1.1 CODES AND STANDARDS The design, manufacture, inspection and testing of Monorails and Hoists shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Monorails & Hoists shall conform to the latest edition of the following
standards & codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Owner shall be final and binding. 14.2 IS:3938 : Specification for Electric Wire Rope Hoist IS:3832 : Chain pulley blocks IS:2429 : Round steel short link chain IS:6216 :Short link chain grade 80 IS:8610 :Points hooks with shank for general engineering purposes IS:210 : Cast Iron Castings
DESIGN REQUIREMENTS
14.2.1 For the Hoists with more than 2.0 tonne lifting capacity or more than 10.0 M lift, with the exception of hoists for GTU and bend pulleys motor operated hoist blocks for both long travel and lift shall be provided. Other hoist blocks shall be of hand operated type for both travel and lift. For hoists for GTUs and bend pulleys clause no. 1.02.18 shall be referred to. All monorails coming out of the buildings shall be provided with electric hoist blocks, irrespective of load and lift. Minimum 3 meter length of Cantilever shall be provided in monorails coming out of the building to lower the equipment to ground level clearing the building sidewalls and any other facilities beneath the floor upto ground level. 14.2.2 The exact lift/travel and the number of the hoisting mechanisms and the mode of lifting equipments to various floors of the buildings shall be as decided by the Owner at the time of detailed engineering. Use of single hoist shall be avoided for handling more than one equipment. Clear height shall be maintained when handling one equipment over other, in such case dismantling of any equipment shall not be permitted. The center line of monorail shall not deviate by more than 500 mm from the center of gravity of any equipment that is to be lifted. Contractor shall take clear note of the fact that the number and monorail hoisting systems shall also be decided considering the movement of the equipment being lifted over/by the side of other equipments without removing the later. The necessary levels of floors in various buildings shall be decided considering the above requirement. 14.2.3 Monorails shall be extended outside the building to handle the equipment to ground level. For monorail/hoist routed inside the buildings, suitable machinery well and removable handrailing and grating shall be provided on various floors of buildings, as necessary, to handle the equipment. 14.2.4 Electrically operated monogirder type hoists shall consist of following major components. a) Electrically operated trolley complete with drive motor (Trolley travel speed maximum 15 m/min.).
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b) Hoist cable, hoisting block and hooks complete with drive motor (Hoisting speed maximum 6m/min.). c) Limit switch to prevent overhoisting, over lowering and over travel. d) Festoon arrangement of feeding power to trolley assembly. e) Erection hardware. f) Pendent control station suspended from hoist. g) Control Panel mounted on wall. 14.2.5 The electric hoist shall be designed and constructed in accordance with the latest revision of IS:3938 and shall be suitable for duty class 2. 14.2.6 For electric hoists, trolley movement and hoisting shall be effected by using two separate motors. Motors shall be as per technical requirements discussed elsewhere. However the motors shall be suitable for 150 starts per hour at 40% CDF. 14.2.7 Trolley for motorized / manual cross travel shall be designed to accommodate a wide range of I beams and shall be capable of travelling on straight as well as curved monorails with the design being such to maintain uniform distribution of pressure on the flanges. 14.2.8 Motor operated geared trolley shall have two (2) pairs of wheels, one pair of which shall be driven through motor. 14.2.9 Wire rope shall be of pre-formed type, hemp cored, regular lay 6/36 construction with a breaking strength of 160 -175 kgf/ sq. mm. Reverse bend of ropes is not acceptable. Minimum number of falls of rope shall be four (4). 14.2.10 All gears and pinions shall be of hardened and tempered steel with machine cut teeth in metric modules. Surface hardening of steel is not acceptable. 14.2.11 All running shafts and wheels shall be fitted with roller bearings with a rated life not less than 20 years based on equivalent running time as per IS:3938. 14.2.12 An electromechanical brake shall provided for hoisting as well as cross travel. Brake lining shall be of asbestos. 14.2.13 Cast iron parts, wherever used, shall be of minimum grade 30, IS:210. 14.2.14All chain pulley blocks shall be designed to IS:3832, the operating hand chain shall conform to IS:2429 grade 30 pitched and polished and the load chain to IS:6216 grade 80. The chain pulley block shall be suitable for duty class 2. Hooks shall be as per IS: 8610 & with antifriction bearing for bottom look.
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14.2.15 All hoists/chain pulley blocks shall be selected to have minimum headroom and shall be selected to lift heaviest piece of equipment. Further, it shall be possible to handle any equipment without disturbing other equipment. 14.2.16 The hand chain wheels shall be of cast steel, the wheels shall be with flanges and designed to ensure effective operation of hand chain. Further, suitable local brake shall be provided as per IS:3832 to arrest and sustain loads in all working positions. 14.2.17 The velocity rates, effort on chain required to raise the safe working load and travel and speed shall be within the limit specified in IS:3832. Proof load test shall be carried out as per IS:3832. Balance requirements shall be as discussed in earlier clauses pertaining to electric hoists. 14.2.18 Hoist for Gravity Take up arrangement and bend pulley. For handling bend pulley, take-up pulley and counter weights following hoisting arrangement shall be provided: (1) For handling bend pulleys, hooks of adequate capacity shall be provided at the top of gallery. Further minimum four (4) nos. manually operated chain pulley blocks of adequate capacity shall also be provided for the entire coal handling plant for handling bend pulleys. (2) For handling take-up pulleys, manual hoist along with mono rail beam of adequate capacity having cross travel, arrangement shall be provided at bottom of gallery to handle take-up pulley only of conveyors. (3) For handling take-up weight, a separate manual hoist with mono rail beam of adequate capacity shall be provided to hold complete counter weight (inclusive of all counter weight blocks). This hoist shall be provided for holding the counter weight and shall be located in the zone of counter weight travel. 14.3 CONSTRUCTION REQUIREMENT
14.3.1 The hoist mechanism shall consist of a grooved rope drum driven by electric motor through gears. Each end of the rope shall be anchored to the drum in such a way as the anchorage is readily available for maintenance. Each rope shall have not more than two (2) full turns of the drum when the hook is at its lowest position and one (1) spare groove when the hook is at its highest position. The leading rope taken by the drum should not slope sideways when slack and it should not be caught between the gear wheel. 14.3.2 Rope drum, gear box, block etc. should be fabricated out of weldable quality steel. 14.3.3 Trolley wheels shall be of single flange type in the taper treads. The wheels shall be mounted on antifriction bearings and shall be easily removable for repair/replacement. 14.3.4 The load hook shall be swiveling type forged circular shank section and shall confirm to IS:8610. 14.3.5 All gears and bearings shall be lubricated by grease. All lubricating points shall be grouped together in easily accessible position.
14.3.6 The bottom block shall be of enclosed type and shall have guard against rope jamming in normal use. It shall have standard forged swivel shank hook fitted on antifriction thrust bearing. Lock to prevent hook from rotation and locking arrangement to prevent accidental unlocking shall be provided. Pulley of the bottom block shall be provided with antifriction bearings. 14.3.7 All parts requiring replacement/inspection/lubrication shall be accessible without need for dismantling of other parts/structures. 14.3.8 All components of hoists of identical capacity and duty shall be interchangeable. 14.3.9 Hoists shall have permanent inscription in English on each side readily recognizable from floor level stating safe working load. 14.3.10 Pendant shall be provided with flourscent up/down/forward/reverse travel push buttons and indicating lamps. Its power supply shall be limited to 24V AC. 14.3.11 The control panel shall be wall mounted type & easily approachable from the floor by a standing man. 14.3.12 For Inspection / maintenance of hoist components a fixed platform (of min 1.5 x 1.5m) with ladder shall be provided for each hoist. 14.3.13 Each inline magnetic separator shall have independent motorised hoist for its handling / maintenance purpose. Each suspended magnet shall also be provided with a dedicated electric hoist. 14.4 DATA SHEET : MONORAILS AND HOISTS 1.0 GENERAL 1.1 Functional Requirement : To transfer equipments to maintenance area or outside the building. DESIGN & CONSTRUCTION REQUIREMENT Hoists Drive (i) More than 2.0 tonne or more than 10.0 m lift or hoists coming out-side the buildings: Motor driven for both travel & lift. (ii) Other hoists including the hoists for handling takeup pulley and takeup weight: Manual for both travel & lift. Maximum trolley travel speed for electric hoists: 15m/min Maximum Hoisting speed for electric hoists: 6 m/min
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2.0 2.1.0 2.1.1
2.1.2 2.1.3
2.1.4 2.1.5 2.1.6
Drive Motors: SQIM, Separate for travel & lift No. of starts for drive motor: 150 starts/hr at 40% CDF Wire Rope (i) Type/Construction: Pre-formed type, hemp cored, regular lay 6/36 construction (ii) Breaking Strength: 160-175 kgf/sq. mm 2.1.7 Bearing (i) Type: Ball/Roller bearing (ii) Life: 20 years 2.1.8 2.1.9 Brake: Electro Mechanical type with asbestos lining. Load Hook: Swiveling type forged circular shank section.
2.1.10 Duty: Class 2 2.2.0 2.2.1 2.2.2 2.2.3 2.3.0 2.3.1 15.0 15.1 Monorail location/layout Cross section I beam Distance between C/L of monorail & C.G. of equipment to be lifted Maximum 500 mm Power Cables Support Festoon type arrangement Manual Hoists Maximum manual effort for operation. 30 Kg
CHUTES AND HOPPERS GENERAL Chutes & Hoppers, flap gates and shall be furnished integral with coal handling system being supplied. All necessary accessories, electricals etc. shall be provided to ensure proper flow/storage/bifurcation of coal as per system requirements.
15.1.1 CODES AND STANDARDS The design, manufacture, inspection and testing of Chutes & Hoppers shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The chutes, hoppers shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the ,contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Owner shall be final and binding. IS:4682 :Code of practice for lining of vessels and equipment for chemical processes. IS:226 : Structural Steel (Standard Quality) IS:11592 : Code of practice for selection and design of Belt Conveyors.
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15.2 DESIGN AND CONSTRUCTION 15.2.1 Chutes, Hoppers 15.2.2 The minimum valley angle of chutes shall be 60 degrees from horizontal. 15.2.3 Transfer chutes shall be adequately sized and sloped to ensure smooth flow of coal without any accumulation anywhere. 15.2.4 Complete chute work above the drive floor for conveyors provided with In-line belt magnetic separators shall be of 10 mm thick SS - 304 in the zone of magnetic field. 15.2.5 Direct impact of material on conveyor belt shall be avoided by providing an inclined surface at 60 degrees valley angle at the feeding point to guide the material in the direction of belt travel. Further, chute construction below flap gate shaft shall be such that there will not be any accumulation of coal dust between chute and flap gate in that zone. 15.2.6 Hoppers and Chutes shall be made of minimum 20 mm thick TISCRAL or equivalent material. However, Contractor to submit test certificates stating composition of material and mechanical properties of these wear resistant steel to the Owner during detail engineering. Long chutes guiding flow from considerable height shall be provided with impact plates wherever change in direction of flow takes place. Hinged inspection doors (generously sized) of leak proof construction shall be provided for access/ maintenance purpose, at approachable heights for chutes and flap gates. All chutes should have one inspection door at every floor and for the ones in between the floors (more then 1.5 meter above the operating floor level) suitable access for trouble free maintenance shall be provided. Maximum distance between two inspection doors in a chute shall be 2 mtrs. For sealing of inspection doors labyrinth type arrangement (with rubber inserted in grooves) to be provided. In addition to positive locking arrangement, mounting bolts, to tighten the door further against rubber shall also be provided. 15.2.7 Bottom side of the chutes on which the coal slides shall be welded to the side plates to form a trough. Bottom sides along with its adjacent sides shall be flanged and made from TISCRAL or equivalent material of 20 mm thickness. The non-striking surface i.e. the covers of the trough shall be of 10 mm thick mild steel and bolted to the flange provided on the trough. Inside welding shall be provided in the corners for permanent sealing. Further, the chute boxes not more than 1.5 m in length shall be joined through bolted flange connection to form the chute legs. Adequate care shall be taken to locate the flange joint away from floor level for easy maintenance. Bolted flange joints shall be of dust tight construction and necessary sealing material shall be provided in all the flange connections for adequate sealing. Complete chute work in the region of flap gates shall be fabricated from 20 thk TISCRAL or equivalent. In case of vertical chute (valley angle more than 80 degree) complete chute, work shall be of 20 mm thick TISCRAL or equivalent material. While finalising the chute work inside the building, arrangement for shifting and replacing chute legs, proper handling arrangement/wall openings, trolleys, hoists shall also be provided. While fabricating the chute, the constituent plates used shall be in one piece. No welds in between shall be allowed. In the zones of direct impact due to Coal trajectory, wear resistant backing plate with
stiffners shall be provided in coal flow chutes. Similar backing plates & stiffening arrangement shall also be provided on the chute surfaces having direct coal fall. 15.2.8 Hoods over the conveyor head pulleys shall be made of suitably stiffened minimum 4 mm M.S. Plates and shall be provided with hinged and gasketed inspection doors with suitable access to them. Further, serrated rubber seal shall also be provided at the very inlet of head chute to minimise dust nuisance. 15.2.9 Separate maintenance sealed door shall be provided for access to belt cleaners in head pulley hood impact plates, flap gates for maintenance and inspection doors shall be of hinged with positive locking facility. 15.3. Skirt Boards
15.3.1 Skirt board shall ensure centralised loading of conveyor belt to avoid coal spillage. Suitable Skirt Plates of minimum 3.0 meters length shall be provided at each feeding point of conveyor. The width of the Skirt Boards shall be two-third the conveyor belt width. In the belts before Sizer House where coal of appreciable lump size (250 mm) is being conveyed, the gap between the bottom of the skirt board and the belt shall be made to increase uniformly in the direction of belt travel. The height of the skirt boards shall be sufficient to contain the material volume as it is loaded on the belt and shall not be less than 750 mm. The skirt plates shall be fitted with modular segmented and replaceable rubber skirting pads having facility of adjusting the pressure on the belt conveyor and shall have provision of on line removal for the purpose of easy maintenance. Such segmented rubber pads with its holding down adjustment arrangements shall be of proven design. The edges of segmented pads shall be installed at an angle for providing a better seal. All care shall be taken while designing, to combine good sealing with minimum belt wear. 15.4 Flap Gates
15.4.1 The motor operated 2 position flap gates shall be provided in transfer chutes as specified and shall be complete with electrically operated actuators. The gates shall be of robust construction and suitable for trouble free operation. The face of the flap gate shall be made out of 20 mm thick TISCRAL or equivalent material. 15.4.2 The equipment shall be capable of being operated for at least 15 switchings per hour at rated load and thrust and shall be suitable for 10 Nos. consecutive switchings at rated load and thrust. The equipment shall be shop tested to prove this requirement. 15.4.3 The motor rating for the actuator shall be so selected as to provide sufficient thrust for operation of the flop gates against the moving weight of coal and/or flap gate. The flap gate travel shall be in the range of 60 deg. to 70 deg. The motor shall be completely dust tight. 15.4.4 Lever arm shall be provided between actuator and flap gate shaft for obtaining required thrust. The linkage mechanism proposed shall be indicated in the Bid.
15.4.5 The actuators shall be capable of preventing any over travel. Suitable travel dependent limit switches controlling the travel of the flop gates on either direction shall be furnished. These shall be placed internal to the drive unit and shall be completely dust-proof. The limit switches shall be capable of adjustments to vary the total length of travel of the gates. 15.4.6 Suitable thrust dependent limit switches shall be provided in the actuator, which shall trip off the actuator motor in case of excessive thrust due to jamming of the gates during its travel in either direction. The same shall also be integral to the drive unit and shall be dust proof. 15.4.7 Provision for alternative manual operation shall also be made using declutchable handwheel. The diameter of handwheel shall be selected considering convenient force to be applied by a single operator. However, minimum diameter of hand wheel shall be 500 mm. Limit switch for safety of person operating the hand wheel shall be provided. 15.4.8 All the two way chutes, one way of which is leading towards the future conveyor, shall be provided with blind flange and flap gate with a provision to mount an actuator in future. 15.4.9 The Contractor shall furnish calculations for selection of actuator for each location for approval of Owner. 15.4.10 Suitable stiffening arrangement shall be provided between the two faces of the gate plate. At the end of the travel the total length of edge of the flap gate shall rest on a suitable projected surface from chute to prevent leakage of coal dust through the available clearance between chute and flap gate. 15.4.11 Maximum feasible counterweights shall be provided for better utilisation of system. However, for calculation of thrust required, the benefit of counterweight shall not be taken into considerations. 15.4.12 Suitable self aligned double row ball bearings in dust tight housing shall carry the gate shaft. Suitable provision for re-greasing shall be provided. 15.4.13 For standardisation purposes, only one standard type of actuator for flap gates shall be provided. The standard type actuator shall be selected for maximum thrust as calculated for various locations. Flap gate actuator as a whole and individual component wise shall be completely interchangeable for all locations. 15.4.14 The material of shaft shall be EN-8 or equivalent. The diameter of the shaft shall be suitable for motor stalled condition and associated twisting. 15.4.15 Approach/maintenance platforms complete with the chequered plate floor, hand rails, ladders etc. shall be provided for all flap gates.
15.4.16 Shaft & flap gate shall be tightly fitted to each other. 15.4.17 On both faces of flap gate main plate, 20mm thick TISCRAL liner plate or equivalent material shall be provided. 15.5 DATA SHEET : CHUTES AND HOPPERS 1.0 GENERAL 1.1 Coal Parameters As specified elsewhere 2.0 DESIGN & CONSTRUCTION 2.1.0 Chutes & Hoppers 2.1.1 Minimum Valley Angle: 60 degrees 2.1.2 Material : (a) Chute work Sliding zones & adjacent sides No striking/ Non sliding zones Chute with valley angle 80 degree and above
: 20 mm thk. TISCRAL / equivalent : 10 mm thk MS : All four sides of 20 mm thk. TISCRAL/equivalent material In the zone of magnetic field of ILMS (chute above floor level) : SS-304 10 mm thk. In the zone of flap gates : 20 thk TISCRAL/ equivalent material Discharge Hoods over head pulleys : 4 mm thk M.S. with rubber curtain 2.1.3 Size of Chutes : Minimum 1200mm X 1000mm (inside both ways) 2.1.4 Inspection Doors :Hinged & leak proof construction (min. size 35 x 45 cm) 2.1.5 Chute Construction (a) Corners: One face of removable bolted flange connection (b) Joints Bolted: flange joints of dust tight construction (c) Bolt size: Min. M-16 (d) Bolts spacing: Not more than 125 mm C/C (e) Fixing Arrangement: Bolts with plain spring washers 2.2.0 Skirt Boards 2.2.1 Length : Min. 3 m for each feeding point 2.2.2 Height : Not less than 750 mm 2.2.3 Width : 2/3 of belt width Side plate : Min. 10 thk TISCRAL/equivalent Top cover : 6 mm thk M.S. 2.3.0 Flap Gate 2.3.1 Type: Linear actuator operated, 2 position 2.3.2 Travel: 60 to 70 deg. (with limit switches on both sides).
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2.3.3 Automatic operation (i) Drive: Dust tight motor driven with suitable linkages (ii) Minimum Actuator Rating: 2500 kg with 1 m lever arm (iii) No. of Operation / Hr: 15 (with 10 consecutive switchings) (iv) Protection: Travel and Thrust dependent limit Switches. 2.3.4 Manual Operation (a) Maximum effort : Convenient for single operator by declutchable hand wheel regardless of electrical power. (b) Minimum Handwheel : Diameter 500 mm 2.3.5 Flap gate shaft (i) Diameter: minimum 130 mm (ii) Material: EN-8 16.0 16.1 DUST CONTROL AND MISCELLANEOUS SYSTEM GENERAL INTENT OF SPECIFICATION 16.1.1 The specification is intended to cover design, engineering, manufacture, supply, erection, testing and commissioning of the complete, Dust Control and Miscellaneous Systems as specified hereinafter required for the Wagon Tippler Package. The Contractor shall refer to the other sections and scheme indicated in the tender drawings to appraise himself of the work and scope of supply of the other Contractors/Owner's and shall coordinate his work with the work of other Contractors. 16. 1.2 Dust Control System The dust control system to be furnished under this specification is required for control of fugitive dust emissions from dust generation points such as transfer points, feeders etc. Dust control is achieved by dust suppression system. Contractor shall guarantee and offer dust control system which shall not allow a dust concentration in the ambient air inside the buildings more than acceptable limits as per Owner approved guidelines or any internationally recognized hygienic Standards/Codes. The Capacity of dust control system specified elsewhere is for Contractors guidance only. Contractor shall provide adequately sized fool proof dust control systems the performance of which should be guaranteed by the Contractor. However, the capacity of the offered system shall not be less than the specified values. Further, for computation of design capacity of the pumps, permanent recirculation lines as shown in tender drawings shall also be considered. Water scheme dust suppression shall be provided as indicated in tender drawings. Clarified water shall be used for Service water system, Plain water dust suppression system shall be used for all receipt and discharge points in Transfer. 16.1.3 Miscellaneous Systems Service water system, potable water system, cooling water system & sump pumps shall be provided as specified elsewhere in this specification and as indicated in tender drawings.
16.2 Scope 16.2.1 Plain Water Dust Suppression System Complete with water supply system, piping, spray heads, pumps, drive motors with canopy (wherever required), couplings with enclosure, electricals, supporting structures, approach/maintenance platforms, handling for equipment, civil and structural works and necessary accessories shall be provided for WT hopper top & all transfer points, etc. 16.2.2 Sump Pump 4x100% sump pumps alongwith level switches and piping up to nearest Owner's drain (max. up to 50.0 meters from outside the building) shall be provided at all locations wherever natural drainage is not possible. Sump pumps along with drain pits shall be provided at other locations also, if required, during detailed engineering stage. Sealing pumps with valves, piping fittings and other accessories for sealing of sump pumps shall be provided. 16.2.3 Service Water System Service water distribution system complete with water supply system, valves, quick couplings, hose pipes with nozzle, piping, pumps, drive motors with canopy, couplings with enclosure, electricals, including supporting structures, handling for equipments, civil and structural works and necessary accessories shall be provided throughout the coal handling plant area in Contractors scope. 16.2.4 Pipings, Fittings, Valves and Specialities The material to be supplied for completing the pipe work shall include but not be limited to the following : (1) Straight piping, bends, tees, elbows, branches, laterals, crosses, reducing unions, couplings, caps, blank flanges, saddles etc. necessary for making reliable piping system. (2) Gaskets, ring joints, jointing material etc. as required. (3) Instrument tapping connections, stubs. (4) Gate, globe and check valves to start/stop, regulate and to prevent back flow. (5) Duplex Strainers. (6) Anchors, hangers and supports as required including secondary steel embedments etc. (7) Bolts, nuts, fasteners as required for interconnection piping, valves and fittings as well as for terminal points. (8) The entire water piping of DS/SW/PW/CW shall be routed/supported on concrete pedestal and conveyor galleries. Whereever the layout does not permit the pipes to be routed over ground, the same shall be buried in conformity to the relevant standards & shall be provided with necessary protective coating as per relevant standards. (9) Painting, anti-corrosive coatings etc. inside and outside pipes as necessary. (10) Welding electrodes and welding rods.
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(11) The area around storage tanks strainers, two valves etc. (located out side pump house) shall be paved with drains. 16.3 Terminal Points Owner shall provide supply of water for dust suppression system, service water, potable water at one terminal point as elaborated elsewhere. Beyond the terminal point, the complete pipe work along with associated valves, specialities, instruments, fittings and supports, pumps, tanks, etc. as required for the satisfactory operation of dust control, service water & potable water systems shall be furnished by the Contractor. 16.4 Codes and Standards The design, manufacture, inspection and testing of Dust Control & Miscellaneous Systems shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Dust Control & Miscellaneous Systems shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Owner shall be final and binding. 16.5 IS:778 : Gun Metal gate, globe & check valves for general purpose. IS:780 :Sluice valves for water works purposes (50 to 300 mm) IS:1239 : Mild Steel tubes & fittings. IS:2379 :Colour for the identification of pipe line. IS:2906 :Sluice valves for water work purposes. IS:3589 :Electrically welded steel pipes for water, gas & sewage (200 to 2000 mm) IS:5312 : Swing check type reflux (non return) valves. IS:1520 : Horizontal centrifugal pump for clean, cold fresh water. IS:5120 :Centrifugal pump for clean, cold & fresh water. ANSI B 31.1:Code for pressure piping. Hydraulic institute Standards of U.S.A.
DESIGN REQUIREMENT Plain Water Dust Suppression
16.5.1 At specified locations dust suppression system shall be provided which comprises spray nozzles discharging plain water in a fine spray to capture air borne dust particles and direct them into the main coal flow. Water shall be discharged via a pipe work system through spray heads at the dust suppression zones.
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16.5.2 Water shall be drawn from the water storage tank by 2x100% electric motor driven pumps and discharged into tank from where 2x100% duty electric motor driven pumps shall discharge the water via a pipe network system through spray heads at the dust suppression zones. Solenoid valves shall be provided for open/close control of water line to each spray head. Each spray head shall consist of minimum 4 nos. nozzles. Spray heads shall be provided at coal loading and receipt zone. Pressure at inlet to spray head shall not be less than 2.5 Kg/sq.cm(g). 16.5.3 The dust suppression system over the WT hopper shall have a canopy on which fogging nozzles are fixed at specified distance. Each nozzle header shall be provided with adequate number of spray nozzles spaced at 500 mm interval so that the entire length & width of the wagon tippler hopper are covered by a grid of nozzles. Further, the water spray shall be of fogging type with a minimum pressure of 2.5 kg/sq.cm(g) at spray nozzle inlet. It should be possible to operate any number of zones simultaneously. The operation of wagon tippler dust suppression system shall be automatic so that the fogging water spray shall get activated only when the tippling is in operation. 16.5.4 Each spray head shall have a provision for installing a pressure gauge whenever required. Further, pressure gauges shall be provided at least at two locations. 16.5.5 Sump Pumps Sump pumps shall be vertical centrifugal type with separate discharge pipe and shall be capable of developing required head at rated capacity for continuous operation. Sump pumps shall be suitable for handling coal slurry & sludge. Head capacity curve of the pump shall be rising type up to the shut off condition. Sump pumps alongwith level switches & piping upto nearest Owner's drain (max upto 50.0 mtrs. from outside the building) shall be provided at all locations wherever natural drainage is not possible. Further sump pumps alongwith drain pits shall be provided at other locations also, if required, during detailed engineering stage. The capacity of each pump shall not be less than 50 cub. M/hr. Continuous motor rating (name plate rating) at 50 deg. C. for sump pump shall have at least 10% margin above the maximum load demand of the equipment in the entire operating range (including run out condition of pumps in case of parallel operation). The maximum load demand shall include the drive losses in the transmission system. Size of the sump pit shall not be less than 2.0 meters x 2.0 meters x 2.5 meters. One no. of settling pit, of adequate size, before the sump pit shall also be provided so that water without heavy coal particles goes into sump pump pit. High and low level switches shall be provided in the sump pump pit. 16.5.6 Service Water (SW) System Service water connections are to be provided in conveyor galleries and tunnels at 50 meter intervals. Adequate number of these connections shall be provided in all transfer houses with minimum one no. at each floor. Each connection shall be provided with one (1) no. 32 NB globe valve and quick coupling. One (1) No. Hose pipe with nozzle shall be provided in each building.
Service water distribution system shall be designed considering the water scheme and water requirement indicated in tender drawings. 16.6 CONSTRUCTION REQUIREMENT
16.6.1 Water Supply Pumps 16.6.1.1 Water supply pumps shall be provided as required. 16.6.1.2 The pumps shall be complete with drive motors, baseplate and other accessories. The constructional features of the pump shall be as follows:
a. Pump casing may be axially or radially split. The casing shall be of robust construction. Casing drain and vent connections shall be provided. b. Impeller shall be made in one piece and securely keyed to the shaft. Locking device shall be provided to prevent its loosening during all conditions of operation. c. Wearing rings shall be of renewable type. Opposed wearing surface shall be of hardened material and shall have a hardness difference of at least 50 BHN. d. Replaceable shaft sleeves shall be provided to protect the shaft where it passes through bearings and stuffing boxes. The end of the shaft sleeve assembly shall extend through the packing gland. Shaft sleeve shall be securely locked or keyed to the shaft to prevent loosening or rotation. Shaft and shaft sleeves shall be machined and assembled for concentric rotation. e. The design of the shaft shall take into consideration the critical speed, which shall be at least 20% away from operating speed. f. Pump bearings shall be of antifriction type. Bearings shall be readily accessible without disturbing the alignment of pump. g. Packed stuffing boxes shall be of sufficient length to prevent leakage along the shaft and shall be complete with all packing and lantern rings required. h. Pumps shall be furnished complete with an approved type of flexible -coupling. i. Couplings guards made of expanded metal and bolted to the base plate shall be furnished. j. The common base plate for pumps and motor shall be in one piece and shall be made of fabricated steel. k. Pump speed shall be less than 1500 rpm for pumps of capacity more than 10 cum/hr.
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16.6.1.3
The power, head and flow characteristics of each pump shall be suitable for parallel operation. The Power characteristics of the pumps shall be of non overloading type. All rotating parts of the pumps shall be statically and dynamically balanced. The motor shall be rated for continuous operation and confirm to companion electrical specification. However, motor rating shall not be less than the max. power demand throughout the entire range of operation of pump. Design duty point of pump shall match with the average value of maximum and minimum flow rates of the pump in the stable operation zone. Materials of construction of pump components shall be as stated in data-sheet to this section. Sump Pumps The column pipe shall serve as a housing for the line shaft and bearing and support for bowl (casing). The line shaft bearing shall be supported from the pump column pipe. Individual sections of column pipe shall be coupled by flanged joints. The flange outside diameter shall not exceed the bowl outside diameter. Casing shall house the impeller and shall be hydraulically designed to minimize radial thrust. Further suitable sealing arrangement shall be provided to prevent the leakage of pumped liquid into the column pipe. The impeller shall be semi open or open (non clogging) as per standard design of the Manufacturer. All rotating parts including the impeller shall be statically and dynamically balanced. Impeller shall be securely fastened to the impeller shaft with keys taper bushings or locknuts and shall be specifically designed to pass large solids or unscreened liquids. The clearances between stationary and moving part shall be such as to allow sustained performance without excessive maintenance. The discharge pipe should be terminated above the base plate or mounting channel. Type of end connection shall be as specified in data sheets. No support shall be provided for the bottom elbow (near pump bowl) to facilitate easy removal of line pump from top without the necessary to go down to the sump for removal of bottom support, if provided. The design of the bunt shaft shall also take into consideration the critical speed of the shall which shall be minimum 20% higher than any operating or run away speed. Individual sections of the shaft shall be interchangeable. The type of couplings for the line shaft shall be such to prevent loosening during reserve rotation.
16.6.1.4 16.6.1.5
16.6.1.6
16.6.1.7 16.6.2 16.6.2.1
16.6.2.2
16.6.2.3
16.6.2.4
16.6.2.5 16.6.2.6 16.6.2.7
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16.6.2.8
Line shaft bearings shall be water lubricated. Line shaft bearings shall be spaced not more than 1.5 meters apart. For lubrication purpose clarified water shall be used. For meeting the sealing/lubricating water requirement, Contractor to provide seal water pumps (2x100% capacity).
16.6.2.9
16.6.2.10 Replaceable shaft sleeves shall be furnished. The shaft sleeve shall be securely locked to shaft to prevent loosening while in operation. 16.6.2.11 Replaceable type wear rings shall be provided for casing and/or impellers wherever applicable. 16.6.2.12 For the following accessories shall be provided for sump pumps (i) Base plates together with foundation bolts and nuts. The base plate shall accommodate the discharge pipe, which is to be terminated above the floor level. (ii) Motor stool. (iii) Non-return valves and gate valves on pump discharge lines (unless otherwise specifically excluded). (iv) Lifting lugs, eye bolts etc. (v) Pre-lubricating tank with accessories (if necessary). (vi) Sleeves and inserts to be embedded in concrete. (vii) Coupling guard, if necessary 16.6.2.13 The pump shaft shall be connected to motor shaft by a heavy duty rigid/flexible coupling or the pump shall be V-belt driven. 16.6.3 PIPING, FITTINGS, VALVES AND SPECIALTIES 16.6.3.1 Piping & Fittings (a) Material of construction of piping and fittings shall not be inferior to those given in data sheet of this section. (b) All piping shall be capable of withstanding the maximum pressure in the corresponding line at the relevant temperature. (c) In general pipe sizes 65 mm NB and larger are to be joined by butt welding and pipe work of size 50 mm NB and below by socket welding/screwed connections. Joints at valves or specialities shall be flanged for sizes 65 mm NB or large and screwed for sizes 50 mm NB and below. All galvanized piping shall be joined by screwed connections. Minimum pipe diameter selected for DS/SW/PW/Cooling Water System (along with branch pipes) shall be 32 NB. (d) End preparation for butt welding shall be done by machine/flame cutting. Socket weld and preparation shall be saw/machine cut. (e) Hangers and supports shall be capable of carrying the sum of all concurrently acting loads. They shall be designed to provide the required supporting effects and allow pipe line movements as necessary. All guides, anchors, braces, dampers, expansion joints and structural steel to be attached to the building/structure, trenches etc. shall be provided. The type of
hangers and components for all piping shall be selected and approval obtained from the Owner. (f) All piping shall be routed on ground on concrete pedestals and at road crossings, these shall be laid through hume pipes. 16.6.3.2 Valves and Specialties (a) Valves & Specialties shall be used to start, stop or regulate the flow. All valves/specialities below 50 mm size (for isolation purpose) in service water/dust suppression/potable water lines should be plug type of proven make. (b) All valves shall be suitable for most stringent service conditions i.e. flow, temperature and pressure under which they may be required to operate. (c) Gate/sluice valves shall be used for isolation of flow of pipe lines above 50 NB and Globe valves shall be used for regulating the flow. (d) Valves shall be provided with back seating bush to facilitate gland renewal during full open operation. (e) All gate and globe valves of size 65 NB and large shall be bolted bonnet, outside screw, rising type with flanged ends. Valves of size 50 NB and smaller shall be with screwed ends. (f) Valves shall be provided with the following as necessary: i. Hand wheel ii. Position indicator iii. By-pass valve and spur gear reduction unit for larger valves. iv. Draining arrangement.
(g) Material of construction of valves shall not be inferior to those given in data sheet of this section. (h) Globe valves shall be provided with contoured plug to have well controllability. (i) Non-return valves shall be swing check type. These valves will have a permanent arrow inscription on its body to indicate direction of motion of the fluid. All valves shall be provided with hand wheel, chain operated, extension spindle and floor stand wherever required so that they can be easily operated either at a lower or higher elevation as the case may be.
(j)
(k) Strainer shall be of duplex type designed with 3 way valves so that one filter can be cleaned while the other is in operation. Suitable vent and drain valves shall also be provided. Screen opening area shall be at least four times the pipe cross sectional area. Pressure drop in clean conditions shall not exceed 1.5 MWC at full flow.
(l)
Bib cocks provided for potable water system shall be made of stainless steel
16.6.4 Special cleaning, protection and painting 16.6.4.1 Piping & Fittings (a) Surfaces to be painted shall be thoroughly cleaned of loose mill scale, rust etc. by wire brushing. (b) For over ground exposed steel pipes, one shop and one site coat of red oxide zinc phosphate and two coats of synthetic enamel finishing paints unless specified otherwise shall be applied. A minimum of 120 microns Dry Film Thickness (DFT) after finished coat of paint shall be ensured. (c) For steel buried pipeline, three (3) coats of heavy duty bitumastic paint shall be applied on the cleaned surface. Finally, it should be wrapped with minimum 3 mm thick bitumen impregnated tar felt. The lap joint of the felt shall be generally touched with heavy duty bitumastic paint. 16.7 DATA SHEET : DUST CONTROL & MISCELLANEOUS SYSTEM 1.0 GENERAL 1.1 1.2 Dust Control: Plain water dust suppression Miscellaneous systems: Service water system, Potable water system, Cooling water system & Sump pumps. DESIGN REQUIREMENT Dust Suppression Operation: Water sprayed through nozzles. Pumps: 2x100% for water Spray Head (i) Minimum No. of nozzles per spray head: 4 (Four) (ii) Pressure at inlet: Minimum 2.5 kg/sq. cm Plain Water Dust Suppression Pumps: 2x100% electric motor driven Minimum Pressure at inlet of spray nozzles: 2.5 kg/sq. cm Nozzle spacing on WT Top: 500 mm Nozzles: Fogging type Flow from each nozzle: 2.0 Lpm Sumps Pumps (i) Type: 2x100% electric motor driven (ii) Capacity: 50 cub.m/hr minimum with 10% margin (iii) Head: 20% margin on computed head
2.0 2.1 2.1.1 2.1.2 2.1.3
2.2.0 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.3.0
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2.3.1
Drain Pits: Minimum 2x2x2.5 mts. and 1 No. settling pit for slurry & high/low level switches in drain pit. Piping: To nearest plant drain Service Water System Water connections (a) Conveyor Galleries and tunnels: every 50 m (b) Transfer points: Min. 1 no. at every floor Connection details: 1 No. 32 NB globe valve & quick coupling Hose pipes with hose reel: One in each building of 25 mtr. Length with nozzle CONSTRUCTION REQUIREMENTS Water Supply Pumps for DS/SW/PW/CW Casing Axial or radially split with drain & vent connection Impeller One piece, keyed to shaft along with locking device Shaft Critical speed atleast 20% away from operating speed Shaft sleeves at bearings & stuffing boxes. Bearings Antifriction type Wearing rings Renewable type (preferable) Pump speed Below 1500 rpm for capacity more than 10 cub. m/hr. Head flow characteristics Suitable for parallel operation. Materials (a) Casing: Cast Iron to IS:210, FG 260 (b) Impeller: Bronze conforming to Gr.I of IS:318 (c) Impeller Wearing ring: Bronze conforming to Gr.I of IS:318 (d) Casing Wearing ring: Bronze conforming to Gr.I of IS:318 (e) Shaft: Medium carbon steel (f) Shaft sleeve: Stainless steel conforming to AISI-416 hardened. (g) Gland packing: Impregnated Teflon Sump Pumps Type: Vertical, centrifugal, single stage, semi open or open (non clogging) type impeller. Duty: Intermittent. However, to be designed for contineous operation. Fluid to be Pumped: Sludge/Coal slurry Suction Condition: Submerged Pump speed (maximum): 1000 RPM Type of coupling between pump and motor: Directly driven through flexible or rigid coupling/V-Belt Location of pump thrust bearing: In motor stool
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2.3.2 2.4.0 2.4.1
2.4.2 2.4.3 3.0 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8 3.1.9
3.2.0 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7
3.2.8 Materials (a) Casing: Alloy Cast Iron (350 BHN) (min. 2.7% Ni, 1% Cr.) (b) Impeller: Alloy Cast Iron (350 BHN) (min. 2.7% Ni, 1% Cr.) (c) Impeller: Shaft Stainless steel (d) Line Shaft: EN-8 to BS; 970 (e) Column pipe and discharge pipe: Fabricated steel to IS: 226 (min. 6mm thick). (f) Shaft sleeve: Hardened stainless steel to 400 BHN (g) Base Plate: Steel to IS: 226 up to 20mm thickness and IS: 2062 over 20mm thickness. 3.2.9 Accessories Provided with the Pump i. Lubrication and sealing water system: Yes ii. Common base plate for Pumps and Motor and Motor stool: Yes iii. Anchor Bolts, nuts, sleeves and inserts (which will be embedded in concrete): Yes iv. Coupling, guards lifting lug, eye bolt, positioning Dove: Yes 3.3.0 Pipings & Fittings 3.3.1 Joints (i) Pipe to pipe Pipe size < 50 NB: Socket welding/screwed Butt Pipe size > 65 NB: welding (ii) Pipe to valves Pipe size 50 NB: Screwed Pipe size 65 NB: Flanged 3.3.2 3.3.3 Isolation of flow: Plug / Gate / Sluice valves Regulation of flow: Globe Valve
3.3.4 Valves i. Size > 65 NB: Bolted bonnet outside screw rising type. ii. Size < 50 NB: Union bonnet with screwed ends for Globe valves & screwed ends for plug valves. 3.3.5 Materials for Pipework (a) For sizes 200 NB and Larger: ERW carbon steel pipes to API-5LGr.B minimum thick 6.35 mm or plate fabricated and welded pipes to IS:3589, Class-2. (b) For sizes 150 NB to 65 NB: ERW carbon steel black pipes to IS:1239 (Part-I, Heavy Class). (c) For sizes upto 50 NB: ERW carbon steel galvanized pipes to IS:1239 (Part-I) Heavy class. 3.3.6 (a) Materials for Valves & Specialities Cast Iron Valves: (65 NB & above) i. Body and bonnet: Cast Iron to IS:210, Gr.FG-200
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(b)
(c)
ii. Disc for non- return: Cast Iron to IS:210, Gr.FG-200 valves iii. Seating surfaces and rings: 13% chromium steel iv. Hinge pin for non return valves: Stainless steel type AISI-316 v. Stem for gate and globe valves: 13% chromium steel vi. Back seat bush: 13% chromium steel Gun metal valves (50 NB & below and upto a working pressure of 10 kg/cm2) (i) Body: Gun metal to IS:318, Gr-2. (ii) Trim: Gun metal to IS:318, Gr-2. Duplex Strainer (i) Body: MS fabricated (ii) Strainer: Stainless steel type element AISI-316 Pressure Gauge/Switch (to be provided with isolating valves, gauge cock, snubber and syphon) (i) Dial size : 150 mm (ii) Accuracy : (+/-) 1% of range span (iii) Bourdon : AISI 316 SS (iv) Block : AISI 316 SS (v) Movement : AISI 316 SS (vi) Case and Bezel : Die cast Alum. Weather proof case stove enameled block with screwed type inner bezel of ABS plastic and glycerin filled. (vii) No. of contacts : 2 NO + 2 NC (viii) Type of contact : Adjustable throughout the range. (ix) Degree of protection : IP. 65 Solenoid valve (to be provided with isolating valve) (i) Type : 2/2 way Diaphragm type pilot operated (ii) Diaphragm : molded synthetic rubber (iii) Body : Forged brass / SS (iv) Pressure : 0.5 to 20 kg/cm2 (v) Protection : Class IP 65 Flow Switch (to be provided with isolating valves) (i) Body : Forged steel (ii) Extension Rod/wire : SS-304 (iii) Sleeve and Sleeve pipe: SS-304 (iv) Cover : Die cast aluminum (v) Max. working pressure : 10 kg/sq.cm (vi) Repeatability : 0.5% (vii)No. of contacts : 2 NO + 2 NC (viii)Type of contact : Adjustable throughout the range. (ix) Protection : class IP 65 Level Switch
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(d)
(e)
(f)
(g)
(i) Type : Displacer operated magnetic type (ii) Displacer: SS 316 (iii) Wire rope: SS 316 (iii) Spring Housing Spring and sleeve pipe: SS 316 (iv) Cover: Cast Aluminum (v) No. of Contacts: 2 NO + 2 NC (vi) Type of Contact: Adjustable throughout the range. (viii) Protection: class IP 65 (h) Level gauges (i) Type: Float type mechanical gauge with arrow scale (ii) Accuracy: (+/-) 1% of full scale range (iii) Material of construction (a) Float & Guide wire: 316 SS (b) Elbows: Suitable grade of SS (c) Housing: Mild Steel (d) Cable fastener: SS 304 (i) Nozzles (i) Type: Fogging, non-clogging type (ii) Material: Stainless Steel (iii) Nozzle housing : To ensure protection of nozzle against damage. (j) Y Strainer (a) Body: SS 304 (b) Plug: SS 304 (c) Filter Element: SS 316, 60 mesh 17.0 VENTILATION SYSTEMS
17.1 GENERAL 17.1.1 INTENT OF SPECIFICATION The specification is intended to cover design, engineering, manufacture, supply, erection, testing and commissioning of the complete Ventilation & air conditioning systems as specified hereinafter for the smooth and trouble free operation of plant & equipment of Wagon tippler package. 17.1.1.1 The Contractor shall refer to the other sections enclosed to appraise himself of the work and scope of supply of the other Contractors and shall coordinate his work with the work of other Contractors. 17.2 GENERAL DESCRIPTION
17.2.1 Mechanical Ventilation system
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The air quantity for mechanical ventilation system shall be estimated based on equipment and solar heat loads and the temperature rise inside the building. Necessary air filters shall be provided to supply only clean air into building. Exhaust air shall be discharged at a suitable height above building. Exhaust fans shall be provided for Toilets, Battery rooms. All underground structure shall be provided with supply air as well as exhaust air fans. 17.2.2 Pressurised Ventilation System The pressurised ventilation system having adequate nos. of supply and exhaust air fans with washable metallic pre filters, HDPE fine filters, and exhaust fans with self closing flaps, ducting along with 3 phase AC motor drives, electricals, supporting structures, access / maintenance platforms shall be provided in all MCC/switchgear room areas of coal handling plant to be furnished under this specification. The pressurized ventilation system shall be designed considering 20 air changes per hour to maintain these areas pressurised slightly above atmospheric pressure to prevent ingress of dust from outside. 17.2.3 Air Conditioning System Air conditioning system shall be furnished for control room area of Wagon tippler control building, it shall be designed considering the equipment heat loads, solar heat loads, heat gain into the room, adequate no. of air changes etc. to maintain a uniform temperature and relative humidity within the air conditioned areas. 17.3 SCOPE
17.3.1 Mechanical Ventilation System The ventilation system generally consisting of adequate number of supply and exhaust air fans, air filters, ducting along with 3 phase AC motor drives, electricals, supporting structures, approach/maintenance platforms, civil and structural works and necessary accessories shall be furnished for ventilating the WT hopper, underground portion of transfer points, underground conveyor tunnels and pent houses. Exhaust fans shall be provided for Toilets & Battery rooms. 17.3.2 Pressurised Mechanical Ventilation System The ventilation system generally consisting of adequate number of supply and exhaust fans, metallic pre filters, HDPE fine filters, ducting along with 3 phase AC motor drives, electricals, supporting structures, approach / maintenance platforms, necessary shed, civil & structural works and necessary accessories shall be furnished for all MCC/switchgear rooms. 17.3.3 Air Conditioning System 17.3.4 2x100% capacity air conditioning units shall be provided for Wagon Tippler Control Room. 17.3.5 Supply and return air distribution ducting complete with insulation, of resin bonded mineral wool equivalent of density at least 24 Kg/m and thermal conductivity of max. 0.49 mw/cmC
conforming to IS:8183 including supporting structures, approach/ maintenance platforms, civil and structural works and necessary accessories shall be provided. 17.3.6 PAC shall be housed inside building. 17.3.7 Area around centrifugal fans, filters, motor foundation shall be paved to have a clear surrounding. 17.4 Codes & Standards The design, manufacture, inspection and testing of Ventilation & A/C System shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. The Ventilation & A/C System shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the Owner shall be final and binding. IS:3588 : Specification for electrical axial flow fans. IS:2312 :Propeller type AC Ventilation fans IS:3963 :Specification for roof-extractor units IS:4894 :Centrifugal Fans IS:655 :Specification for Metal Air Duct ARI:210 :Standard for Unitary air conditioning equipment. ARI:270 :Standard for application, installation and servicing of unitary equipment. IS:8183 :Specification for bonded mineral wool. IS:661 :Thermal insulation for cold surfaces. IS:4671:Expanded polystyrene for thermal insulation purpose. IS:8148 :Packaged Air conditioners.
17.5 DESIGN REQUIREMENT 17.5.1 Roof Ventilators & Accessories 17.5.2 Roof ventilators & accessories shall be provided as required. Impeller shall be axial flow type. 17.5.3 Design duty point of the fan shall match with the average value of maximum and minimum flow rates of the fan in stable operation zone. 17.5.4 The speed of the roof ventilators shall not exceed 960 rpm for ventilators with impeller diameter above 450 mm & 1440 rpm for ventilators with impeller diameter 450 mm and less. The first critical speed of rotating assembly shall be at least 25% above operating speed. 17.5.5 Motor shall be totally enclosed type suitable for vertical mounting. Motors shall comply with the companion electrical specifications.
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17.5.6 Axial Fans 17.5.7 Design duty point of the fan shall match with the average value of maximum and minimum flow rates of the fan in the stable operation zone. The speed of the fan shall not exceed 960 rpm for fan with impeller diameter above 450 mm and 1440 rpm for fan with impeller diameter 450 mm and less. The first critical speed of rotating assembly shall be at least 25% above operating speed. 17.5.8 Impellers shall be axial flow type single piece. 17.5.9 Centrifugal Fans 17.5.10 The fan units shall be centrifugal type with radial bladed impeller. For design purpose out door ambient temperature shall be taken as 50 deg.C. 17.5.11 Fans shall be manufactured vibration free in operation and shall be designed to limit noise level within limits specified in Data Sheet. 17.5.12 The motor shall be rated for continuous operation and conform to companion electrical specification. However, motor rating shall not be less than the max. power demand throughout the entire range of operation of fan. 17.5.13 All fan mountings shall have adequate arrangement for vibration isolation. 17.5.14 The reverse flow through non-working fan shall be prevented by dampers. The dampers shall be made out of 18 SWG MS sheets. 17.5.15 Design duty point of the fans shall match with the average value of maximum and minimum flow rate of the fan in the stable operation zone. 17.5.16 Filters 17.5.16.1 Metallic Filters Metallic cleanable filters shall be provided as required. Max. air velocity considered shall be 2 m/sec. 17.5.16.2 HDPE Filters HDPE filters should have an efficiency of 90% down to 5 microns. Velocity across the filter shall be limited to 2.5 m/sec. 17.5.17 High efficiency filter (for A/C purpose). Filtration efficiency shall not be less than 99.9% down to 5 microns. Pr. drop across the filter under clean condition shall not be more than 10 mm w.c.
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17.5.18 Packaged Air-Conditioning Unit PAC units shall be provided as required. 17.5.19 PAC units shall be factory tested and assembled self contained units complete with refrigerant compressor, coils, fans, insulation and wiring. Various parts of PAC units wherever required shall be insulated with expanded polyethylene conforming to IS:4671. 17.5.20 The PAC unit shall comprise of an evaporator (indoor air) blower section and an air cooled condenser (outdoor air) section. Heavy gauge steel cabinet factory finished with two coats of epoxy paint of approved colour, shall be used to house components of PAC. 17.5.21 The evaporator and condenser coils shall be arranged for direct expansion cooling and shall be formed of aluminum fins mechanically bonded to seamless copper tubes and electrically tinned. The inter-connecting refrigerant circuits shall comprise of multiple cylinder hermetic compressor(s) and motor(s) with all necessary isolation valves, suction gas controlled thermal expansion valves, with adjustable set point, sight glass, copper tubing and pipeline ancillaries. The condenser coils shall be air cooled by propeller type fans complete with safety guards. The condensing coils shall be suitably arranged to avoid radiant heat pick-up from solar sources. 17.5.22 Condenser capacity control shall be provided by means of variable speed fans and head pressure sensing. 17.5.23 The evaporator air blower(s) shall be centrifugal forward curved type belt driven by individual motor(s) and suitable for the external static pressure. The fan assembly shall be isolated from the casing by anti-vibration mounts. The fan/motor drive shall be capable of capacity adjustment by pulley changes within +15% of design duty. 17.5.24 High efficiency filters shall be provided in the main supply air duct and in the fresh air connection to return air duct. 17.6 Construction Requirements
17.6.1 General construction details of various equipment under Contractors scope shall be as elaborated in subsequent clauses below. 17.6.2 Roof Ventilators and accessories Roof ventilators and accessories shall be provided as required. 17.6.3 Impeller shall be axial flow type, cast in one piece finished all over and carefully dynamically balanced after final assembly. All impellers shall consist of high efficiency aerofoil blades. Impellers shall be mounted directly on the motor shaft.
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17.6.4 Casing shall be of heavy gauge construction and shall be properly reinforced for rigidity. Access door with suitable locking arrangement shall be provided. 17.6.5 Hood shall be of hinged type providing easy access to motor and impeller. It will also protect them from rain and any other contingencies. Weather-proof lockable type disconnect switch shall be provided such that the hoods can be opened only when the disconnect switch is in OFF positions. On larger sizes of roof ventilators, hoods shall be of split construction. 15 mm mesh galvanised bird screen shall be provided. The hoods will have low pressure drop across it. 17.6.6 Suitable arrangement shall be provided for mounting the roof ventilators such that ingress of rainwater into the building will be avoided completely. 17.6.7 Axial Flow Fans Axial flow fans shall be provided as required. 17.6.8 Impellers shall be axial flow type and single piece cast aluminum with aerofoil blades construction. It shall be finished all over and balanced dynamically. Impeller shall be mounted directly on the motor shaft. 17.6.9 Casing shall be of heavy gauge construction properly reinforced for rigidity. It shall be provided with suitable supports. Access door shall be provided in the casing for easy access to motor and impeller. Suitable arrangement for mounting of motor shall be provided. 17.6.10 Rain protection cowls will be designed to suit wall exhausters/supply fans for protecting fans/motors from rain. It will be provided with bird screen. 17.6.11 Inlet cone or bell and outlet cone shall be provided as required. It should be made of G.I. or M.S. 17.6.12 Motor shall be of totally enclosed type complying with the companion electrical specification. Suitable rain/sun shade for motors shall also be provided. 17.6.13 Centrifugal Fan Centrifugal fans shall be provided as required. 17.6.14 The casing shall be of welded construction fabricated with heavy gauge material. It shall be rigidly reinforced and supported by structural angles. The seams shall be permanently sealed airtight. Split casing shall be provided on larger sizes of fans. Casing drain with valves shall be provided wherever required. 17.6.15 The impeller shall have die formed curved blades fabricated out of MS heavy gauge welded to the rim and back plate to have a non overloading characteristics of the fan. Rim shall be spun to have a smooth contour. If required intermediate stiffening rings shall be required. The impeller, pulley and shaft sleeves shall be secured to the shaft by key and/or nuts. The impeller along with driven pulley shall be dynamically balanced. Fan shaft shall be of EN-8 equivalent.
17.6.16 The bearings shall be self-aligning heavy-duty ball or roller bearings. They shall be adequately supported. They shall be easily accessible and lubricated properly from outside. 17.6.17 Filters 17.6.18 Metallic Filters Metallic cleanable filters shall consist of V-fold galvanised wire mesh inter spaced with a flat layer of galvanised wire mesh. The density of the filter medium shall increase in the direction of airflow. Wire mesh edges shall be suitably hemmed to eliminate the danger of abrasion during handling. Filter medium shall be supported on either side by galvanised expanded metal casing. Filter frame shall be constructed from galvanised sheet of thickness not less than 18 gauge. 17.6.19 HDPE Filters HDPE filters shall be provided as required. This shall be constructed of HDPE fabric with continuous water spraying on it from a header for keeping it clean. 17.6.20 High efficiency filter (for A/C purpose) The media of the filter shall be made from either special synthetic non-woven bond fiber design or made from micro fiber glass media. It shall be supported with GI wire mesh or aluminum mesh and shall be housed in an aluminum sheet frame. It shall be of washable type several times. 17.6.21 Package A/C Unit 17.6.22 A separate cubicle shall be provided within the overall casing to house the thermostatic controls, which shall be electric/electronic solid state, prewired and tested. The refrigerant system shall be protected by pressure limiting devices, electric and thermal overloads and unloading facilities to provide the required control range tolerances. A low voltage room thermostat shall be provided for wall mounting. The casing shall be fitted with all necessary coil drains and service connections/ entries. 17. 6.23 PAC (duty/standby) units shall be selected manually and be ON/OFF switched. The units shall be fully packaged and incorporate integral room air sensing control thermostats and manufacturers work fitted safety interlocks. All controls shall be prewired to unit mounted control/power terminal boxes. 17.6.24 Ventilation and Air Conditioning system ducting 17.6.25 All GI sheet metal ductwork required for ventilation and air conditioning system shall be furnished by the supplier. All ducts and plenums unless otherwise noted shall be constructed out of standard quality galvanised steel sheet. All sheet metal ducts shall be fabricated and installed in
conformity to the requirements of IS:655. Steel supports for the ductwork shall be furnished as required. The thickness of ducting steel shall be 1 mm min. For ducting with large size exceeding 1300 mm it shall be 1.25 mm. The flexible connection between fan and ducting shall be on Teflon impregnated canvas. The zinc coating on GI sheet shall be 275 gm/cm2. 17.7 DATA SHEET : VENTILATION SYSTEM 1.0 GENERAL 1.1.0 Mech. Ventilation System: To provide ventilation using fans for specified areas. 1.1.1 No. of air changes per hour (a) For overground building: Not less than 10 supply air changes & 7 Exhaust air changes (b) For underground areas: Not less than 15 supply air changes & 7 Exhaust air changes 1.1.2 Equipment (1) Underground tunnel: Centrifugal fans/Axial Fans (2) All other places: Axial fans, roof ventilators 1.2.0 Pressurised ventilation system: To provide clean air to all MCC / Switchgear buildings 1.2.1 No. of air changes per hour: Not less than 20 1.2.2 Equipment: Centrifugal fans/Axial Fans and exhaust air fan 1.3.0 Air-conditioning system As specified 1.3.1 Temperature to be maintained : 24 1 deg. C 1.3.2 Humidity to be maintained : 50 5% relative humidity 1.3.3 Fresh Air intake : More than 1.5 air changes per hour. 1.3.4 Equipment: 2 x 100 % roof mounted package AC units along with ducting etc. and window AC 1.4.0 Outside Ambient Conditions (i) Summer: As per weather data given in project synopsis. (ii) Monsoon: - Do (iii) Winter: - Do 2.0.0 DESIGN & CONSTRUCTION 2.1.0 Roof Ventilators 2.1.1 Capacity: 10% more of actual requirement 2.1.2 Head: 20% more of actual requirement 2.1.3 Speed (a) Impeller: dia above 450 mm Max. 960 rpm (b) Impeller: dia less than or equal to 450 mm Max. 1440 rpm (c) Critical speed: 25% above operating speed. 2.2.0 Axial Fans 2.2.1 Capacity: 10% more of actual requirement 2.2.2 Head: 20% more of actual requirement
2.2.3 Speed (a) Impeller: dia above 450 mm Max. 960 rpm (b) Impeller: dia less than or equal to 450 mm Max. 1440 rpm (c) Critical speed: 25% above operating speed. 2.3.0 Centrifugal Fans 2.3.1 Capacity: 10% more of actual requirement 2.3.2 Head: 20% more than actual requirement 2.3.3 Speed: Max. 1500 rpm 2.3.4 Outdoor temperature: 50 deg.C. 2.3.5 Rating: Continuous 2.4.0 Packaged Air-Conditioning Unit 2.4.1 Type: Roof top mounting 2.4.2 Service/application: Continuous, round the clock. 2.4.3 Capacity (i) TR: Suitable (ii) CFM: Suitable 2.4.4 Type of compressor: Multiple cylinder hermetic compressor. 2.4.5 Condenser: Air cooled type 2.4.6 Fan: Forward curved centrifugal fan 2.4.7 Filter: High efficiency filter 2.4.8 Cooling Coil (a) Type: Direct Expansion (b) Material: Copper (c) Fins: Aluminum mechanically bonded. 2.4.9 Refrigerant: Piping Copper 2.4.10 Insulation for PAC parts: Expanded polyethylene of density at least 15 kg/cub.m. 2.5.0 Filters 2.5.1. Metallic Filters (1) Max. air velocity: 2m/sec. 2.5.2 HDPE filters (1) Efficiency: 90% down to 5 microns (2) Max. velocity: 2.5 m/sec. (3) Testing: As per BS 2831 / Sqv. 2.5.3 High Efficiency Filter (1) Efficiency: 99.9% down to 5 microns. (2) Pr. drop across: 10 mm W.C. (3) Testing: As per BS 2831 / Sqv. 2.6.0 Insulation for A/C Ducting Resin Bonded Mineral wool as per IS:8183 2.6.1 Density: 24 kg/cub.m
2.6.2 Thermal conductivity: 0.49 mw/cm deg.C 18.0 18.1 DESIGN OF CONVEYOR GALLERIES AND JUNCTION HOUSES Design Considerations a) The general parameters for conveyor galleries shall conform to the provision of IS : 11592-1985 unless specified otherwise in Technical Specifications. The structures shall be designed so as to meet functional requirements and shall provide space for operation, maintenance and removal of machinery and give the workers good and safe environment. b) Gallery floors shall be of chequered plates supported on steel beams. c) Steps shall be provided with (rise not exceeding 130 mm along the walkways if the gallery slope exceeds 12. In case the slope of gallery is between 6 to 12, suitable ribs (without any sharp edges) shall be provided on floor at 250 to 300 mm intervals. d) Roof and side walls of conveyor galleries shall be covered with GCS/ Aluminium/ colour coated sheets. with a provision of gap of 300 mm below roof and 150 mm from top of floor level on the side wall for ventilation.
e) Adequate provision for natural light inside conveyor gallery shall be made through side walls by providing translucent sheets (FRP sheets as per IS: 12866-1989). Every sixth sheet on side wall shall be FRP sheet and shall be staggered on opposite wall. f) Roof slopes of conveyor galleries shall be 1:5 (1 vertical, 5 Horizontal). g) The level of underside of the base plate of gallery supporting trestles shall be 300 mm above the average ground level of the surrounding area. h) Protective hand railing shall be provided along gallery walkways, open platform, stairways, landings, edges of walkways when the gallery is not enclosed, and around erection openings, if any, to ensure safety of operating personnel. i) Conveyor galleries longer than 150 m shall be provided with expansion joints with twin trestles/supports. Each expansion block shall have fixed support/rigid trestle with adequate arrangement (provision of top chord and bottom chord bracing to gallery girder etc.) for transferring the transverse and longitudinal forces to the foundation. j) Gallery girders near junction house shall be preferably supported on trestle located as close to the junction house as possible, with part of gallery girder between junction house and trestle cantilevered from the trestle. Supporting gallery girders on junction house shall be generally avoided.
k) The underside of the belt conveyor shall be fully covered with 3 mm sheet in case of conveyors located within the boundaries of the plant area. including the gallery crossing the roads / railway lines / areas of public gatherings. l) When conveyor gallery crosses above or below H.T cables, a minimum clear distance of 1.0 m between the structural elements/cladding and HT cables shall be maintained. m) When the conveyor bridge passes over plant roads, clearance between the road surface and the lowest points of the bridges shall not be less than 8.0 m or the height needed for the passage of the largest individual components of the plant equipment, whichever is the larger. n) The junction house shall be designed to suit the functional requirement. Number of floors, height of building etc. shall be decided accordingly. o) In general the junction house shall be designed as framed structures on shorter span side and vertically braced on longer side to achieve stability. p) Floor of junction houses shall be of RCC slab / Chequered plate supported on steel beams, unless required otherwise from technological suitable lugs. q) Roof and side covering of junction houses shall be with GCS/Aluminum sheets / troughed colour coated sheets as specified. Roof slope shall be 1: 5 ( 1 Vertical : 5 Horizontal). r) Suitable access staircase with safety hand railing shall be provided to all floors of junction houses. s) Wall sheeting shall generally start from the lowest working floor and extend up to roof level with louvers at each floor level to ensure adequate natural ventilation. t) Monorails for maintenance hoists shall be provided for maintenance and repair of various equipments located on the floors. 18.2 Components of structures a) Gallery Trusses and Roof Gallery truss shall be of latticed type construction. The trusses shall be adequately braced at top and bottom chord level to transfer the horizontal wind forces to end portals. b) Stringer Beam These beams shall be suitably spaced to support the conveyor stringer supports and shall transfer load to gallery. Walkways on either side of the conveyor shall also be supported on these stringer beams.
c) Supporting Trestles Intermediate trestles shall be two legged and shall deliver loads from gallery trusses to the foundations. In addition, four legged trestles shall be provided which will act as fixed support to transmit all longitudinal forces between expansion block, in addition to other forces. d) Junction Houses i) Floors - Floor beam layout shall be arranged to suit equipment layout as well as equipment anchoring system. ii) Columns - In addition to loads from floor and roof, columns shall be designed to transmit horizontal load due to belt tension/snapping of belts to the foundation. e) Belt Tensioning Device Suitable structures shall be provided to accommodate belt-tensioning device which may be located either under the conveyor gallery or in the junction house itself. f) (i) (ii) Wall Structures Wall runners with necessary sag rods shall be provided to support wall sheeting in conveyor galleries and junction houses. Walls shall be provided with louvers and translucent sheeting at appropriate levels, to provide natural ventilation and lighting.
g) Access stairs, walkways, platforms, ladders, hand railing etc. (i) Wherever possible, access shall be provided by means of stairs. (ii) All walkways and stairs leading to working platforms shall have minimum 800 mm width of walkways/flight of stair. (iii) All other walkways and stairs leading to areas for maintenance purpose, or due to restriction of space, shall have a minimum width of 800 mm of walkway/flight of stair, unless required otherwise. (iv) Staircases shall be generally designed with slope of approximate 37.5 with the horizontal. (In no case the slope shall exceed 40 with the horizontal). Intermediate landings shall be provided wherever required such that vertical rise of each flight does not exceed 3000mm. Risers in one flight shall be equally spaced. (v) Walkway floors and stair treads shall be designed with chequered plate (or non-slip type plates). Ribbed floor/treads may be provided wherever the possibility of accumulation of dust exists, taking care that such provisions do not crate a nuisance to the operating personnel on the shop floor. (vi) Rise of treads in staircases shall not exceed 200 mm. (vii) A minimum headroom of 2200 mm shall be provided over operating platforms, visitor's galleries, or other areas with possibility of public gathering. In all other platforms, walkways
and stairs, minimum headroom of 2000 mm shall be provided. Only in special cases, local headroom of 1800 mm may be allowed (i.e. at intersection with structural members etc.). (viii) Cat ladders shall be provided for access, wherever provision of staircase is impractical due to limitations of space, or the access is required very infrequently. (ix) Wherever the height of cat ladder exceeds 4.0 m, safety cage shall be provided. Intermediate landing shall be provided to cat ladders such that vertical height of single rise does not exceed 8.0 m. (x) Cat ladders shall be designed with following provisions: i. Width of rung = 500 mm ii. Minimum rise of rung = 250 mm; Maximum rise of rung = 300 mm iii. Minimum clearance from rung of ladder to back of cage (in case of caged ladders) = 700 mm iv. Minimum clearance from the centre of cage all round = 350 mm v. Slope of cat-ladders: I. For normal cat-ladders, slope shall be within the range of 75-90 with the horizontal. II. For ship-type ladders (i.e cat-ladders with short side handrails) the slope shall be within the range of 65-75 with the horizontal. (xi) All walkways, platforms and stairs shall be provided with safety handrails. All handrails shall be constructed with steel tubes / angles for posts, top and middle rail and plates/sheets for toe plates. In case of stairs, the toe guards need not be provided. (xii) The vertical height of hand-railings on walkways and stairs shall be minimum 1000 mm above floor level. (xiii) Hand-railing along edge of roof and gutters shall have a minimum height of 600 mm over top edge of gutters/sheets. In such hand railings toe guards need not be provided. (Only top handrail and midrail shall be provided). 18.3 ADDITIONAL DESIGN CRITERIA a) b) Design of steel structures shall be done in accordance with IS:800-1984. In absence of specified dynamic factor to be considered for the load from the belt conveyor, a dynamic factor of not less than 1.3 shall be considered for the design of floor beams and gallery girders. Gallery trusses and stringers as well as floor beams of junction house shall be checked for obviating occurrence of resonance and shall be designed such that the ratio of applied frequency to natural frequency shall not lie within the range 0.7 to 1.5. As far as possible gallery structure shall be made independent of junction houses. A trestle shall be planned close to the junction house to avoid gallery span resting on the junction house. The contractor after the award of work shall submit design criteria to owner / consultant for approval before submission of design drawings.
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c)
d)
e)
f)
The design drawings shall be submitted in complete for a unit along with design calculations both in hard copy and soft copy. Design shall be done using STAAD.
g) The effective ratio of utility of all main sections shall be limited to 0.85 h) Structural schematic general arrangement with plans at various levels, elevations along each row and axes, sections, considered loads and load diagrams with location etc. and Structural design drawings with BOQ and Table of members containing design forces shall be submitted for Owners/Consultants approval. However the approval shall be limited to checking of overall dimensions, general stability of system, effective load transfer and deflection limits etc. The approval shall not relieve the contractor of his responsibility of correctness in design, adequacy of connections, accuracy etc. i) Submission of Stability certificate for all the steel structures is under the scope of the contractor. 18.4 Description of loads and loading codes a) b) c) d) e) Unless specified otherwise hereinafter, all the live loads shall be considered in accordance with IS: 875 (Part-2) -1987. Wind loads shall be considered in accordance with IS: 875 (Part-3)-1987. Seismic loads shall be considered in accordance with IS:1893(part1)-2002 and 1893(part 4)2005 Live loads from conveyor on the gallery floor shall be as per conveyor suppliers load data. While designing the fixed support/rigid trestles in an expansion block of conveyor gallery the following loads (in addition to wind load) shall be considered. (i) Forces due to difference in frictional resistance of top and return idle rollers of conveyor. (ii) Forces due to inertia of rollers at the time of starting of conveyor belt. (iii) Break down load caused by snapping of belt (in case of multiple conveyors, snapping of one belt at a time) shall be considered. (iv) Special loads if any Gallery girders and floor shall be designed for the following live loads,inclusive of spillage loads on floors. i) Walkway/Supporting beams for floor - 4.0 KN/m ii Under the conveyor belt - 0.75 KN/m iii) Gallery girder, for floor load of - 3.0 KN/m Dust load on roof of junction house and conveyor galleries shall be considered as follows: i. For building and structures located at a distance of 300m from the dust producing units - 0.5 KN/m ii. At a distance of 300 m to 800 m from the dust producing unit - 0.25 KN/m As per technological requirements, provision of supporting the following, and load arising thereof shall be considered in the design of conveyor gallery.
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f)
g)
h)
i)
i) Ventilation duct. ii) Electrical cables/cable racks. iii) Fire Fighting equipment. Junction house floors shall be designed for the following loads: i) Live load on floor - 5.0 KN/m ii) Tension from conveyor belt ii) Load due to equipment located on floor. iv) Load due to jamming of chutes. v) Erection loads anywhere on the floor. Combination of loads The various loads specified shall be combined in accordance with clause 8.0 of IS: 875 (Part5)-1987 to give the most severe loading condition for design of structures.
j)
k)
Stress enhancements Permissible limits of stress may be increased, wherever permissible, in accordance with IS:800-1984.
18.5
Limiting deflection a. b.
i) ii) iii)
The deflection shall be limited in various elements of structures in accordance with clause 3.13 IS: 800-1984. In addition following limitation in deflection shall be observed in design:
Gallery Trusses Top of End portal of gallery truss Traverse deflection of top of Trestle Span / 400 H / 325 where H =Height of portal above beams H/1000 where H = Height of trestle above foundation
18.6
FABRICATION OF STEEL STRUCTURES
18.6.1 Drawings The Contractor shall prepare fabrication drawings, erection drawings, bill of materials, drawing office despatch lists / shipping documents, schedule of bolts and nuts and as built drawings. All drawing work shall be in metric system and all writing work shall be in English. The work shall be carried out as described in General Technical Specifications for structural works. 18.6.2 Material of Construction 18.6.2.1All steel and other materials used for steelwork and in association with steelwork shall conform to appropriate Indian standards. Only tested materials shall be used unless written authority is obtained for the use of untested materials for certain secondary structural members.
Unless otherwise specified in the drawings i. ii. iii. All rolled sections and plates upto 20 mm thk. Shall conform to Grade-E250 & quality A of IS: 2062-2006 and shall generally be of tested quality. Plates above 20 mm thk. and plated structures subjected to dynamic loading shall conform to Grade-E 250 & quality B as per IS: 2062-2006. For High Tensile steel requirements, material conforming to IS: 8500 or SAIL- MA (HYA or HYB) shall be used.
18.6.2.2 18.6.2.3 18.6.2.4
Steel sheets shall conform to IS: 1079. Steel tubes for structural purpose shall conform to IS: 1161 (of Grade Yst 240) Corrugated Galvanised Sheets shall conform to IS: 277 with appropriate Zinc coating for the selected thickness of sheet on roof and sides. (1.0mm thk for roof and 0.8mm thk for sides) Aluminium industrial troughed sheets conforming to IS: 1254 shall be used as follows: i) On roof - 0.91mm thick ii) On side walls - 0.71mm thick Translucent sheets shall be fibre glass reinforced polyester sheets of matching profile as per IS: 12866. Colour coated sheets shall be as per appropriate standard. Gutters shall be of copper bearing steel conforming to Grade "A" as per IS:2062. Rails shall conform to IS: 3443.
18.6.2.5 18.6.2.6
18.6.2.7 18.6.2.8 18.6.2.9
18.6.2.10 All black bolts, nuts and locknuts shall conform to IS: 1363 and IS: 1364 (for precision and semi precision hexagonal bolts) of property class 6.4unless otherwise specified. Washers shall conform to IS: 6610 18.6.2.11 All tapered washer shall be as per IS: 5372 for channels, and IS: 5374 for Joists. Spring washers shall conform to IS: 3063. 18.6.2.12 All HSFG bolts shall conform to IS: 3757. Assembly of joints using HSFG bolts shall conform to IS: 4000. Nuts and washers for HSFG bolts shall be as per IS: 6623 & IS:6649 respectively. 18.6.2.13 Covered electrodes for arc welding shall conform to IS:8142004. Electrode to be used for submerged arc welding shall conform specification IS: 7280-1974. Alternatively Covered electrodes for arc welding shall confirm to AWS Specifications and shall be as follows. - E 6013 for all fillet welds of IS 2062 steel dr E250 , quality A & B - E 7018 for all fillet welds of SAIL-MA 350 HYA steel - E 7018 for all but welds including site welds irrespective of the quality of steel.Viz. IS 2062 gr E250 , quality A , B or SAILMA-350 HYA steel.
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18.6.2.14
Certified mill test reports of materials used in the work shall be made available for inspection by the Owner / Consultant upon request. Fabrication
18.6.3
18.6.3.1 Fabrication of all structural steelwork shall be in accordance with IS:800 or their equivalent foreign national standard of the country of origin of supply unless otherwise specified, and in conformity with various clauses of the Technical Specification. 18.6.3.2 Wherever practicable and wherever perfect matching of parts is required at site, members shall be shop assembled before despatch to minimise site work. Parts not completely assembled in the shop shall be secured, to the extent possible, to prevent damage during despatch. 18.6.3.3 ERECTION OF STEEL STRUCTURES 18.6.3.3.1 Scope The scope of work under erection includes in addition to provision of erection and transport equipments, tools and tackles, consumables, materials, labour and supervision, the following: a) Storing and stacking at site of erection of all fabricated structural components/ units/assemblies till the time of erection. b) Transportation of structures at site. c) Receiving at site of structures including site handling /movement, unloading, storing and stacking at site of erection of technological structures such as bunkers and the related structures d) All minor rectification / modification such as : i) Removal of bends, kinks, twists, etc. for parts damaged during transportation and handling; ii) Cutting chipping, filing, grinding, etc., if required, for preparation and finishing of site connections; iii) Reaming for use of next higher size bolt for holes which do not register or which are damaged. iv) Welding of connections in place of bolting for which holes are either not drilled at all or wrongly drilled during fabrication. e) Other rectification work such as i) Re-fabrication of parts, damaged beyond repair during transportation and handling or incorrectly fabricated. ii) Fabrication of parts omitted during fabrication by oversight or subsequently found necessary. iii) Plug-welding and re-drilling of holes which do not register and which cannot be reamed for use of next higher size bolt. f) Fabrication of minor items/missing items or such important items as directed by the Owner / Consultant. g) Assembly at site of steel structural components wherever required including temporary supports and staging.
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h)
i) j) k) l) m) n) o)
Making arrangements for and providing all facilities for conducting ultrasonic X-ray or gamma ray tests on welds; getting the tests conducted by reputed testing laboratories, making available test films/ graphs,reports and interpretation. Rectifying at site, damaged portions of shop primer by cleaning and touchup paint. Erection of structures including making connections by bolts/high strength friction grip bolts / welding. Alignment of all structures true to line, level plumb and dimensions within specified limits of tolerances as per IS :12843 Tolerance for Erection of Steel Structures. Application of second coat of primer paint and two coats of finishing paint at site after erection. Grouting of all column bases after proper alignment of columns and only after obtaining clearance from Owner / Consultant. Conducting preliminary acceptance and final acceptance tests. Preparation of as built drawings, preparing of sketches/drawings to suit field engineering decisions, availability of material, convenience of fabrication, transportation and erection and changes during fabrication and erection. All such works are subject to approval by the Owner / Consultant.
18.6.4 PAINTING OF BUILDING STEEL STRUCTURES 18.6.4.1All steel structural work shall be painted as follows unless otherwise stated in the drawing / Technical Specification. 18.6.4.2 Surface preparation The steel surface which is to be painted shall be cleaned of dirt and grease, and the heavier layers of rust shall be removed by chipping prior to actual surface preparation to a specified grade. Following are the type and standards of surface preparation to be followed based on the requirement of a particular painting system or as specified in the design drawings. Manual/Power tool cleaning :- Manual/Power tool cleaning shall be done as per Grade St-2 or St-3 of Swedish Standard Institution SIS 05 5900 or cl.6.2.1.1 & 6.2.1.2 of IS : 1477 - 1987 (Part - 1). Grade St-2 :- Thorough scraping and wire brushing, machine brushing, grinding etc. This grade of preparation shall remove loose mill scale, rust cleaner or with clean compressed air or clean brush. After preparation, the surface should have a faint metallic sheen. The appearance shall correspond to the prints designated St-2. If no grade of surface preparation is specified, St-2 grade of preparation as per Swedish Standard shall be followed. 18.6.4.3 Paint System (i) Surface preparation :- St-2 (ii) Primer paint:- Two coats of zinc phosphate in phenolic alkyd medium (35microns/coat). (iii) Finishing paint:- Two coats of synthetic enamel (25 microns/coat) conforming to IS : 2932 - 1974.
All paints shall be of approved and shade as per Purchaser / Consultant's requirements. 18.6.4.4 Paint and Painting Manufacture of paints, mixing of paints, etc. shall be generally according to the relevant IS codes of practice. Generally compatibility between primer intermediate and finishing paint shall be certified by the paint manufacturer supplying the paints. Guarantee period shall commerce from the date of completion of finishing coat of paint on entire structures. The guarantee period shall be indicated depending on the type of surface preparation and system of painting. To fulfill this obligations, the Contractor may obtain from the painting manufacturer, guarantee for the performance of paint/painted surfaces. Application of paint shall be by spraying or brushing as per IS : 486-1983 and IS : 487-1985 and in uniform layers of 50% overlapping strokes by skilled painters. Painting shall not be done when the temperature is less than 5 degree C or more than 45 degree C and relative humidity is more than 85% unless manufacturer's recommendations permit. Also painting shall not be done in foggy weather. During application, paint agitation must be provided where such agitation is recommended by the manufacturer. Painting shall be applied at painting manufacturer's recommended rates. The number of coats shall be such that minimum dry film thickness specified is achieved. The dry film thickness (DFT) of painted surfaces shall be checked with ELCOMETER or measuring gauges to ensure specified DFT. All structures shall receive one coats of primer paint at shop after fabrication before despatch after surface preparation has been done as per requirements. Unless otherwise specified all structures after erection shall be given one coat of primer and two coats of finishing paint of approved colour and quality. The under coat shall have different tint to distinguish the same from the finishing coat. The proposed make, quality and shade of paint shall have the approval of Purchaser / Consultant.
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SECTION 5
1.0 INTRODUCTION This part covers technical requirements which will form an integral part of the Contract. The following provisions shall supplement all the detailed technical requirements brought out in the Technical Specifications and the Technical Data Sheets. 2.0 BRAND NAME Whenever a material or article is specified or described by the name of a particular brand, manufacturer or vendor, the specific item mentioned shall be understood to be indicative of the function and quality desired, and not restrictive; other manufacturer's products may be considered provided sufficient information is furnished to enable the Employer to determine that the products proposed are equivalent to those named. 3.0 3.1 COMPLETENESS OF FACILITIES Contractors may note that this is a contract inclusive of the scope as indicated elsewhere in the specification. Each of the plant shall be engineered and designed in accordance with the specification requirement. All engineering and associated services are required to ensure that a completely engineered plant is provided. All equipments furnished by the Contractor shall be complete in every respect, with all mountings, fittings, fixtures and standard accessories normally provided with such equipment and/or those needed for erection, completion and safe operation & maintenance of the equipment and for the safety of the operating personnel, as required by applicable codes, though they may not have been specifically detailed in the respective specifications, unless included in the list of exclusions. All similar standard components/ parts of similar standard equipment provided, shall be interchangeable with one another. CODES & STANDARDS In addition to the codes and standards specifically mentioned in the relevant technical specifications for the equipment / plant / system, all equipment parts, systems and works covered under this specification shall comply with all currently applicable statutory regulations and safety codes, including the following: a. Bureau of Indian Standards (BIS) b. Indian electricity act c. Indian electricity rules
3.2
4.0 4.1
Technical Specifications: General Technical Requirements
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d. Indian Explosives Act e. Indian Factories Act and State Factories Act f. Indian Boiler Regulations (IBR) g. Regulations of the Central Pollution Control Board, India h. Regulations of the Ministry of Environment & Forest (MoEF), Government of India i. Pollution Control Regulations of Department of Environment, Government of India j. State Pollution Control Board. k. Rules for Electrical installation by Tariff Advisory Committee (TAC). l. Guideline for wagon tippler G33 Rev.01 of May 2010. m. Any other statutory codes / standards / regulations, as may be applicable. 4.2 Unless covered otherwise by Indian codes & standards and in case nothing to the contrary is specifically mentioned elsewhere in the specifications, the latest editions (as applicable as on date of bid opening), of the codes and standards given below shall also apply: (a.) Japanese Industrial Standards (JIS) (b.) American National Standards Institute (ANSI) (c.) American Society of Testing and Materials (ASTM) (d.) American Society of Mechanical Engineers (ASME) (e.) American Petroleum Institute (API) (f.) Standards of the Hydraulic Institute, U.S.A. (g.) International Organisation for Standardization (ISO) (h.) Tubular Exchanger Manufacturer's Association (TEMA) (i.) American Welding Society (AWS) (j.) National Electrical Manufacturers Association (NEMA) (k.) National Fire Protection Association (NFPA) (l.) International Electro-Technical Commission (IEC) (m.) Expansion Joint Manufacturers Association (EJMA) (n.) Heat Exchange Institute (HEI) In the event of any conflict between the codes and standards referred to in the above clauses and the requirement of this specification, the requirement of Technical Specification shall govern. In case of any change in codes, standards & regulations between the date of bid opening and the date when vendors proceed with fabrication, the Employer shall have the option to incorporate the changed requirements or to retain the original standard. It shall be the responsibility of the Contractor to bring to the notice of the Employer such changes and advise Employer of the resulting effect. EQUIPMENT FUNCTIONAL GUARANTEE The functional guarantees of the equipment and the system under the scope of the Contract is given elsewhere in the technical specification. These guarantees shall supplement the general provisions covered under General Conditions of Contract.
4.3
4.4
4.5
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4.6 4.6.1
DESIGN OF FACILITIES/ MAINTENANCE & AVAILABILITY CONSIDERATIONS Design of Facilities All the design procedures, systems and components proposed shall have already been adequately developed and shall have demonstrated good reliability under similar conditions elsewhere. The Contractor shall be responsible for the selection and design of appropriate equipments to provide the best co-ordinated performance of the entire system. The basic requirements are detailed out in various clauses of the Technical Specifications. The design of various components, assemblies and subassemblies shall be done so that it facilitates easy field assembly and dismantling. All the rotating components shall be so selected that the natural frequency of the complete unit is not critical or close to the operating range of the unit.
4.7 4.7.1
DOCUMENTS, DATA AND DRAWINGS TO BE FURNISHED BY CONTRACTOR Contractors may note that this is a contract inclusive of the scope as indicated elsewhere in the specification. Each of the plant and equipment shall be fully integrated, engineered and designed to perform in accordance with the technical specification. All engineering and technical services required ensuring a completely engineered plant shall be provided in respect of mechanical, electrical, control & instrumentation, civil & structural works as per the scope. The Contractor shall furnish engineering data/drgs. in accordance with the schedule of information as specified in Technical Specification and data sheet. The number of copies/prints/flopy discs/CD-ROMs/manuals to be furnished for various types of documents is given in Annexure-A. Distribution schedule shall be informed to successful Contractor. The documentation that shall be provided by the Contractor is indicated in the various sections of specification. This documentation shall include but not be limited to the following : INSTRUCTION MANUALS The Contractor shall submit to the Employer, Instruction Manuals for all the equipments covered under the Contract. The Instruction manuals shall contain full details required for erection, commissioning, operation and maintenance of each equipment. The manual shall be specifically compiled for this project. The Instruction Manuals shall comprise of the following.
4.7.2
4.7.3
4.8
4.8.1
Erection Manuals The erection manuals shall be submitted prior to the commencement of erection activities of particular equipment/system. The erection manual should contain the following as a minimum. a) Erection strategy.
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b) Sequence of erection. c) Erection instructions. d) Critical checks and permissible deviation/tolerances. e) List of tool, tackles, heavy equipments like cranes, dozers, etc. f) Bill of Materials g) Procedure for erection. h) General safety procedures to followed during erection/installation. i) Procedure for initial checking after erection. j) Procedure for testing and acceptance norms. k) Procedure / Check list for pre-commissioning activities. l) Procedure / Check list for commissioning of the system. m) Safety precautions to be followed in electrical supply distribution during erection 4.8.2 Operation & Maintenance Manuals i. The operating and maintenance instructions together with drawings (other than shop drawings) of the equipment, as completed, shall be in sufficient detail to enable the Employer to operate, maintain, dismantle, reassemble and adjust all parts of the equipment. They shall give a step by step procedure for all operations likely to be carried out during the life of the plant / equipment including, operation, maintenance, dismantling and repair including periodical activities wherever required. Each manual shall also include a complete set of drawings of the equipment. ii. If after the commissioning and initial operation of the plant, the manuals require any modification / additions / changes, the same shall be incorporated and the updated final instruction manuals shall be submitted to the Employer for records. iii. A separate section of the manual shall be for each size/ type of equipment and shall contain a detailed description of construction and operation, together with all relevant pamphlets and drawings. iv. The manuals shall include the following : a) List of spare parts along with their drawing and catalogues and procedure for ordering spares. b) Lubrication Schedule including charts showing lubrication checking, testing and replacement procedure to be carried daily, weekly, monthly & at longer intervals to ensure trouble free operation. c) Where applicable, fault location charts shall be included to facilitate finding the cause of mal-operation or break down. v. Detailed specifications for all the consumables including lubricant oils, greases, chemicals etc. system/equipment/assembly/subassembly - wise required for the complete plant.
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vi. On completion of erection, a complete list of bearings / equipment giving their location, and identification marks etc. shall also be furnished to the Employer indicating lubrication method for each type/category of bearing. 4.8.3 Project Completion Report The Contractor shall submit a Project Completion Report at the time of handing over the plant. 4.8.4 DRAWINGS (a.) All documents submitted by the Contractor for Employer's review shall be in electronic form (soft copies) along with the number of hard copies. The soft copies to be supplied shall be either in CDs, or through direct transfer via E-mail, etc. depending upon the nature/volume/size of the document. The drawings submitted for approval could be in the Image form. (b.) Final copies of the approved drawings shall be submitted in vector form on CDROM along with the requisite number of hard copies. (c.) All documents/text information shall be in latest version of MS Office. (d.) All drawings submitted by the Contractor including those submitted at the time of bid shall be in sufficient detail indicating the type, size, arrangement, weight of each component for packing and shipment, the external connection, fixing arrangement required, the dimensions required for installation and interconnections with other equipments and materials, clearance and spaces required between various portions of equipment and any other information specifically requested in the drawing schedules. (e.) Each drawing submitted by the Contractor (including those of sub-vendors) shall bear a title block at the right hand bottom corner with clear mention of the name of the Employer, the system designation, the specifications title, the specification number, the name of the Project, drawing number and revisions. If standard catalogue pages are submitted the applicable items shall be indicated therein. All titles, notings, markings and writings on the drawing shall be in English. All the dimensions should be in metric units. (f.) The drawings submitted by the Contractor (or their sub-vendors) shall bear Employers drawing number in addition to contractors (their sub-vendors) own drawing number. Employers drawing numbering system shall be made available to the successful Contractor so as to enable him to assign Employers drawing numbers to the drawings to be submitted by him during the course of execution of the Contract. (g.) The Contractor shall also furnish a Master Drawing List which shall be a comprehensive list of all drawings/ documents/ calculations envisaged to be furnished by him during the detailed engineering to the Employer in line with engineering information flow schedule (to be tied up with successful Contractor). Such list should clearly indicate the purpose of submission of these drawings i.e. FOR APPROVAL or FOR INFORMATION ONLY.
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(h.) Similarly, all the drawings/ documents submitted by the Contractor during detailed engineering stage shall be stamped FOR APPROVAL or FOR INFORMATION prior to submission. (i.) The furnishing of detailed engineering data and drawings by the Contractor shall be in accordance with the time schedule for the project. The review of these documents/ data/ drawings by the Employer will cover only general conformance of the data/ drawings/ documents to the specifications and contract, interfaces with the equipments provided by others and external connections & dimensions which might affect plant layout. The review by the Employer should not be construed to be a thorough review of all dimensions, quantities and details of the equipments, materials, any devices or items indicated or the accuracy of the information submitted. The review and/ or approval by the Employer / Project Manager shall not relieve the Contractor of any of his responsibilities and liabilities under this contract. (j.) After the approval of the drawings, further work by the Contractor shall be in strict accordance with these approved drawings and no deviation shall be permitted without the written approval of the Employer. (k.) All manufacturing, fabrication and execution of work in connection with the equipment / system, prior to the approval of the drawings, shall be at the Contractors risk. The Contractor is expected not to make any changes in the design of the equipment /system, once they are approved by the Employer. However, if some changes are necessitated in the design of the equipment/ system at a later date, the Contractor may do so, but such changes shall promptly be brought to the notice of the Employer indicating the reasons for the change and get the revised drawing approved again in strict conformance to the provisions of the Technical Specification. (l.) Drawings shall include all installations and detailed piping and wiring drawings. (m.) Assessing & anticipating the requirement and supply of all piping and equipment shall be done by the contractor well in advance so as not to hinder the progress of piping & equipment erection, subsequent system charging and its effective draining & venting arrangement as per site suitability. (n.) Any software used by the contractor shall be given to the project manager and concerned engineer of employer. The contractor shall make the engineer of the employer aware of the programme. Any computer aided programme shall be approved subject to giving entire detail to the project manager. (o.) Drawings must be checked by the Contractor in terms of its completeness, data adequacy and relevance with respect to Engineering schedule prior to submission to the Employer. In case drawings are found to be submitted without proper endorsement for checking by the Contractor, the same shall not be reviewed and returned to the Contractor for re-
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submission. The contractor shall make a visit to site to see the existing facilities and understand the layout completely and collect all necessary data / drawings at site which are needed as an input to the engineering. The contractor shall do the complete engineering including interfacing and integration of all his equipment, systems & facilities within his scope of work as well as interface engineering & integration of systems, facilities, equipment & works under Employers scope and submit all necessary drawings/ documents for the same. (p.) All drawings shall be reviewed and approved by Engineering coordinator, including the following drawings / data which require specific approval. 1. Data sheets for various equipments / systems. 2. Field testing procedures for various equipment and piping system. 3. Pre commissioning / commissioning procedures including flushing, Chemical cleaning, steam blowing and hydro test etc. (Wherever applicable) O&M manual shall also be reviewed and approved by Employer. The content of O&M manual shall be as specified elsewhere in the specification. 4. Guarantee test procedures. 5. Any other drawings that may be required by the Engineer from time to time.) 6. Data furnished in the bid shall be binding on the contractor even if superior to the technical specification requirement and any revision shall be done with the owners agreement. (q.) The Contractor shall submit adequate prints of drawing / data / document for Employers review and approval. The Employer shall review the drawings and return one (1) copy to the Contractor authorizing either to proceed with manufacture or fabrication, or marked to show changes desired. When changes are required, drawings shall be re-submitted promptly, with revisions clearly marked, for final review. Any delays arising out of the failure of the Contractor to submit/rectify and resubmit in time shall not be accepted as a reason for delay in the contract schedule (r.) Upon review of each drawing, depending on the correctness and completeness of the drawing, the same will be categorised and approval accorded in one of the following categories : CATEGORY I Approved CATEGORY II Approved subject to incorporation of comments/ modification as noted. Resubmit revised drawing incorporating the Comments CATEGORY III Not approved. Resubmit revised drawings for approval after incorporating comments/modification as noted. CATEGORY IV For information and records. (s.) Vendor shall resubmit the drawings approved under Category II and III within three (3) weeks of receipt of comments on the drawings, incorporating all comments. Every revision of the drawing shall bear a revision index wherein such revisions shall be highlighted in the
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form of description or marked up in the drawing identifying the same with relevant revision Number enclosed in a triangle (eg. 1, 2, 3 etc). In case Vendor does not agree with any specific comment, he shall furnish the explanation for the same to owner / consultant for consideration. In all such cases vendor shall necessarily enclose explanations along with the revised drawing (taking care of balance comments) to avoid any delay and/or duplication in review work. It is responsibility of the Vendor to get all the drawings approved in the Category I & IV (as the case may be) and complete engineering activities within the agreed schedule. Any delay arising out of submission and modification of drawings shall not alter the contract completion schedule. Vendor shall not make any changes in the portions of the drawing other than those commented upon. If changes are required to be made in the portions already approved, the vendor shall resubmit the drawing identifying the changes for owners review and approval. (t.) If Vendor fails to resubmit the drawings as per the schedule, construction work at site will not be held up and work will be carried out on the basis of comments furnished on previous issues of the drawing. These comments will be taken care by the contractor while submitting the revised drawing. (u.) All engineering data submitted by the Contractor after final process including review and approval by the Project Manager/ Employer shall form part of the contract documents and the entire works covered under these specification shall be performed in strict conformity with technical specifications unless otherwise expressly requested by the Project Manager in writing. (v.) After final acceptance of individual equipment / system by the Employer, the Contractor will update all original drawings and documents for the equipment / system to as built conditions. 4.8.5 ENGINEERING INFORMATION SUBMISSION SCHEDULE Prior to the award of Contract, a Detailed Engineering Information Submission Schedule shall be tied up with the Employer. For this, the Contractor shall furnish a detailed list of engineering information along with the proposed submission schedule. This list would be a comprehensive one including all engineering data / drawings / information for all bought out items and manufactured items. The information shall be categorised into the following parts. Information that shall be submitted for the approval of the Employer before proceeding further, and Information that would be submitted for Employers information only. The Engineering Information Schedule shall be updated month wise. The schedule should allow adequate time for proper review and incorporation of changes/ modifications, if any, to meet the contract
without affecting the equipment delivery schedule and overall project schedule. The early submission of drawings and data is as important as the manufacture and delivery of equipment and hardware and this shall be duly considered while determining the overall performance and progress. 4.9 ENGINEERING COORDINATION PROCEDURE Identification of Principal Engineering Coordinators The following principal coordinators will be identified by respective organisations at time of award of contract EMPLOYERS COORDINATORS NALCO- Engineering Coordinators (NALCO EC) Name : Designation : Address : a) Postal : b) Telegraphic : TELEX : FAX : TELEPHONE : NALCO- SITE CO-ORDINATOR (NALCO SC) Name : Designation : Address : a) Postal : b) Telegraphic : TELEX : FAX : TELEPHONE : VENDOR ENGINEERING CO-ORDINATOR (VENDOR EC) Name : Designation : Address : a) Postal : b) Telegraphic : TELEX : FAX : TELEPHONE : All engineering correspondence shall be in the name of above coordinators on behalf of the respective organisations.
4.9.1
4.9.2
4.9.3 Vendors Drawings (a) The contractor shall furnish, discuss and finalise with the Employer, the engineering information flow schedule at the time of award of the contract. The dates for submission of drawings as
finalised in the above engineering schedule, shall be strictly adhered to. This is essential for the timely completion of the project. (b) A detailed drive list shall be furnished along with the tender. Further drive list shall be submitted to the Engineering coordinator within 60 days from the date of award of the contract. (c) In any case, in order to achieve the project completion dates, the contractor must strictly comply with engineering schedules. (d) Final distribution copies of all approved drgs. (in Cat. I & IV) shall be submitted by the contractor to the Engineer within two (2) weeks of the approval. (e) Copies of all approved drgs. (in cat. I & IV) shall be submitted incorporating all site modifications, if any, during construction, erection, commission stages and performance and guarantee testing (till its continuous operation) as As Built Drgs. (f) The contractor shall use a single transmittal for drgs. Submission. This shall include transmittal numbers and date, number of copies being sent, names of the agencies to whom are all the copies being sent drg. numbers and titles, remarks or special notes if any etc. (g) All manufacturing and fabrication work in connection with the equipments prior to the approval of the drg. shall be at contractors risks. (h) Approval of contractors drgs. or work by the Engineer shall not relieve the contractor of any of his responsibilities or liabilities under the contract. 4.9.4 Erection Drawings (a) Contractor shall furnish erection drawings for the guidance of his/ Employers site staff at least 4 weeks before scheduled commencement of erection or the first shipment, whichever is earlier. These shall generally comprise of fabrication/assembly drawings, various component/part details drawings, assembly, clearance, data requirements etc. The drawings shall contain details of components/ equipment with identification numbers, match marks, bills of materials, assembly procedures etc. (b) For all major equipment apart from above details, assembly sequence and instructions with check lists shall be furnished in the form of erection manuals CLAUSE NO. 4.9.5 ENGINEERING PROGRESS AND EXCEPTION REPORT A report giving the status of each engineering information including the list of drawings/engineering information which remains unapproved for more than four (4) weeks after the date of first submission Drawings which were not submitted as per agreed schedule.
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4.9.6
TECHNICAL CO-ORDINATION MEETING (a) The Contractor shall be called upon to organise and attend monthly Design/ Technical Coordination Meetings (TCMs) with the owner/owners representatives and other Contractors of the Employer during the period of contract. The Contractor shall attend such meetings at his own cost as and when required and fully co-operate with such persons and agencies involved during the discussions. (b) The Contractor should note that Time is the essence of the contract. In order to expedite the early completion of engineering activities, the Contractor shall submit all drawings as per the agreed Engineering Information Submission Schedule. The drawings submitted by the Contractor will be reviewed by the Employer as far as practicable within three (3) weeks from the date of receipt of the drawing .The comments of the Employer shall then be discussed across the table during the above Technical Co-ordination Meeting (s) wherein best efforts shall be made by both sides to ensure the approval of the drawing. (c) The Contractor shall ensure availability of the concerned experts / consultants/ personnel who are empowered to take necessary decisions during these meetings. (d) Should any drawing remain unapproved for more than six (6) weeks after its first submission, this shall be brought out in the monthly Engineering Progress and Exception Report with reasons thereof. (e) Any delays arising out of failure by the Contractor to incorporate Employers comments and resubmit the same during the TCM shall be considered as a default and in no case shall entitle the Contractor to alter the Contract completion date.
4.9.7 DESIGN IMPROVEMENTS The Employer or the Contractor may propose changes in the specification of the equipment or quality thereof and if the parties agree upon any such changes the specification shall be modified accordingly. If any such agreed upon change is such that it affects the price and schedule of completion, the parties shall agree in writing as to the extent of any changing the price and/or schedule of completion before the Contractor proceeds with the change. Following such agreement, the provision thereof, shall be deemed to have been amended accordingly. 4.9.8 EQUIPMENT BASES A cast iron or welded steel base plate shall be provided for all rotating equipment which is to be installed on a concrete base, unless otherwise specifically agreed to by the Employer. Each base plate which support the unit and its drive assembly, shall be of a neat design with pads for anchoring the units.
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4.9.9
PROTECTIVE GUARDS Suitable guards shall be provided for protection of personnel on all exposed rotating and/or moving machine parts. All such guards shall be designed for easy installation and removal for maintenance purpose.
4.9.10 LUBRICANTS, SERVO FLUIDS AND CHEMICALS (a) The Contractors scope includes all the first fill of consumables such as oils, lubricants including grease, servo fluids, gases and essential chemicals etc. Consumption of all these consumables during the initial operation and final filling after the initial operation shall also be included in the scope of the Contractor. (b) The variety of lubricants shall be kept to a minimum possible. Detailed specifications for the lubricating oil, grease, gases, servo fluids, control fluids, chemicals etc. required for the complete plant covered herein shall be furnished. On completion of erection, a complete list of bearings/ equipment giving their location and identification marks shall be furnished to the Employer along with lubrication requirements. 4.9.11 Lubrication Equipment shall be lubricated by systems designed for continuous operation. Lubricant level indicators shall be furnished and marked to indicate proper levels under both standstill and operating conditions. 4.9.12 Material of Construction All materials used for the construction of the equipment shall be new and shall be in accordance with the requirements of this specification. Materials utilised for various components shall be those which have established themselves for use in such applications. 4.9.13 RATING PLATES, NAME PLATES & LABELS Each main and auxiliary item of plant including instruments shall have permanently attached to it in a conspicuous position, a rating plate of non-corrosive material upon which shall be engraved manufacturers name, equipment, type or serial number together with details of the ratings, service conditions under which the item of plant in question has been designed to operate. Each item of plant shall be provided with nameplate or label designating the service of the particular equipment. Such nameplates or labels shall be of white non hygroscopic material with engraved black lettering or alternately, in the case of indoor circuit breakers, starters, etc. of transparent plastic material with suitably coloured lettering engraved on the back. The name plates shall be suitably fixed on both front and rear sides.
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Items of plant such as valves, which are subject to handling, shall be provided with an engraved chromium plated nameplate or label with engraving filled with enamel.. All segregated phases of conductors or bus ducts, indoor or outdoor, shall be provided with coloured phase plates to clearly identify the phase of the system 4.9.14 TOOLS AND TACKLES The Contractor shall supply with the equipment one complete set of all special tools and tackles and other instruments required for the erection, assembly, disassembly and proper maintenance of the plant and equipment and systems (including software). These special tools will also include special material handling equipment, jigs and fixtures for maintenance and calibration / readjustment, checking and measurement aids etc. A list of such tools and tackles shall be submitted by the Contractor alongwith the offer. The price of each tool / tackle shall be deemed to have been included in the total bid price. These tools and tackles shall be separately packed and sent to site. The Contractor shall also ensure that these tools and tackles are not used by him during erection, commissioning and initial operation. For this period the Contractor should bring his own tools and tackles. All the tools and tackles shall be of reputed make acceptable to the Employer. 4.9.15 Welding If the manufacturer has special requirements relating to the welding procedures for welds at the terminals of the equipments to be per formed by others the requirements shall be submitted to the Employer in advance of commencement of erection work. 4.9.16 COLOUR CODE FOR ALL EQUIPMENTS/ SERVICES All equipment/ services are to be painted by the Contractor in accordance with Employers standard colour coding scheme, which will be furnished to the Contractor during detailed engineering stage. 4.10 PROTECTION AND PRESERVATIVE SHOP COATING
4.10.1 PROTECTION All coated surfaces shall be protected against abrasion, impact, discoloration and any other damages. All exposed threaded portions shall be suitably protected with either metallic or a nonmetallic protection device. All ends of all valves and pipings and conduit equipment connections shall be properly sealed with suitable devices to protect them from damage. The parts which are likely to get rusted, due to exposure to weather, should also be properly treated and protected in a suitable manner. All primers/paints/coatings shall take into account the hot humid, corrosive & alkaline, subsoil or over ground environment as the case may be.
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4.10.2 Preservative Shop Coating All exposed metallic surfaces subject to corrosion shall be protected by shop application of suitable coatings. All surfaces which will not be easily accessible after the shop assembly, shall be treated beforehand and protected for the life of the equipment. All surfaces shall be thoroughly cleaned of all mill scales, oxides and other coatings and prepared in the shop. The surfaces that are to be finish-painted after installation or require corrosion protection until installation, shall be shop painted with atleast two coats of primer. Transformers and other electrical equipments if included shall be shop finished with one or more coats of primer and two coats of high grade resistance enamel. The finished colors shall be as per manufacturers standards, to be selected and specified by the Employer at a later date. Shop primer for all steel surfaces which will be exposed to operating temperature below 95 degrees Celsius shall be selected by the Contractor after obtaining specific approval of the Employer regarding the quality of primer proposed to be applied. Special high temperature primer shall be used on surfaces exposed to temperature higher than 95 degrees Celsius and such primer shall also be subject to the approval of the Employer. All other steel surfaces which are not to be painted shall be coated with suitable rust preventive compound subject to the approval of the Employer. All piping shall be cleaned after shop assembly. Painting for Civil structures shall be done as per relevant part of technical specification 4.11 QUALITY ASSURANCE PROGRAMME The Contractor shall adopt suitable quality assurance programme to ensure that the equipment and services under the scope of contract whether manufactured or performed within the Contractors works or at his sub-contractors premises or at the Employers site or at any other place of work are in accordance with the specifications. Such programmes shall be outlined by the Contractor and shall be finally accepted by the Employer/authorised representative after discussions before the award of the contract. The QA programme shall be generally in line with IS/ISO- 9001.A quality assurance programme of the contractor shall generally cover the following: (a) His organisation structure for the management and implementation of the proposed quality assurance programme (b) Quality System Manual (c) Design Control System (d) Documentation and Data Control System (e) Qualification data for Contractors key personnel.
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(f)
(g) (h) (i) (j) (k) (l) (m) (n) (o) (p)
The procedure for purchase of materials, parts, components and selection of subcontractors services including vendor analysis, source inspection, incoming raw-material inspection, verification of materials purchased etc. System for shop manufacturing and site erection controls including process, fabrication and assembly. Control of non-conforming items and system for corrective actions and resolution of deviations. Inspection and test procedure both for manufacture and field activities. Control of calibration and testing of measuring testing equipment. System for Quality Audits. System for identification and appraisal of inspection status. System for authorising release of manufactured product to the Employer. System for handling, storage and delivery. System for maintenance of records, and Quality plans for manufacturing and field activities detailing out the specific quality control procedure adopted for controlling the quality characteristics relevant to each item of equipment/component.
4.12
GENERAL REQUIREMENTS - QUALITY ASSURANCE
4.12.1 All materials, components and equipment covered under this specification shall be procured, manufactured, erected, commissioned and tested at all the stages, as per a comprehensive Quality Assurance Programme. An indicative programme of inspection/tests to be carried out by the contractor for some of the major items is given in the respective technical specification. This is, however, not intended to form a comprehensive programme as it is the contractors responsibility to draw up and implement such programme duly approved by the Employer. The detailed Quality Plans for manufacturing and field activities shall be drawn up by the Contractor and will be submitted to Employer for approval. Schedule of finalisation of such quality plans will be finalised before award. Monthly progress reports on MQP/FQP submission/approval shall be furnished on enclosed format No. QS-01-QAI-P-02/F1. 4.12.2 Manufacturing Quality Plan will detail out for all the components and equipment, various tests/inspection, to be carried out as per the requirements of this specification and standards mentioned therein and quality practices and procedures followed by Contractors/ Subcontractors/ sub-supplier's Quality Control Organisation, the relevant reference documents and standards, acceptance norms, inspection documents raised etc., during all stages of materials procurement, manufacture, assembly and final testing/performance testing. The Quality Plan shall be submitted on electronic media e.g. floppy or E-mail in addition to hard copy, for review and approval. After approval the same shall be submitted in compiled form on CD-ROM. 4.12.3 Field Quality Plans will detail out for all the equipment, the quality practices and procedures etc. to be followed by the Contractors "Site Quality Control Organisation", during various stages of site activities starting from receipt of materials/equipment at site.
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4.12.4 The Contractor shall also furnish copies of the reference documents/plant standards/acceptance norms/tests and inspection procedure etc., as referred in Quality Plans along with Quality Plans. These Quality Plans and reference documents/standards etc. will be subject to Employers approval without which manufacturer shall not proceed. These approved documents shall form a part of the contract. In these approved Quality Plans, Employer shall identify customer hold points (CHP), i.e. test/checks which shall be carried out in presence of the Employers Project Manager or his authorised representative and beyond which the work will not proceed without consent of Employer in writing. All deviations to this specification, approved quality plans and applicable standards must be documented and referred to Employer along with technical justification for approval and dispositioning. 4.12.5 No material shall be despatched from the manufacturers works before the same is accepted, subsequent to predespatch final inspection including verification of records of all previous tests/inspections by Employers Project Manager/Authorised representative and duly authorised for despatch by issuance of Material Despatch Clearance Certificate (MDCC). 4.12.6 All material used for equipment manufacture including casting and forging etc. shall be of tested quality as per relevant codes/standards. Details of results of the tests conducted to determine the mechanical properties; chemical analysis and details of heat treatment procedure recommended and actually followed shall be recorded on certificates and time temperature chart. Tests shall be carried out as per applicable material standards and/or agreed details. 4.12.7 The contractor shall submit to the Employer Field Welding Schedule for field welding activities in the enclosed format No.: QS-01-QAI-P-02/F3. The field welding schedule shall be submitted to the Employer along with all supporting documents, like welding procedures, heat treatment procedures, NDT procedures etc. at least ninety days before schedule start of erection work at site. 4.12.8 All welding and brazing shall be carried out as per procedure drawn and qualified in accordance with requirements of ASME Section IX/BS-4870 or other International equivalent standard acceptable to the Employer. All welding/brazing procedures shall be submitted to the Employer or its authorized representative for approval prior to carrying out the welding/brazing. 4.12.9 All brazers, welders and welding operators employed on any part of the contract either in Contractors/sub-contractors works or at site or elsewhere shall be qualified as per ASME Section-IX or BS-4871 or other equivalent International Standards acceptable to the Employer. 4.12.10 Welding procedure qualification & Welder qualification test results shall be furnished to the Employer for approval. However, where required by the Employer, tests shall be conducted in presence of Employer/authorised representative. 4.12.11 Unless otherwise proven and specifically agreed with the Employer, welding of dissimilar materials and high alloy materials shall be carried out at shop only.
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4.12.12No welding shall be carried out on cast iron components for repair. 4.12.13 All the heat treatment results shall be recorded on time temperature charts and verified with recommended regimes. 4.12.14 All non-destructive examination shall be performed in accordance with written procedures as per International Standards, The NDT operator shall be qualified as per SNT-TC-IA (of the American Society of non-destructive examination). NDT shall be recorded in a report, which includes details of methods and equipment used, result/evaluation, job data and identification of personnel employed and details of correlation of the test report with the job. All Bar stock / forgings of diameter equal to or greater than 50mm shall be ultrasonically tested. In general all plates of thickness equal to or greater than 40mm and for pressure parts, pates of thickness equal to or greater than 25mm shall be ultrasonically tested unless as specified otherwise in respective equipment specification. 4.12.15The Contractor shall list out all major items/ equipment/ components to be manufactured in house as well as procured from sub-contractors. All the subcontractor proposed by the Contractor for procurement of major bought out items including castings, forging, semi-finished and finished components/equipment etc., list of which shall be drawn up by the Contractor and finalised with the Employer, shall be subject to Employer's approval. The contractors proposal shall include vendors facilities established at the respective works, the process capability, process stabilization, QC systems followed, experience list, etc. along with his own technical evaluation for identified sub-contractors enclosed and shall be submitted to the Employer for approval within the period agreed at the time of pre-awards discussion and identified in "DR" category prior to any procurement. Monthly progress reports on sub-contractor detail submission / approval shall be furnished. Such vendor approval shall not relieve the contractor from any obligation, duty or responsibility under the contract. 4.12.16For components/equipment procured by the contractors for the purpose of the contract, after obtaining the written approval of the Employer, the contractors purchase specifications and inquiries shall call for quality plans to be submitted by the suppliers. The quality plans called for from the sub-contractor shall set out, during the various stages of manufacture and installation, the quality practices and procedures followed by the vendors quality control organisation, the relevant reference documents/standards used, acceptance level, inspection of documentation raised, etc. Such quality plans of the successful vendors shall be finalised with the Employer and such approved Quality Plans shall form a part of the purchase order/contract between the Contractor and sub-contractor. Within three weeks of the release of the purchase orders /contracts for such bought out items /components, a copy of the same without price details but together with the detailed purchase specifications, quality plans and delivery conditions shall be furnished to the Employer on the monthly basis by the Contractor along with a report of the Purchase Order placed so far for the contract. **
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4.12.17Employer reserves the right to carry out quality audit and quality surveillance of the systems and procedures of the Contractors or their sub-contractors quality management and control activities. The contractor shall provide all necessary assistance to enable the Employer carry out such audit and surveillance. 4.12.18The contractor shall carry out an inspection and testing programme during manufacture in his work and that of his sub-contractors and at site to ensure the mechanical accuracy of components, compliance with drawings, conformance to functional and performance requirements, identity and acceptability of all materials parts and equipment. Contractor shall carry out all tests/inspection required to establish that the items/equipment conform to requirements of the specification and the relevant codes/standards specified in the specification, in addition to carrying out tests as per the approved quality plan. 4.12.19Quality audit/surveillance/approval of the results of the tests and inspection will not, however, prejudice the right of the Employer to reject the equipment if it does not comply with the specification when erected or does not give complete satisfaction in service and the above shall in no way limit the liabilities and responsibilities of the Contractor in ensuring complete conformance of the materials/equipment supplied to relevant specification, standard, data sheets, drawings, etc. 4.12.20 For all spares and replacement items, the quality requirements as agreed for the main equipment supply shall be applicable. 4.12.21 Repair/rectification procedures to be adopted to make the job acceptable shall be subject to the approval of the Employer/ authorised representative. 4.13 QA DOCUMENTATION PACKAGE The Contractor shall be required to submit the QA Documentation in two hard copies and two CD ROMs. 4.13.1 Each QA Documentation shall have a project specific Cover Sheet bearing name & identification number of equipment and including an index of its contents with page control on each document. The QA Documentation file shall be progressively completed by the Suppliers subsupplier to allow regular reviews by all parties during the manufacturing. The final quality document will be compiled and issued at the final assembly place of equipment before despatch. However CD-Rom may be issued not later than three weeks. 4.13.2 Typical contents of QA Documentation is as below:(a) Quality Plan (b) Material mill test reports on components as specified by the specification and approved Quality Plans.
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(c) Manufacturer / works test reports/results for testing required as per applicable codes and standard referred in the specification and approved Quality Plans. (d) Non-destructive examination results /reports including radiography interpretation reports. Sketches/drawings used for indicating the method of traceability of the radiographs to the location on the equipment. (e) Heat Treatment Certificate/Record (Time- temperature Chart) (f) All the accepted Non-conformance Reports (Major/Minor) / deviation, including complete technical details / repair procedure). (g) Inspection reports duly signed by the Inspector of the Employer and Contractor for the agreed Customer Hold Points. (h) Certificate of Conformance (COC) wherever applicable. (i) MDCC 4.13.3 Similarly, the contractor shall be required to submit two sets (two hard copies and two CD ROMs), containing QA Documentation pertaining to field activities as per Approved Field Quality Plans and other agreed manuals/ procedures, prior to commissioning of individual system. 4.13.4 Before despatch / commissioning of any equipment, the Supplier shall make sure that the corresponding quality document or in the case of protracted phased deliveries, the applicable section of the quality document file is completed. The supplier will then notify the Inspector regarding the readiness of the quality document (or applicable section) for review. If the result of the review carried out by the Inspector is satisfactory, the Inspector shall stamp the quality document (or applicable section) for release. If the quality document is unsatisfactory, the Supplier shall endeavor to correct the incompleteness, thus allowing to finalize the quality document (or applicable section) by time compatible with the requirements as per contract documents. When it is done, the quality document (or applicable section) is stamped by the Inspector. If a decision is made despatch, whereas all outstanding actions cannot be readily cleared for the release of the quality document by that time. The supplier shall immediately, upon shipment of the equipment, send a copy of the quality document Review Status signed by the Supplier Representative to the Inspector and notify of the committed date for the completion of all outstanding actions & submission. The Inspector shall stamp the quality document for applicable section when it is effectively completed. The submission of QA documentation package shall not be later than 3 weeks after the despatch of equipment. 4.13.5 TRANSMISSION OF QA DOCUMENTATION On release of QA Documentation by Inspector, one set of quality document shall be forwarded to Corporate Quality Assurance Department and other set to respective Project Site of Employer. For the particular case of phased deliveries, the complete quality document to the Employer shall be issued not later than 3 weeks after the date of the last delivery of equipment. 4.14 Project Managers Supervision
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4.14.1 To eliminate delays and avoid disputes and litigation, it is agreed between the parties to the Contract that all matters and questions shall be referred to the Project Manager and without prejudice to the provisions of Arbitration clause in GCC, the Contractor shall proceed to comply with the Project Manager's decision. 4.14.2 The work shall be performed under the supervision of the Project Manager. The scope of the duties of the Project Manager pursuant to the Contract, will include but not be limited to the following: (a) Interpretation of all the terms and conditions of these documents and specifications: (b) Review and interpretation of all the Contractors drawing, engineering data, etc: (c) Witness or his authorised representative to witness tests and trials either at the manufacturers works or at site, or at any place where work is performed under the contract : (d) Inspect, accept or reject any equipment, material and work under the contract: (e) Issue certificate of acceptance and/or progressive payment and final payment certificates (f) Review and suggest modifications and improvement in completion schedules from time to time, and (g) Supervise Quality Assurance Programme implementation at all stages of the works. 4.15 INSPECTION, TESTING AND INSPECTION CERTIFICATES
(a) The word Inspector shall mean the Project Manager and/or his authorized representative and/or an outside inspection agency acting on behalf of the Employer to inspect and examine the materials and workmanship of the works during its manufacture or erection. (b) The Project Manager or his duly authorised representative and/or an outside inspection agency acting on behalf of the Employer shall have access at all reasonable times to inspect and examine the materials and workmanship of the works during its manufacture or erection and if part of the works is being manufactured or assembled on other premises or works, the Contractor shall obtain for the Project Manager and for his duly authorised representative permission to inspect as if the works were manufactured or assembled on the Contractors own premises or works. (c) The Contractor shall give the Project Manager/Inspector fifteen (15) days written notice of any material being ready for testing. Such tests shall be to the Contractors account except for the expenses of the Inspectors. The Project Manager/Inspector, unless the witnessing of the tests is virtually waived and confirmed in writing, will attend such tests within fifteen (15) days of the date on which the equipment is noticed as being ready for test/inspection failing which the contractor may proceed with test which shall be deemed to have been made in the inspectors presence and he shall forthwith forward to the inspector duly certified copies of test reports in two (2) copies. (d) The Project Manager or Inspector shall within fifteen (15) days from the date of inspection as defined herein give notice in writing to the Contractor, or any objection to any drawings and all
or any equipment and workmanship which is in his opinion not in accordance with the contract. The Contractor shall give due consideration to such objections and shall either make modifications that may be necessary to meet the said objections or shall inform in writing to the Project Manager/Inspector giving reasons therein, that no modifications are necessary to comply with the contract. (e) When the factory tests have been completed at the Contractors or sub-contractors works, the Project Manager /Inspector shall issue a certificate to this effect fifteen (15) days after completion of tests but if the tests are not witnessed by the Project Manager /Inspectors, the certificate shall be issued within fifteen (15) days of the receipt of the Contractors test certificate by the Project Manager /Inspector. Project Manager /Inspector to issue such a certificate shall not prevent the Contractor from proceeding with the works. The completion of these tests or the issue of the certificates shall not bind the Employer to accept the equipment should it, on further tests after erection be found not to comply with the contract. (f) In all cases where the contract provides for tests whether at the premises or works of the Contractor or any sub-contractor, the Contractor, except where otherwise specified shall provide free of charge such items as labour, material, electricity, fuel, water, stores, apparatus and instruments as may be reasonably demanded by the Project Manager /Inspector or his authorised representatives to carry out effectively such tests on the equipment in accordance with the Contractor and shall give facilities to the Project Manager/Inspector or to his authorised representative to accomplish testing. (g) The inspection by Project Manager / Inspector and issue of Inspection Certificate thereon shall in no way limit the liabilities and responsibilities of the Contractor in respect of the agreed Quality Assurance Programme forming a part of the contract. (h) To facilitate advance planning of inspection, the Contractor shall furnish quarterly inspection programme indicating schedule dates of inspection at Customer Hold Point and final inspection stages. Updated quarterly inspection plans will be made for each three consecutive months and shall be furnished before beginning of each calendar month. (i) All inspection, measuring and test equipment used by contractor shall be calibrated periodically depending on its use and criticality of the test/measurement to be done. The Contractor shall maintain all the relevant records of periodic calibration and instrument identification, and shall produce the same for inspection by NALCO. Wherever asked specifically, the contractor shall recalibrate the measuring/test equipment in the presence of Project Manager / Inspector. 4.16 PRE-COMMISSIONING AND COMMISSIONING FACILITIES (a) As soon as the facilities or part thereof has been completed operationally and structurally and before start-up, each item of the equipment and systems forming part of facilities shall be thoroughly cleaned and then inspected jointly by the Employer and the Contractor for correctness of and completeness of facility or part thereof and acceptability for initial pre-
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commissioning tests, commissioning and start-up at Site. The list of pre-commissioning tests to be performed shall be as mutually agreed and included in the Contractors quality assurance programme as well as those included elsewhere in the Technical Specifications. (b) The Contractors pre-commissioning/ commissioning/start-up engineers, specially identified as far as possible, shall be responsible for carrying out all the pre-commissioning tests at Site. On completion of inspection, checking and after the pre-commissioning tests are satisfactorily over, the commissioning of the complete facilities shall be commenced during which period the complete facilities, equipments shall be operated integral with sub-systems and supporting equipment as a complete plant. (c) The time consumed in the inspection and checking of the units shall be considered as a part of the erection and installation period. (d) The check outs during the pre - commissioning period should be programmed to follow the construction completion schedule. Each equipment/system, as it is completed in construction and turned over to Employer's commissioning (startup) Engineer(s), should be checked out and cleaned. The checking and inspection of individual systems should then follow a prescribed commissioning documentation [SLs (Standard Check List) / TS (Testing Schedule) / CS (Commissioning Schedule)] approved by the Employer. (e) On completion of all pre-commissioning activities / tests and as a part of commissioning the complete facilities shall be put on 'Trial Operation' during which period all necessary adjustments shall be made while operating over the full load range enabling the facilities to be made ready for the Guarantee Tests (f) The duration of 'Trial Operation' of the complete facility as an integral unit shall be fourteen (14) days. The Trial Operation shall be considered successful, provided that each item/part of the facility can operate continuously at the specified operating characteristics, for the period of Trial Operation with all operating parameters within the specified limits and at or near the predicted performance of facility/equipment.
(g) For the period of 'Trial Operation', the time of operation with any load shall be counted. Minor interruptions not exceeding four (4) hours at a time caused during the 14 days trial operation period shall not effect the total duration of Initial Operation. If in the opinion of the Employer the interruption is long, the Trial Operation shall be prolonged for the period of interruption (h) A Trial Operation report comprising of observations and recordings of various parameters to be measured in respect of the above Trial Operation shall be prepared by the Contractor. This report, besides recording the details of the various observations during trial operation shall also include the dates of start and finish of the Trial Operation and shall be signed by the representatives of both the parties. The report shall have sheets, recording all the
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details of interruptions occurred, adjustments made and any minor repairs done during the Trial Operation. Based on the observations, necessary modifications/repairs to the plant shall be carried out by the Contractor to the full satisfaction of the Project Manager to enable the latter to accord permission to carry out the Guarantee tests on the facilities. However, minor defects which do not endanger the safe operation of the equipment, shall not be considered as reasons for with- holding the aforesaid permission (i) Contractor shall furnish the commissioning organization chart for review & acceptance of employer at least eighteen months prior to the schedule date of synchronization of 1st unit. The chart should contain: a) Experience of the Commissioning Engineers. b) Role and responsibilities of the Commissioning Organisation members. c) Expected duration of posting of the above Commissioning Engineers at site.
4.17
GUARANTEE TESTS (a) The final tests as to the guarantees shall be conducted at Site, by the Contractor. The Contractor's Commissioning and start-up Engineers shall make the unit ready for such tests. Such test will be commenced, within a period of three (3) months after the successful completion of Trial Operation. Any extension of time beyond the above three months shall be subject to Employer's approval. (b) These tests shall be binding on both the parties of the Contract to determine compliance of the equipment with the performance guarantee. (c) Any special equipment, tools and tackles required for the successful completion of the Guarantee Tests shall be provided by the Contractor, free of cost. (d) The guarantee figures and design/performance parameters of the equipment shall be proved by the Contractor during these Guarantee Tests/ and or during the 'Trial operation' as detailed out elsewhere. Should the results of these tests show any deterioration from the guaranteed values, the Contractor shall modify the equipment as required to enable it to meet the guarantees. In such case, the Guarantee Tests shall be repeated and all cost for modifications including labour, materials and the cost of additional testing to prove that the equipment meets the guarantees, shall be borne by the Contractor. (e) The specific tests to be conducted on equipment have been brought out in the technical specification.
4.18
Test Codes The provisions outlined in the ASME Performance Test Codes shall be used as a guide for all the above test procedures unless otherwise specified in the technical specifications.
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4.19
TAKING OVER Upon successful completion of Initial Operations and all the tests conducted to the Employer's satisfaction, the Employer shall issue to the Contractor a Taking over Certificate as a proof of the final acceptance of the equipment. Such certificate shall not unreasonably be with held nor will the Employer delay the issuance thereof, on account of minor omissions or defects which do not affect the commercial operation and/or cause any serious risk to the equipment. Such certificate shall not relieve the Contractor of any of his obligations which otherwise survive, by the terms and conditions of the Contract after issuance of such certificate.
4.20
TRAINING OF EMPLOYER'S PERSONNEL The scope of service under training of Employers engineers (min. 3 nos.) shall include a training module in the areas of Operation & Maintenance. Such training should cover the following areas as a minimum in order to enable these personnel to individually take the responsibility of operating and maintaining the wagon tippler system in a manner acceptable to the Employer: The scope of services under training shall also necessarily include training of Employer's personnel. This shall cover all disciplines viz, Mechanical, Electrical, C&I, & operation etc. and shall include all the related areas like Design familiarization, training on product design features and product design softwares of major equipment and systems, engineering, manufacturing, erection, commissioning, training on operating features of equipment, quality assurance and testing, plant visits and visits to manufacturer's works, exposure to various kinds of problems which may be encountered in fabrication, manufacturing, erection, welding etc. The training module prepared by the contractor, shall be submitted for the Employers approval, prior to imparting training. Contractor shall furnish in his offer, details of training module(s) covering above requirements which shall be subject to Employer's approval. Consolidated training period included above (for O&M and Engineering) is indicative only. Employer reserves the right to reappropriate the training period between O&M and engineering depending upon the details of training module proposed by the Contractor. Training schedule shall be finalised based on the Contractor's proposal within two (2) months prior to commissioning. In all the above cases, wherever the training of Employer's personnel is arranged at the works of the manufacturer's it shall be noted that the lodging and boarding of the Employer's personnel shall be at the cost of Contractor.
4.21 SAFETY ASPECTS DURING CONSTRUCTION AND ERECTION In addition to the requirements given in Erection Conditions of Contract (ECC) the following shall also cover:
1. Working platforms should be fenced and shall have means of access. 2. Ladders in accordance with Employers safety rules for construction and erection shall be used. Rungs shall not be welded on columns. All the stairs shall be provided with handrails immediately after its erection. 4.22 NOISE LEVEL The equivalent 'A' weighted sound pressure level measured at a height of 1.5 m above floor level in elevation and at a distance of one (1) metre horizontally from the nearest surface of any equipment / machine, furnished and installed under these specifications, expressed in decibels to a reference of 0.0002 microbar, shall not exceed 85 dBA. 4.23 PACKAGING AND TRANSPORTATION All the equipments shall be suitably protected, coated, covered or boxed and crated to prevent damage or deterioration during transit, handling and storage at Site till the time of erection. While packing all the materials, the limitation from the point of view of the sizes of railway wagons available in India should be taken account of. The Contractor shall be responsible for any loss or damage during transportation, handling and storage due to improper packing. The Contractor shall ascertain the availability of Railway wagon sizes from the Indian Railways or any other agency concerned in India well before effecting despatch of equipment. Before despatch it shall be ensured that complete processing and manufacturing of the components is carried out at shop, only restricted by transport limitation, in order to ensure that site works like grinding, welding, cutting & pre-assembly to bare minimum. The Employer's Inspector shall have right to insist for completion of works in shops before despatch of materials for transportation. 4.24 ELECTRICAL ENCLOSURE All electrical equipments and devices, including insulation, heating and ventilation devices shall be designed for ambient temperature (500C) and a maximum relative humidity (75%). 4.25 INSTRUMENTATION AND CONTROL All instrumentation and control systems/ equipment/ devices/ components, furnished under this contract shall be in accordance with the requirements stated herein, unless otherwise specified in the detailed specifications. All instrument scales and charts shall be calibrated and printed in metric units and shall have linear graduation. The ranges shall be selected to have the normal reading at 75% of full scale. All scales and charts shall be calibrated and printed in Metric Units as follows: a) Temperature - Degree centigrade (deg C) b) Pressure - Kilograms per square centimetre (Kg/cm2). Pressure instrument shall have the unit suffixed with 'a' to indicate absolute pressure. If nothing is there, that will mean that the indicated pressure is gauge pressure.
c) d) e) f) g) h)
Draught - Millimetres of water column (mm wc). Vacuum - Millimeters of mercury column (mm Hg) or water column (mm Wcl). Flow - Tonnes/ hour Flow (Liquid) - Tonnes / hour Flow base - 760 mm Hg. 15 deg.C Density Grams per cubic centimetre.
All instruments and control devices provided on panels shall be of miniaturized design, suitable for modular flush mounting on panels with front draw out facility and flexible plug-in connection at rear. All electronic modules shall have gold plated connector fingers and further all input and output modules shall be short circuit proof. These shall also be tropicalised & components shall be of industrial grade or better. 4.26 ELECTRICAL NOISE CONTROL The equipment furnished by the Contractor shall incorporate necessary techniques to eliminate measurement and control problems caused by electrical noise. Areas in Contractor's equipment which are vulnerable to electrical noise shall be hardened to eliminate possible problems. Any additional equipment, services required for effectively eliminating the noise problems shall be included in the proposal. The equipment shall be protected against ESD as per IEC-801- 2. Radio Frequency interference (RFI) and Electro Magnetic Interference (EMI) protection against hardware damage and control system mal-operations/errors shall be provided for all systems. 4.27 TAPPING POINTS FOR MEASUREMENTS Tapping points shall include probes, wherever applicable, for analytical measurements and sampling. For direct temperature measurement of all working media, one stub with internal threading of approved pattern shall be provided along with suitable plug and washer. The Contractor will be intimated about thread standard to be adopted. The following shall be provided on equipment by the Contractor. The standard which is to be adopted will be intimated to the Contractor. Temperature test pockets with stub and thermo well Pressure test pockets 4.28 ELECTRONIC MODULE/COMPONENT DETAILS The Contractor shall have to furnish all technical details including circuit diagrams, specifications of components, etc., in respect of each and every electronic card/module as employed on the various solid state as well as microprocessor based systems and equipment including conventional instruments, peripherals etc. It is mandatory for the Contractor to identify clearly the custom built ICs used in the package. The Contractor shall also furnish the details of any equivalents of the same.
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4.29
JUNCTION BOXES The junction boxes shall be made of minimum 2 mm thick sheet steel. Gland plates shall be removable type and made of 3 mm thick sheet steel. The boxes shall be provided with detachable cover or hinged door with captive screws. Top of the box shall be arranged to slope towards the rear of the box. The box shall be hot dip galvanized and shall be provided with suitable neoprene gaskets to achieve degree of protection of IP-55 as per IS: 2147. Adequate spacing shall be provided to terminate the external cables. The boxes shall be suitable for mounting on various types of steel structures. The terminal blocks provided shall be of 650 V grade, rated for 10 A for control cables. Suitable numbering for terminal blocks shall be done. In case of junction box for power cable, the box shall be rated for maximum current carrying capacity. Terminal blocks shall be of one piece, klippon RSF-1 or ELMEX CSLT-1 type with insulating barriers.
4.30
INCOMING POWER SUPPLY TO WAGON TIPPLER In coming power supply to Wagon tippler, apron feeder, crusher & conveyor system will be taken from 33KV substation located near the 220KV switch yard. Laying Power cable/Transmission line from the substation to wagon tippler area along with provision of transformer , switch gear system & panels will be the scope of the tenderer. Approximate distance from the substation to the wagon tippler area will be 2.00 Km. However, actual distance & Suitable route for laying of cable will be assessed by the party in consultation with NALCO.
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ANNEXURE-A S. NO. DESCRIPTION OF MANUALS 1. 2. 3. 4. 5. NO OF PRINTS (SETS) NO. OF CDROMs / FLOPPIES(SETS) 1 FLOPPY 1 FLOPPY 2 CD-ROMs 2 CD-ROMs
6. 7. 8 9 10 11 12 13 14
Drawings "FOR APPROVAL" 4 Drawings "FOR INFORMATION" 4 Drawings "FINAL DRAWING" 10 Drawings "AS BUILT " 10 DATASHEETS,DESIGN CALCULATIONS, etc. and Other type of documents i) For Approval 4 ii) FINAL 10 iii) Analysis reports of equipments/ piping/ structures components/ systems employing software packages as detailed in the specifications a) Input 4 b) Output 4 c) Drawings/ Sketches 4 Erection manual "DRAFT" Erection manual "FINAL" Operation & Maintenance manual "DRAFT" Operation & Maintenance manual "FINAL" Plant Hand Book "DRAFT" Plant Hand Book "FINAL" Commissioning and Performance Procedure manual "DRAFT" Commissioning and Performance Procedure manual "FINAL" Performance and Functional GURANTEES TEST REPORT Progress Reports Project completion report 4
1 FLOPPY 2 CD-ROMs -
2CD ROMS 2CD ROMS 2CD ROMS 2CD ROMS 2CD ROMS 2CD ROMS 2CD ROMS 2FLOPPIES
15 16 17
4 10
2 FLOPPIES 2CD ROMS
QA programme including Organisation for implementation and QA system manual (with revision-servicing) 1 Vendor details in respect of proposed vendors including contractors evaluation report.
18
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19
20
21 22 23
Manufacturing QPs, Field QPs, Field welding schedules and their reference documents like test procedures, WPS, (i) For review/comment 3 (ii) For final approval 4 Welding Manual, Heat Treatment Manuals, Storage & preservation manuals Draft Final 4 sets Monthly Vendor Approval and QP approval status 2 QA Documentation Package for items / equipment manufactured and dispatched to site 2 QA Documentation Package for field activities on equipment / systems at site 2
1 set floppies
4 sets 2 CD ROMS 1 FLOPPY 1 FLOPPY 2 CD ROMS 2 CD ROMS
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SECTION 6
ELECTRICS FOR ADDITIONAL COAL STORAGE AND HANDLING SYSTEM 1.0 1.1 SPECIAL INSTRUCTIONS TO BIDDERS Inspection of site by Bidder Bidder shall inspect the site and examine and obtain all information required and satisfy himself regarding all matters such as access to site, communication, transport, right of way, the availability of local labour, availability and rates of materials, local working conditions, extreme weather conditions, uncertainty of weather, obstructions and hindrances that may arise, etc, which may affect the work or cost thereof, before the submission of his tender. Ignorance of site conditions shall not be accepted as basis for any claim for compensation. The submission of tender by Bidder will be construed as evidence that such an examination was made and any later claims / disputes in regard to price quoted shall not be entertained or considered. Bidder shall also indicate in his bid all the major assumptions including major design assumptions / criteria made by him on which the bid is based. 1.2 Compliance with Specification All equipment and accessories covered under this specification shall conform to the Technical Specifications given in this document. In case alternative type of equipment is offered, all technical particulars of equipment offered, number of such equipment supplied in India, reference list of installations where such equipment is in operation as per qualifying requirements, type test certificates of their collaborators, type test certificates of indigenously made equipment, extent of import content and availability of spares indigenously, along with any other data for considering the alternative equipment shall be furnished with the offer. The Purchaser, however, reserves the right to accept or reject the proposal without assigning any reason. All equipment shall be suitable for voltage/frequency variations and other data given in Electrical System Design. The contractor shall be responsible for satisfactory working of system with guaranteed parameters. All the major equipment shall be installed, tested and commissioned under supervision of representative of manufacturer of respective equipment.
Technical Specification: Electrical
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1.3
Standards and Regulations The design, manufacture, performance, testing and installation (including earthing and other essential provisions) of equipment and accessories covered under this specification shall, in general, comply with the latest issue of the following: Applicable Standards and Codes of Practices published by Bureau of Indian Standards. Central Board of Irrigation and Power Indian Electricity Act, 2003 Central Electricity Authority Indian Electricity Rules Equipment specific statutory regulations Indian Factory Act
Equipment complying with other recognized Standards such as IEC, BS, VDE, DIN etc. will also be considered if it ensures performance equivalent to or superior to Indian Standards. Equipment and accessories for which Indian Standards are not available, shall be designed, manufactured and tested in accordance with the latest issues of recognized Standards such as IEC, BS, VDE, DIN etc. In case of conflict between applicable Standards referred to in this part and technical specifications, the Technical Specifications shall govern to the extent of such difference. 1.4 Make & Interchangeability This specification is issued for procurement of specified equipment and system preferably from indigenous suppliers who may make use of imported systems / sub-systems / equipment / parts and who have valid collaboration agreement with reputed foreign suppliers with experience in design and supply of similar systems as specified. The Bidder shall furnish division list of supplies from foreign and Indian sources indicating the name of the agency or make against the respective items. It shall be the responsibility of the successful Bidder to arrange the import license for the imported items offered and to co-ordinate the supply of equipment from foreign and Indian sources and execute the contract within the agreed time schedule. The make of major equipment shall be limited to preferred makes indicated under List of preferred makes'. Makes of all other equipment and accessories are subject to prior approval by the Purchaser. Similar equipment and components shall be of same make; equipment of same type and rating shall be interchangeable.
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The Purchaser has the option of selecting the manufacturer of electrical equipment, instruments and controls and any other specialized items in the interest of standardization and the successful Bidder shall have to supply equipment of particular make, if so required. 1.5 Safety All equipment shall be complete with approved safety devices wherever a potential hazard exists and with provision for safe access of personnel to and around equipment for operational and maintenance functions. The design shall include not only those usually furnished with elements of machinery but also the additional covers, staircases, ladders, etc which are necessary for safe operation of the plant. All danger and caution notice boards shall be in Hindi, English and Oriya. The Contractor must take sufficient care in moving his construction plants and equipment from one place to another so that those may not cause any damage to the property of the Purchaser particularly to the overhead and underground cables and other service lines. When the work is carried out at night or in the obscure day light, adequate arrangements for flood lighting in the working area shall be made by the Bidder at his own cost and got approved by the Purchaser. The safely postures/regulations for the prevention of accidents shall be displayed by the Bidder at appropriate places. Notices and warning signs shall be displayed for all sources of dangers. All electrical drives and equipment must be equipped with safety devices. The safety provisions shall conform to the recognized standards, safety codes and statutory regulations. All safety measures as required to be adopted as per the statutory regulations and the safety rules of the plant shall be strictly followed by the Contractor during the execution of the Contract. Adequate number of first aid boxes as defined in the State Factory Rules shall be provided and maintained at all the work sites. 1.6 Coding/Numbering Scheme A coding scheme for identifying the drawings, plant and equipment, structures, spares and shipping documents shall be adopted by the contractor in a sequential manner. 1.7 Contractor's License The contractor shall possess a valid and competent contractor's license of specified voltage issued by the electrical licensing authorities of the Govt. of Orissa for carrying out electrical
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installation work of the type and magnitude covered in this document, in the state of Orissa. The contractor shall also be required to obtain labour license from Statutory Authority. Copy of the license shall be made available to the Purchaser/consultant for verifications during the execution of contract. All linemen, wiremen, electricians, supervisors and engineers engaged by the Bidder or his subBidder shall possess necessary valid license issued by the statutory authority and the same shall be submitted for verification, if called for. 1.8 Compliance with rules, regulations, and obtaining statutory approval All equipment/materials shall be installed in accordance with the requirements of relevant standards, Indian electricity Rules, Indian Electricity Act, 2003 and also the Factory Act. It is the responsibility of the Bidder to see that the electrical installation supplied and erected by him shall be to the entire satisfaction of Chief Electrical Inspector, Central Electricity Authority or any other statutory body having jurisdiction in the area and also to the Purchaser/ consultant. The responsibility for obtaining all statutory approvals for the installation to be carried out rests entirely with the contractor. It shall be the responsibility of the contractor to prepare and submit all necessary drawings, calculations, test certificates and relevant details (other than those given by the Purchaser/consultant) to the Electrical Inspector and obtain prior approval for commencing the work and for the complete installation work done. The inspection fee for statutory approvals shall be reimbursed by the Purchaser on submission of documentary evidence. 2.0 2.1 SCOPE AND BRIEF DESCRIPTION OF WORK AND ELECTRICAL SYSTEM DESIGN CRITERIA General The scope of work includes the basic engineering, detailed engineering, manufacture or procurement of electrical equipment, shop testing, packing, transportation, loading, delivery at site, unloading, storage at site, handling, erection, pre-commissioning tests and commissioning of all equipment/system including preliminary acceptance test, performance guarantee and post commissioning services, including insurance cover during transit, storage, erection and commissioning. After successful commissioning, the commissioning spares not used, will be the property of the Purchaser. The job shall be done on turnkey basis. Scope of Bidder shall also include the following: Supply of commissioning spares Supply of mandatory spares required for two years normal O&M Supply of special tools and tackles for the equipment/systems supplied 2.2 Bidder shall provide complete design inputs in form of assignment indicating complete requirements of civil building to accommodate comfortably an electrical substation consisting of
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electrical equipment under his scope as well as the equipment under scope of the Purchaser (as indicated later on in this specification) meeting all the required statutory clearances. The building shall be finalized and constructed by the bidder Bidder shall also provide the following design inputs for detailed design and engineering of civil and structural works i.e. foundations, room, etc. The same shall be taken into consideration while designing the civil buildings by purchaser: Static and dynamic loading of the equipment Clearances, approach, safety exits required Clearances from all the four sides of the walls shall be maintained, wherever applicable in the electrical premises while giving the design inputs. The civil buildings for the complete WTP substation (including switchgear room, battery room, transformer rooms, etc), dust suppression MCC room, electric room for WTP, Apron feeder, Sizer etc shall be under the scope of Purchaser. Electrical sub-station will be installed in the out door near the wagon tippler station. 2.3 Bidder shall also take into consideration of various aspects like clearances, approach, safety exists, cable trenches, foundations, floor opening, inserts, underground GI pipes, office premises, etc while finalizing the designing of civil installations and building within battery limit of the package. For HT drives like sizer scope of the Bidder starts from outgoing terminals of 6.6 kV switchboard (to be installed at the switchgear room) and includes complete electrics down below up to and including the drives / mechanism including power and control cabling (standard power and control cables shall be issued free of cost to the Successful Bidder), motors, local push button stations, equipment earthing, etc. For WT System Bidder shall include complete electrics including all the equipment/services on turnkey basis as per requirement irrespective of the same is specified in the specification or not. Separate set of suitable rated 6.6/0.433 kV transformers, dedicated MCC for WT System machine, PLC, UPS with sealed maintenance free batteries, VVVF drive control system, junction boxes, other equipment, etc shall be included for smooth operation of wagon tippler system. Air conditioning of control room to be done with provision of split air condition of suitable capacity. For other LT drives and mechanism, Bidder shall include dedicated MCCs consisting of required number and capacity of outgoing feeders. For dry fog type dust suppression systems of transfer points in junction houses, Bidder shall include a dedicated MCC in pump cum compressor house. For miscellaneous and non-critical loads like power socket cabinets, ventilation, AC power requirement of 6.6 kV switchboard / 415V PCC / transformer marshalling boxes, etc, Bidder shall include a dedicated PDB.
Technical Specification: Electrical Page 5 of 77
2.4
For illumination of WT System (Wagon Tippler, Apron feeder, Sizer) including conveyors and substation, dust suppression room and adjoining areas / sub areas, Bidder shall consider a dedicated LDB and sufficient number of SLDBs. SLDB shall be timer control. Two numbers flood light high mast towers shall be included for illumination of WT Area with metal Hlide Lamps. Illumination of street light and conveyor gallery shall be with LED lamps. A separate room shall be provided adjacent to WT control room to house the Dust suppression MCC, Pumps, compressors etc for the DS System by the Bidder. Bidder shall furnish the complete requirements including size, cable trenches/opening, etc. The pressurized ventilation shall be provided by the Bidder in this Dust Suppression Room. For DC power/control supply, Bidders scope shall start from DCDB to be installed at WT substation by the bidder. The number of MCCs / DBs shall be provided as per requirement and it will be subject to approval of Purchaser / his consultant. Following shall also be included in the Bidders scope: Pressurized ventilation system for the switchgear cum MCC room Pressurized ventilation system for the Dust Suppression MCC room Air-conditioning of battery and battery charger room Exhaust fan in the transformer rooms. The bidder shall supply the PLC for safe operation of WT System. Necessary integration with existing PLC of new coal yard will be scope of tender. Design and installation of electrics shall ensure operation of complete integrated electrics of the various drives/mechanism without any constraint during maintenance. Bidder shall also consider sufficient numbers of local auxiliary PDBs to cater miscellaneous loads of WT System. These PDBs shall be located at various places and exact locations shall be finalized during detailed engineering. HT Power cables and LT power/control cables shall be laid in different cable trays. LT power cables and LT control cables shall also be laid in different trays, however, if necessity arises due to space constraints or lesser number of cables, LT power cables and LT control cables can be put on the same trays keeping sufficient gap between them. 24V DC cables, if required, shall be laid entirely in different dedicated trays. Cable trays in single tier or in multitier shall be installed in vertical arrangement everywhere to avert coal accumulation and space reduction. Cable trays shall be supplied by the bidder. Power of any other voltage (except 415 V AC or 220 V DC), e.g. 24 V DC or 110 V DC, etc, shall be arranged by Bidder himself by providing suitable systems. 24V DC supply shall be through screened cable to be supplied by the Bidder. Following HT cabling shall also be included by the Bidder apart from the above:
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1. 2. 3.
ACSR conductor for O/H transmission of 33kv line. Cabling required for reinforcement of incoming cabling to existing 6.6 kV WT System switchboard. Cabling from existing 6.6 kV WT SYSTEM switchboard to proposed 6.6 kV switch board.
Standard power and control cables (Trailing Cables) of required sizes in adequate quantum shall be supplied and terminated by the Bidder. Hence, complete HT & LT trailing cables for Wagon Tippler, etc shall be supplied and laid by the bidder. Cables used for 24 V DC supply for PLC system shall be laid separately from 230 V AC control cables. All cables Power cable, Control Cable, Trailing Cable, instrumentation cables, signal cables, screened cables, special cables, fibre optic cables shall be supplied, laid and terminated by the Bidder as per actual site requirement. Cabling shall include laying and termination at both ends, cable trays and cable accessories for the cables to be laid by the Bidder. Bidder shall consider all required cables for cable engineering, preparation of cable schedule, terminal plans, cable support structure layout, cable layout drawings, etc. All cable trays, accessories, termination kits, glands, lugs, clamps including clamps, etc shall be included in the scope for all the cables (to be supplied by the Successful Bidder) interconnecting both side equipment or one side equipment of the Bidders scope. The Bidder shall also include in his scope of work the voltage drop calculation for the HT motors of capacity considered by him for their safe starting. All HT and LT drives shall be controlled and monitored at existing WT SYSTEM control room from the existing PLC. Bidder shall include PLC and all the interfacing/ interconnecting cabling and cable trays. Cables other than standard power and control cables, if required for this interfacing, shall be supplied and laid by the Bidder. Copper power cables, if required by the bidder, shall also be under scope of supply and laying of the bidder. Ampere meters for all conveyor belts are to be installed at the control room for monitoring the current of each drive. Bidder shall consider PLC based on number and type of Inputs / Outputs (I/Os) required for WT system for smooth and trouble free operation of various drives / mechanism from the existing WT SYSTEM control room. Sufficient number of I/Os in PLC extension shall be considered as per actual requirement. Exact number and type of I/Os shall be decided during detailed engineering based on approved schemes. Bidder shall also consider sufficient number of I/Os in PLC for control and monitoring of Purchasers electrical power distribution equipment like 6.6 kV switchboard, 415 V PCC, 220 V DC system, etc to be installed at WT SYSTEM substation. New PLC of WT shall be interfaced with existing PLC of Coal Handling Plant # 2 for operation of BC 115 and BC 103.
The earthing system shall be provided for complete WT SYSTEM plant. The new earthing system shall be connected to the existing earthing system. Bidder shall also consider earthing of following equipment: 33kv substation equipments. 6.6kV WT switchboard at WT SYSTEM substation in switchgear cum MCC room WT LT distribution transformers Neutral as well as body earthing 415 WT SYSTEM PCC at WT SYSTEM substation in switchgear cum MCC room Control panel for power distribution equipment at existing WT control room LT busducts Charger panels, DCDB, etc at WT substation in switchgear cum MCC room Bidder shall consider earthing ring mains at each electrical premise and connect the electrical equipment with the rings. The earthing ring mains shall be connected with underground earthing mats to be provided by the Purchaser made of 2x40mm dia MS rod. Adequate number of risers shall be made available to the Bidder for connection with his earthing ring main. For transformer neutral earthing, bidder shall consider dedicated earthing pits (minimum two pits per transformer). Lightning protection shall be provided by the bidder for complete WT SYSTEM including tall installations covered under the battery limit. Bidder shall also include complete illumination of the premises under the battery limit and all the above electrical premises coming at WT SYSTEM substation and adjoining areas. Air-conditioning, ventilation and exhaust fans for various rooms / premises of WT SYSTEM along with their complete electrics shall be under scope of the Bidder. The battery and battery charger room shall be air-conditioned. Switchgear cum MCC room of WT substation shall have pressurized ventilation. Transformer rooms of the WT substation shall have exhaust fans. Battery and battery charger room of the WT substation shall be air- conditioned. All interconnection for power, control and instrumentation/signal amongst equipment supplied by the Bidder shall be under Bidder's scope of work. Similar interconnections including power, control and signal between Purchaser's equipment and Bidder's equipment shall be done by the Bidder. All the cable terminations at both ends, cable trays and cable accessories shall be under Bidder's scope. 2.5 Electrical system design criteria a) General
The design, manufacture, assembly and testing as well as performance of the equipment shall conform to the relevant IS : specifications (latest revision) and other relevant standards. In case the Bidder is not in a position to comply fully with certain IS specifications, or in respect of
certain items for which there are no IS specifications, the Bidder may base his proposals on IEC/BS/VDE/DIN recommendations or other reputed national or international standards subject to the approval of the Purchaser. All equipment supplied and all work done including system design and detailed engineering shall also comply with the statutory requirements of the Government of India and the Government of Orissa. b) Climatic Conditions
Electrical Equipment selection and derating shall generally be based on ambient temperature of 50oC. The equipment offered shall be suitable for smooth, efficient and trouble free service in the climate prevailing at Angul. c) Standard Voltage levels
Following power utilization standard voltage levels shall be adopted for various systems: 1. Station supply 2. A.C. drive motors 3. Power supply to PLC extension 4. DC control supply 5. Plant illumination Welding socket / power 6. receptacles Special socket outlets for 7. portable lamps 8. Sockets for electrical tools, etc d) Permissible variations 6.6 kV, 3 phase, 3 wire, unearthed system 6.6 kV, 3 phase, 3 wire, unearthed system 415 V, 3 phase, 4 wire, solidly earthed 240 V, 1 phase, 2 wire, 50 Hz, A.C. (from UPS) 220 V, 2 wire, unearthed 240 V, 1 phase, 2 wire, 50 Hz, A.C. 415 V, 3 phase, 50 Hz, A.C. outlets 240 V, 1 phase, 2 wire, 50 Hz, A.C. outlets 24 V, 1 phase, 2 wire, 50 Hz, A.C. through suitable transformers 240 V, 1 phase, 2 wire, 50 Hz, with one point earthed
The system / unit / plant / equipment shall be designed suitably for following variation in voltage and frequency;
Permissible variation with rated performance and control effectiveness maintained Permissible variation for control and regulation equipment with rated performance and control quality maintained Permissible voltage dip at HT switchgear bus during starting of HT motor Permissible voltage dip at MCC bus during starting of LT motors
Voltage +/-10% +/- 10 % - 15 % - 15 %
Frequency +/-5% +/-5% -
e)
Symmetrical short circuit ratings

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The short circuit ratings of all the equipment like MCCs, motors, PDBs / LDBs, cables, power socket & lighting cabinets, etc shall be selected keeping in view the fault level capacities of the Purchasers electrical equipment. The three phase symmetrical short circuit rating at 6.6 kV level shall be 43.7kA. The three phase symmetrical short circuit rating at 415 V level shall be 50kA. The rated short circuit withstand duration for 6.6 kV shall be 3 sec, whereas for 415 V system, it shall be 1.0 sec. f) Criteria for selection of voltage levels for drive motors
AC squirrel cage induction motors above 160 kW shall be fed at 6.6 kV from Purchasers switchboard. Motors of 75 kW and above shall be fed from MCC through air circuit breakers with numeric type comprehensive motor protection relays. Motors below 75 kW shall be fed from MCC through MCCB/MPCB with power contactor and overload relay. g) System Earthing
6.6kv system is unearthed 415v system is solidly earthed. 2.6 ELECTRICAL SYSTEM REQUIREMENTS Minimum number of spare feeders in each of the MCC / PDB / LDB / SLDB shall be 10% subject to minimum one no. of each type and rating in each section. The rating and type of spare feeder shall be decided during detailed engineering stage. Sizes and requirement of various power and control cables shall be decided and intimated to the Purchaser well in advance to suit the approved scheme/to achieve scheme requirement. Space heater power supply to the motors shall be fed from the MCC through same cubicle or through separate dedicated cubicles through 415/240 V transformers. Space heaters shall be interlocked with motor main power supply. Bidder to submit a system wise drive list indicating required process interlocks, permissive conditions etc. with places and mode of control, control system philosophy with provision of various control, indication, measuring devices at various places. The Purchaser shall approve this based on above approved philosophy and Bidder shall have to provide all equipment / materials and prepare a control scheme/logic diagram which shall be utilized for designing the motor feeders at 6.6 kV switchboard and 415 V MCC at Bidders end. Above-mentioned control philosophy and interlocking logic shall be prepared as per the technological requirement.
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Suitable electrics for all the material handling equipment like hoist, etc shall be provided for handling the various drives and mechanism. Warning hooter shall be of brushless type Siren and AC single phase. All actuators shall be of geared motors. Complete 24 V system, wherever required, shall be provided by the bidder. 24 V and 230 V AC shall be taken through separate cables. Screened cables shall be supplied and used for 24 V power supply. All the indication lamps shall be LED based with LVGP (Low Voltage Glow Protection) up to 100 V. All the hoist control panel shall be located at workable height and platform shall be provided for each hoist at one point for maintenance purpose. One number Ammeter Control Panel shall also be provided in existing WT control room for monitoring of currents of Wagon Tippler, Apron feeder, Sizer and Conveyors: 3.0 PERFORMANCE REQUIREMENT AND GUARANTEE The Bidder shall study the specification and satisfy himself thoroughly regarding the workability of the plant, equipment and systems offered and also take full responsibility for the guaranteed operation and performance of the same as well as for their smooth, safe and reliable working. All equipment shall be guaranteed for workmanship, materials design and satisfactory performance to the parameters in accordance with the specification document and relevant clauses of the General Conditions of Contract. The guarantee for performance shall cover individual items and systems for their ratings / outputs. Bidder shall also guarantee the integrated operation of all the systems and equipment covered in his scope as a whole including interfaces required to be established with other related systems and equipment. The Successful Bidder shall conduct performance / acceptance tests on each of the major items of equipment supplied to demonstrate that the equipment and system supplied are capable of achieving the performance parameters specified. The total system performance shall also be guaranteed and demonstrated. Should the tests specified show that the plant has failed to achieve the guaranteed parameters, the supplier shall carry out necessary modifications or part replacements to achieve the guaranteed parameters and for successful demonstration the tests shall be repeated, without any cost implications to Purchaser. Loading of the various systems and their performance shall be demonstrated to the maximum possible extent. 4.0 4.1 TECHNICAL SPECIFICATION CONTROL & PROTECTION SYSTEM AND LAYOUT CONTROL PHILOSOPHY The control, monitoring, interlocking, annunciation and metering functions of various drives/mechanism shall be performed through PLC at WT SYSTEM control room. All the drives
shall also be operated from local control stations for emergency stop as well as for decoupled trial run of motors. Following interlocks / alarm, etc shall be provided for various drives/mechanism of cooling water system: When conveyor trips, Sizer will trips. When sizer will trip, Apron feeder will trip. When apron feeder trips, Wagon tippler will trip. When any of the running drive trips, the standby drive shall start automatically. When any of the running conveyor trips, the preceding/succeeding conveyor shall trip automatically. A conveyor shall take start only when its preceding conveyor starts Auto-Tripping of conveyor drives through various mechanism like pull chord, belt sway switch, etc The above interlocks/alarms and control philosophy are minimum and indicative. The detailed requirements for the above shall be finalized during detailed engineering. Bidder shall furnish details of control, monitoring, interlocking, protection, annunciation and metering system for all the HT drives for designing the Purchasers equipment like 6.6 kV switchgears. Similarly, control, monitoring, interlocking, protection, annunciation and metering system for all the LT drives duly approved by the Purchaser shall be utilized by the Bidder in designing the MCCs. Bidder shall use state of art technology while fulfilling the functional requirement of all the equipment for smooth and trouble free operation through PLC. Various transducers (4-20 mA range) as per requirement shall be provided to facilitate control and monitoring from PLC. Required transducers and wirings to hook up all analog and digital inputs / outputs to / from PLC shall be included in the scope. Interlocking arrangement shall also be furnished to take care of all the approved logic schemes. Bidder shall provide necessary wiring, control and required items to achieve the approved logic / scheme. Selecting local / remote switch of local control station in local position shall carry out local mode operation of the drives for test/trial etc. Permissive conditions for start and tripping of various drives shall be provided as per approved logic diagrams. A dedicated hardwired control panel / desk shall also be provided by the bidder at WT control room to control and monitor electrical power distribution system. PROTECTION SYSTEM Protections for the different electrical equipment are enlisted below:
Protection of HT motor and LT motor (75 kW and above) Comprehensive numeric motor protection shall be provided in the 6.6 kV switchboard for HT motors and in the 415 V MCC for LT motor of 75 kW and above. Laying of control and power cables including supply and laying of signal cables from motors to 6.6 kV switchboard /415 V MCC shall be in the scope of Bidder. Bidder shall include winding temperature monitoring / scanning as well as bearing temperature indicators for HT motors in PLC for monitoring and control. Comprehensive numeric motor protection including but not limited to the following: Instantaneous over current protection Differential protection (for rating above 1000 kW) Instantaneous time over current protection in two phases and definite time delayed over current alarm on the third phase Negative phase sequence protection Thermal overload taking -ve and +ve phase sequence into account Earth fault Locked rotor protection Winding temp monitoring and alarm for rating beyond 1000 kW Under voltage protection Microprocessor based numeric motor protection relay shall also have following facilities: Communication facility with open protocol like IEC/Modbus. Relay should store last five fault records (minimum) with date and time stamping. Relay should have no. of start menu for start inhibition. Relay should have facility for displaying three phase and neutral current Relay should have heavy duty tripping contact which will be used for breaker tripping Battery backup facilities The Motor Protection Relays shall also have the following additional features: Fault recording facility Password protection Local/remote communication facility with open protocol Minimum 4 nos. BI and 4 nos. BO Bidder shall furnish complete characteristic data and curves of HT motors to facilitate the Purchaser for proper relay settings at 6.6 kV switchboard end. Protection of LT motor (less than 75 kW)
Motors below 75 kW shall be fed from MCC through MCCB with power contactor and overload relay. Motors of 5 kW and above but below 75 kW, shall have fed through MCCBs (for short circuit protection), numeric motor protection relay like MPR-300 or equivalent (for overload and other motor protection) and power contactors. For motor below 5 kW, MPCBs smay be considerd in place of MCCBs. Single phasing protection shall also be provided in the MCC modules. METERING Following metering shall be provided in various MCC/DBs; 415 V MCC 1. 415 V INCOMER (EACH) AMMETER (DIGITAL TYPE) VOLTMETER kWH METER 2. BUS COUPLER AMMETER 3. OUTGOING AMMETER (DIGITAL TYPE) MOTOR FEEDER (EACH) PDB 1. 415 V INCOMER (EACH)
4.2
AMMETER (DIGITAL TYPE) VOLTMETER 2. OUTGOING (EACH) AMMETER (DIGITAL TYPE) LT MOTOR CONTROL CENTRE (LT MCC)
Constructional Features Fully drawout type with modules having service, test and isolated positions. Floor mounting, free standing with base channel 50 mm high for fixing on the inserts on the floor. MCC shall be single front, totally enclosed, dust and vermin proof. All the module of the MCCs shall be spacious to facilitate maintenance of equipment inside the module. Pollution degree applicable shall be pollution degree 4 as per IS-13947 (Pt-I), 1993. Incomer and bus coupler panels MCC incomers and bus couplers shall have Air circuit breakers. Incomers and bus couplers shall be rated for at least 125% of maximum demand taking into account the spare feeders and shall be suitable for the specified fault level. Incomers and bus coupler shall be electrically interlocked to prevent parallel operation. However, a definite delay defeat Interlock switch shall be provided to facilitate parallel operation. Auto changeover facility shall also be provided between the two incomers.
Feeder Modules Feeders for motors of 75 kW and above shall be fully drawout type air circuit breakers (ACBs) with numeric type comprehensive motor protection relays. Other motor feeders shall be consisting of MCCB, contactor, overload relay as main power components to ensure type 2 protection. The short circuit release of MCCBs shall be suitably selected to the applications concerned. At least 10% spare feeders (minimum one spare feeder of each type and rating bus section-wise) shall be provided. Ammeters with selector switches shall be provided for all continuous / intermittent running motors beyond 15 kW rated drives.
Busbars and terminations Busbars and connection shall be of high conductivity aluminium/aluminium alloy of suitable hardness and purity complying with as per IS-5082-1981. Busbars shall be insulated by colour coded heat shrinkable sleeves. Busbars shall be rated for the nominal current rating of incoming breaker and for the full shortcircuit rating. Earth bus shall run throughout the length of MCC at bottom . Control bus shall be provided in the bus bar chamber isolated with main bus in all the MCCs. Similarly power and control terminations shall be in separate chambers in the MCCs. Cable allay shall have sufficient space for maintenance and minimum width of cable allay shall be 300 mm. Shrouding/isolation shall be provided for outgoing power terminations in the cable allays. Modules of MCCs shall be spacious for easy maintenance of the various equipment inside. Short circuit strength Rated short time withstand current shall not be less than 50 kA for 1 second. Rated peak withstand current not less than 2.1 times the specified short circuit level. Air circuit breaker (ACB) Air break, drawout type conforming to IS 13947 (1993) and symmetrical breaking capacity not less than 50 kA for 1 second shall be provided. Service short circuit breaking capacity (Ics) shall be 100% of rated ultimate short circuit breaking capacity (Icu). Performance category of the MCC shall be B. ACB used for incomer & bus coupler should have numerical feeder protection relay. Motor operated mechanism shall be applicable with air circuit breakers. Spring charged stored energy mechanism shall be there to ensure high speed closing and tripping independent of the operating forces. Electrical anti pumping and trip free feature shall also be provided. Spring charging universal motor suitable for rated control voltage (220 DC). The closing coil and trip coil shall be suitable to DC operation.
Closing and tripping of ACB shall be by closing coil (operating range 85% to 110% of rated voltage) and tripping by trip coil (operating range 70% to 110% of rated voltage) respectively. Built-in direct acting type microprocessor based numerical releases for short circuit, over current and earth fault shall be provided. Auto changeover shall be done through under voltage relays and check synchronization relay with time delay. All the relays shall be microprocessor based numerical relays. Motor protection moulded case circuit breaker (MCCB) The characteristic shall match the motor duty application. Rated ultimate short circuit breaking capacity (Icu) shall be 50 kA. Ratings selected shall be at least 125% of the full load current of the motor. For small rating drives such as valves, Siemens 3UV13 type (or equivalent) or motor protection circuit breaker (MPCB) shall be used. Utilisation category shall be A. Magnetic contactors Pick up shall be positively at voltage between 85% to 110% of rated value. For frequently reversing drives, AC 3 rating selected shall be 50% higher than full load current of the motor at the specified duty cycle shall be provided. For reversible drives, mechanically as well as electrically interlocked contactors shall be used. Thermal overload relay Thermal overload relay shall be triple pole, ambient temperature compensated, inverse time lag, hand reset type, bimetallic with adjustable setting and built in single phase protection. The relay shall be able to withstand prospective short circuit-current without damage or injurious heating till the motor protection MCCB clears the fault. Tripping indication and reset push button operable from outside shall be provided. Push Buttons / Indicating Lamps / Indicating instruments Push buttons shall be spring return, push to actuate type and their contacts shall be suitable to carry and break 240 V AC, 10 A and 220 V DC, 1 A. Indicating lamps shall be LED LVGP (Low Voltage Glow Protection up to 100V) type. Standard colours shall be applicable for push buttons and for indicating lamps. Indicating instruments shall be flush mounting, square dial with 900 scale with zero adjusting device for external operation. Accuracy class shall be 1.0 or better. KWh meter shall also be provided with incomers. MCC shall have run / start, stop, tripped, and ready to start push button cum indication lamp for motor feeders. Current transformers The thermal and dynamic stability current for CTs and CT ratio shall be as per requirement. Protection and measuring current transformer shall be bar primary/ window type with 1A secondary. Burden of CTs shall be as required by the associated measuring equipment.
Potential transformers Potential transformers shall be provided on incomers as well as on buses and shall be in same circuit breaker cubicle. 415 V side of PTs shall have fuses. Accuracy class 1.0 shall be used. VA burden shall be selected based on meters and relays connected with the PT. Control transformer Control transformers shall be dry type 415V/240V, primary taps at +2.5 %, +5 % and shall be mounted in drawout trolley if outgoing feeders are in drawout execution. Control supply shall have supervision facility, alarm shall be provided for non availability of any one of the control supply. Automatic/manual changeover facility shall also be provided. Auto-changeover shall be blocked if power supply to respective section is not available. For capacity consideration of control transformers, each shall be capable to meet 100 % load including spare feeders and 10 % cushion for future and 15 VA for each module for remote aux. relays and indication lamps. Separate DC and AC control (3 ph & neutral) copper busbars shall be considered for each MCC. From AC control bus, motor space heater supply shall be tapped with suitable control and interlocking arrangement. DC Control supply DC supply is required for electrically controlled ACBs. For two sections, two DC buses shall be there. In bus coupler panel, manual switch shall be there for changeover of one supply to other section. Non-availability of DC supply shall be annunciated in MCC or nearby control room. Internal Control Wiring and external Terminations Internal control wiring shall be by 660V grade PVC insulated, single core stranded copper conductor of minimum cross section 2.5 sq.mm. for CTs and space heater circuits and 1.5 sq.mm for other circuits. For CT secondary wiring, disconnecting type terminal blocks (CAD type) shall be considered. For external terminations, DIN rail mounting type bakelite type terminal blocks shall be used complete with insulated barriers, stud type terminals, washers, nuts and lock nuts and identification strips. Power and control terminals segregated. Other accessories Following items shall be provided for the MCCs under the scope of the Bidder: Breaker lifting/handling trolley (for ACBs) : 1 No. per MCC Room Breaker racking handle (for ACBs) : 4 Nos. per MCC Room Panel key (if applicable) : 5 Nos. per MCC Room Selection of power components & wiring for continuous duty cage motor drives is given below:
Motor Rating at S1 Duty (KW ) Up to 3.7 5.5 7.5 11 15 18.5 22 30 37 45 55 75 90 110 125 135 160
Minimu m rating of MCCB * * * * * * * * * * * * * * * * *
Minimum rating of contactor (AMPS) AC3 duty 25 40 40 40 63 63 63 100 100 160 160 200 400 400 400 400 400
Minimum size for internal power connections Copper Aluminium flat wire (mm x mm )** (sq.mm) 4 4 6 6 10 16 16 25 35 50 70 95 12 x 2 12 x 2 12 x 2 15 x 3 15 x 3 20 x 3 20 x 5 20 x 5 30 x 5 40 x 5 40 x 5 40 x 5
Minimum size of power cable Aluminium (sq.mm) 4x 2.5(copper) 4x 2.5(copper) 4x6 4 x 16 4 x 16 3.5 x 35 3.5 x 35 3.5 x 70 3.5 x 70 3.5 x 95 3.5 x 120 3.5 x 185 3.5 x 185 2(3.5 x 120) 2(3.5 x 120) 2(3.5 x 120) 2(3.5 x 185)
*Minimum rating of MCCB shall be selected to achieve type 2' protection. ** Copper flat of equivalent size can be used instead of aluminium flat. NOTES : Overload relay shall be selected based on actual full load current and starting time. GENERAL TECHNICAL PARTICULARS OF MCC GENERAL 1. System : 415V, 3 phase, 4 wire, 50 Hz. Solidly earthed neutral 2. Type : Indoor type, cubicle construction, free standing 3. Pollution degree :4 4. Creepage distance : As per IS-13947 (1993), Part-I 5. Enclosure : IP54 6. Mounting : I/C & B/C in single tier and O/G in multi-tier arrangement execution 7. Neutral earthing : Effectively earthed 8. Control supply : 240V AC / 220 DC for ACB 9. Short time rating : 50 kA for 1 sec 10. Autochangeover required? :Yes 11. Delay drop off required? :Yes
12. Control supply AIR CIRCUIT BREAKER
: 220 V DC for ACB, 240V AC/220 DC for spring charge motor and 240 V AC for MCCB, etc.
1. Service : Indoor 2. Type : Air break 3. Insulation level : 6 kV (1.2x50 micro Sec) Impulse withstand 4. Utilization Category :B 5. Operating mechanism : Stored energy type I. Closing : Motor wound spring operated II. Opening : Shunt trip coil III. Latching : Mechanically and electrically trip free arrangement 6. Auxiliary Voltage I. Closing : DC (85% - 110%) II. Tripping : DC (70% - 110%) III. Spring charging : 240V + 10% AC or DC motor IV. Space heater & Lamp : 240V + 10% AC 50 Hz 7. No. of poles of C.B :3 CURRENT TRANSFORMERS 1. Type : Resin cast, window type 2. Rated voltage : 415 V +10% 3. C.T. secondary : 1 Amp rating 4. Accuracy i. Protection : 5P10 or better for protection ii. Metering : Class - 1 POTENTIAL TRANSFORMERS 1. Type : Cast Resin 2. Primary/secondary voltage ratio :
415V 3
110V 3
3. Method of connection :Star/Star connection 4. Rated voltage : 1.2 continuous, 1.9 for 30 Sec factor 5. Class of insulation : Class E or better CONTROL TRANSFORMER 1. Type : Dry cast resin, class B or better 2. Voltage ratio : 415V/240V 3. Rated burden : As per requirement (Minimum 1.5 kVA) 4. Quantity : 2 nos. per board and minimum capacity shall be 1 kVA MOULDED CASE CIRCUIT BREAKER 1. Type : Air break (Motor duty) 2. Rated service : 415 V +/- 10% voltage
3. Utilization Category 4. Protection
:A : Type `2 to the contactor
CONTACTORS 1. No. poles :3 2. Rated service : 415 V + 10% voltage 3. Control circuit : 240V +10% 1ph, 50Hz +5% 4. Utilisation category : AC23A for uni-directional motors 5. Limits of operation i. Closing (pick-up) : 85% to 110% ii. Dropout : Shall not be higher than 75% RELAYS/RELEASE 1. Relay type 2. Release type
: Numeric : Microprocessor based.
THERMAL OVERLOAD RELAYS 1. Type : Ambient temperature compensated bimetal operated hand reset type (direct or C.T. operated) 2. Hand resetting : To be provided at the front of the panel feature 3. Single phasing protection : Built in 4.3 CABLE AND CABLE ACCESSORIES
TYPES OF CABLES All cables, other than standard power and control cables, viz. HT/LT trailing cables, signal, instrumentation, screened, fire optics, copper power cables and special purpose cables required for applications concerned and for satisfactory operation of the all the HT/LT drives at coal handling plant shall be in the scope of the Bidder. All power cables should be FRLS (Fire Retardant low sulphur) type. Bidder shall include all the cable accessories in his scope of supply as well as installation as per actual requirement at site. Trailing Cables All the trailing cables shall be 4 core. HT trailing cables shall be 6.6 KV (UE) heavy duty power cable 4 core, flexible. The detailed specification for the HT trailing cables required shall be furnished by the Bidder along with the tender. 1.1 kV grade flexible trailing cable shall be of heavy duty type having tinned annealed high conductivity flexible copper conductors, butyl rubber or ethylene propylene (EPR) insulation and CSP or PCP sheathing. The conductor shall conform to IS:8130 - 1984 and insulation and
sheathing shall be as per IS:6380 - 1984. For high temperature zone and side-arm-charger the insulation shall be of silicone rubber. For all the cabling, Bidder shall include laying including all the GI prefabricated cable trays/hot dip galvanized perforated trays and other cable accessories like cable termination/jointing kits, glands, cable identification tags, connectors, ferrules, clamps, etc HT Cable End Termination & Straight through jointing kits All high voltage cable terminations shall meet the test procedures and requirements stipulated in IEEE 48-1990 as class-I termination. Heat shrinkable type of cable termination and joints shall be used for HT cables in indoor and outdoor applications as specified. The stress control and grading wherever necessary shall be by means of semi conducting heat shrinkable tubing. Environmental sealing between heat shrinkable material and cable surfaces shall be achieved by using hot melted sealants or adhesives. Where such sealants or adhesives shall be exposed to high electrical stress, same shall be track resistant type. Straight through joints and end sealing termination kits of 6.6 KV (UE) grade cross-linked polyethylene cables shall be of well tried out design compatible for XLPE insulation. The joints/ends sealing kits shall be of heat shrinkable type and shall be complete with stress grading material, protective and lug sealing sleeves, self tightening earthing clamp, slide angle sleeve etc. Outdoor termination shall have necessary skirting over protective sleeving to increase the creepage distance and the sleeves shall ensure total protection against ingress of moisture. Straight through joints shall feature moisture proof environmental seal, mechanical protection and impact resistance envelope around the joined cables. The end termination and straight through joints shall conform to the relevant standards. The complete termination / joint kits shall be of reliable and field proven design having been fully type tested and relevant type test reports shall be furnished. In addition the termination and joint shall be tested for various accelerated aging tests such as thermal aging, weathering etc. to have long and trouble free service. Necessary type test certificates for aging tests shall also be furnished. Following type of cable termination and joints shall be used for HT cables in indoor and outdoor applications: 1. 2. 3. Tapex type Heat shrinkable type Pre moulded push on type
Tapex type system

The stress grading material shall be wrapped around the cable core, over lapping the edge of the outer conducting layer. The tape layer shall fuse together to form a compact rubber body around the stress grading material and cable core and thereby exert an active pressure on cable. This system shall be used for straight through joint only. Heat Shrinkable type system The stress control and grading wherever necessary shall be by means of semi-conducting heat shrinkable tubing. Environmental sealing between heat shrinkable material and cable surfaces shall be achieved by using hot melted sealants or adhesives. Where such sealents or adhesives shall be exposed to high electrical stress, same shall be track resistant type. Pre-moulded Push On type system Premoulded refers to moulded Ethylene Propylene Diene monomer rubber components. Sealing between the pre-moulded push on material and cable surface shall be achieved by semi conducting pad which has cold flow properties. Cable trays All the cable trays shall be prefabricated hot dip galvanised sheet steel trays. Prefabricated GI ladder type / perforated type cable racks/trays shall be used for laying of cables in cable trenches, cable spreader floors, cable cellers, through piping and while routing cables along technological structures etc. The factory made system of cable trays shall be complete in all respects with all standard accessories like reducers, bends, tees, risers etc. and shall be suitable for bolted type assembly at site so as to avoid any welding. The GI ladder type factory fabricated cable trays made from 2.5 mm thick hot welded steel sheets grade o shall be provided as per IS : 2062. Hot dip galvanizing of 86 micron thick as per IS-2629, IS-4759 and IS- 209. Trays shall be of standard length of 3 M / 2.5 M with max deflection not exceeding 1/400 of span with sufficient load bearing capacity. Sheet steel thickness shall be minimum 2.5 mm. Rung hall be provided at every 250 mm. At one meter interval two rungs shall be provided side by side to facilitate clamping. Beside, Bidder shall also provide suitable pre-fabricated bends of cable trays at all the bending points as per actual site requirement. Horizontal tees and 900 bends shall be provided for each size of cable trays as per actual requirement at site. Lugs/connectors
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Cable termination shall be made with aluminium / tinned copper crimped type solderless lugs of approved make for all aluminium conductor and stud type terminals. The lugs shall be tinned copper compression type. Glands Cable glands to be supplied shall be nickel plated brass double compression type. Glands for classified hazardous areas shall be certified by CMRS and approved by CCE, Nagpur. Cable glands for terminating PVC insulated armoured/unarmoured cables (as applicable) shall be made of brass and shall be of double compression type with necessary provision for armour earthing.
Cable clamps All cables shall be clamped with GI (minimum size of 25x3mm) / Al (minimum size of 25x4) clamps and single core cables shall be clamped with trefoil clamps made of non-magnetic materials. Specifications for miscellaneous materials Cable identification Cable tags shall be of 2 mm thick, 20 mm wide aluminium strap of suitable length to contain cable number as per cable schedule. Ferrules Ferrules shall be approved interlocked type & size to suit core size mentioned and shall be employed to designate the various cores of control cable by the terminal numbers to which the cores are connected, for ease in identification and maintenance. Cable clamps All cables shall be clamped with metal clamps and single core cables shall be clamped with trefoil clamps made of aluminium. 4.4 ELECTRIC MOTORS General All motors shall generally conform to IS 325 and CBIP publication No. 140. Motors shall run continuously at rated output with + 5 % variation in frequency and + 10 % variation in voltage and + 10 % combined variation of frequency and voltage (absolute sum). Motor shall not stall due to momentary drop in voltage up to 70 % of rated value and shall run satisfactorily for five minutes at a supply voltage of 75 % of rated value.
The limiting value of voltage at rated frequency under which motor will successfully start and accelerate to rated speed with load shall be assumed to be a constant value of 80 % rated voltage throughout the starting period. All motors shall be supplied with foundation bolts (if applicable), drain holes with plugs. Motors shall be designed for 50oC ambient temperature. Motors supplied shall be complete with required double compression cable glands, crimp type cable lugs and first filling of lubrication, name plate, etc. Lifting facility to be provided for all HT motors and big size LT motors. Guards shall be provided to prevent accidental touch for couplings and for free shaft ends shall be provided. Degree of protection for motor and bearings shall be IP-55 for indoor and IP55 with rain canopy and weather proof construction for outdoor. Motor shall be suitable to withstand at least three successive starts from system cold condition and two starts from hot condition at normal system voltage and frequency. The drive motor shall have at least 15 % margin over the maximum power requirement of the driven equipment after considering all losses, de-rating due to temperature and specific site and operating conditions. The motor may be subjected to sudden application of 150% rated voltage during bus transfer, due to phase difference between the incoming voltage and motor residual voltage. Motor handling facility and canopy Handling facility and space shall be provided for all the HT and LT motors. Mono rail shall be provided and shall be extended up to open maintenance space for each of the HT motors. Canopies made of GI sheet of minimum thickness of 2 mm shall be provided to each of the HT/LT motors located outdoor. All motors, in general, including conveyor motors shall be 4 pole construction, hence speed of maximum 1500 rpm. However, motors for travel drives of yard machines shall be of 6 pole construction, hence speed of 1000 rpm. LOW VOLTAGE INDUCTION MOTORS Frame sizes shall be as per IEC. Casing feet shall be integral with the motor body. For motor of rating up to 5 kW, ball bearings shall be used for both DE & NDE end. For ratings above 5 kW the DE end shall be provided with ball/roller bearing and NDE end shall be provided with ball bearing. Bearings shall be suitable for running of motor in either direction. Motors 110 kW and above shall be provided with bearing temperature indicators. Explosion proof/increased safety design for explosion hazardous areas as per requirement. Terminal box shall be of suitable dimension to receive aluminium cables and shall be rotatable by 4x90o
Cooling of motors shall be of TEFC (IC0141) design. Ventilation shall be effective irrespective of direction of rotation. Motors shall be dynamically balanced. Vibration intensity shall be limited as per IS 12075 (1987). Continuous noise level should not exceed 75 dBA at a distance of 1.0 m from motor body. Starting current shall be less than or equal to six times the rated current with IS tolerance. Motors shall have class ' F' insulation with temperature limited to class B. Permissible temperature shall be limited to 120oC in case of class 'B' insulation and 130oC in case of class F insulation as measured by resistance method. Class H insulation shall be considered in specific cases. Limiting temperature shall also be limited to 130 deg C in case of Class H insulation as measured by resistance method. Space heaters shall be provided for all motors rated above 30kW. Adequate handling space shall be provided for all the big LT motors. HIGH VOLTAGE MOTORS Degree of protection for motor and bearings shall be IP-55 for indoor use and IP-55 with removable rain canopy for outdoor use. Vibration monitor with contacts shall be provided at the DE end of motor bearing for motors of ratings 1000 kW and above. On line vibration measurements shall be provided for larger and critical motors. All motors shall be provided with Bearing (DE & NDE) temperature detectors and 6 nos. stator winding temperature detectors, RTDs for monitoring alarm and trip conditions. Temperature shall be displayed on VDU's. RTD's shall be of PT100 type and suitable for digital scanner or PLC input requirement. Digital type bearing temperature indicator for all motors shall be provided for local measurement with adjustable alarm contacts. Each terminal box shall have fault withstand capacity equal to at least rated short circuit level of the system voltage for 0.25 sec and shall have pressure relief device. Terminal boxes shall be suitable for termination of FRLS, XLPE cables with cable end seals. Separate terminal boxes shall be provided for space heaters, RTDs for winding/ bearings temperatures, vibration monitors etc. All terminal boxes shall be provided with two earthing studs for termination of protective earth conductor. Box covers shall be provided with handle to facilitate easy removal. Low kW range machines may be of TEFC (IC0141) design. For higher rating, type of cooling shall be CACA (IC0151). General accessories like flow switches, space heater, terminal boxes, drain plug, dowel pipe cable lugs, glands clamp etc. shall be provided.
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Vibration intensity shall be limited to values as stipulated in the IS. Motor shall be designed to withstand the vibration produced by the driven equipment. Continuous noise level should not exceed 75 dBA at a distance of 1.0 m from the motor body. Electrical design shall be same as in case of low voltage induction motors except the following: All HT motors shall have class F insulation but with total permissible temperature limited to 1300C (as measured by resistance method). Space heaters to be provided for all HT motors. Heaters to be automatically OFF when the motor is switched ON. Starting current of the drives shall be limited to six times of full load current. Motors of rating 1000 kW and above shall be provided with differential protection. Matching CT and cabling up to switchgear shall be provided by the Bidder. Motors shall be capable of withstanding locked rotor current at 110 % rated voltage for at least 2.5 sec (for motors having staring time up to 20 sec) or 5 sec (for motors having staring time more than 20 sec) longer up to than starting time under rated load condition at 80 % voltage. If above condition is not possible then, centrifugal type speed switch to be provided which has to be connected to the motor protection relay. Speed switch shall be capable to withstand 120 % of the overspeed in either direction. Insulation of motors shall be designed conforming to IEC 34-15/ 1990. Gland plate for single core cable shall be non-magnetic type. All HT motors shall have individual dedicated handling and lifting facilities preferably by dedicated electric hoist. 4.5 POWER DISTRIBUTION BOARD /AUXILIARY POWER DISTRIBUTION BOARD POWER DISTRIBUTION BOARD PDB shall be suitable for 415V, 3 phase, 4 wire, 600A, 50 kA (short time rating for 1 sec) indoor type. Board shall be single front, metal clad, front matched, dust and vermin proof, draw-out (incomer & bus coupler) / fixed (outgoing), fully compartmentalized and extensible on both sides, IP54 type enclosure. Shall have isolated busbar chamber for main busbar at the top, running throughout the length of the board. Chamber shall have removable cover. Busbars shall have same cross section throughout the length . Rating of the neutral busbar shall be 50% of the main busbar. Earth bus bar shall run in bottom chamber throughout the length of the panel. Shall have Moulded case circuit breaker (MCCB) triple pole, air break type with independent manual quick make and quick break type. MCCB shall be capable of breaking rated current at 0.3 pf at rated voltage. MCCB shall withstand the fault current envisaged for 415V system.
Generally PDB will have following feeder arrangement. However, details of feeders e.g no. type and capacity, etc shall be finalized during detailed engineering: Incomer Outgoings : : ACB of 630A (or as per requirement) MCCBs of 400/250/125A/63A/16A (or as per requirement)
Number and capacity of PDB given in the enclosed Single Line Diagram is minimum and indicative. Bidder shall provide as per actual load requirement and same shall be finalized during detailed engineering. AUXILIARY POWER DISTRIBUTION BOARD Aux. PDBs shall be suitable for 415V, 3 phase, 4 wire, 250A, 50 kA (short time rating for 1 sec.) indoor type. Board shall be single front, metal clad, front matched, dust and vermin proof, nondrawout, fully compartmentalized and extensible on both sides, IP54 type enclosure. The other technical particulars of aux. PDBs shall be similar to PDB. The tentative feeder arrangement shall be as follows. However, details of feeders e.g no. type and capacity, etc shall be finalized during detailed engineering: Incomer : MCCB of 250A (or as per requirement) Outgoings : MCCBs of 125A/63A/16A (or as per requirement) 4.6 6.6 kV ON-LOAD ISOLATOR WITH EARTH SWITCH Technical features Triple pole air break, fault make load break type. Independent manual, quick make, quick break type Mechanical trip device Mechanical ON- OFF indicator Suitable to connect cables on incoming and outgoing side. Shall have 3 NO and 3 NC aux. contacts. Earthing switch shall be provided on transformer side having rating same as that of main switch. Totally enclosed, floor mounted, outdoor kiosk type with IP-55 protection along with a canopy Shall have padlocking facility Panel door shall be mechanically interlocked so that isolator cannot be closed on open position of door and door cannot be opened on close position of isolator. Earthing switch shall be interlocked with isolator blades to prevent simultaneous closing of both. Isolator shall be interlocked with Purchasers upstream breaker. Technical particulars 1. System voltage
: 6.6 kV
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2. System earthing : Resistance earthed 3. Type : Air break, fault make & load break type 4. Nos. of poles : Three 5. Continuous current 6. carrying capacity : As per requirement 7. S/c withstand capacity : 43.7 kA for 3 sec. 8. Pf withstand voltage : 20 kV 9. Impulse withstand voltage : 60 kV 10. Termination 11. Incomer : To accept cables of required size 12. Outgoing : To accept cables of required size 4.7 LT TRANSFORMERS (DRY CAST RESIN TYPE) 4.7.1 Design
Design shall be generally as per IS 2026. Transformer shall be suitable for rated frequency 50 Hz, -5%, +5%. Insulation level shall be designed according to the voltages specified below:
Description Capacity Nominal voltage (kV) Max system voltage (kV) Power frequency withstand voltage (kV) System earthing No. of phases Frequency Impulse test withstand voltage (kV) Short time current rating (for all current carrying parts) Fault level (3 phase symmetrical) Clearance in air (mm) Phase to earth Phase to phase
6.6 kV 0.415 kV As per requirement (Bidder shall furnish) 6.6 0.415 7.2 < 1.1 20 3 Low resistance earthed Solidly earthed 3 3 50 Hz 50 Hz 60 -43.7 kA for 3 sec 50 kA for 1 sec 43.7 100 120 50 kA 19 25.4
All transformers shall be of the latest design, dry type as per IS : 11171. All dry type air natural transformers shall be suitable for indoor use line up with power control centre as unit type. Bidder shall ensure that manufacturer shall have his own in-house core cutting facilities on CNC machines. Special care shall be taken to make enclosed equipment proof against entry of rats, lizards and other creeping reptiles which may create electrical short- circuits inside live equipment. The
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design of each transformer shall be such that the risk of accidental short-circuits due to reptiles or vermin shall be obviated. The transformer shall be of cast resin type. The tap changing arrangement shall be of removable link type. Each transformer shall be suitable for operation at full rated power on all tappings without exceeding the temperature rise of 800C over the ambient of 50oC. Minimum class of Insulation shall be F. The transformers shall be designed to be capable of withstanding, without injury, the thermal and mechanical effects of short-circuits between phases or between phase and earth at the terminals of any winding with full voltage applied across the other winding. All transformers shall be capable of withstanding specified through fault current for minimum of 2 seconds as per IS: 2026 (Part-1). The transformers shall be designed to suppress harmonic currents, especially the third and fifth, so as to eliminate distortion in the wave form and consequent additional insulation stress, noise on communication system and undesirable circulating currents between the neutrals at different transformer stations. The Transformers shall operate with minimum noise and vibration. The cores, protective housings and other structural parts shall be properly constructed and windings properly braced so that the mechanical vibrations are kept to the minimum, thus reducing the noise. To this effect, the laminations shall also be bonded together with appropriate resin. The core-coil assembly shall also be fixed in such a manner that no shifting or deformations occur during shipment or installation. Each transformer shall be designed for minimum no-load and load losses within the economic limit. All electrical connections and contacts shall be of ample section for carrying the rated current without excessive heating. All mechanism shall be of stainless steel, brass, gunmetal or other suitable material to prevent sticking due to rust or correction. If any temporary fitting is fixed to the protective housing of the transformer for transporting / handling purpose, these shall be identical as well as instructions and illustrated drawings shall be furnished to facilitate their removal at site after erection. 4.7.2 Core
The framework, clamping arrangement and general structure of the cores of each transformer shall be of robust construction and shall be capable of withstanding any shock to which they may be subjected during transport, installation and operation. The assembled core shall be
securely clamped on the limbs and the yoke to build up a rigid structure. The clamping pressure shall be uniform over the whole of the core and so adjusted as to minimize noise and vibration in the core when the transformer is in operation. The framework and the core bolts shall be effectively insulated from the core so as to reduce the eddy-currents to the minimum. The magnetic circuit shall be built of high quality, low loss, non-ageing. Cold rolled, grain oriented, silicon steel laminations (CRGO Prime Grade) having excellent magnetic properties and specially suitable as core material. Laminations shall be insulated from each other with material having high inter-lamination insulation resistance and rust inhibiting property and also capable of withstanding stress and mechanical vibration. Necessary cooling ducts shall be provided for heat dissipation from the core so that the anticipated maximum hot spot temperature in the core shall not be injurious to any material used in the core assembly. The core-clamping frame shall be provided with lifting eyes having ample strength to lift the complete core and winding assembly. Suitable provision shall be made in the dry type transformers for effective core earthing. 4.7.3 Winding
The coils used for transformer winding shall be made of insulated, continuous and smooth electrolytic copper conductors of high conductivity and of 99.9% purity. Similar coils shall be connected by accessible joints brazed or welded and finished smooth. No corona discharge shall result on the winding during induced voltage test as specified in applicable standard. The insulating materials for dry type transformers shall be of type not inferior to Class F. All insulating materials shall be of proven nature and shall be suitable for the suitable for the limits indicated in the applicable standards as well as the maximum possible winding temperature and shall not deteriorate when the transformer is operated continuously at its specified rating at the specified ambient temperature. The inter-turn and inter-coil insulation shall be so designed that the dielectric stress is uniformly distributed throughout the winding under all operating conditions. The windings shall be dry cast resin type. The transformer windings shall be designed for basic Impulse insulation level not lower than those specified above. 4.7.4 Protective Housing for Dry type Transformer
Dry type transformer shall be provided with suitable protective sheet steel housing, with minimum IP 23 degree of protection for the enclosure. The housing shall have ventilation louvers provided with wire mesh screens and shall be supplied with suitable lifting lugs. Safety limit switches shall be provided and wired in such a way that the incoming supply may be
disconnected whenever any one of the sides of the enclosures are opened with the transformer in energized condition. Sufficient precautions shall be taken so that doors are closed fully. Door locks shall be provided and keys shall be universal type. 4.7.5 Off-Circuit Links
The off-circuit tapping links shall be provided on the HV side with appropriate register plate to show the link location. The links shall be provided with a separate door for access. The door shall be provided with appropriate safely limit switches which will trip the transformer HV / LV sides in open condition. 4.7.6 Cooling
The cooling system for dry type transformers shall have Air-Natural (AN) cooling.
4.7.7
Neutral Bushing Current Transformers
CTs for back up earth fault (51N) as well as for restricted earth fault (64) shall be provided on the neutral end. Neutral bushing CT shall be removable at site without opening transformer tank cover/active part. Secondary leads of 4 sq.mm shall be brought to a weatherproof terminal box and from there to the marshalling box. Neutral bushing CTs of suitable ratio, class and adequate burden shall be provided by the Bidder to cater to the requirement of all standard protection associated with the transformer of this capacity. CTs for REF shall be PS class. 4.7.8 Marshalling Box
Enclosure mounted marshalling box to be supplied with all controls instruments, protection, accessories & fitting as required for the transformer and its associated ancillaries. The box shall be made of 2 mm sheet steel with IP 54 degree of protection. Sheet steel marshalling box of dust-proof design shall be provided to accommodate temperature measurement as well as control system, as may be necessary. The box shall be mounted on the transformer enclosure and shall be provided with internal lighting, space heater and thermostat with their controls accessible from outside. The box shall be provided with suitable hinged steel doors at the front and all equipment shall be so placed as to accessible from the front. Provision shall be made for padlocking the doors. Suitable glazed windows shall be provided at appropriate positions to give an unrestricted view of the temperature indicators etc, without opening the door.
All initiating contacts of shall be wired up to the terminal block in the box. All control wiring shall be with 1.1kV grade stranded PVC insulated armoured copper cable of 2.5 sq.mm. Terminal blocks shall have 20% spare capacity. The external connections between the apparatus on the transformer and the marshalling box shall be done with suitable heat resisting copper conductor cables of core size not less than 2.5 sq. mm. The cables required to connect the marshalling box and transformer accessories shall be adequately protected against mechanical damage. There shall be no joints or tappings between two terminations of any cable. Not more than two terminations shall be made at any one terminal. All terminations at various devices and terminal blocks shall be provided with plastic ferrules having engraved numbers. All terminals and links shall be so arranged as to facilitate easy checking and testing of relays, instruments etc. Provision shall be made for termination of power cables as well as multi-core control cables in the marshalling box. The control circuit terminal blocks provided for external cable connections shall be provided with screw type terminals and shall be complete with terminal screws, links, cable carries etc, Each terminal block shall have 20% spare terminals and all wiring shall be such that it is easily identifiable and accessible for maintenance. All devices, wires and terminal blocks within the marshalling box shall be clearly identified by symbols corresponding to those used on relevant schematic or wiring diagrams. Enclosure class of marshalling box shall be IP-55. Terminal Arrangement HV/LV terminals shall be suitable for cables considered. 4.7.9 Transformer Fittings & accessories
Each transformer shall be fitted with all standard and special fittings and accessories and shall include but not be limited to the following: Inspection covers. Off circuit links in the primary for voltage variations. Rating, diagram and tap connection plates. Terminal marking plate Two nos. earthing terminals with lugs. Winding temperature detectors with microprocessor based Temperature scanners with digital read out and requisite set of remote signaling contact for alarming/tripping operation. Under carriage with bi-directional rollers with locking and bolting devices. Marshalling box complete with all instruments, accessories and fittings as required for the transformer. Off load tap changers with position indicators and padlocking faciliy Neutral bushing CTs with terminal arrangement
HV cable box with disconnecting chamber and supporting arrangement LV side flanges suitable to receive busducts Jacking pads Haulage lugs Flat base, foundation bolts and clamps and other accessories as required 4.7.10 Details of Fittings
Requisite number of Resistance type temperature detectors shall beprovided with solid state type temperature signaliser for dry type transformer. The temperature signaliser shall be provided with two sets of contacts, one for alarm and the other for circuit-breaker trip. The signaliser shall be provided with digital read out for the temperature being measured and for the zone where the current measurement. Two nos. earthing terminals of adequate mechanical and electrical capacity shall be provided. Separate earthing terminals shall also be provided on the enclosure, marshaling box and terminal boxes. Rating and diagram plates shall be provided as per adopted standards for each transformer. Lifting lugs and hauling holes as required shall be provided for the transformer as well as for the enclosure. Suitable under-carriage fitted with flat rollers shall be provided. The rollers shall have adequate mechanical strength and shall be so designed that the transformer shall roll without undue effort after it has remained immobile for a long period. The edges of rollers shall be duly rounded off to permit skidding of transformer on flat surface. 4.7.11 Technical Particulars of HT Transformers (33KV/6.6KV) 1.0 1.1 1.2 1.3 1.4 1.5 1.6 2.0 2.1 2.2 2.3 2.4 General Make Type Service Duty Degree of Protection Reference Standard Rating Rated output Quantity Type of cooling Rated voltage Volt H. V. L. V. No. of phases
: : : : : : : : : : : : :
Reputed Make Two winding Outdoor Continuous IP:55 IS/IEC Equiv 5MVA 1 no ONAN 33kv 6.6kv 3
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2.5
2.6 2.7 2.8
2.9
2.10
3.0 3.1 3.2 a) b) 4.0 4.1 4.2 4.3 5.0 6.0 6.1 6.2 6.3 6.4 6.5 6.6 7.0 7.1 7.2 8.0 9.0 10.0 10.1 10.2 11.0
Rated Frequency Hz : 50 Vector group reference : Dyn11 Connection H. V. : Delta L. V. : Star LVn : Grounded through NGR Insulation H. V. : Uniform L. V. : Uniform Insulation level kVp/kV H. V. : 75/28 L. V. : 40/10 Temperature : Reference ambient temp. : 500C Temp. rise over reference ambient Top Oil measured by : 500C Thermometer In winding by : 550C Resistance Tappings Type : Off circuit Tap Changer (OCTC) Taps : 10% in steps of 2.5% Taps provided on HV winding : Yes Method of earthing : Neutral Grounding Resistor Neutral grounding Resistor Rated current : Less than 100A for 10 seconds Application : Grounding through Resistor Service : Outdoor Resistor material & connection : Punched stainless steel grid element type Maximum allowable temperature rise : As per Standards over ambient 500C Enclosure degree of protection : IP - 55 System Fault Level H. V. : 40kA L. V. : 40kA Conductor material : Electrolytic grade copper Creepage distance mm/KV : 3lmm/kV Terminal connections H. V. : Segregated phase bus duct/Cable L. V. : Segregated phase bus duct/Cable Marshalling box Degree of protection : IP:55
Power frequency to withstand voltage of 6.6 KV system should be 28KV.Impulse test voltage should be 75 Kv for system voltage of 6.6 KV. 4.7.12 Technical Particulars of Dry type transformers (LT)
1. Rated capacity 2. Cooling 3. Duty 4. Voltage ratio (HV/LV) 5. Impedance 6. Winding connection 7. Vector group 8. Termination
: As per requirement : AN : Indoor : 6.6 kV / 0.433 kV : As per IS : Delta/star : Dyn11 : HV : 6.6 kV cable LV : Cable 9. Tap changer : OFTC 10. Range of tap changer : +5% in 5 steps @2.5% 11. Short circuit level : 43.7 kA (6.6 kV) for 3 sec 12. Earthing system (6.6 kV) : Low Resistance earthed 13. Earthing system (415 V) : Solidly earthed 14. Bushing CTs : On neutral 15. Ratio of neutral bushing CTs : As required for Standby E/F Restricted E/F 16. Impulse test withstand voltage (HT/LT) : As per IS/IEC 17. Power frequency rated short duration : As per IS/IEC withstand voltage (HT/LT) 18. Temp. rise above 500C : 800C 19. Overload capacity : As per ANSI standard 20. Auxiliary supply voltage : 240V AC 21. Suitable for parallel operation : Yes VARIABLE VOLTAGE VARIABLE FREQUENCY DRIVE Basic design particulars All VVVF Converters shall have Digital Control Technology with vector less control. VVVF shall communicate to basic automation system. Type of connection Three phase frequency converters with rectification and inversion i.e. variable voltage and variable frequency output with current source / voltage source (PWM) inverters. Line reactors for harmonic and noise suppression Suitable for 415 V , 3 phase ,50 Hz , 4wire neutral earthed system Overload capacity 150% of the rated current for 1 minutes following 100% load & to meet the drive overload capacity. Efficiency more than 95% at full load Suitable to withstand vibrations more than 0.59. Output frequency : 5-50 Hz (Constant torque) 50-100 Hz (Constant power)
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4.8
Ramp rate: Linear acceleration and deceleration adjustable independently. Power components The main power components of the VVVF equipment shall have the following incoming AC side: Matching input power transformer / reactor AC line surge suppression network. ACB/MCCB Line contactors
Converter Inverter Equipment Load side Filter network Step-up transformer, as required Isolator and over-load relay for each motor. Thyristor converter bridge for AC/DC DC link circuit with reactor/capacitor Inverter bridge for DC/AC PLC to take care of interlocking and sequencing etc. Mimic panel where drive is HT
By-pass Arrangement By-pass arrangement shall be provided to operate the motor in case of failure in frequency converter.
Thyristor converter Minimum ratings of thyristor cells PIV rating dv/dt rating : : : 2.5 times the peak value of line voltage 200V/microsecond for voltage control and 1000V/microsecond for inverter control. 100A/ microsecond.
di/dt rating Protective features
AC line surge suppression network Under voltage in supply network Phase sequence protection and monitoring RC snubber network across each thyristor cell
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Thyristor fuse failure Under voltage in Dc line Over voltage in Dc line Over speed monitor Over load Earth fault Instantaneous over current Transformer fault
Cooling fan failure Stall monitor for motor Alarms Above condition shall be annunciated. Following warning signals shall also be provided as minimum in addition to above. Motor fault (winding / bearing temperature, vibration) as applicable Loss of frequency command Meters, Switches, Lamps Following shall be provided as minimum meters: Input volt meter and ammeter with selector switches Output voltmeter and ammeter with selector switches. Output frequency meter Selector switches, pushbuttons, and lamps as required. kW meter for drive ratings above 200 kW Regulation and controls Control facilities shall include following but not limited to: Reference speed setter Ramp generator Speed feed back Current feed back Trigger module Pulse transformers Logic control module Sequence module Zero speed/over speed monitor as applicable V/f control Current limiter Counter current/ regenerative braking unit as applicable active electronic components used shall be of industrial grade hermetically sealed Regulated power supply for reference setting:
Voltage variation of (+/-) 0.1 % with an input variation of +10% - 15% Steady state regulation of (+/-)0.25% guaranteed against 100 to 200 % load disturbance and + 3%, -6% input supply frequency variation. Facility to accept speed reference from computer/ programmable controller Construction features Floor mounted, free standing Dust and vermin proof Sheet steel clad Minimum 2.5 mm thick for panels. Minimum 2.0 mm thick for doors and side covers. Suitable to withstand vibrations to be encountered in steel plant application. Cubicles with illumination lamps, door switches, space heaters and adequate sockets for soldering. All control blocks plug in-type with necessary test sockets. Units shall be self contained and serviceable. Enclosure and Ventilation Enclosure conforming to IP-52 or more with weather proof enclosures Units shall be provided with cooling fans and louvers at the bottom sides. All louvers shall have fine mesh behind them. Ventilation through individual ventilation ducts, from bottom not acceptable. 4.9 RELAY PANELS Relay panels (RP) housing aux. contactors, timers, relays, etc. shall be provided for equipment control, sequential control, monitoring, safety alarm signals, annunciation signals, interlocking of drives ,signal exchange, interface with future system etc. shall be provided. Constructional features of R.P. shall be similar to MCC. At least 20 % spare auxiliary contactors, timers &relays shall be provided in the relay panel whose contacts and coils shall be wired up to terminals.20 % spare terminals shall also be provided. 10 % of auxiliary contactors, timer and relays shall be provided as spares which will be wired upto terminals. 4.10 PROGRAMMABLE LOGIC CONTROLLERS (PLC) Power supply system Input power supply shall be fed through UPS system. However, PLC shall be capable of withstanding power supply from electrical feeder. Built-in power supply units Suitable for the power supply system as specified above.
Independent units for the following: CPU and associated electronic units i) sensing the status of input devices ii) driving outputs if outputs are relays iii) Insulation level 2.5 kV for 1 minute. Protection against surge protection & short circuit Electronic over current protection with feedback feature. Central processor unit Modular and plug-in type 32 bit microprocessor based Scan time 2 m sec per one K Words of instructions or better Provision to latch desired outputs. The processor shall have in-built provision for examining input conditions, compare, compute, logical, conversion from/ to BCD, bit manipulation, block memory manipulation, diagnostic, shift, sequencing, conditional jumping, subroutine instructions. In-built PID instruction shall be preferred over separate PID hardware Module. Timer & counter modules shall be provided wherever required. Memory units Modular and plug-in type Word length 32 bit as per CPU Expandable in blocks of 4K Words Minimum size 16K Words EPROM/ RAM with battery back-up Back-up battery shall be as follows: i) Rechargeable Ni-Cd batteries with necessary charging circuit, Lithium or any other internationally acceptable type. ii) Able to retain memory for a minimum of 1 year with no power applied to the controller. Input units High density (32/16 Channels), modular and plug-in type Insulation level of 1.5 kV Input interrogation voltage 24V DC Discrete input units shall have the following: i) Filter to take care of contact bounce ii) Opto-isolation to isolate the input device from the controller iii) LED status indication iv) BCD input units suitable for four digit input Analog input units shall be as follows: i) Suitable for 4-20 mA / 0-10V / +/-10V inputs ii) With necessary A/D converter Pulse/ frequency input module shall have range up to 50 kHz. For very high frequency applications, the range shall be up to 1 MHz. Output units
High Density (32/16 Channel), modular and plug-in type Discrete output units shall be as follows: i) Opto-isolated outputs with insulation level of 1.5 kV ii) Rated for 24V DC, 2A Power devices like contactor or odd voltage actuating device shall be actuated through relays LED status indication BCD output units shall be as follows: i) Suitable for four digit output ii) Rated to drive seven segment LED displays iii) With insulation level of 1.5 kV Analog outputs shall be as follows i) Suitable for 4-20mA/ 0-10V/ +/-10V outputs capable of driving Digital / Analog Panel Meters ii) With necessary D/A converters iii) With insulation level of 1.5 kV iv) Any special requirement to control field devices shall be met by using separate interface modules PC based programming unit: PC used for Programming Terminal shall be commercial grade and latest available in the Suitable for developing programs in ladder diagram/ block diagram or statement form With facility for loading the program from floppy The terminal shall be capable of developing multiple programs offline without connecting to the programmable controller. Self diagnostic features Parity errors, cycle errors and under voltage Failure in central processor unit, memory and power supply. Indication of type of failure Automatic turning OFF of all outputs or optionally holding of all outputs in their last state on failure detection. Additional features Fully pre-programmed Connection of field devices with input units through ordinary multi-core copper control cables of 1.5 sq. mm size, upto a length of 500 m. Connection of remote input/ output units to programmable controller through remote I/O units, wherever substantial saving in cabling is envisaged. Serial interface, RS232C and better shall be provided High speed communication among PLC and operator consoles/ display units shall be provided through ethernet Latest appropriate model of HP Inkjet Printer to get hard copy of the program dump/ data logging / alarm logging / event logging / data trending etc. [Printer covered also under Programming Unit. Only one printer shall be supplied.]
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Special features Switch to disable all outputs of the controller during start-up/ debugging Fuse failure indication for outputs Mounted spares Min of 30 % of I/O modules used of each input & output type (with at least one module of each type) shall be offered as unused spare for each I/O rack. Minimum of 30% I/O rack slots shall be kept reserved for future expansion. 30 % spare memory capacity shall be provided Constructional features Unitised construction Floor mounted, free standing and indoor type Bottom cable entry Sheet steel clad Dust and vermin proof Suitable to withstand vibrations as per application All modules plug-in type Enclosure Conforming to IP-42 class Conforming to IP-54 class for remote I/O cubicles located in shops/ bays. Miscellaneous Programmable controllers, even if housed in air-conditioned enclosure, shall be suitable for normal industrial environment and ambient temperature upto 500C. A suitable fan with inlet air filter shall be provided at the top of each PLC panel for proper air circulation. Dual redundant processor shall be envisaged. Redundancy shall be provided in such a way that in case of failure of the main processor, the standby shall takeover automatically. The changeover shall be bump less and the system shall be fail proof. Redundancy shall be provided for complete processor system including CPU, Memory, Power supply and Communication sub system. Failure of a single processor shall not affect the system. In case of failure of complete processor system, outputs shall take fail safe state automatically. It shall be possible to generate the first out alarm contact by the PLC in case where a group of parameters are likely to trip a system. The communication subsystem between PLC processor and I/O subsystem shall be dual redundant. The communication subsystem between processor subsystem and PLC console shall be dual redundant, consisting of two separate communication interfaces and two buses, each one configured in redundant mode. No hardwired alarm system is required. All the alarms are to be displayed in OWS of PLC with multi tone buzzer and with alarm history provision. The software provided at the time of supply should be of latest version. Necessary license to be provided along with the software. The OS (Operator Station) desk and operator chair to be supplied by the bidder.
4.11
UNINTERRUPTIBLE POWER SYSTEM (UPS) General System Description The required kVA, 50 Hz, single phase UPS system shall provide continuously operating uninterrupted power supply to critical AC loads such PLC, instrumentation, etc. The capacity of UPS shall be suitable to feed power requirement of the PLC which shall control and monitor all the drives/mechanism of proposed additional coal handling system. The UPS system shall include but not necessarily limited to the following equipment: One 100% rated battery bank One set of Float Charger (FC) and one set of Float cum Boost Charger (FCBC) complete with associated incoming AC switchgear. Two nos. 100% capacity inverter banks. One no. DC switchgear, connecting above and also inverter banks stated above One no. 3 phase to 1 phase transformer and associated AC switchgear, 230V, 1 phase voltage stabilizer and backup source static switch. One no. 240 V UPS ACDB One no. four way manual bypass switch Static switches All inter connecting cables/wiring with connection accessories and other required items to make the system complete. Mode of Operation Normal Mode During the normal operation the UPS shall be used to provide power to the critical loads. The primary AC source shall be used to supply power to the rectifier charger. Two (2) no. chargers shall feed regulated DC power to their individual inverter banks and simultaneously float charge the backup batteries.
Emergency Mode Upon failure of primary AC source supplying three phase power to the battery chargers, the input power to the inverters shall be supplied from the back up batteries. When the AC power is restored, input power for the inverter and power for recharging the battery shall automatically be supplied from the rectifier charger. The batteries shall supply the inverter whenever the chargers are unable to supply the sudden load demand or their response to the load change is slow.
The output of the UPS shall feed all the essential loads through the ACDB. The connection from the UPS to ACDB shall be through a switch and fast acting semiconductor fuses, trip fuses and micro switch with alarm contacts. The feeders shall be designed by the bidder to suit the load requirements. Battery Charger Two (2) nos. each of 100% capacity, battery chargers shall be provided for each UPS system. These chargers shall be of static type and shall be provided with suitable transformer and full wave, SCR type rectifiers. Chargers shall share automatically the load during parallel operation of the inverter system and shall maintain output voltage within plus or minus one percent of the nominal value from no load to full load. Suitable ripple filtering circuits shall be provided to give a smooth DC output. The ripple content shall be limited to less than +5% on resistive load. The rectifier charger shall have float, equalising and boost charging facility as well as furnish the inverter input current. In the `Boost' mode, the boost' chargers shall recharge the completely discharged battery to full capacity in eight (8) hours. In charger system, all the standard protection, metering and static annunciation shall be provided. Static Inverters The two (2) nos. 100% capacity, (IGBT) required kVA inverters shall be static type consisting of SCR type inverter, static filters, integrated control modules including necessary oscillators, voltage regulators, current limiting and surge suppression networks. In addition, the inverters shall have features of soft start, wave shaping, transient recovery etc. Any other equipment required for normal operation of the inverter shall be included irrespective of whether specified or not. The output from the inverter shall be 240V AC, sine wave 1 phase. The output of the UPS shall be distributed to the essential loads through the AC switchgear. The connection from the UPS to the AC switchgear shall be through a switch and a quick acting fuse. The feeders shall be designed by the bidder to suit the load requirements. Static Transfer Switches The static transfer switches shall use SCRs and other static devices, for automatic transfer of load from the Normal source to the Alternate source. The continuous capacity of each static switch shall be equal to the full load capacity of one inverter. Maximum transfer time including sensing shall not be more than 1/4 cycle. The transition shall be "make before break" in both directions. The static switch shall be provided with fuses in both `normal' and `alternate' power
source. Provision for annunciation of failure of fuse or failure of alternate source shall be made. The switch shall be provided with surge suppression networks and shall also be rated to withstand transient voltages upto 150% of rated voltage. The short time rating of the switch shall be 150% of the rated full load current for two (2) minutes. Three phase/single phase Transformer and voltage stabilizer The transformer connection shall preferably be of Le Blanc type with delta connected winding on the three phase side or of open delta connection type. Other alternatives shall also be considered, provided the connection has minimum unbalance on the primary side. The transformer shall be encapsulated in Class B insulation. The transformer shall be adequately rated for the duty involved. The actual value may be slightly increased to take care of any losses in the static voltage stabiliser. The voltage stabiliser shall employ silicon solid state circuitry and shall maintain the specified output voltage for 0 to 100% load, with maximum input voltage variation as specified. Manual Bypass Switch The manual bypass switch shall be a four (4) position switch. It shall be used to isolate a static switch from its load and alternate power supply and to take it out of service without power interruption to the load. It shall be make before break type contacts, so that power supply to the loads is continuous during switch operations. It shall be capable of carrying rated continuous full load inverter current. Fault Diagonistic Unit Unit Fault diagonistic unit shall be provided to supervise UPS operation. Facility to take print out and recording of important parameters shall be provided. All the alarms shall be interfaced with DDCMIS. Battery DC battery shall be VRLA, sealed maintenance free type. Battery capacity should be 500Amp Hr with float charger of 110 Amps. Float cum boost charger should be 110Amps also. Battery shall be located in the battery room. Battery shall be suitable to maintain the power supply for at least 60 minutes (battery back time) in the event of mains failure. Necessary distribution board for distribution of power from UPS output to individual consumers. Permissible variations for mains power supply system shall be as follows: Voltage Frequency Harmonic distortion
: + 10 % , -15 % : As per IS : < 5%

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Output of the uninterruptable power supply system while delivering a load of its rated capacity (P.F of load shall not effect its output) shall have following variations; Voltage regulation :1% (For 0-100% load) Frequency : (+/-) 0.5% (For 0-100% load) Efficiency :Above 80% 100% to 0% and 0% to 100% load : Volt dip +10% Enclosure and ventilation Enclosure conforming to IP-41 class. Units shall be provided with cooling fans and louvers at the bottom sides. Individual ventilation ducts for each unit shall be provided. Distribution Board The DB shall have two buses, main and standby and shall be protected by semiconductor fuses with fuse monitoring device, bus healthy lamps, voltmeters and ammeters. Each load shall be fed by two independent feeders. Isolating and buscoupling switches shall be provided. The enclosure sheet steel thickness shall be 2.0 mm. with cold rolled sheets and 2.5 mm for hot rolled sheets and enclosure class protection shall be IP-54. TECHNICAL PARTICULARS 1. Application 2. Capacity 3. Degree of protection 4. Cable entry 5. Input Supply Voltage : Uninterruptible Power supply for PLC and other essential loads : 200 % of PLC load : IP 54 : Bottom : 415V+/- 10%, 3 phase 4 wire, 50 Hz +/- 5%
Batteries 1. Type 2. Application 3. Number of cells in each bank in series 4. Ambient temperature 5. D.C. nominal system voltage 6. Ampere hour capacity 7. Charging method proposed 8. Emergency load duration 9. Continuous load/duration
: VRLA, SMF : UPS System : As per requirement : Min.temp. :5.0 deg.C Max.temp. :50 deg. C : Suitable to inverter system : Bidder to furnish along with calculations : . Float and boost : 60 Minutes (battery back up time) : As per requirement
Battery chargers 1. Number required 2. Type 3. Method of charging 4. DC system voltage 5. Automatic voltage regulator required(AVR) 6. Regulation with AVR
: 2 nos. (1 FC + 1 FCBC) : Static : Float and boost charge type : To suit the system : Yes : +/-1%
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7. Permissible harmonics at rated continuous load : +/-2% 8. D.C. load requirement a) Momentary : As per requirement b) Emergency : As per requirement c) Continuous : As per requirement 9. Maximum time for boost charging : 8 Hours Inverters 1. Type 2. Suitable for parallel oper 3. Service 4. Output rating 5. Output Voltage 6. Phase 7. Frequency 8. Total harmonic content any single harmonic. 9. Duty 10. Overload capacity 11. Efficiency 12. Cooling 13. Synchronization with source Static transfer switch 1. Capacity Continuous 2. Type 3. Voltage 4. Frequency 5. Transfer time Manual bypass switch 1. Capacity Continuous 2. Type 3. No. of positions 4. Short time rating 5. Transfer 4.12
: Static : suitable for parallel operation : Indoor : As required : 240 V A.C. : Single phase : 50 Hz : 5% RMS maximum not more than 3% distortion in : Continuous. : 125% for 15 minute at 0.8 p.f : Not less than 80% at rated load : Natural air cooled : Yes
: Make and carry F.L. current of inverter at 0.8 p.f. : Make before break : 240V, single phase : 50 Hz : 1/4 cycle maximum
: Make and carry F.L. current of inverters at 0.8 p.f. : Make before break. :4 : Short time rating of the inverter for 1Sec & 150% of full load current for 2 minutes. : Manual.
RESISTORS AND RESISTANCE BOXES The resistors offered shall be arduous duty, industrial application, shock and vibration proof, unbreakable, rigid and rust proof punched chromium steel alloy grid and conforming to the requirements stipulated in IPSS 1-10-002-82 "Specification for resistance boxes for power circuits" with latest amendments. Cast iron resistors shall not be acceptable.
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The resistors shall be assembled on high quality asbestos or mica insulated high tensile steel tie rods and separated from one another by mica or asbestos washers in required numbers and rigidly supported to eliminate vibration, breakage, displacement or deformation. Tappings shall be provided with every resistance element indicating resistance value to enable adjustments, if required. Individual grids shall be TIG welded at the junctions and terminal taps shall be welded to grids, ensuring a consistent current path. The grids shall be assembled on heavy steel frames which shall be suitably stacked, housed and mounted in minimum 2.5 mm CRCA sheet steel enclosed cubicles with louvers along with wire mesh to ensure good ventilation and mounted on a base frame of ISMC 125 . The panel of resistor units shall be free standing, floor mounting type and provided with two numbers of grounding pads, tapped holes and bolts suitable for connection of grounding conductor of 50x6 mm G.I flat. Enclosure shall be in single front execution. Individual banks shall be mounted on bracket welded to the frame, as such individual bank can be withdrawn out from enclosure without disturbing other banks. All resistor banks shall be provided with adequate lifting facility for handling during installation and over hauling. The terminals shall be brought out in the separate terminal box (IP-55) on one side and marked with metallic tags for external connection with AYFY cables. The current carrying capacity of the resistor shall be so selected that the temperature shall not exceed 370 deg. C. 4.13 PLANT ILLUMINATION SYSTEM The scope includes complete plant illumination system to achieve required illumination levels as per IS or as per CBIP guidelines. The scope shall cover the following illumination systems: Normal AC lighting DC Emergency lighting. Maintenance lighting Peripheral, road/street and area lighting within battery limit
Illumination shall be provided in all the following premises: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Switchgear room at WT substation Battery room at WT substation Transformer rooms A/C & ventilation Room Peripheries of buildings Coal conveyor galleries Dust suppression MCC room Junction houses and transfer towers Wagon Tippler System Control room of WT
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11. 12. 13. 14.
MCC room for WT Roads/streets within battery limit Area/sub areas within battery limit Any other premise coming under the battery limit
The illumination system shall include the following in required quantities: Lighting DBs/ Sublighting DBs Light fittings with lamps Lighting fixtures and accessories Cables and wiring Ceiling fans Receptacles For street light LED lamps preferable High mast system should have Metal Halide Lamps Steel tubular poles Switches Conduits & brackets Hangers & clamps JBs Timers/photocell
All lighting in outdoor area such as coal yard, stacker/reclaimer areas, road/street and area lighting as well as peripheral lighting shall have auto ON/OFF facility with suitable 24 hrs timer. All the light fittings shall be dust and weather proof.
Illumination levels envisaged for different areas will be as indicated below: S.N. Area 1 Switchgear room 2. 3. 4. 5. 6. 7. 8. 9. Battery room Transformer room MCC room WT Control Room Junction house Conveyor gallery Peripheral lighting Street / road / area lighting Lux 250 100 200 250 lighting 250 200 100 150 100 Fitting type FTL FTL FTL FTL FTL MH MH MH SV Remarks AC normal lighting DC emergency lighting AC normal lighting DC emergency lighting AC normal lighting AC normal lighting DC emergency AC normal lighting DC emergency lighting AC normal lighting AC normal lighting AC normal lighting AC normal lighting
Lighting DBs of all the areas shall preferably be located inside the rooms like switchgear cum, control room, etc.
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Sufficient numbers of LDBs, SLDBs, lighting poles, 415/240 V switch socket outlets, ceiling fans with regulators, earthing pits, MCB controlled socket outlet, junction boxes, etc shall be considered under scope of the Bidder as per actual requirement. DC emergency lights shall be fed from separate DCELDB. Similarly, power receptacles shall be fed from dedicated Receptacles DB. DCELDB at WT SYSTEM substation shall be fed from Purchasers DCDB. Receptacle DB shall be fed from Bidders PDBs/aux. PDBs. Sufficient numbers of DCELDBs and Receptacles DBs shall be considered by the Bidder as per requirement. LIGHTING DISTRIBUTION BOARD (LDB) 415V, 3 phase, 4 wire, 600A, 50 kA (short time rating for 1 sec.) indoor type. Board shall be single front, metal clad, front matched, free standing, floor mounted, dust and vermin proof, non-draw-out, fully compartmentalized and extensible on both sides, IP54 type enclosure. Incomers shall be draw out type. LDBs shall have a series of panels of uniform height placed side by side having front access for operation as well as cabling and access for maintenance of busbars. LDBs shall have two incomers and one bus coupler. Separate busbar compartments provided on the top shall have bolted covers in the front and rear. The main busbars shall have continuous current rating as required. The rating of the neutral busbar shall be 50 % of the phase busbars. The busbars shall be of aluminum alloy conforming to IS 5082. The busbar sizes shall be so selected that with the passage of rated current, the temperature rise over 500C ambient does not exceed 400C as measured by thermometer. Each cubicle shall have segregated feeder compartments arranged in tier formation with each compartment housing one feeder circuit with lockable hinged door having neoprene gasket all around. Modular construction shall be adopted to cater for different sizes of feeders. The cubicles shall have common horizontal busbar chamber at the top and vertical risers at the back. The cable compartment shall be provided on the side with cable entry arrangement from bottom. The busbar and cable compartments shall be provided with bolted cover plates. The rear cover shall be easily removable type construction. The LDBs shall conform to IS 8623 for factory built assemblies, IS 13947 for general requirement of switchgear and IS 5578 & IS 11353 Guide for making and identification of conductors and apparatus terminals. The LDBs shall be fabricated from CRCA sheets with 2 mm thickness for all members except the doors of the modules, the rear covers, the covers of cable chambers and busbar chambers which may be of 1.6 mm with adequate stiffeners to prevent buckling. Non-load bearing partition walls may be of 1.6 mm thick sheet steel.
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The cubicles shall be made up of bolted sheet steel members and side panels of pressed sheet steel with neoprene gasket at all joints and openings including doors. Bus bars shall have same cross-section throughout the length. Rating of the neutral bus bar shall be 50% of the main bus bar. Earth bus bar shall run in bottom chamber throughout the length of the panel. The LDBs shall have necessary provision at either end for future extension by bolting additional section. The busbar shall be supported with high quality non-hygroscopic, insulating, self extinguishing and fire retardant insulating material, of adequate mechanical strength so as to withstand, without damage, effects of available short-circuit current. The busbars shall also be properly spaced of facilitate taking vertical connections to individual units. The connections to individual units shall be taken by taped busbars. The busbars shall be of uniform cross-section and the main busbars shall run throughout the length of the board. Similarly vertical droppers shall extend for the full height of the panel except the bottom chamber. The connection between busbars of different metals as well as their connection with the terminals of the equipment shall be made in such a way to prevent corrosion and local heating. Liberal space shall be provided for cabling and to accommodate any conventional type of cable glands for PVC insulated and PVC sheathed armoured aluminum conductor cables. The cables compartment shall have provision for clamping of cables inside compartment on perforated sheet steel sections. The LDB shall have following meters in each of the two incoming feeders: One no. digital type voltmeter with accuracy class of 1.0 One no. digital type ammeter with accuracy class of 1.0 One no. digital energy meters with accuracy class of 1.0 Suitable CTs with accuracy class of 1.0 shall be provided in the incomer modules for the above metering. Moulded Case Circuit Breakers LDBs shall have moulded case circuit breaker triple pole, air break type with independent manual quick make and quick break type. MCCB shall be capable of breaking rated current at 0.3 pf at rated voltage. MCCB shall withstand the fault current envisaged for 415V system and shall be current limiting type. All outgoing feeders shall have earth fault protection. The MCCBs shall be suitable for panel mounting and shall be fixed type. All live parts shall be enclosed in moulded case and all contacts shall be silver plated. The breakers shall be trip-free and with quick make & break operating mechanism. The MCCBs shall be provided with ambient
temperature compensated bi-metal overload releases and a magnetic short-circuit release with inverse time characteristic. Releases shall be either static or microprocessor based. The operating handle shall be included with module door such that the door can be opened only with the breaker in the OFF position. The MCCB handle after the breaker tripped due to a fault shall occupy an intermediate position. The breaker shall be capable of interrupting a full fault current corresponding to the fault level specified. MCCBs shall have a breaking capacity of 50kA at 415V. Current limiting MCCBs are not permitted. The LDB shall be consisting of following feeders: Incomer : Bus coupler : Outgoing : 63 A MCCB 10 Nos. 2 Nos. each of 600 A MCCB 1 No. of 600 A MCCB 125 A MCCB 6 Nos.
SUB LIGHTING DISTRIBUTION BOARD (SLDB) 415V, 3 phase, 4 wire, 125/63A (as applicable), indoor/outdoor type (as applicable) generally conforming to IS 13947 and IS 8623 as applicable. The SLDB shall comprise of one number of incoming TPN MCCB, three nos. of DP MCBs, and requisite number of outgoing SPN MCBs (as specified) and adequately rated bus bars. The SLDBs shall also have timer, contactors, A/M switch, etc as per requirement. The enclosure class of SLDB shall be IP 54. The terminals of MCCB shall be fully shrouded. The boards shall be of industrial, totally enclosed dust-proof, wall mounted, sheet steel cubicle design. The thickness of the sheet steel shall be 2 mm. The boards shall have welded back and sides and gasketted hinged door at the front with door handle and suitable locking devices. For boards with incoming isolating switch the access to the operating handle shall be from the front of the cubicle without opening the front door. Operating knobs of outgoing MCBs shall be accessible only after opening the front door of the cubicle. Protective insulated cover plate shall be provided inside the cubicle to shroud all the live parts with only the operating knobs of the MCBs protruding outside the cover plate. The boards shall also be dust-proof in door-open position. Adequate space shall be provided within the boards to facilitate termination of incoming and outgoing cables. The boards shall be factory wired and assembled. Where specifically called for, the boards shall be of special weather-proof design suitable for outdoor installation. The miniature circuit-breakers (MCBs) shall be heat resistant plastic moulded type generally designed, manufactured and tested as per IS 8828. Unless specified otherwise all MCBs shall be provided with quick break trip free mechanism and direct acting thermal overload and shortcircuit trip elements. The short-circuit breaking capacity of the MCBs shall not less than 9 kA at 0.8 power factor. Single-phase MCBs which are not provided with built-in phase barriers, and
mounted adjacent to each other and connected to different phases, shall be provided with adequate insulated phase barriers, shall be selected from standard current rating. The TPN busbars shall have continuous current rating as required. The busbars shall be of copper and sizes shall be so selected that with the passage of rated current, the temperature rise over 500C ambient does not exceed 400C as measured by thermometer. The minimum size of busbars shall be 25 x 3 mm. The busbars shall be properly supported with high quality nonhygroscopic, self extinguishing and fire retardant insulating material of adequate mechanical strength so as to withstand, without damage, effects of available short circuit current. The busbars shall also be properly spaced to facilities mounting of MCBs and taking connections to individual units. Detachable cover plate shall be provided at top and bottom for cable glands suitable for PVC insulated, PVC sheathed armoured aluminum conductor cables or for direct entry of conduit. Cable terminals shall be suitable for aluminum conductor cables and so arranged to enable connecting of each circuit without disturbing any other circuits. Identification labels, inscription plates, danger boards, etc shall also be provided as per requirement. Earthing arrangement and danger plates shall be as specified. SLDBs shall have automatic group switching arrangement for which timer of robust construction and suitable contactors shall be provided in each board. Bypass arrangement of timer in form of auto/manual switch shall also be provided in the SLDBs. The controller shall sense the outdoor light and shall switch ON through auxiliaries contacts when the sunlight falls bellow a present value. It shall remain in this position till dawn when it shall switch OFF when the sunlight remains a preset level. Suitably engraved identification labels and inscription plates shall be provided for each circuit. The same shall also be provided for the boards. One continuous G.I earth bus shall be provided in the bottom part of SLDB along the full length of the board with two bolted type earthing terminals to comply with the requirements of Indian Electricity Rules. Proper danger plates shall also be provided on each board. Each SLDB shall be provided with padlocking facility with sufficient number of keys. The following types of SLDBs shall be provided: SLDB, Type A (To be used for 2x40 W FTL light fittings) Incomer Outgoing Outgoing : : : MCCB, 4 POLE, 63 A : 1 No. MCB, DP (63 A) : 3 Nos. MCB, SPN (10 A) : 10 Nos./Phase (Total 30 Nos.)
SLDB, Type B (To be used for 250 W HPSV/MH light fittings inside the building) Incomer : MCCB, 4 POLE, 63 A : 1 No.
Outgoing Outgoing
: :
MCB, DP (63 A) : 3 Nos. MCB, SPN (16 A) : 6 Nos. per phase (Total 18 Nos.)
SLDB, Type C (To be used for 250W/150W/70 W HPSV/MH light fittings outside building) Incomer Outgoing Outgoing : : : MCCB, 4 POLE, 63 A : 1 No. MCB, DP (63 A) : 3 Nos. MCB, SPN (20 A) : 5 Nos. per phase (Total 15 Nos.)
SLDB, Type D (To be used for 250 W HPSV/MH street light fittings) Incomer Outgoing : : MCCB, 4 POLE, 125 A : 1 No. MCB, TPN (63 A) : 8 Nos.
Sufficient number of SLDBs of different types (A, B, C and D) shall be used as per requirement of different areas and sub-areas of the coal handling plant. Exact quantity of SLDBs of various types shall be finalized during detailed engineering. Bidder shall consider as per requirement subject to minimum one number of each type of SLDB. RECEPTACLE DISTRIBUTION BOARD Receptacles DB shall be suitable for 415V, 3 phase, 4 wire, 125 A, indoor type. Board shall be single front, metal clad, front matched, dust and vermin proof, draw-out, fully compartmentalised and extensible on both sides, IP54 type enclosure. Shall have isolated busbar chamber for main busbar at the top, running through out the length of the board. Chamber shall have removable cover. Busbars shall have same cross section through out the length . Rating of the neutral busbar shall be 50% of the main busbar. Earth bus bar shall run in bottom chamber throughout the length of the panel. Shall have Moulded case circuit breaker (MCCB) triple pole, air break type with independent manual quick make and quick break type. MCCB shall be capable of breaking rated current at 0.3 pf at rated voltage. MCCB shall withstand the fault current envisaged for 415V system. Generally all boards will have following feeder arrangement. Incomer Outgoings : : MCCB TPN of 125A : 1 Nos. MCCB TPN of 32 A : 10 Nos.
220V DC Emergency LDB (DCELDB)
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The DCELDB used for emergency lighting distribution shall be industrial heavy duty type suitable for 2-wire 220V DC operation, and shall have a DC double pole power contractor and requisite number of auxiliary contractors and timers and outgoing feeders protected with DP MCBs of suitable ratings. The incomer shall be of double pole load break design suitable for operating on 220V DC. The enclosure shall be made of 2 mm thick sheet steel and shall have requisite number of cable glands and terminal strips for incoming and outgoing cables. The control circuit voltage shall be of 220V DC. The DCELDBs which feed all the emergency lighting points shall be automatically switched on the event of power failure through a separate circuit which sense under voltage of normal AC supply at the specified location. These emergency lighting fittings shall glow for a preset time and shall be switched OFF automatically through a time relay in case the normal AC power supply is not restored within that time. Feeder configuration of DCELDB shall be as follows: Incomer Outgoing : : MCCB, DP (63 A) 1 No. MCB, DP (10 A) 16 Nos.
415 V switch outlets Switch socket outlets and plugs for 415 V, 3-phase circuits shall be of four-pin (three pole and one earth), non-reversible type enclosed in dust-proof 2 mm thick sheet steel enclosures. The socket outlets shall be provided with fuses and shall have isolating switch interlocking as per IS:4160 such that it can be switched ON only when the plug has been inserted and plug can be provided for the socket outlets. The isolating switches shall be of category AC 23 conforming to IS 13947 (Part 3). The socket outlet shall be suitable for terminating aluminum conductor cables either directly or through GI pipe and shall be provided with compression type lugs. The socket outlet shall be supplied with metal clad plug. The socket outlets and plugs shall have porcelain base and shall be of 32A rating. Weather-proof enclosure shall be used for outdoor installation. Inscription plate shall be provided indicating the voltage rating for the switch outlet. 240 V switch socket outlets Socket outlet for 240 V supply shall be of 3-pin (two-pole and one earth) nonreversible, metalclad, dust-proof, industrial type suitable for horizontal insertion generally as per IS 1293. 240 V socket outlets shall be controlled by rotary type switch mounted flush in the socket outlet box. Operating handle of the rotary switch shall be fixed in such a manner that it will not be possible either to insert or to withdraw the plug without switching off the supply. All socket outlets shall be supplied with heavy duty type plug and cap with chain. The isolating switches shall be of industrial type of category AC 23. The isolator shall be housed in dust and vermin-proof sheet
steel enclosure suitable for terminating aluminum conductor cables either directly by means of cable gland or through conduits. The current rating for the socket outlets shall be 20 A. Wherever called for HRC fuses shall be incorporated in the socket outlet box. Inscription plate shall be provided indicating the voltage rating and feeder identifications for the switch socket outlet. MCB Controlled Socket Outlet The MCB controlled socket outlet shall be similar to the above switch socket outlet and provided with industrial type socket outlet with cover suitable for 240V, 20A single phase AC and controlled through single pole 20A MCB. Ceiling Fans and Regulators Ceiling fans regulators shall be designed, manufactured and tested as per IS:374. The fans shall have totally enclosed, capacitor start and run motors, suitable for operation on 240V, single phase, 50 Hz AC system. The electronic type regulator shall have ON OFF position next to the lowest speed contact, shall be provided with necessary harmonic filters and shall be suitable for operation at 500C ambient temperature. Down rods required for installation of ceiling fans shall be included by the Bidder. Lighting Poles Steel tubular road lighting poles with single outreach shall be of swaged and welded construction conforming to IS:2713-1969 with latest amendments. The outer surface of pole above foundation shall be painted with two coats of red oxide zinc chromate primer paint as per IS:2713 and finished with two coats of synthetic enamel paint of approved shall not be less than 100 microns. The outer surface of the pole embedded in concrete foundation as well as the entire inner surface shall be painted with two coats tar based general type black paint. The poles shall be provided complete with fixing arrangement for loop-in and loop out box and lighting fittings. The Bidder shall submit a drawing indicating the general arrangement and the final design and arrangement shall be subject to purchasers approval. The 415 loop-in loop-out box shall be weather-proof, dust tight, sheet steel enclosure suitable for outdoor installation. The box shall have hinged front with front locking device. 3 Nos. open type terminals for taking looping connection of 4C x 16 sq.mm Al conductors. Conductor power cables and 21C x 2.5 sq.mm PVC copper wiring cable through rewirable fuse cutout to the control gear. The box shall be supplied complete with 63A terminal block, 5A rewirable fuses cutouts, brass / aluminum alloy cable gland, clamps, lugs, earthing terminals, danger plates and other required hardwares.
Street lighting pole shall have a single outreach suitable to hold the street lighting fitting. Flood lighting pole shall have a cross bar on top of the pole and shall be suitable for fixing the flood light fitting. Earthing provision of lighting poles 2 Nos. 8 SWG GI wire shall run throughout along with street light poles in loop in loop out arrangement. One number of earth pit shall be provided for every 5 nos. of lighting poles. Each earth pit shall be consisting of 40 NB GI pipe of 3 mtr length, funnel, salt, charcoal, cast iron cover, clamps, etc. Junction Box The 415/240V, TPN junction boxes shall be of fabricated from 2mm thick sheet steel suitable for mounting on wall / column. The box shall have suitable provision for entry and termination of aluminum conductor, PVC insulated cable supplied complete with terminal blocks, earthing terminal, wire support etc. The box shall be painted with anti-corrosive primer both inside and outside and furnish with two coats of approved colour paint. The junction boxes used outdoors shall be with suitable canopy arrangement. The junction boxes shall be suitable for terminating one (1) incoming cable and two outgoing cables. Lighting Fittings High Mast light fittings shall be with Metal Halide (MH) lamps).All over fittings shall be with LED lamps. All lighting fittings and accessories shall be manufactured from best quality materials and shall be completed in all respect ready for installation at site. Unless otherwise stated lighting fittings shall have provision for 25 mm / 19 mm dia conduit (as applicable) entry for low-bay fittings. Medium bay fittings shall have eyebolt suspension arrangement. Terminals off all fittings shall be suitable for connecting 2.5 sq mm flexible, copper conductor, PVC insulated and PVC sheathed cable for low-bay fittings and 2.5 sq mm flexible copper conductor cable for high bay fittings. All the LED fittings and MH fittings shall be non-integral type. Control gear boxes shall be mounted at man height for ease of maintenance.
High mast fittings (Non-integral type) : 2 nos
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Non-integral type asymmetrical beam flood light fittings with 2x400W MH lamps complete with control gear, accessories, etc suitable for installation on 30 M high lighting mast as per technical specification (Bajaj BGENF 22 or equivalent with MH lamps) shall be mounted on the lantern carriage of each of the high lighting mast. Lamps All lamps shall be of high lumen output and with long life. Incandescent Lamp All general service incandescent lamps shall be gas filled, clear finished and coiled coil type where possible. Incandescent lamp cap shall be of screwed type having GES/ES thread depending on the sizes of the lamp. Fluorescent Lamp All fluorescent lamps shall be of day-light type unless otherwise specified and shall be suitable for suitable for switch-start with bi-pin type cap. Sodium vapour lamps shall be suitable for universal burning position. The elliptical outer bulb shall be coated inside the diffusing powder and shall have good colour appearance. The sodium vapour lamp shall be of screwed type E40/E27 base depending upon the wattage of the lamp.
Ballast The ballast shall be of electronic type and well tried out design to give trouble-free operations with long service life having provisions for suitable tappings in steps. Capacitor Capacitor shall consist of element wound from layers of higher purity aluminum foil and capacitor paper contained in aluminum cylindrical can. The capacitor shall be vacuum dried and impregnated. The can shall be hermetically sealed and terminals provided over porcelain insulations. The capacitor shall conform to IS 1569. Lamp Holder The lamp holders shall have spring loaded contacts for positive contact with pins so as to prevent the lamp from being extinguished due to vibration. The holder shall be such that the lamps can be removed easily whenever required for cleaning or replacement purposes. For fluorescent lamp, bi-pin lamp holder shall be provided. The holder of incandescent lamps upto 200 W shall be of ES type.
The starter holders shall be of well tried-out design and of robust construction with provisions for easy insertion and removal of the starter ensuring correct contacts by means of strong spring action. Push button for group switching of lights The push buttons (one no. ON and one no. OFF) shall be mounted on cast iron box with 2NO+2NC contacts and terminal block. Conduits and Conduit Fittings Surface conduit installation shall be carried out using hot dip / electro galvanised rigid steel seamed by welding, screwed type, designed, manufactured and tested in accordance with IS 9537. The various conduit accessories like couplers, bends, elbows, reducers, saddles, clamps, lock nuts, junction boxes etc. shall conform to IS 3837 shall be supplied and erected as per requirement along with the conduits. Point wiring materials and Accessories The point wiring materials and accessories for lighting for installation, fan points, sockets etc. where specified shall include wiring cables, conduits and conduit fittings, wiring accessories inclusive of switches, sockets, fan regulators, switch boxes, junction boxes etc.
Point wiring The wiring cables used in point wiring installation shall be 1100 volts grade PVC insulated single core flexible stranded copper conductor type confirming to IS:694. The size of conductors to be adopted shall be 2.5 sq.mm for lighting, fan and 5/15A socket outlet circuit and 2.5 sq.mm for 15A socket power circuits. Wiring Accessories The various electrical wiring accessories viz. Switch boxes, switches and sockets shall confrom to IS 5133, IS 3854 and IS respectively. The switch boxes shall preferably be of passed sheet steel cadmium coated and passivated or galvanised with knockouts at the top and the bottom for conduit entry. The surface mounted type boxes shall have necessary provisions for mounting on the wall. Earthing terminals shall be provided in the box. Junction boxes provided at intermediate points shall also be identical in construction to the switch boxes. The switch and junction boxes shall be of standard dimensions with adequate wiring space. The switches and sockets shall be made of superior quality engineering plastic with excellent dielectric properties. The switches shall be of piano key design and shall have adequately rated switch contacts. The switch contacts shall be silver tipped electrolytic grade copper. The switch plate forming part of the switch box cover shall be made of plastic material and shall be made with number of slots in
which the switches and sockets shall be assembled. The sockets shall be of three pin design with phase neutral and earth conducts. Earthing All electrical equipment shall be effectively earthed as to meet the requirements to Indian Electricity Rules and IS:3043. Earthing conductors for individual equipment shall be of either galvanised mild steel flat or stranded/solid G.I. wire as specified. Earth pits for street/area lighting poles The earth pits shall be consisting of 40 NB GI pipe of 3 mtr length, funnel, salt, charcoal, cast iron cover, clamps, etc. The Bidder shall include all civil work as per requirement. All accessories shall be included as per requirement. 4.14 LIGHTING HIGH MAST WITH FLOOD LIGHT FITTINGS General a. High mast tower for floor lighting shall be factory fabricated mild steel plates welded, polygon section, hot dip galvanized and provided in standard lengths. b. The structure shall be 30 meter high, well tried, proven design to withstand high wind speed of 180KM/ hr. c.The mast shall have a movable lantern carriage tower from the top of tower to bottom and vice-verse with the help of a motorised winch arrangement (with motor of minimum 2.2 kW capacity) and shall be provided with suitable gears, pulleys and ropes. The reeling of ropes shall be such that to prevent twisting & tangling. Means shall be provided for normal operation of the winch in case of failure/ non availability of power to the motors. Safety of lantern carriage in case of breakage of the rope shall be ensured by arresting free fall of the lantern carriage to the ground by providing Safety locking arrangements. d. All the carriage components shall be galvanised and mounted inside the tower. The tower shall be provided with a suitable man entry door at the bottom section to facilitate inspection and maintenance. The door shall be weather proof and provided with safety lock to prevent unauthorised access. e. The lantern carriage shall be symmetrical, robust construction housing the luminaire and control gear boxes. The cables to the luminaries shall be run inside the tubes of the lantern with junction boxes provided for branch off cables. f. Proper luminaries carriage ring support arms shall be provided for supporting the luminaries carriage ring when the latter is lowered for maintenance of luminaries. Lantern carriage ring should be in channel tube and with concealed wiring the carriage should be essentially have
a 3 points suspensions system. The mobile luminaries carriage shall be evenly balanced Rubber Paddle Guide Ring shall be incorporated as a buffer arrangement between mobile luminaries carriage and mast shaft. This is to prevent damage to mast surface during raising and lowering operation of mobile luminaries carriage. g. The winch shall be provided with a separate control panel housing the control for the winch drive motor and controls for switching the luminaries. It shall be complete with switch fuse units/MCCBs, starters, contactors, etc that may be necessary to the operation of the light tower. It shall be suitable for outdoor installation with IP-65 degree of protection. It shall be suitable for mounting on a suitable plinth adjacent to the high mast tower. h. The winch must be of robust design and completely self-sustaining type without the need for brake -shoe, springs or clutches. It can be removed from the mast for maintenance if the need arises in the future with the lower carriage on the top. The reduction gear of the winch shall be of endless worm gear, operating in oil bath. The minimum safe working limit of the winch shall not be less than 750 Kg. i. A minimum 6 turns of wire rope shall be on the drum when the mobile luminaries ring is fully lowered to rest on the luminaries supporting arms. j. The winch is entirely self- sustaining under all normal circumstances and it is not dependent on the brake or restraining device that uncontrolled or dangerous runaway speed shall occur in the event of the total failure of this device. Slip test on winch is carried out by the manufacturer. Test certificate and report shall be submitted up, on request. k. The speed of the raising and lowering of lantern carriage ring shall be at least 1.5 meter Per minute. l. The high mast shall be fitted with flexible standard G.I / S.S. hoisting wire ropes of 7 x 19 construction with a minimum breaking strength of 1900 kgs. The combine lifting capacity of the hoisting wire ropes shall have a factor of safety not less than 5 times the safe working load (SWL) of the winch and shall be entirely suitable for the design application. m. A transition plate shall be incorporated to balance the carriage from below of the mast. n. Cable for lighting and winch control shall be as per approved scheme. The cables shall be clamped or rolled so that no twisting of cables happens while the winch is hoisted or lowered. Electrical cable shall be PVC coated round flexible cable suitable for small bending radius. One standard multi core flexible electrical cable with 4 sq mm conducting areas shall be provided for connecting of power supply to the light source and shall terminate at the stationary connecting board in the base compartments. o. The high mast shall be suitable for asymmetrical loading of with 16 nos. of 2 x 400 W MH luminaries mounted on the lantern carriage. The luminaries shall be grouped in individual 240V RYB circuits fed through time switches. It shall be possible to switch the lamp bypassing the timer. The timer shall be programmable digital/analogue quartz controlled, high accuracy
real time clock. It shall be set from 6 PM to 6 AM or any other intermediate time. The tendered shall indicate the controls offered by him clearly in the offer. p. The successful Bidder shall submit design and preliminary data for the design of foundation of the high mast tower indicating the requirements of embedded inserts etc. The foundation shall be designed and provided by the purchaser. Bidder to include foundation bolts etc which shall be embedded in the foundation. Grouting of the bolts shall be done by the Bidder. q. The high mast shall be provided with lightning protection with air- termination and downcomers as per requirements of BIS and aviation warning lamps as per statutory and civil aviation requirements. All metallic portions of the high mast shall be effectively earthed and provided with two earth pits near the base. Effective earthing for luminaries shall be provided during normal operation and in lowered position. r. Mast structure is designed to withstand wind velocity conforming to IS 875 (Part-III)-1987. Mast Design Criteria The high mast and the lowering system with the required number of floodlights and lamp controls gears etc. In place shall be capable of withstanding a sustained basic wind speed of 180 Km/ hrs. The design shall be in such a manner that it is capable of withstanding external forces exerted by wind pressure and should have a minimum wind load factor of 1.25 and material factor of 1.15. Design life of mast shall be 25 years. CONSTRUCTIONAL FEATURES OF MAST The mast shaft shall be made with the best steel grade, in compliance with MS IS- 2062/BSEN 10025 having adequate characteristics w.r.t. minimum yield strength, tensile strength and minimum elongation for thickness. The steel grade for accessories shall also be MS IS 2062 or equivalent, having adequate characteristics w.r.t. minimum yield strength, tensile strength and minimum elongation for thickness. Each mast section to be delivered to site shall have a minimum length of 10.7 Mtrs. The Mast sections shall have Single longitudinal weld from Bottom to Top. The base shall have a flange plate for high mast onto the concrete foundation by anchor bolts. The mast shall be fabricated and welded longitudinally to form a tapered section with telescopic friction slip joints. All welding shall be to IS 816 / 82 having the following basic requirements.
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The wall thickness of each section shall be designed to withstand the loads to which the high mast shall be subjected to, but shall not be less than 8 mm for base section and 6 mm for other sections and minimum base dia shall not be less than 530 mm. Connection between the various sections, shall be achieved by telescopic slip joints, the overlapping length being at least 1600mm slip joint assembly shall be perform at site. Shaft section shall not be joined by circumferential weld or bolting at site. The base plate shall be free from lamination and shall be single flange constructed with holes jig drilled for anchor bolts passage. The bottom of the base mast section shall be securely welded to the base plate by complete penetration fillet welding. The welded connection of the base plate to the mast section shall fully develop the strength of the section. The base section shall be equipped with a hinged service door. The service door opening shall be complete with a close fitting weatherproof and equipped with a vandal resistant lock. The service door shall not be smaller than 1400 mm x 300 mm the opening shall be reinforced by a thick steel door frame. Base plate of suitable dimensions and thickness, diameter, size and the placement of anchor bolts shall be determined by calculations. Anchor bolts shall be of deformed steel reinforcement bars having the adequate characteristics w.r.t. tensile strength. Welding of two or more anchor rods of shorter lengths to achieve the design length shall not be permitted. No welding shall be allowed on the anchor rod body. Adequate earthing and earthing terminal shall be provided within the access door area of each Mast. All high mast shall be hot dip galvanized, in accordance with IS 2629 / TR 7 Timer control panel shall be provided with overload and single phase preventor. Timer control panel shall be outdoor type. Motor capacity of the winch Motor shall be of hoist duty and of adequate capacity with 15 % minimum margin over mechanical power requirement. Minimum capacity of 2.2 kW shall be considered. 4.15 EARTHING AND LIGHTNING PROTECTION EARTHING PROTECTION Bidder shall include complete earthing of WT substation, MCC rooms, Wagon tippler, apron feeder, sizer & conveyor drives etc. The underground earthing mats also shall be done by the Bidder. Risers shall be available at all the premises for interconnection of own earthing network. However, Bidder shall provide complete separate earthing for transformer neutrals. Bidder shall include the following in each and every substation:
1. 2. 3.
Earthing ring mains at WT substation and all the electrical rooms/premises Equipment earthing Transformer neutral earthing providing dedicated pits
Bidder shall include complete earthing material including earthing strips, earth electrodes other accessories for treated earth pits, etc. and carry out earthing ring mains, earth pits, interconnections, equipment earthing, all associated civil works, etc at all the ubstations. All the connections of earthing ring mains with available underground earthing grid of respective substation/premise shall be under scope of the Bidder. Separate dedicated treated earth pits shall be provided for transformer neutrals. Two nos. such earth pits shall be provided for each of the transformers. The treated earth pits shall be consisting of 3 mtr 65 NB GI pipes, funnels, clamps, 3 mtr long 40 mm MS rod electrodes, MS cover with lifting lugs, associated civil works, etc. All the equipment located in the WT premises / sub-premises e.g. 6.6 kV switchboards, LT PCCs, busducts, transformer bodies, charger panels, DCDBs, LDBs, SLDBs, receptacles, control panels, MCCs, etc shall be connected by the Bidder with earthing ring mains at least two different points. Electronic earthing shall be considerd for PLC, etc Bidder shall also consider earthing of following equipment to be installed by the Purchaser in separate contract. 6.6kV WT switchboard at WT substation in switchgear cum MCC room WT distribution transformers (2 nos.) Neutral as well as body earthing 415 WT SYSTEM PCC at WT SYSTEM substation in switchgear cum MCC room Control panel for power distribution equipment at existing WT control room LT busducts (2 sets) Charger panels, DCDB, etc at WT substation in switchgear cum MCC room Bidder shall consider earthing ring mains at each electrical premise and connect the electrical equipment with the rings. The earthing ring mains shall be connected with underground earthing mats (consisting of 2x40MM dia to be installed by the purchaser). For transformer neutral earthing, bidder shall consider dedicated earthing pits (minimum two pits per transformer). Bidder shall include complete earthing material including earth electrodes, risers, GI earthing strips, other accessories, etc. and carry out main earth grid mat, earthing ring mains, earth pits, risers, interconnections, equipment earthing, all associated civil works, etc within battery limit of the package. All the interconnections with other earthing systems of the plant and with existing systems shall be under scope of the Bidder.
The Bidder shall obtain the actual soil resistivity of the plant area by carrying out soil resistivity tests and design the earthing system accordingly. While designing the earthing system, Bidder shall note the following fault levels at 415 V bus shall be 50 kA. Plant earthing system shall be designed such that overall earthing resistance is less than 1(One) Ohm without interconnections. The materials shall be galvanized steel laid over the ground and mild steel buried inside the ground/concrete. Fault clearing time for sizing of earth conductors and for calculations of the maximum allowable step and touch potential shall be taken 1 sec. Maximum allowable temperature rise for steel bolted joints shall be taken as 3100C taking ambient temperature of 50oC. The earthing system shall be generally designed on the basis of the following codes & standards: IS 3043 Code of practices for safety and standards IEEE 80 Guide for safety in AC substation grounding Indian Electricity Rules
Entire system shall be earthed so that the values of the step and contact potentials in case of faults are kept within safe permissible limits. Parts of all electrical equipment and machinery not intended to be alive shall have two separate and distinct earth connections each to conform to the stipulation of the Indian Electricity Rules. In case of HT system, E/F current will be made to flow through copper screen tape provided over inner sheathing. Screen will be connected to earth bus at both ends. In case of LT the TN-S system will be followed, i.e. neutral bus of the switchgear shall be connected to switchgear earth bus and then to DBs shall be through armouring of cable. Bidder shall submit the layout drawings of earthing network with supported calculations for approval of purchares/consultant. Taking approval of Electrical inspector/CEA and providing all inputs to them like data/drawings are under scope of the Bidder. The materials shall be galvanized steel laid over the ground and mild steel buried inside the ground/concrete. Earthing of SLDBs, power receptacles, etc shall be connected with respective source LDBs through armouring of cables. Earthing conductors run on walls/floors/cable and equipment structures etc. shall be supported at suitable intervals and painted with black oxide paint. The armour of cables and all conduits for cables shall also be connected to the earthing mains. A continuous earth strip shall run in each side of cable channel and in cable ducts/tray route.
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All joints in the branch connections except at earthing electrode shall be welded and painted black. At road/rail crossings earthing strips/rods shall be laid through conduits/concrete ducts. The armour of cables and all conduits for cables shall also be connected to the earthing mains. A continuous earth strip shall run in each side of cable trenches. All joints in the run of the main earthing conductors will be welded or brazed type. Connection to equipment structure shall be bolted type. All welded joints shall be protected from corrosion by applying bitumen paint. Earthing system shall be distinct and separate from the lightning equipment earthing system. Earthing Conductors and Installation Accessories for Equipment Earthing System All electrical equipment installed by the successful Bidder as well as equipment installed by Purchaser shall be effectively earthed in conformity with relevant clauses of Indian Electricity Rules (1956) and in accordance with IS: 3043 to the complete satisfaction of the Chief Electrical Inspector to Government of Orissa State. All non-current carrying metallic conduit parts of various electrical equipment as well as cable armouring, metallic conduits, GI pipe, cable racks, trays, brackets, supporting structures etc. shall be effectively earthed. Main earth mat comprising 40 mm dia MS rods and earth electrodes and riser upto + 1.0 M level shall be supplied and installed by the ownr. All other equipment to complete the earthing of equipment installed by the Bidder shall be in the scope of the Bidder. The Bidder shall also connect his sub earth mat to the main earth mat provided by the Bidder. Conductor size adopted for earthing ring shall in no case be less than that of the earth continuity conductors connected to it. The size of conductors used for overground sub earth mat in switchgear rooms/ control rooms/ plant buildings/ areas shall be 65 mm x 8 mm galvanized mild steel strips. 50 mmx 6mm galvanized MS strips will be used for earth buses inside the buildings/ floors/ platforms etc. and also for earth conductors laid along cable trays. For buildings having a number of floors, separate earthing ring shall be established in each floor and shall in turn be connected to the Purchasers earth mat. Separate earthing system shall in no case have cross-sectional area less than 6 sq mm stranded GI wire. Size of earth conductors selected for system earthing and earthing of various equipments shall be as follows. Galvanized Iron flat conductor strips shall be used for neutral earthing. The minimum size of conductors for neutral earthing of various transformers shall be as given below unless a higher size is required from the viewpoint of higher available fault current. LV neutral of 6.6/0.433 kV, 1600 KVA transformers : 75mm x 10mm
The minimum size of galvanized Iron flats for earthing of various equipment shall be as follows: Ring mains 6.6 kV switchboards LT PCCs/board Control Panels LT Busducts DC Distribution Board LDB SLDB Push button station Transformer bodies Cable tray (running earthing) LIGHTNING PROTECTION All buildings and plant structures including switchgear building and junction houses shall be protected against atmospheric flash over and lightning strokes in such a manner as to eliminate any danger to the personnel employed therein. Stipulations of IS : 2309 - 1969 shall be followed. A 'Faraday Cage' made of hot galvanised strip steel connected to all buried pipes and steel structures crossing this cage ring shall be laid around plant as earthing device. This shall be separate from the electrical equipment earthing ring main. Design shall be as per the standard like IS 2309 (latest revision) and Indian Electricity Rules. All lightning arrestor earth leads of the plant shall be connected to this cage ring. Air termination network should cover all salient points of the structure. All metallic structures, ducts and the like above the roof of the structure shall be bonded to and form part of the air termination network. Vertical air termination points shall project at least 30 cm above the object on which it is fixed. Down conductors shall follow the most direct path possible between air termination and earth termination avoiding sharp bends. Down conductor shall have a testing point adjacent to the earth electrode. Each conductor shall have an independent earth termination. All earth terminations shall be interconnected. Earthing electrodes and grid for lightning protection will be distinct separate from the earthing system for earthing of electrical equipment and at no place will be connected to other earthing system. 4.16 MISCELLANEOUS ELECTRICS SAFETY
: : : : : : : : : : :
75mm x 10mm 75mm x 10mm 65mm x 8mm 50mm x 6mm 50mm x 6mm 50mm x 6mm 50mm x 6mm 25mm x 3mm 6 sq mm stranded 50mm x 6mm 50mm x 6mm
All equipment shall be complete with approved safety devices wherever potential hazard to personnel exists and with provision for safe access of personnel to and around equipment for operational and maintenance functions. The design shall include all reasonable precautions and provisions for the safety of operating and maintenance personnel. Special care shall be taken to make enclosed equipment proof against entry of rats, lizards and other creeping reptiles which may create electrical short- circuits inside live equipment. MINOR CIVIL WORKS Minor civil works associated with cabling, earthing, conduit installation, illumination systems, lighting poles, for buried cables, for erection of equipment supplied by the Bidder, foundation of lighting masts/poles, etc shall be included under scope of bidder. Similarly minor civil works like widening of floor openings / cable trenches, wall opening for cables, minor chipping, etc shall be included under scope of bidder. LOCAL CONTROL STATION Near all drives local control stations shall be provided. Local stations shall have Cast Aluminium body, dust and vermin proof, and structure mounting. Stat and stop push buttons shall be mounted on front hinged gasketted and lockable door. Local/remote selector switches shall be provided on local control stations. Stop push button shall be lockable type. In addition, ammeters shall be provided on local control stations for HT drives. Suitable knockouts with glands shall be provided on the bottom or top cover for cable entry. Terminals shall be suitable for 2 cores of 2.5 sq.mm conductors with 10% spare terminals. Enclosure shall be conforming to IP55 with proper rain canopy. ELECTRICS OF DUST SUPPRESSION SYSTEM Bidder shall include complete electrics of dust suppression systems coming in the scope within the battery limit. Bidder shall provide complete electrics including MCC, drives/mechanism, associated cabling & their termination, local DBs, all power and control ccessories, all related annunciations, etc. ELECTRICS OF AIR-CONDITIONING AND VENTILATION SYSTEM Bidder shall include complete electrics of air-conditioning system and ventilation system. Complete electrics for the following shall be included: Ventilation system for the switchgear cum MCC room at WT SYSTEM substation Exhaust fans for the two numbers transformer rooms at WT SYSTEM substation Air-conditioning system for the battery and battery charger room at WT SYSTEM substation Ventilation system for dust suppression MCC room Air-conditioning system of Ventilation system for Electrics House/MCC rooms of stacker/reclaimer
Airconditioning system for cabin for stacker/reclaimer A/C or ventilation system for any other premise/room coming at WT SYSTEM ELECTRICS OF HOISTING AND HANDLING EQUIPMENT Bidder shall include complete electrics of hoists coming in the scope within the battery limit. Bidder shall provide complete electrics including source feeders, associated cabling & their termination, local DBs, all power and control accessories, all related annunciations, etc. All the hoist control panel shall be located at workable height and platform shall be provided for each hoist at one point for maintenance purpose. 33 kV OVERHEAD LINES For incoming power supply to wagon tippler system, 33KV overhead line will be drawn from 220 KV/33KV substation near 220KV s/y by the bidder. A&SR conductor with Rail pole will be supplied & erected by the bidder for above 33KV line. Suitable route for 33KV overhead transmission line will be decided by the bidder in consultation/coordinating with NALCO to avoid any local/field interference. HT transformer of 5 KVA capacity (33KV/6.6KV) will be supplied by the bidder confirming to latest features. Supply of associated switch gear and measuring equipments will be supplied by the bidder for the HT system. Technical details of HT transformer and other switch gear will be submitted to NALCO / RITES for its approval. The conductor for 33KV line shall be of ACSR (dog/Rabbit) type. However, a generalized specification for HT transformer is given earlier. The HT transformer (33KV/6.6KV) will be located in the upcoming switch gear near the wagon tippler area. The switch gear will be designed in conformity to CEA norms having provision of LA, PT, CT, ISO etc. Fencing and development of switch gear will be the scope of the bidder. The switch gear will be located near wagon tippler area. Further reduction from 6.6KV to 415V for LT device is also included in the scope of work. Room size to be diecided by the party to house all required equipments (HT & LT switch gears) at the ground floor. WT Control room and operating panel will be located at first floor of the building. Bidders are also advised to visit the site and assess the actual quantum of work to be done for this diversion and include accordingly.
The operation of the WT SYSTEM plant shall be monitored and controlled from the existing WT control rooms by means of VDU operator interface on a microprocessor based programmable logic controller (PLC). The system shall be envisaged for the purpose of initial operation, protection and interlock, data acquisition, close loop control, data archiving, etc for fully automatic operation. The system shall be capable of monitoring and displaying the status of equipment, including the analog and digital signal displaying of status in the form of diagram, trend bar chart, overview, logs, etc with the help of CRT, keyboard, mouse and printers. Necessary hardware and software license of the proposed PLC shall be provided The preferred make of PLC shall be GE-FANUC make. BELT SWAY SWITCH The belt sway switch shall be shall be auto reset type and provided at both ends and at an interval of 50 mtrs (for conveyor length greater that 200 mtrs) on both sides of conveyors and also before and after belt weighing system on both sides. It shall be of auto reset type. The belt sway switch shall be industrial heavy duty type housed in dust and vermin proof box with degree of protection IP-54. The switch shall be designed that conveyor does not come in direct contact with the switches and mechanism shall have strong rest spring to absorb high impact of loaded belt edge. The switch element shall be self rest type and shall have 2NO+2NC contacts each rated for 10A, 240V AC. It shall be suitable for ambient temp. of 600C. Resetting spring mechanism, built in terminal box, actuating rollers, roller shafts, supporting frame, etc shall be provided as per requirement. Belt sway switch shall be J&N make. PULL CHORD SWITCH Pull chord switches shall be auto reset type industrial heavy duty enclosed in dust and vermin proof enclosure with degree of protection IP-65. They shall be provided with following facilities;
Switch elements shall be 2NO+2NC each rated for 10A, 240V AC. Automatic locking arrangement in the operated position with manually reset Snap action type for positive operation of contacts Number of position shall be 1-0-1 Separate compartment for built in terminal box Suitable base plate Pull rope shall be stranded galvanized steel wire with at least 1 mm thick PVC cover and having overall diameter of 6mm to 7mm.
Pull rope switch shall be placed at an interval of 25 mtr on both sides of conveyor with minimum of one pair for conveyor length less than 25 mtr.
ZERO SPEED SWITCH The unit shall be provided with MS flags, sensing probes, monitoring unit and interconnecting special cables. The unit shall be of multi speed range with setting facility and shall be provided with output contacts (2NO+2NC) with facility for initial bypass adjustable time delay, nuisance tripping delay and analog/digital speed display. 4-20mA isolated DC signal shall be applicable for external metering. Sensing probe shall be provided with metallic enclosure of degree of protection IP-67 and LED lamp for visual indication of correct functioning of sensing probe. PASSIVE FIRE PROTECTION Fire protection for cables at entry/exit points of the wall shall be provided with proper sealing by fire sealing material. The fire sealing compound shall be rated for minimum 2 Hours. Fire retardant painting shall also be provided on cables for 2 Mtrs on both sides of the wall/floor crossing. ERECTION & INSTALLATION ACCESSORIES All cable accessories like conduits, inserts, cable tag markers, clamps, sealing compound, pull boxes, marshalling boxes etc. shall be considered as part of the Bidders scope to complete the erection job in all respect. OTHER ITEMS Bidder shall provide all required switches, cabling and other devices needed for proper control, operation, interlocking and sequencing of the any other offered systems and technological mechanism, if specified in technological, e.g. hanging magnets and wipers (if applicable), roof exhaust fans & wall exhaust fans (if applicable), etc. All required safety items like rubber mats in front of MCC/DB/Panel, shock treatment chart, first aid boxes, danger boards, boards indicating 'Man on Work, Do not switch ON', 'Do not switch OFF', 'EARTHED' etc. shall be provided in each electrical premises. Wall mounted aux. AC and DC distribution boards shall be provided in sufficient number to facilitate proper distribution of the power supply to various users. Bidder to include closing of all cable and panel openings through a Fire sealing material. This shall include closing of all bottom opening of control room panels/desks, MCC switch boards, wall openings in all the areas, etc. Bidder shall also include earthing of all equipments/system, wherever required, under his scope of supply. Bidder shall include painting of all the plant and equipment with approved shades and include primers as well as finishing paints.
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Sufficient quantity of GI ladder type factory fabricated cable trays made from 2.5 mm thick hot welded steel sheets grade o as per IS: 2062 shall be provided. Hot dip galvanizing of 85 micron thick as per IS-2629, IS-4759 and IS- 209. Trays shall be of standard length of 3 m with max deflection not exceeding 1/400 of span with sufficient load bearing capacity. 4.16 ERECTION OF ELECTRICAL EQUIPMENT Bidder shall include erection of all the equipment under his scope of supply. Erection of equipment shall have to be carried out as follows: 1. Procedure mentioned in manufacturers manual 2. Under the expert supervision 3. Sequence and plan of erection as per the guidance of Purchasers Site In charge or their consultant 4. During erection of suppliers equipment, existing equipment /system shall not be disturbed. 5. Erection shall be in accordance with approved layout drawing and installation details. 6. Cable laying shall be as per approved cable layout drawings and work shall be carried out in a neat manner. All erection-installation accessories required for erection/installation of equipment and handling equipment required for handling of equipment from store to installation site are included in the scope of work of Bidder as a whole. Bidder shall ensure that the work erection and erected equipment shall comply with all statutory norms, regulations and standards applicable to the works/equipment and any additional work/equipment required, if any, shall be under scope of the Bidder. Necessary clearance from the wall shall be maintained as per IS/IE Rules from front/rear/ side of all the panels inside a room. HT Power cables and LT power/control cables shall be laid in different cable trays. LT power cables and LT control cables shall also be laid in different trays, however, if necessity arises due to space constraints or lesser number of cables, LT power cables and LT control cables can be put on the same trays keeping sufficient gap between them. 24V DC cables, if required, shall be laid entirely in different dedicated trays. Cable trays in single tier or in multitier shall be installed in vertical arrangement everywhere to avert coal accumulation and space reduction.
5.0
INSPECTION AND TESTING 5.1 Inspection Extent of inspection
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The extent of inspection & testing by the Purchaser shall vary from equipment to equipment as per design requirements. However, indicative extent of inspection for electrical equipment is furnished below: Extent of inspection to be carried out shall be finalised with the Contractor after award of the contract on the basis of scope of supply, technical specification and approved GA drawings. However, in case of similar bulk manufactured items, methods of sampling for inspection of different lots shall be governed by relevant Indian or international standards. In case of critical components, the Purchaser reserves the right to undertake 100% inspection. Final inspection & testing shall be done as per the following: Verification of test certificates Visual, Workmanship & painting Dimensional Witnessing of routine/acceptance/type/special tests as per relevant standards. Witnessing of proto-type tests, as applicable Verification of type test certificates for identical equipment Approved QAP The inspection shall be carried out on the basis of QAP dully approved by Purchaser / consultant. INSPECTION CATEGORIES All the electrical equipment have been classified in three categories for inspection and issuing dispatch clearance by the Purchaser/consultant. The three categories are: Category-A All the tests shall be inspected by the Purchaser/Consultant. Dispatch clearance shall be given by Purchaser/Consultant after the equipment is inspected and found as per requirement and as per TS. All types tests certificates shall e submitted by the Bidder in this case. Category-B Inspection shall be carried out by prime bidder and inspection waiver certificate shall be issued by Purchaser/Consultant based on type test certificates and routine tests certificates furnished by the Bidder. Purchaser/Consultant shall issue dispatch clearance accordingly. Category-C Dispatch clearance shall be given by Prime bidder without any certificates based on technical data sheet furnished by the Bidder.
S. N. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 5.2 Testing General
DESCRIPTION HT MOTORS LT MOTORS MCC TRANSFORMER FOR STACKER/RECLAIMER PLC & CONTROL DESK UPS ON LOAD 6.6 kV ISOLATOR TRAILING CABLE / FLEXIBLE (EPR) CABLE PDB/LDB/SLDB/AUX. PDB SIGNAL, INSTRUMENTATION AND OTHER SPECIAL CABLES CABLE ACCESSORIE LIGHT FITTINGS EARTHING AND LIGHTNING PROTECTION MATERIALS FIRE SEALING MATERIALS LOCAL PUSH BUTTON STATIONS POWER SOCKET CABINET AND LIGHTING CABINET
INSPECTION CATEGORY A B A A A A A A B B C C C C B B
Test of all equipment shall be conducted as per latest BIS. Wherever no such standard exists, tests shall be as per International Standards like IEC/DIN/BS/IEEL/JIS, etc. All routine tests shall be carried out at manufacturer's works in presence of Purchaser or his representative. The Bidder shall submit type test certificates (not more than 5 years old) for similar equipment supplied by him elsewhere. In case type test certificates for similar equipment is not available, the same shall be conducted in presence of Purchaser or his representative, without any financial implications to Purchaser. The Bidder shall be responsible for satisfactorily working of complete integrated system and guaranteed performance.
Site Tests and Checks General

All the equipments shall be tested at site to know their condition and to prove suitability for required performance. The test indicated in following pages shall be conducted after installation. All tools, accessories and required instruments shall have to be arranged by contractor. Any other test which is considered necessary by the manufacturer of the equipment, contractor or mentioned in commissioning manual has to be conducted at site. In addition to tests on individual equipment, some tests/checks are to be conducted / observed from overall system point of view. Such checks are highlighted under miscellaneous tests but these shall not be limited to as indicated and shall be finalized with consultation of client before charging of the system. The contractor shall be responsible for satisfactory working of complete integrated system and guaranteed performance. All checks and tests shall be conducted in the presence of clients representative and test results shall be submitted in six copies to client and one copy to Electrical Inspector. Test results shall be filled in proper Performa. After clearance from Electrical Inspector system/ equipment shall be charged in step by step method. Based on the test results clear cut observation shall be indicated by testing engineer with regard to suitability for charging of the equipment or reasons for not charging are to be brought by the contractor. Trial Run Test After the successful test of each equipment as per standard test procedure the entire control system shall be put on trial run test on actual site conditions and operation of the system. Acceptance Test The acceptance test on the system shall be carried out by the supplier as per mutually agreed test procedures to establish satisfactorily functioning of the system as a whole and each equipment as part of the system. Site Tests The tests to be carried out on the equipment at pre-commissioning stage shall include following but not limited to the following: MCC 1. 2. 3.
IR test before and after HV test. HV test with 2.5 kV megger Functional test for all feeders
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4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Testing and calibration of all meters Checking and calibration of protective relays as per supplier's commissioning manuals Check operation of contactors from local and remote points Checking of interlockings between incomers/bus coupler and other feeders. Test to prove interchangeability of similar parts Tests to prove correct operation of breakers at minimum and maximum specified control voltages Checking of earthing connection for neutral-earth bus, cable armour, location of E/F CT etc. as per the scheme. Check test, service and drawout position of all the breakers and operations of mechanical flag indicator and electrical indication lamps. Check functioning of various elect. schemes like autochangeover signalling etc. Breaker : IR value checking with breaker ON. Phase to phase & phase to earth and between phases in off position
MOTORS 1. IR test of stator and rotor windings. 2. Ensure that checking/testing of associated switchboard, cables, relays /meter interlocks as mentioned in relevant are completed. 3. Check tightness of cable connection 4. Winding resistance measurement of stator and rotor. 5. Checking continuity of winding. 6. Check tightness of earth connections. 7. Check space heaters and carryout heating of winding (if required) 8. Check direction of rotation in de-coupled condition during kick start 9. Measure no load current for all phases. 10. Measurement of temperature of body during no load and load conditions. 11. Check for tripping of motor from local/remote switches and from electrical/technological protection. 12. Checking of vibration 13. Checking of noise level 14. Shaft voltage measurement (if required) 15. Tan delta test, if required 16. During load running, measurement of stator and bearing temperatures (if applicable) for every half an hour interval till saturation comes. 17. Checking tightness of foundation bolts 18. Check operation of speed switch (if there) 19. Check continuity of temp. detectors. 20. Check alignment, paralleling of shafts, level of lubricating oil etc. as per manufacturer's manual 21. Check for polarisation index of stator winding, R10/R1 by motorised megger (The value should not be less than 2.0). R60/R10 absorption co-efficient shall not be less than 1.5. TRANSFORMER 1. IR test on each winding to ground and between windings.
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Turns ratio test on each tap Polarity and vector group test Measurement of winding resistance by Kelvin bridge IR, wiring and operational tests on all control devices in control cabinet, oil level indicator, winding and oil temp. indicators etc. Checking of earthing wrt transformer tank (flexible from top cover to tank) other parts, neutrals. Testing of buchholz relay for alarm and trip conditions. For bushing CTs, tests applicable shall be as for current transformers. Setting of oil/winding temperature indicators, level gauge and checking of alarm/trip circuits. Check insulators for cracks. Checking for oil leakage and arresting of leakages (if there) Checking of operation of all valves. Checking for open position of all the valves (except drain and filter valves) Filtration of oil by using line filter, vacuum pump, and heater set. BDV test on oil samples from top and bottom. Checking of oil for acidity, water content tan delta etc. as per IS 335. Measurement of magnetising current and no load loss. Measurement of PI value. Checking of silica gel breather. Checking of noise level at no load and at full load. Checking of air circulation conditions for indoor transformers. Conducting magnetic balance test Checking of other points given in manufacturer's commissioning manual. Frequency response analysis for HT transformers (at manufacturers works)
UNINTERRUPTED POWER SUPPLY (UPS) 1. Visual check 2. IR value by megger 3. Current limit test 4. Ripple test 5. Supply variation 6. Functional test 7. Capacity test wrt time PDB/LDB/SLDB/AUX. PDB 1. IR test before and after HV test. 2. HV test with 2.5 kV megger 3. Functional test for all feeders 4. Testing and calibration of all meters 5. Checking and calibration of overload relays and protective relays as per supplier's commissioning manuals. 6. Check operation of contactors from local and remote points 7. Checking of interlockings between incomers/bus coupler and other feeders.
8. 9. 10. 11. 12. 13.
Test to prove interchangeability of similar parts Tests to prove correct operation of breakers at minimum and maximum specified control voltages Checking of earthing connection for neutral-earth bus, cable armour, location of E/F CT etc. as per the scheme. Check test, service and drawout position of all the breakers and operations of mechanical flag indicator and electrical indication lamps. Check functioning of various elect. schemes like autochangeover signalling etc. Breaker : IR value checking with breaker ON. Phase to phase & phase to earth and between phases in off position
CABLES & CABLE SUPPORTING STRUCTURES 1. Checking of continuity/phasing and IR values for all the cables before and after HV test. 2. Checking of earth continuity for armour. 3. Check for mechanical protection of cables. 4. Check for identification (tag number system) distance placement of cable marker, cable joint etc. as per the cable layout drawing. 5. Check earthing of cable structures. 6. Check clearances from light fittings for cable structures 7. Check proper fixing of cable structures. 8. Check for proper drainage and removal of water from cable trenches EARTHING & LIGHTNING PROTECTION 1. Check tightness of all earth connections 2. Check earthing of all metallic equipment, cable trays, busbar supporting structures, all elect. equipments, etc. as per the requirement of IE rules and IS 3043 3. Measurement of earth resistance for each electrode. 4. Measurement of total earth resistance. 5. Measurement of earth loop resistance for E/F path of biggest LT drive.
ILLUMINATION 1. Lux level measurement in each area/premise 2. Test for black spot, if any 3. Check operation of complete lighting system MISCELLANEOUS 1. Checking of continuity of the system 2. Checking safe accessibility of all operating points 3. Ensure availability of first aid box, rubber glove, etc. 4. Check for safe movement of operators to pump house w.r.t. proper illumination, light, uncovered openings, etc 5. Placement of shock treatment chart, danger boards, provision of boards indicating Man on Work, Do not switch ON', 'Do not switch OFF', 'EARTHED' etc.
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6. 7. 8.
Check proper dressing of cables, mechanical protection of cables, placement of cable markers Check sealing of all cable openings including conduit opening with fire resistance material Check sealing of all openings at bottom of panels
9.
Check proper road crossing of cables/earthing materials.
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SECTION 7
1.0 1.1
GENERAL The following provisions shall supplement the conditions already contained in the other parts of these specifications and documents and shall govern that portion of the work of this contract which is to be performed at site. The erection requirements and procedures not specified in these documents shall be in accordance with the recommendations of the equipment manufacturer, or as mutually agreed to between the Employer and the Contractor prior to commencement of erection work. The Contractor upon signing of the Contract shall, in addition to a Project Coordinator, nominate another responsible officer as his representative at Site suitably designated for the purpose of overall responsibility and co-ordination of the Works to be performed at Site. Such a person shall function from the Site office of the Contractor during the pendency of Contract. REGULATION OF LOCAL AUTHORITIES AND STATUTES
1.2
2.0
2.0.1 In addition to the local laws and regulations, the Contractor shall also comply with the Minimum Wages Act and the Payment of Wages Act (both of the Government of India) and the rules made there under in respect of its labour and the labour of its subcontractors currently employed on or connected with the contract. 2.0.2 All registration and statutory inspection fees, if any, in respect of his work pursuant to this Contract shall be to the account of the Contractor. However, any registration, statutory inspection fees lawfully payable under the provisions of the Indian Boiler Regulations and any other statutory laws and its amendments from time to time during erection in respect of the plant equipment ultimately to be owned by the Employer, shall be to the account of the Employer. Should any such inspection or registration need to be re-arranged due to the fault of the Contractor or his Sub-Contractor, the additional fees for such inspection and/or registration shall be borne by the Contractor. 2.1 Qualification of Weld Procedures Only qualified welding procedures as per ASME Section IX shall be used by contractor at site. Procedure qualification records along with WPS shall be submitted to NALCO for review. Welding procedure shall indicate all essential and non-essential parameters as
Technical Specification: Conditions of Contract for Field Services Page 1 of 26
per ASME Section IX. Makes of welding consumables shall be subject to employers approval. 3.0 SITE RUN MISCELLANEOUS PIPING Sketches or diagrams of the proposed routings of all piping, not already indicated and routed on the shop drawings which were reviewed by the Employer, shall be submitted to the Employer for review, Employer's acceptance of such site routings shall be obtained before the piping is erected. All these site run piping shall be installed in such a manner as to present an orderly and neat installation. They shall be located as to avoid obstruction of access and passages. Valves, instruments or any other special items shall be located convenient for operation by the operating personnel. Pipe runs shall be plumb or level except where pitch for drainage is required. Pipe runs that are not parallel to the building structure, walls or column rows shall be avoided. No miscellaneous pipe shall be routed and installed above or adjacent to electrical equipment. 4.0 4.1 PIPING SUPPORTS Hangers, supports and anchors shall be installed as required to obtain a safe, reliable and complete pipe installation. All supports shall be properly levelled and anchored when installed. The anchors shall be so placed that thermal expansion will be absorbed by bends without subjecting the valves or equipment to excessive strains. The hanger assemblies shall not be used for the attachment of rigging to hoist the pipe into place. Other means shall be used to securely hold the pipe in place till the pipe support is completely assembled and attached to the pipe and building structures and spring support is set to accommodate the pipe way. All temporary rigging shall be removed in such a way that the pipe support is not subjected to any sudden load. All piping, having variable spring type supports, shall be held securely in place by temporary means during the hydraulic test of pipe system. Constant support type spring hangers used during hydraulic test shall be pinned or blocked solid during the test. After complete installation and insulation of the piping and filling of the piping with its normal operating medium, the pipe support springs shall be adjusted to the cold positions. If necessary, the spring support shall be re-adjusted to the hot positions after the line has been placed for service at its normal maximum operating temperature conditions. Electric arc welding only shall be used to weld all pipe supports to structural steel members that form part of the building supporting structure. The structural beams shall not be heated more than necessary during welding of supports and such welds shall run parallel to the axis of the span. All lugs or any other attachments welded to the piping shall be of the same material as the pipe.
4.2
Technical Specification: Conditions of Contract for Field Services
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5.0
CODE REQUIREMENTS The erection requirements and procedures to be followed during the installation of the equipment shall be in accordance with the relevant Indian Electricity Rules & Codes, Indian Boiler Regulations, ASME codes and accepted good practices, the Employer's Drawings and other applicable Indian recognised codes and laws and regulations of the Government of India.
6.0 6.1
ELECTRICAL SAFETY REGULATIONS In no circumstances will the Contractor interfere with fuses and electrical equipment belonging to the other Contractor or Employer. Before the Contractor connects any electrical appliances to any plug or socket belonging to the other Contractor or Employer, he shall: a) Satisfy the Employer that the appliance is in good working condition; b) Inform the Employer of the maximum current rating, voltage and phases of the appliances; c) Obtain permission of the Employer detailing the socket to which the appliances may be connected. No repair work shall be carried out on any live equipment. The equipment must be declared safe by the Employer and a permit to work issued before any work is carried out. The Contractor shall employ the necessary number of qualified, full time electricians to maintain his temporary electrical installation. REMOVAL OF MATERIAL No material brought to the Site shall be removed from the Site by the Contractor and/or his Sub-Contractors without the prior written approval of the Employer.
6.2
6.3
6.4
7.0
8.0
INSPECTION, TESTING AND INSPECTION CERTIFICATES The provisions of the clause entitled Inspection, Testing and Inspection Certificates given in General Technical Requirement, shall also be applicable to the erection portion of the Works. The Employer shall have the right to re-inspect any equipment though previously inspected and approved by him at the Contractors works, before and after the same are erected at Site. If by the above inspection, the Employer rejects any equipment, the
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Contractor shall make good for such rejections either by replacement or modification/ repairs as may be necessary to the satisfaction of the Employer. Such replacements will also include the replacements or re-execution of such of those works of other Contractors and/or agencies, which might have got damaged or affected by the replacements or re-work done to the Contractors work. 9.0 9.1 ACCESS TO SITE AND WORKS ON SITE Suitable access to site and permission to work at the Site shall be accorded to the Contractor by the Employer in reasonable time. In the execution of the Works, no person other than the Contractor or his duly appointed representative, Sub-Contractor and workmen, shall be allowed to do work on the Site, except by the special permission, in writing by the Employer or his representative.
9.2
10.0 CONTRACTORS SITE OFFICE ESTABLISHMENT The Contractor shall establish a Office at the Site and keep posted an authorized representative for the purpose of the Contract. Any written order or instruction of the Employer or his duly authorised representative, shall be communicated to the said authorised resident representative of the Contractor and the same shall be deemed to have been communicated to the Contractor at his legal address. 11.0 CO-OPERATION WITH OTHER CONTRACTORS 11.1 The Contractor shall co-operate with all other Contractors or tradesmen of the Employer, who may be performing other works on behalf of the Employer and the workmen who may be employed by the Employer and doing work in the vicinity of the works under the Contract. The Contractor shall also arrange to perform his work as to minimise, to the maximum extent possible, interference with the work of other Contracts and their workmen. Any injury or damage that may be sustained by the employees of the other Contractors and the Employer, due to the Contractors work shall promptly be made good at his own expense. The Employer shall determine the resolution of any difference or conflict that may arise between the Contractor and other Contractors or between the Contractor and the workmen of the Employer in regard to their work. If the work of the Contractor is delayed because of the any acts of omission of another Contractor, the Contractor shall have no claim against the Employer on that account other than an extension of time for completing his works. Employer shall have full access to visit the contractors site at any time for inspection and surveillance checks.
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11.2 The Employer shall be notified promptly by the Contractor of any defects in the other Contractors works that could affect the Contractors Works. The Employer shall determine the corrective measures if any, required to rectify this situation after inspection of the works and such decisions by the Employer shall be binding on the Contractor. 12.0 DISCIPLINE OF WORKMEN The Contractor shall adhere to the disciplinary procedure set by the Employer in respect of his employees and workmen at Site. The Employer shall be at liberty to object to the presence of any representative or employee of the Contractor at the Site, if in the opinion of the Employer such employee has mis-conducted himself or is incompetent, negligent or otherwise undesirable then the Contractor shall remove such a person objected to and provide in his place a competent replacement. 13.0 CONTRACTORS FIELD OPERATION 13.1 The Contractor shall keep the Employer informed in advance regarding his field activity plans and schedules for carrying out each part of the works. Any review of such plan or schedule or method of work by the Employer shall not relieve the Contractor of any of his responsibilities towards the field activities. Such reviews shall also not be considered as an assumption of any risk or liability by the Employer or any of his representatives and no claim of the Contractor will be entertained because of the failure or inefficiency of any such plan or schedule or method of work reviewed. The Contractor shall be solely responsible for the safety, adequacy and efficiency of plant and equipment and his erection methods. 13.2 The Contractor shall have the complete responsibility for the conditions of the WorkSite including the safety of all persons employed by him or his Sub-Contractor and all the properties under his custody during the performance of the work. This requirement shall apply continuously till the completion of the Contract and shall not be limited to normal working hours. The construction review by the Employer is not intended to include review of Contractors safety measures in, on or near the Work- Site, and their adequacy or otherwise. 14.0 PHOTOGRAPHS AND PROGRESS REPORT 14.1 The Contractor shall furnish three (3) prints each to the Employer of progress photographs of the work done at Site. Photographs shall be taken as and when indicated by the Employer or his representative. Photographs shall be adequate in size and
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number to indicate various stages of erection. Each photograph shall contain the date, the name of the Contractor and the title of the photograph. 14.2 The above photographs shall accompany the monthly progress report detailing out the progress achieved on all erection activities as compared to the schedules. The report shall also indicate the reasons for the variance between the scheduled and actual progress and the action proposed for corrective measures, wherever necessary. 14.3 The Contractor shall submit the progress of work in video cassettes (2 copies) quarterly highlighting the progress and constraints at site. 15.0 MAN-POWER REPORT 15.1 The Contractor shall submit to the Employer, on the first day of every month, a man hour schedule for the month, detailing the man hours scheduled for the month, skillwise and area-wise. 15.2 The Contractor shall also submit to the Employer on the first day of every month, a man power report of the previous month detailing the number of persons scheduled to have been employed and actually employed, skillwise and the areas of employment of such labour. 16.0 PROTECTION OF WORK The Contractor shall have total responsibility for protecting his works till it is finally taken over by the Employer. No claim will be entertained by the Employer or the representative of the Employer for any damage or loss to the Contractors works and the Contractor shall be responsible for complete restoration of the damaged works to original conditions to comply with the specification and drawings. Should any such damage to the Contractors Works occur because of other party not being under his supervision or control, the Contractor shall make his claim directly with the party concerned. If disagreement or conflict or dispute develops between the Contractor and the other party or parties concerned regarding the responsibility for damage to the Contractors Works the same shall be resolved as per the provisions of the as specified at clause no 11 of this chapter entitled Co-operation with other Contractors. The Contractor shall not cause any delay in the repair of such damaged Works because of any delay in the resolution of such disputes. The Contractor shall proceed to repair the Work immediately and no cause thereof will be assigned pending resolution of such disputes. 17.0 EMPLOYMENT OF LABOUR
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In addition to all local laws and regulations pertaining to the employment of labour to be complied with by the Contractor pursuant to GCC, the Contractor will be expected to employ on the work only his regular skilled employees with experience of the particular work. No female labour shall be employed after darkness. No person below the age of eighteen years shall be employed. All travelling expenses including provisions of all necessary transport to and from Site, lodging allowances and other payments to the Contractors employees shall be the sole responsibility of the Contractor. The hours of work on the Site shall be decided by the Employer and the Contractor shall adhere to it. Working hours will normally be eight (8) hours per day Monday through Saturday. Contractors employees shall wear identification badges while on work at Site. In case the Employer becomes liable to pay any wages or dues to the labour or any Government agency under any of the provisions of the Minimum Wages Act, Workmen Compensation Act, Contact Labour Regulation Abolition Act or any other law due to act of omission by the Contractor, the Employer may make such payments and shall recover the same from the Contractors payments. 18.0 FACILITIES TO BE PROVIDED BY THE EMPLOYER 18.1 Space The Contractor shall advise the Employer within thirty (30) days from the date of acceptance of the Notification of Award about his exact requirement of space for his office, storage area, pre-assembly and fabrication areas, labour and staff colony area, etc. The above requirement shall be reviewed by the Employer and space as decided by Employer will be allotted to the Contractor for construction of his temporary structures/ facilities like office, storage sheds, pre-assembly and fabrication areas, labour and staff colony, toilets, etc. for Contractor's as well as his Sub-Contractors use. 18.2 Electricity The Contractor shall submit to the Employer within thirty (30) days from the date of acceptance of the Notification of Award, his electrical power requirements, if any, to allow the planning of the same by the Employer. The Contractor shall be provided with free supply of electricity for the purposes of the Contract, only at two locations in the Employers Site and at 415V voltage level. The Contractor shall make his own further distribution arrangement. All temporary wiring must comply with local regulations and will be subject to Employers inspection and approval before connection to supply. The free supply of power will not be provided for the use in the labour and staff colony. Power supply for labour and staff colony shall be provided at one point and the
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Contractor shall be charged at rates prevalent at the site. Illumination of wagon tippler and the conveyor area shall be the scope of the tenderer. 18.3 Water Contractor shall make all arrangements himself for the supply of construction water as well as potable water for labour and other personnel at the worksite/colony. 18.4 Communication The Employer will extend the telephone facilities, if available at Site, for purposes of Contract. The Contractor shall be charged at actuals for such facilities.
19.0 FACILITIES TO BE PROVIDED BY THE CONTRACTOR 19.1 Contractor's site office Establishment The Contractor shall establish a site office at the site and keep posted an authorized representative for the purpose of the contract, pursuant to GCC. 19.2 Tools, tackles and scaffoldings The Contractor shall provide all the construction equipments, tools, tackles and scaffoldings required for pre-assembly, installation, testing, commissioning and conducting Guarantee tests of the equipments covered under the Contract. He shall submit a list of all such materials to the Employer before the commencement of preassembly at Site. These tools and tackles shall not be removed from the Site without the written permission of the Employer. The Contractor shall arrange Dozer, Hydra, Cranes, Trailer, etc. for the purpose of fabrication, erection and commissioning. 19.3 Testing Equipment and Facilities: The contractor shall provide the necessary testing, equipment and facilities. 19.4 Site laboratory for civil works: Contractor shall provide and maintain a site laboratory for the testing of construction material under the direction and general supervision of employer. 19.5 First-aid 19.5.1 The Contractor shall provide necessary first-aid facilities for all his employees, representatives and workmen working at the Site. Enough number of Contractors personnel shall be trained in administering first-aid. 19.5.2 The Employer will provide the Contractor, in case of any emergency, the services of an ambulance for transportation to the nearest hospital.
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19.6 Cleanliness 19.6.1 The Contractor shall be responsible for keeping the entire area allotted to him clean and free from rubbish, debris etc. during the period of Contract. The Contractor shall employ enough number of special personnel to thoroughly clean his work-area at least once in a day. All such rubbish and scrap material shall be stacked or disposed in a place to be identified by the Employer. Materials and stores shall be so arranged to permit easy cleaning of the area. In areas where equipment might drip oil and cause damage to the floor surface, a suitable protective cover of a flame resistant, oil proof sheet shall be provided to protect the floor from such damage. 19.6.2 Similarly the labour colony, the offices and the residential areas of the Contractors employees and workmen shall be kept clean and neat to the entire satisfaction of the Employer. Proper sanitary arrangements shall be provided by the Contractor, in the work-areas, office and residential areas of the Contractor. 20.0 LINES AND GRADES All the Works shall be performed to the lines, grades and elevations indicated on the drawings. The Contractor shall be responsible to locate and layout the Works. Basic horizontal and vertical control points will be established and marked by the Employer at Site at suitable points. These points shall be used as datum for the works under the Contract. The Contractor shall inform the Employer well in advance of the times and places at which he wishes to do work in the area allotted to him so that suitable datum points may be established and checked by the Employer to enable the Contractor to proceed with his works. Any work done without being properly located may be removed and/or dismantled by the Employer at Contractors expense. 21.0 FIRE PROTECTION 21.1 The work procedures that are to be used during the erection shall be those which minimise fire hazards to the extent practicable. Combustible materials, combustible waste and rubbish shall be collected and removed from the Site at least once each day. Fuels, oils and volatile or flammable materials shall be stored away from the construction and equipment and materials storage areas in safe containers. Untreated canvas, paper, plastic or other flammable flexible materials shall not at all be used at Site for any other purpose unless otherwise specified. If any such materials are received with the equipment at the Site, the same shall be removed and replaced with acceptable material before moving into the construction or storage area. 21.2 Similarly corrugated paper fabricated cartons etc. will not be permitted in the construction area either for storage or for handling of materials. All such materials used shall be of water proof and flame resistant type. All the other materials such as working
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drawings, plans etc. which are combustible but are essential for the works to be executed shall be protected against combustion resulting from welding sparks, cutting flames and other similar fire sources. 21.3 All the Contractors supervisory personnel and sufficient number of workers shall be trained for fire-fighting and shall be assigned specific fire protection duties. Enough of such trained personnel must be available at the Site during the entire period of the Contract. 21.4 The Contractor shall provide enough fire protection equipment of the types and number for the warehouses, office, temporary structures, labour colony area etc. Access to such fire protection equipment, shall be easy and kept open at all time. 22.0 SECURITY The Contractor shall have total responsibility for all equipment and materials in his custody stores, loose, semi-assembled and/or erected by him at Site. The Contractor shall make suitable security arrangements including employment of security personnel to ensure the protection of all materials, equipment and works from theft, fire, pilferage and any other damages and loss. All materials of the Contractor shall enter and leave the Employer Site only with the written permission of the Employer in the prescribed manner. 23.0 CONTRACTORS AREA LIMITS The Employer will mark-out the boundary limits of access roads, parking spaces, storage and construction areas for the Contractor and the Contractor and his personnel shall not trespass the areas into other areas of the plant. In case of a need for the Contactors personnel to work in the areas beyond that marked out for him, the same shall be done only with the written permission of the Employer. 24.0 CONTRACTORS CO-OPERATION WITH THE EMPLOYER In case where the performance of the erection work by the Contractor affects the operation of the system facilities of the Employer, such erection work of the Contractor shall be scheduled to be performed only in the manner stipulated by the Employer and the same shall be acceptable at all times to the Contractor. The Employer may impose such restrictions on the facilities provided to the Contractor such as electricity, etc. as he may think fit in the interest of the Employer and the Contractor shall strictly adhere to such restrictions and co-operate with the Employer. It will be the responsibility of the Contractor to provide all necessary temporary instrumentation and other measuring
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devices required during start-up and operation of the equipment systems which are erected by him. The Contractor shall also be responsible for flushing and initial filling of all the oil and lubricants required for the equipment furnished and installed by him, so as to make such equipment ready for operation. The Contractor shall be responsible for supplying such flushing oil and other lubricants. 25.0 PRE-COMMISSIONING AND COMMISSIONING ACTIVITIES (a) GENERAL The Contractor upon completion of installation of equipments and systems, shall conduct pre-commissioning and commissioning activities, to make the equipment/systems ready for safe, reliable and efficient operation on sustained basis. All pre-commissioning/commissioning activities considered essential for such readiness of the equipment/systems including those mutually agreed and included in the Contractors quality assurance programme as well as those indicated in clauses elsewhere in the technical specifications shall be performed by the contractor. (b) The pre-commissioning and commissioning activities including Guarantee tests, checks and trial operations of the equipment/systems furnished and installed by the contractor shall be the responsibility of the Contractor as detailed in relevant clauses in Technical Specification. The Contractor shall provide, in addition, test instruments, calibrating devices etc. and labour required for successful performance of these operations. If it is anticipated that the above test may prolong for a long time, the Contractors workmen required for the above test shall always be present at site during such operations. The following activities shall be carried out by the contractor, prior to schedule date of commissioning of the equipment/systems installed by him. (i) The contractor shall furnish the organization chart of his operation and commissioning engineers for the acceptance of employer. Adequate number of operation and commissioning engineers shall be deployed by the contractor to effectively meet the requirement of round the clock operation in shifts also, till the plant is taken over by the employer. (ii) The contractor shall submit the bio-data containing the details of experience of his operation and commissioning engineers for the acceptance of employer. (iii) The contractor shall furnish the deployment schedule of his operation and commissioning engineers for the acceptance of the employer. (iv) Apart from above, contractor shall ensure deployment of sufficient skilled/semiskilled/unskilled manpower during pre-commissioning and commissioning activities.
(c)
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(d)
It shall be the responsibility of the Contractor to provide all necessary temporary instrumentation and other measuring devices required during start-up and initial operation of the equipment/systems which are installed by him. The Contractor shall also be responsible for flushing and initial filling of all oils and lubricants required for the equipment furnished and installed by him so as to make such equipment ready for operation. The Contractor shall be responsible for supplying such flushing oil and other lubricants unless otherwise specified elsewhere in these specifications and documents.
(e)
26.0 COMMISSIONING DOCUMENTATION (a) The contractor shall submit the commissioning documentation, comprising of Standard checklists, pre-commissioning procedures, testing schedules, commissioning schedules and commissioning networks for various equipment/systems covered under the contract, for the approval of employer. (b) Standard checklist, as the name suggests, shall be a fairly general documents, containing the list of all checks required to be carried out for similar and repetitive type of equipment to ensure consistent and thorough checking. (c) The testing schedule shall be prepared for systematic commissioning of individual equipment/sub-system Commissioning. The format of testing/Commissioning schedule shall be such as to maintain consistency of presentation, content and reporting (d) The contractor shall submit the list of commissioning documentation to be submitted by him, alongwith their submission schedule for various equipment/systems covered under the contract, with in 6(six) month from the date of award of contract, for the acceptance of employer. (e) The Contractor shall submit the commissioning documentation, for various equipment/covered under the contract, for the approval of employer, at least 18 months before the scheduled date of commissioning of the equipment/systems. 27.0 COMMISSIONING ACTIVITIES (a) Upon completion of pre-commissioning activities/tests, the contractor shall initiate commissioning of facilities. During commissioning the Contractor shall carry out system checking and reliability trials on various sub-systems of the facilities.
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(b) Contractor shall carry out the checks/tests at site to demonstrate to the Employer that each of the equipment of the supplied complies with requirements stipulated and is installed in accordance with requirements specified. (c) Before the plant is put into initial operation the Contractor shall be required to conduct test to demonstrate to the Employer that each item of the plant is capable of correctly performing the functions for which it was specified and its performance, parameters etc. are as per the specified/approved values. These tests may be conducted concurrently with those required under commissioning sequence. (d) Other tests shall be conducted, if required by the Employer, to establish that the plant equipment are in accordance with requirements of the specifications. (e) The Contractor shall conduct all the commissioning tests and undertake commissioning activities pertaining to all other auxiliaries and equipments including all electrical equipment/systems not specifically brought out above but are within the scope of work and facilities being supplied and installed by the Contractor and follow the guidelines indicated above or elsewhere in these technical specifications(Section- VI) (f) Initial Operation
Upon completion of system checking/Tests as above and as a part of commissioning of facilities, complete plant/facilities shall be put into initial operation as stipulated in General Technical Requirements. 28.0 MATERIALS HANDLING AND STORAGE (a) All the equipments furnished under the Contract and arriving at Site shall be promptly received, unloaded and transported and stored by the Contractor. (b) Contractor shall be responsible for examining all the shipment and notify the Employer immediately of any damage, shortage, discrepancy etc. for the purpose of Employer's information only. The Contractor shall submit to the Employer every week a report detailing all the receipts during the week. However, the Contractor shall be solely responsible for any shortages or damage in transit, handling and / or in storage and erection of the equipment at Site. Any demurrage, wharfage and other such charges claimed by the transporters, railways etc. shall be to the account of the Contractor. (c) The Contractor shall maintain an accurate and exhaustive record detailing out the list of all equipment received by him for the purpose of erection and keep such record available for the inspection of the Employer.
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(d) All equipment shall be handled with care to prevent any damage. No bare wire ropes, slings, etc. shall be used for unloading and/or handling of the equipment without the specific written permission of the Employer. The equipment stored shall be properly protected to prevent damage to the equipment. The equipment from the store shall be moved to the actual location at the appropriate time so as to avoid damage of such equipment at Site. (e) All electrical panels, controls gear, motors and such other devices shall be properly dried by heating before they are installed and energised. Motor bearings, slip rings, commutators and other exposed parts shall be protected against moisture ingress and corrosion during storage and periodically inspected. Heavy rotating parts in assembled conditions shall be periodically rotated to prevent corrosion due to prolonged storage. (f) The Contractor shall ensure that all the packing materials and protection devices used for the various equipments during transit and storage are removed before the equipment are installed. (g) The consumables and other supplies likely to deteriorate due to storage must be thoroughly protected and stored in a suitable manner to prevent damage or deterioration in quality by storage. (h) All the materials stored in the open or dusty location must be covered with suitable weatherproof and flameproof covering material wherever applicable. (i) If the materials belonging to the Contractor are stored in areas other than those earmarked for him, the Employer will have the right to get it moved to the area earmarked for the Contractor at the Contractors cost. (j) The Contractor shall be responsible for making suitable indoor storage facilities to store all equipment which require indoor storage. Normally, all the electrical equipments such as motors, control gear, exciters and consumables like electrodes, lubricants etc. shall be stored in the closed storage space . The Employer, in addition, may direct the Contractor to move certain other materials, which in his opinion will require indoor storage, to indoor storage areas which the Contractor shall strictly comply with. 29.0 CONSTRUCTION MANAGEMENT (a) The field activities of the Contractors working at Site, will be coordinated by the Employer and the Employer decision shall be final in resolving any disputes or conflicts between the Contractor and other Contractors and tradesmen of the Employer
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regarding scheduling and coordination of work. Such decision by the Employer shall not be a cause for extra compensation or extension of time for the Contractor. (b) The Employer shall hold weekly meetings of all the Contractors working at Site, at a time and place to be designated by the Employer. The Contractor shall attend such meetings and take notes of discussions during the meeting and the decisions of the Employer and shall strictly adhere to those decisions in performing his Works. In addition to the above weekly meeting, the Employer may call for other meeting either with individual Contractors or with selected number of Contractors and in such a case the Contractor if called, will also attend such meetings. (c) Time is the essence of the Contract and the Contractor shall be responsible for performance of his works in accordance with the specified construction schedule. If at any time, the Contractor is falling behind the schedule, he shall take necessary action to make good for such delays by increasing his work force or by working overtime or otherwise accelerate the progress of the work to comply with the schedule and shall communicate such actions in writing to the Employer, satisfying that his action will compensate for the delay. The Contractor shall not be allowed any extra compensation for such action. (d) The Employer shall however not be responsible for provision of additional labour and/or materials or supply or any other services to the Contractor except for the coordination work with other Contractors, if necessary. 30.0 FIELD OFFICE RECORDS The Contractor shall maintain at his Site Office up-to- date copies of all drawings, specifications and other Contract Documents and any other supplementary data complete with all the latest revisions thereto. The Contractor shall also maintain in addition the continuous record of all changes to the above Contract Documents, drawings, specifications, supplementary data, etc. effected at the field and on completion of his total assignment under the Contract shall incorporate all such changes on the drawings and other Engineering data to indicate as installed conditions of the equipment furnished and erected under the Contract. Such drawings and Engineering data shall be submitted to the Employer in requisite number of copies. 31.0 CONTRACTORS MATERIALS BROUGHT ON TO SITE (a) The Contractor shall bring to Site all equipment, components, parts, materials, including construction equipment, tools and tackles for the purpose of the Works under intimation to the Employer. All such goods shall, from the time of their being brought
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vest in the Employer, but may be used for the purpose of the Works only and shall not on any account be removed or taken away by the Contractor without the written permission of the Employer. The Contractor shall nevertheless be solely liable and responsible for any loss or destruction thereof and damage thereto. (b) The Employer shall have a lien on such goods for any sum or sums which may at any time be due or owing to him by the Contractor, under, in respect of or by reasons of the Contract. After giving a fifteen (15) days notice in writing of his intention to do so, the Employer shall be at liberty to sell and dispose off any such goods, in such manner as he shall think fit including public auction or private treaty and to apply the proceeds in or towards the satisfaction of such sum or sums due as aforesaid. (c) After the completion of the Works, the Contractor shall remove from the Site under the direction of the Employer the materials such as construction equipment, erection tools and tackles, scaffolding etc. with the written permission of the Employer. If the Contractor fails to remove such materials, within fifteen (15) days of issue of a notice by the Employer to do so then the Employer shall have the liberty to dispose off such materials as detailed under as specified at clause no 31 (b) above and credit the proceeds thereto to the account of the Contractor. 32.0 PROTECTION OF PROPERTY AND CONTRACTORSLIABILITY (a) The Contractor shall be responsible for any damage resulting from his operations. He shall also be responsible for protection of all persons including members of public and employees of the Employer and the employees of other Contractors and SubContractors and all public and private property including structures, building, other plants and equipments and utilities either above or below the ground. (b) The Contractor will ensure provision of necessary safety equipment such as barriers, sign - boards, warning lights and alarms, etc. to provide adequate protection to persons and property. The Contractor shall be responsible to give reasonable notice to the Employer and the Employers of public or private property and utilities when such property and utilities are likely to get damaged or injured during the performance of his Works and shall make all necessary arrangements with such Employers, related to removal and/or replacement or protection of such property and utilities. 33.0 PAINTING All exposed metal parts of the equipment including pipings, structure railings, etc. wherever applicable, after installation unless otherwise surface protected, shall be first painted with at least two coats of suitable primer which matches the shop primer paint
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used, after throughly cleaning all such parts of all dirt, rust, scales, greases, oils and other foreign materials by wire brushing, scraping or sand blasting and the same being inspected and approved by the Employer for painting. Afterwards, the above parts shall be finished painted with three coats of allowed resin machinery enamel paints. The minimum thickness of paint film shall not be less than 100 microns. The quality of the finish paint shall be as per the standards of Bureau of Indian Standards (BIS) or equivalent and to be of the colour as approved by the Employer. 34.0 INSURANCE 34.1 In addition to the conditions covered under the Clause entitled Insurance in Section General Conditions of Contract (GCC), the following provisions will also apply to the portion of works to be done beyond the Contractors own or his Sub-Contractors manufacturing Works. 34.2 Workmens Compensation Insurance This insurance shall protect the Contractor against all claims applicable under the Workmens Compensation Act, 1948 (Government of India). This policy shall also cover the Contractor against claims for injury, disability disease or death of his or his SubContractors employees, which for any reason are not covered under the Workmens Compensation Act, 1948. The liabilities shall not be less than the following: Workmen's Compensation - As per Statutory Provisions Employee's Liability - As per Statutory Provisions Property Damage: Rs.100,000 for each occurrence 34.3 Comprehensive General Liability Insurance 34.3.1 The insurance shall protect the Contractor against all claims arising from injuries, disabilities, disease or death of members of public or damage to property of others, due to any act or omission on the part of the Contractor, his agents, his employees, his representatives and Sub-Contractors or from riots, strikes and civil commotion. This insurance shall also cover all the liabilities of the Contractor arising out of the Clause entitled Defence of Suits in Section General Conditions of Contract (GCC). 34.3.2 The hazards to be covered will pertain to all the Works and areas where the Contractor, his Sub-Contractors, his agents and his employees have to perform work pursuant to the Contract. 34.4 The above are only illustrative list of insurance covers normally required and it will be the responsibility of the Contractor to maintain all necessary insurance coverage to the
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extent both in time and amount to take care of all his liabilities either direct or indirect, in pursuance of the Contract. 35.0 UNFAVOURABLE WORKING CONDITIONS The Contractor shall confine all his field operations to those works which can be performed without subjecting the equipment and materials to adverse effects during inclement weather conditions, like monsoon, storms, etc. and during other unfavourable construction conditions. No field activities shall be performed by the Contractor under conditions which might adversely affect the quality and efficiency thereof, unless special precautions or measures are taken by the Contractor in a proper and satisfactory manner in the performance of such Works and with the concurrence of the Employer. Such unfavourable construction conditions will in no way relieve the Contractor of his responsibility to perform the Works as per the schedule. 36.0 PROTECTION OF MONUMENTS AND REFERENCE POINTS The Contractor shall ensure that any finds such as relic, antiquity, coins, fossils, etc. which he may come across during the course of performance of his Works either during excavation or elsewhere, are properly protected and handed over to the Employer. Similarly the Contractor shall ensure that the bench marks, reference points, etc., which are marked either with the help of Employer or by the Employer shall not be disturbed in any way during the performance of his Works. If, any work is to be preformed which disturb such reference, the same shall be done only after these are transferred to other suitable locations under the direction of the Employer. The Contractor shall provide all necessary materials and assistance for such relocation of reference points etc. 37.0 WORK & SAFETY REGULATIONS 37.1 The Contractor shall ensure proper safety of all the workmen, materials, plant and equipments belonging to him or to Employer or to others, working at the Site. The Contractor shall also be responsible for provision of all safety notices and safety equipment required both by the relevant legislation and the Employer as he may deem necessary. 37.2 All equipment used in construction and erection by Contractor shall meet Indian/International Standards and where such standards do not exist, the Contractor shall ensure these to be absolutely safe. All equipments shall be strictly operated and maintained by the Contractor in accordance with manufacturers operation Manual and safety instructions and as per Guidelines/Rules of Employer in this regard.
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37.3 Periodical Examinations and all tests for all lifting/ hoisting equipment & tackles shall be carried-out in accordance with the relevant provisions of Factories Act 1948, Indian Electricity Act 1910 and associated Laws/Rules in force from time to time. A register of such examinations and tests shall be properly maintained by the Contractor and will be promptly produced as and when desired by Employer or by the person authorised by him. 37.4 The Contractor shall provide suitable safety equipment of prescribed standard to all employees and workmen according to the need, as may be directed by Employer who will also have right to examine these safety equipments to determine their suitability, reliability, acceptability and adaptability. 37.5 The Contractor shall provide safe working conditions to all workmen and employees at the Site including safe means of access, railings, stairs, ladders, scaffoldings etc. The scaffoldings shall be erected under the control and supervision of an experienced and competent person. For erection, good and standard quality of material only shall be used by the Contractor. 37.6 The Contractor shall not interfere or disturb electric fuses, wiring and other electrical equipment belonging to the Employer or other Contractors under any circumstances, whatsoever, unless expressly permitted in writing by the Employer to handle such fuses, wiring or electrical equipment. 37.7 No electric cable in use by the Contractor/Employer will be disturbed without prior permission. No weight of any description will be imposed on any cable and no ladder or similar equipment will rest against or attached to it. 37.8 The Contractors shall employ necessary number of qualified, full time Electricians/ Electrical Supervisors to maintain his temporary electrical installations. 37.9 In case any accident occurs during the construction/ erection or other associated activities undertaken by the Contractor thereby causing any minor or major or fatal injury to his employees due to any reason, whatsoever, it shall be the responsibility of the Contractor to promptly inform the same to the Employer in prescribed form and also to all the authorities envisaged under the applicable laws. 37.10 The Employer shall have the right at his sole discretion to stop the work, if in his opinion the work is being carried out in such a way that it may cause accidents and endanger the safety of the persons and/or property, and/or equipments. In such cases, the Contractor shall be informed in writing about the nature of hazards and possible injury/accident and he shall comply to remove shortcomings promptly. The Contractor after stopping the
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specific work can, if felt necessary appeal against the order of stoppage of work to the Employer within 3 days of such stoppage of work and decision of the Employer in this respect shall be conclusive and binding on the Contractor. 37.11 The Contractor shall not be entitled for any damages/ compensation for stoppage of work due to safety reasons as provided above and the period of such stoppage of work will not be taken as an extension of time for completion of the facilities. 38.0 FOUNDATION DRESSING & GROUTING FOR EQUIPMENT/ EQUIPMENT BASES 38.1 The surfaces of foundations shall be dressed to bring the top surface of the foundations to the required level, prior to placement of equipment/equipment bases on the foundations. 38.2 All the equipment/ equipment bases, shall be grouted and finished as per these specifications unless otherwise recommended by the equipment manufacturer. 38.3 The concrete foundation surfaces shall be properly prepared by chipping, grinding as required to bring the top of such foundation to the required level, to provide the necessary roughness for bondage and to assure enough bearing strength. 38.4 Grout The grout shall be high strength grout having a minimum characteristic compressive strength of 60 N/mm2 at 28 days. The grout shall be chloride - free, cement based, free flowing, nonmetallic grout. The Grout shall have good flowability even at very low water/ grout powder ratio. The Grout shall have characteristics of controlled expansion to be able to occupy its original volume to fill the voids and to compensate for shrinkage. Grout shall be of pre-mix variety so that only water needs to be added before use. The mixing of the Grout shall conform to the recommendations of the manufacturer of the Grout. 38.5 Finishing of the Edges of the Grout The poured grout should be allowed to stand undisturbed until it is well set. Immediately thereafter, the dam shall be removed and grout which extends beyond the edges of the structural or equipment base plates shall be cut off, flushed and removed. The edges of the grout shall then be pointed and finished with 1:2 cement mortar pressed firmly to bond with the body of the grout and smoothened with a tool to present a smooth vertical surface. The work shall be done in a clean and scientific manner and the adjacent floor spaces, exposed edges of the foundations, and structural steel and equipment base plates shall be thoroughly cleaned of any spillage of the grout.
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38.6 CHECKING OF EQUIPMENT AFTER GROUTING After the grout is set and cured, the Contractor shall check and verify the alignment of equipments, alignment of shafts of rotating machinery, the slopes of all bearing pedestals, centering of rotors with respect to their sealing bores, couplings, etc. as applicable and the like items to ensure that no displacement had taken place during grouting. The values recorded prior to grouting shall be used during such post grouting check- up and verifications. Such pre and post grout records of alignment details shall be maintained by the Contractor in a manner acceptable to the Employer. 39.0 SHAFT ALIGNMENTS All the shafts of rotating equipment shall be properly aligned to those of the matching equipments to as perfect an accuracy as practicable. The equipment shall be free from excessive vibration so as to avoid overheating of bearings or other conditions which may tend to shorten the life of the equipment. The vibration level of rotating equipments measured at bearing housing shall not exceed forty (40) microns and shall conform to VDI 2056.All bearings, shafts and other rotating parts shall be thoroughly cleaned and suitably lubricated before starting. 40.0 DOWELLING All the motors and other equipment shall be suitably doweled after alignment of shafts with tapered machined dowels as per the direction of the Employer. 41.0 CHECK OUT OF CONTROL SYSTEMS After completion of wiring, cabling furnished under separate specification and laid and terminated by the Employer, the Contractor shall check out the operation of all control systems for the equipment furnished and installed under these specifications and documents. 42.0 COMMISSIONING SPARES 42.1 It will be the responsibility of the Contractor to provide all commissioning spares including consumable spares required for initial operation till the Completion of Facilities. The Contractor shall furnish a list of all commissioning spares within 60 days from the date of Notification of Award and such list shall be reviewed by the Employer and mutually agreed to. However. such review and agreement will not absolve the Contractor of his responsibilities to supply all commissioning spares so that initial
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operation do not suffer for want of commissioning spares. All commissioning spares shall be deemed to be included in the scope of the Contract at no extra cost to the Employer. 42.2 These spare will be received and stored by the Contractor atleast 3 months prior to the schedule date of commencement of initial operation of the respective equipment and utilised as and when required. The unutilised spares and replaced parts, if any, at the end of successful completion of guarantee tests shall be the property of the Contractor and he will be allowed to take these parts back at his own cost with the permission of Employer. Employer will be informed of the list of commissioning spares brought to site by the contractor before bringing the same to the site. 43.0 CABLING 43.1 All cables shall be supported by conduits or cable tray run in air or in cable channels. These shall be installed in exposed runs parallel or perpendicular to dominant surfaces with right angle turn made of symmetrical bends or fittings. When cables are run on cable trays, they shall be clamped at a minimum intervals of 2000mm or otherwise as directed by the Employer. 43.2 Each cable, whether power or control, shall be provided with a metallic or plastic tag of an approved type, bearing a cable reference number indicated in the cable and conduit list (prepared by the Contractor), at every 5 meter run or part thereof and at both ends of the cable adjacent to the terminations. Cable routing is to be done in such a way that cables are accessible for any maintenance and for easy identification. 43.3 Sharp bending and kinking of cables shall be avoided. The minimum radii for PVC insulted cables 1100 V grade shall be 15 D where D is the overall diameter of the cable. Installation of other cables like high voltage, coaxial, screened, compensating, mineral insulated shall be in accordance with the cable manufacturers recommendations. 43.4 In each cable run some extra length shall be kept at a suitable point to enable one or two straight through joints to be made, should the cable develop fault at a later date. 43.5 Control cable terminations shall be made in accordance with wiring diagrams, using identifying codes subject to the Employers approval. Multicore control cable jackets shall be removed as required to train and terminate the conductors. The cable jacket shall be left on the cable, as far as possible, to the point of the first conductor branch. The insulated conductors from which the jacket is removed shall be neatly twined in bundles and terminated. The bundles shall be firmly but not tightly tied utilizing plastic or nylon ties or specifically treated fungus protected cord made for this purpose. Control cable conductor insulation shall be securely and evenly cut.
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43.6 The connectors for control cables shall be covered with a transparent insulating sleeve so as to prevent accidental contact with ground or adjacent terminals and shall preferably terminate in Elmex terminals and washers. The insulating sleeve shall be fire resistant and shall be long enough to over pass the conductor insulation. All control cables shall be fanned out and connection made to terminal blocks and test equipment for proper operation before cables are corded together. 44.0 EQUIPMENT DELIVERY AND ERECTION 44.1 General Requirements (a.) This part covers Contractor's responsibilities for packing, shipping, warehousing and the installation of all equipment and materials furnished and installed under this specification. (b.) The Contractor shall submit for Employer's approval draft manual for Equipment Delivery and Erection covering detailed instructions, write up, technical data, drawings, check-lists, documentation formats for all activities after equipment manufacture upto installation of equipment. This manual shall cover general instructions for all equipment and specific instructions for individual equipment wherever required and shall include at least the following : i. Instructions for packing, shipping, receiving handling, ware-housing and storage. ii. Instructions for location and installation of equipment furnished by this specification. iii. Installation drawings for field mounted equipment, panels, cubicles and other equipment covered under this specification. iv. Instruction relating installation of piping/ tubing, support and routing drawings of impulse pipes/signal tubes and tube/cable trays. v. Check lists and quality assurance hold points. vi. Format for all related documentation. (c.) The Manual shall conform to the requirements of this specification, all applicable codes and standards, recommendations of equipment manufacturers and accepted good engineering practices and shall be subject to Employer approval during detailed engineering. (d.) The Contractor shall ensure that all work under this part shall be performed as per the requirements of this specification, Employer approved Manual and drawing/documents approved by the Employer during detailed engineering stage of work.
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44.2 Crating (a) All equipment and materials shall be suitably coated, wrapped, or covered and boxed or crated for moist humid tropical shipment and to prevent damage or deterioration during handling and storage at the site. (b) Equipment shall be packed with suitable desiccants, sealed in water proof vapourproof wrapping and packed in lumber of plywood enclosures, suitably braced, tied and skidded. Lumber enclosures shall be solid, not slatted. (c) Desiccants shall be either silica gel or calcium sulphate, sufficiently ground to provide the required surface area and activated prior to placing in the packaging. Calcium sulphate desiccants shall be of a chemical nature to absorb moisture. In any case, the desiccant shall not be of a type that will absorb enough moisture to go into solution. Desiccants shall be packed in porous containers, strong enough to withstand handling encountered during normal shipment. Enough desiccant shall be used for the volumes enclosed in wrapping. (d) Review by the Employer of the Contractor's proposed packaging methods shall not relieve the Contractor of responsibility for damage or deterioration to the equipment and materials specified. (e) All accessory items shall be shipped with the equipment. ; Boxes and crates containing accessory items shall be marked so that they are identified with the main equipment. The contents of each box and crates shall be indicated by markings on the exterior. (f) All boxes, crates, cases bundles, loose pieces, etc. shall be marked consecutively from No.1 upward throughout all shipments from a given port to completion of the order without repeating the same number. (g) An itemized list of contents shall be enclosed inside each case and one other copy securely fastened to the outside of the case in a tin or light weight sheet metal envelope or pocket. The lists shall be plainly marked and placed in accessible locations to facilitate receipt and inspection. The packing list shall indicate whether shipment is partial or complete and shall incorporate the following information on each container, etc., according to its individual shipping number : 1. Export case markings 2. Case number 3. Gross weight and net weight in Kilograms 4. Dimensions in centimeters 5. Complete description of material (h) Packaging or shipping units shall be designed within the limitations of unloading facilities and the equipment which will be used for transport. Complications involved with ocean shipment and the limitations of ports, railways and roads shall be considered. It shall be the Contractor's responsibility to investigate these limitations
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and to provide suitable packaging to permit safe handling during transit and at the job site. (i) Electrical equipment, control and instrumentation shall be protected against moisture and water damage. All external gasket surfaces and flange faces, couplings, motor pump shafts, bearing and like items shall be thoroughly cleaned and coated with rust preventive compound as specified above and protected with suitable wood, metal or other substantial type covering to ensure their full protection. (j) Equipment having antifriction or sleeve bearings shall be protected by weather tight enclosures. (k) Coated surfaces shall be protected against impact, abrasion, discolouration and other damage. Surfaces which are damaged shall be repaired. (l) All exposed threaded parts shall be greased and protected with metallic or other substantial type protectors. All female threaded openings shall be closed with forged steel plugs. All pipings, tubing, and conduit equipment and other equipment openings shall be sealed with metallic or other rough usage covers and tapped to seal the interior of the equipment piping, tubing, or conduit. (m) Provisions shall be made to ensure that water does not enter any equipment during shipment or in storage at the plant site. (n) Returnable containers and special shipping devices shall be returned by the manufacturer's field representative at the Contractor's expense. (o) While packaging the material, care shall be taken for the limitation from the point of view of availability of railway wagon sizes in India. 44.3 Equipment Installation (a.) General Requirements
The Contractor shall furnish all construction materials, tools and equipment and shall perform all work required for complete installation of all control and instrument equipment furnished under this specification. Contractor shall prepare detailed installation drawings for each equipment furnished under this specification for Employer's approval. Installation of all equipment/systems furnished by this specification shall be as per Employer's approval. Erection procedures not specified herein shall be in accordance with the recommendations of the equipment manufacturers. The procedures shall be acceptable to the Employer. The Contractor shall coordinate his work with other suppliers where their instruments and devices are to be installed under specifications. (b.) Installation Materials All materials required for installation, testing and commissioning of the equipment shall be furnished by the Contractor.
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(c.)
Regulatory Requirements
All installation procedures shall confirm with the accepted good engineering practice and with all applicable governmental laws, regulations and codes. (d.) Cleaning All equipment shall be cleaned of all sand, dirt and other foreign materials immediately after removal from storage and before the equipment is brought to installation site. (e.) Equipment Assembly Equipment installed under these specifications shall be assembled if shipped unassembled. The equipment shall be dismantled and reassembled as required to perform the installation and commi ssioning work described in these specifications. (f.) Defects All defects in erection shall be corrected to the satisfaction of the Employer and the Project Manager. The dismantling and reassembly of Contractor furnished equipment to remove defective parts, replace parts, or make adjustments shall be included as a part of the work under these specifications. The removal of control and instrument equipment in order to allow bench calibration, if required, and the re-installation of the said equipment after calibration shall also be included as a part of the work under these specifications. 45.0 DEVIATIONS DISPOSITIONING: Any deviation to the contract and employer approved documents shall be properly recorded in the format prescribed by NALCO. Al the deviations shall be bought to the knowledge of employers representative for suitable dispositioning. 46.0 NON-DESTRUCTIVE TESTING ( NDT): The contractor shall record results of NDTs carried out at site in the format acceptable to employer. All the radiographs & its report duly signed & correlated to the job shall be handed over to the employer. Sensitivity of all the test equipment shall be compatible to the job & acceptance norms agreed. 47.0 TESTING EQUIPMENT & FACILITIES: Contractor shall provide the testing equipment and facilities necessary to carry out tests & inspections.
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SECTION 8
ANNEXURE-I PAINTING 1.0 1.1 GENERAL This specification covers the materials, tools, facilities and quality requirement for surface preparation and painting of steel structures, equipment, piping including supports, hangers, gas and air ducts including hangers, chutes etc. The term "painting" referred herein covers rust preventive, preventive and decorative coating along with surface protection. 1.2 Surfaces in direct bonded contact with concrete, aluminium, asbestos, brass; bronze, galvanized steel, stainless steel, cast iron and other corrosion resistant alloys, rubber/synthetic polymers are not required to be painted unless specified except for aesthetic purposes or for identification bands. Except for such surfaces, painting and surface preparation shall be provided to protect all surfaces that shall be subjected to atmospheric action and exposed to corrosive medium. All machined mating surfaces (eg. flanges) shall be properly cleaned, greased and protected before dispatch. 1.3 The complete paint system for any item includes the following activities: i) Proper surface preparation ii) Application of primer coats iii) Application of intermediate coats iv) Application of finished coats All the above coats shall be of quality paint products and of approved make as stipulated in this specification. The work shall also include supply of all paint materials as per specification described herein and of approved quality. 2.0 2.1 SURFACE PREPARATION Surface preparation being a pre requisite for any paint application, shall be such as to clean the surface thoroughly of any materials which will be conducive to premature failure of the paint substrates. All surfaces shall be cleaned of loose substances and foreign materials, such as dirt, rust, scale, oil, grease, welding flux, etc. irrespective of whether the same has been spelt out in the standards in
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2.2
Technical Specification: Annexures
order that the prime coat is rigidly anchored to the virgin metal surface. The surface preparation shall conform to pictorial representation of surface quality grade of DIN 55928 (Part 4) or BS 4232 or IS 1477 - 1971 ( Part I ). Any grease, oil, dust or foreign matter deposited on the surface after preparation shall be removed and care taken that the surface is not contaminated with acids, alkalis moisture or other corrosive chemicals. The prime coat shall be applied as soon as possible after the surface preparation is completed. 2.3 The acceptable surface preparation quality / grades are described under each painting system. The procedures covered are solvent cleaning, hand tool cleaning, power tool cleaning and blast cleaning. Solvent cleaning The surface shall be cleaned by wiping, immersion, spraying or vapor contacting of a suitable solvent or washing with an emulsion or alkaline solution to remove oil, grease, dirt, old paint, etc. Solvent cleaning shall not remove rust, scales, mill scales or weld flux. Therefore, before application of paint, solvent cleaning shall be followed by other cleaning procedures as stated elsewhere. 2.5 Hand tool cleaning The surface shall be cleaned by vigorous wire brushing done manually to St-2 quality. This method effectively removes loosely adherent materials, but would not affect residues of rust or mill scales that are intact and firmly adherent. 2.6 Power tool cleaning Electric or pneumatic tools shall clean the surface to St - 3 quality. The tools shall be used carefully to prevent excessive roughing of surface and formation of ridges and burns. This method will remove loosely adherent materials but would not affect residues of rust or mill scales that are firmly adherent. 2.7 Blast cleaning The surface shall be cleaned by impingement of abrasive materials, such as graded sand at high velocity created by clean and dry compressed air blast. This method will remove loosely adherent materials as well as adherent scales and mill scales. Prior to application of blast, heavy deposit of oil and grease are removed by solvent cleaning and excessive surface scales are removed by hand tools or power tool cleaning. The surface shall be cleaned to Sa - 2 1/2 quality i.e. 95 % of surface area is free from all rust, mill scales and visible residues, foreign materials, etc. The blast cleaning is not recommended for sheet metal work. PRIMER PAINTS (P) Primer paints shall be applied only on dry and clean surfaces.
Technical Specification: Annexures Page 2 of 62
2.4
3.0
3.1
Primer paint P1 - (Phenolic - Alkyd based) A single pack air drying phenolic modified alkyd composition with zinc phosphate as a primer paint. Air drying time - About 60 minutes (touch dry) -Overnight (hard dry) Dry film thickness - 40 microns (min) (DFT / Coat)
3.2
Primer paint P2 - (Epoxy based) A two pack air drying Epoxy polyamide with zinc dust of at least 92 % zinc dust on the dry film. Epoxy content (% wt.) - 8 to 10 Air drying time - 10 minutes (touch dry) - 2 hours (hard dry) DFT / coat - 40 microns (min) Primer paint P3 - (Ethyl zinc silicate, EZS, based) A two pack heavy duty zinc dust rich silicate primer which protects the surface with just a single coat. Total solids ( % wt ) - 84 +/- 2 Density ( g / cc ) - 3.07 +/- 0.05 Air drying time - To top coat 16 hours DFT / coat - 60 microns
3.3
4.0
INTERMEDIATE PAINTS ( I ) These paints shall be applied over primer coats as an intermediate layer to provide weatherproof seal of primer coats.
4.1
Intermediate Paint I-1 (Phenolic alkyd based) A single pack high build phenolic based paint of synthetic micaceous iron oxide. -4 to 6 hours (touch dry) -2 days (hard dry) DFT / coat -75 microns (min) Temperature resistance -upto 100 deg C dry heat Compatible with -Primer P1 Air drying time
4.2
Intermediate Paint I-2
A two-pack air drying high build epoxy resin based paint with MIO.
Air drying time DFT / coat Compatible with 5.0 FINISH PAINTS (F)
- 6 to 8 hours (touch dry) - 7 days (full cure) - 100 microns - Primer P2
Finish paint coats shall be applied over primer coats and intermediate coats after proper cleaning and touch up of primed coats. 5.1 Finish Paint F1 A single pack air drying high gloss phenolic alkyd modified synthetic enamel paint suitably pigmented. Air drying time -3 to 4 hours (touch dry) -24 hours (hard dry) DFT / coat - 25 microns (min) Compatible with Intermediate I1 - Primer P1 Colour - generally all shades 5.2 Finish Paint F2 A two pack air drying epoxy polyamide enamel suitably pigmented. Air drying time - 2 to 3 hours (touch dry) - 7 days (full cure) DFT / coat - 40 microns (min) Compatible with Intermediate I2 - Primer P2 Colour - generally all shades 5.3 Finish Paint F3 A single pack heat resistant silicon resin based paint with leafing Aluminium powder. Air drying time - 3 to 4 hours (touch dry)/24 hrs (hard dry) DFT / coat - 20 microns (min) Compatible with - no primer paint except P3 (shall be applied on blast cleaned steel surface) Colour - smooth aluminium
6.0 6.1
PAINT APPLICATION Paint shall be applied in accordance with paint manufacturer's recommendations. Manufacture of paints, mixing of paints, etc. shall be as per the IS codes of practice. The work shall generally
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follow IS 1477 -1971 (Part II) for jobs carried out in India and or DIN 55928 (latest) or equivalent for jobs carried out outside India. 6.2 Paint shall not be applied when the ambient temperature is 50 C and below or 450 C and above. Also paint shall not be applied in rain, wind, fog or at relative humidity of 80 % and above unless the manufacturer's recommendations permit. Application of paint shall be only by spraying or brushing as per IS 486 - 1983 and IS 487 - 1985. Each coat of paint shall be continuous, free of pores and of even film thickness without thin spots. Each coat of paint shall be dry sufficiently before application of next coat. The colour code to be followed during painting shall be intimated to the successful Tenderer during finalization of order. In the event of conflict between this general procedure for painting and the paint manufacturer's specification, the same shall be immediately brought to the notice of the Purchaser. Generally in cases of such conflicts, manufacturer's specifications / recommendations shall prevail. General compatibility between primer and finishing paints shall be certified by the paint manufacturer supplying the paints. Areas that become inaccessible after assembly shall be painted before assembly (after painting clearance has been given by the inspecting authority) after requisite surface cleaning as specified. Surfaces which cannot be painted but require protection shall be given a coat of rust inhibitive grease according to IS 958 - 1975 or solvent deposited compound according to IS 1153 - 1975 or IS 1674 - 1960.
6.3 6.4 6.5
6.6
6.7
6.8 6.9
6.10 Parts of steel structures embedded in concrete shall be given a protective coat of Portland cement slurry immediately after fabrication and after surfaces of this part is thoroughly cleaned from grease, rust, mill scales, etc. No paint shall be applied on this part. 6.11 The proposed make, quality and shade of the paint shall have the approval of the Purchaser. 6.12 Zinc rich primer paints which have been exposed several months before finishing coat is applied shall be washed down thoroughly to remove soluble zinc salt deposits. 6.13 The machine finished surfaces shall be coated with white lead and tallow before shipment or before being put out into the open air. 6.14 Total DFT for heat resistant paints should not exceed 100 -120 microns, otherwise flaking occurs ( as per paint manufacturer's recommendations ). 6.15 Heat resistant paints should be applied by brush. 7.0 PAINTING SCHEME
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7.1
For a complete painting scheme of any item being painted, all types of paints are to be procured from the same manufacturer as approved by the Purchaser. Legend SP Surface preparation quality 2P1 Two (2) coats of primer paint type P1 1I1 One ( 1 ) coat of intermediate paint type I1 2F1 - Two ( 2 ) coats of finish paint type F1 DFT Dry film thickness Type of paint products like P1, P2, P3, I1, I2, F1, F2 and F3 have been specified under sl. nos.03, 04 and 05 of this specification.
7.2
7.3
The painting scheme to be followed for various equipment/ structures is briefly given below for guidance to the Tenderer. Painting scheme Sl. No. Description DFT Total At shop At site SP - St 3 1. Steel structure 2P1+1I1 2F1 205 Mechanical SP - Sa 2 1/2 (or St 3) equipment(temp. not over 80 deg C) Both static and 2P1+1I1 rotary equipment 2F1 & 2F2 or 2P2+1I2 for indoor or outdoor duty Equipment with hot surfaces SP- Sa 2 1/2 (temp. 200 deg C and above) P3
2.
205 (260)
3.
2F3
100
8.0
Colour code For painting certain standard colour as listed below, shall be used by the bidder. For electrical equipment SHADE IS:5 631 538 AS
8.1
DESCRIPTION 11 kV, AC machine 3.3 kV, AC machine

COLOUR Light grey Post office red
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400 V, AC machine 460 V, DC machine 250 V, DC machine 230 V, AC equipment 110 V, AC equipment All indoor control and switchgear panels All outdoor transformers, switchgear, control panel etc. Instrumentation panels Telecommunication panels 8.2
Brilliant green Azure blue Oriental blue Light orange Canary yellow Grey Dark admiralty grey Opaline green Smoke grey
221 104 174 557 309 697 632 275 692
For mechanical equipment -Indoor and outdoor mechanical equipment excepting cranes : Grey. For pipes, ducts, conduits and others Service River water (untreated) Cooling Water Boiler feed water Condensate Colour Base - Sea green Band - White Base - Sea green Band - French blue Base - Sea green Base - Sea green Band - Light brown Base - Sea green First band - French blue Second band - Signal red Base - Sea green Band - Light orange Base - Sea green Band - Black Base - Sky blue Base - Sky blue Band - Light brown Base - Sky blue Band - Black Base - Silver grey if Bitulac or Aljacket Band - Brilliant green Base - Silver grey if Bitulac or Aljacket Band - French blue Base - Al-jacket Shade as IS:5 217 217 166 217 217 410 217 166 537 217 557 217 101 101 410 101 628 221 628 166 -
8.3
Drinking water
Industrial water Hydraulic power water Compressed air Instrument air Vacuum
Steam below 3.5 kg/cm2 (g)
3.5-20 kg/cm2 (g) 21-40 kg/cm2 (g)

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Above 40 kg/cm2 (g) Drainage Lubricating oil Hydraulic oil Transformer oil Fuel oil Coke oven/coal gas/other fuel gases Freon (chlorofluore methane and ethane) Argon Acetylene derivative
LP gas
Nitrogen Oxygen Regenerated acid (dilute) (1)
Hydrochloric acid (conc.) (1)
Spent liquor
Wash liquor
Dilute acidic liquor
Hydrofluoric acid (conc.) (1) Acidic slurries

Band - Dark violet Base - Al-jacket Band - Signal red Base - Black Base - Light brown Band - Light grey Base- Light brown Band - Dark violet Base - Light brown Band - Light orange Base - Light brown Band - Signal red Base - Canary yellow Band - Signal red of Base - Canary yellow Band - Light grey Base - Canary yellow Band - French blue Base - Canary yellow Band - Dark violet Base - Canary yellow First band - Signal red Second band - Traffic green Base - Canary yellow Band - Black Base - Canary yellow Band - White Base - Dark violet Band - Light brown Band - Dark violet First band - Light brown Second band - Light brown Base - Dark violet First band - Light brown Second band - Light brown Base - Dark violet Band - Light grey Base - Dark violet First band - Light grey Second band - Brilliant green Base - Dark violet Band - Silver grey Base - Dark violet
796 537 410 631 410 796 410 557 410 537 309 537 309 631 309 166 309 796 309 537 267 309 309 796 410 796 410 410 796 631 410 796 631 796 631 221 796 628 796
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Alkalis Non-acidic slurries Fire fighting system Rain water down pipes Duct work Lighting conduits Instrument conduits Power conduits
Band - White Base - Dark violet Band - Deep buff Base - Sea green Band - White Base - Signal red Base - Sea green Band - Sky blue Base - Aluminium Base - Black Band- Yellow Base - Black Band - Red Base - Black
796 360 217 537 217 101 309 537
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Annexure-II
LIST OF MANDATORY SPARES A. 1.0 MECHANICAL Belt Conveyor Sl.No. 1. 2. 3. 4. 5. 6. 7. DESCRIPTION Pulleys -Driving Pulley -Non-Driving Pulley Idlers Input shaft assembly (only pinion & input shaft) 1st Reduction Gear Oil seal Coupling Hold back Safety devices 8. 2.0 Pull chord switches Belt sway switches Zero speed switches 5% of total quantity 5% of total quantity 5% of total quantity QTY. 1 no. of each size & type. 1 no. of each size & type 1 no. each type 1 no. each type 2 nos. each type 1 no. each type 1 no. each type
Actuator operated flap gate SL. NO. 1. 2. 3. 4. 5. 6. DESCRIPTION Plummer box Self aligning ball bearing Gaskets Limit Switch Sealing Oil Seal QTY. 1 set. 1 set. 1 set. 1 set. 1 set. 1 set.
3.0
Side Arm Charger SL. NO. DESCRIPTION 1. Gear box spares (complete gear box assy., oil seal and bearing) 2. Carriage wheels a) Bearings b) Oil Seals c) Plummer block d) Carriage wheel fitted with shaft (without Plummer Block) 3. Coupling 4. Travel wheel assembly 5. Bearing
QTY. 1 set. a)1 set. b) 2 sets c) 1 set d) 1set 1 set. 1 No. 1 set.
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6. 7. 8. 9. 3.0
Motor including slip ring motor, Bearings and Oil seal
1 set.each of type and size Brakes complete assembly with lining and springs 1 set. Couplings with complete assembly, pins, bushes, and 1 set. nuts Hydraulic power Pack with all accessories 1 set.
Wagon Tippler and Accessories SL. DESCRIPTION QTY. NO. 1. Speed Reducers (a)complete gear box assy., (b)oil seal and a)1 set. b) 4 sets (c) bearing) c) 2 set of each type and rating 2. Motor a) Motor including slip ring motor, b)Bearings c) Oil a)1 set. b) 1 sets seal c) 1 set of each type and rating 3. Brakes a) Complete assembly b) Linings and springs 1 set. of each type and rating 4. Couplings with complete assembly, pins, bushes, and nuts 1 set. each type and rating/sise 5. a) Thyristor /VVVF cards/ Modules a) 1 No. of each type. B) 2 b) Relays No. of each type and rating 6 (a) Hydraulic Pump with electric motor, coupling, valves (mounted on pump) etc: (b) Hydraulic Motor (c) Valves (d) O.P. Coolers (e) Filter Elements (f)Pressure Switch (g)Temperature Switch Bearings (not covered separately) 1 Set of each type and size
7 8 9 10 11 12 13 14 15 16 17 18
1 No. of each type and size 1 No. of each type and size 1 No. 10 Nos. of each type 1 No. of each type 1 No. of each type 1 Set of each type and size Limit Switches 2 Nos. of each type. Cylinder Manifold block with all valves mounted on it 1 Set Hydraulic cylinder with piston 1 Set of each type and size Seals of hydraulic cylinder and pumps etc. 2 Sets of each type Hydraulic hoses 2 sets Gear box total 1 set Gear flexible coupling 1set Rod end bearings with housing 1 set for all four clamps Pressure Switches, Common manifold block complete with 1 no. each all valves mounted on it, Main Pivot bearing, Pinion support & bearing 1 No each type Pinion 2 nos
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19 20 5.0
Latch (Pinion & rack segment locking device) Chain & Sprocket
1 No. 1 set
Apron Feeder SL. NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 14 15 16 17 DESCRIPTION Head Pulley complete with shaft Tail pulley complete with shaft Drive Motor Gear Box Complete internals of gear box including input and output shafts Reduction gears Fluid coupling, flexible coupling etc. Traction rollers Carrying idlers Return Rollers Sprocket segments Link Chain Pans (flights) Hydraulic cylinder Seal kit of hydraulic cylinders Plummer blocks Bearings QTY. 1 No. 1 No. 1 No. of each type and size 1 No. of each type and size & direction. 1 No. of each type and size 1 Set of each type and size 1 Set of each type and size 20% of population 20% of population 20% of population 2 Sets of each type and size 20% of each type and size 10% 1 set of each type and size 1 set 1 No. of each type and size 1 Set of each type and size
6.0
Twin Shaft Sizer SL. NO. 1. 2. 3. 4. 5. 6. Electric Hoist SL. NO. 1. 2. 3. 4. 5. 6.
DESCRIPTION Gear Coupling Assembly Fluid Coupling Fixed Bearing Assembly Floating Bearing Assembly Input Shaft Assembly Output Shaft Assembly
QTY. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No.
7.0
DESCRIPTION Ball bearing Needle bearing with inner race Bush bearing Rope tightener Rope guide Rope sheave
QTY. 1 set. 1 set. 1 set. 1 set. 1 set. 1 set.

Page 12 of 62
7. 8. 9. 10. 11. 8.0 Manual Hoist SL. NO. 1. 2. 3. 4. B. ELECTRICAL Sl. No. MCC 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. MOTORS 1. 2. 3. 4. 5. 6. 7.
Thrust bearing Roller bearing with inner race Brake lining Limit switch complete Rotor pinion
1 set. 1 set. 1 set. 1 set. 1 set.
DESCRIPTION Grooved sheave Pinion Bearing Shaft pin
QTY. 2 sets 1 set 1 set 1 set
DESCRIPTION Busbar support insulators Current transformers Potential transformers 415/110V Male contact of ACB (main and aux.) Female contact of ACB (main and aux.) Limit switch of ACB Spring charging motor of ACB Closing coil of ACB Tripping coil of ACB Breaker control switch Relays Auxiliary relay Indicating Lamp assembly (LED LVGP type) Phase sequence meter
QUANTITY 10 Nos. of each type / MCC 1No. of each type & rating / MCC 1 No. / MCC 1 set /MCC 1 set / MCC 3 Nos. /MCC 3 Nos. /MCC 2 Nos. /MCC 2 Nos. /MCC 2 Nos. /MCC 1No. of each type/ MCC 2 Nos. of each type / MCC 10 Nos. of each type & colour /MCC 2 Nos.
Bearing (drive end) Bearing (Non-drive end) End shield (DE and NDE) Cooling fan of motors Fan cover Bearing puller Grease gun
1 No. of each type 1 No. of each type 1 set of each type 1 No. of each type 1 No. of each type 1 Nos. of each type 2 Nos.
Page 13 of 62
PDB/LDB/SLDB/AUX. PDB 1. 2. 3. 4. 5. LT TRANSFORMER 1. 2. 3. 4. UPS 1. 2. Thyristor fuse Electronic logic card 1 no. of each rating 1 no. of each type HV bushing (1 set = 3 nos.) LV bushing (1 set = 3 nos.) Temp. scanner Neutral bushing CT 1 set 1 set 1 no. 1 no. of each type/ ratio Bus bar support insulators MCCB MCB Breaker control switch Control switch 3 Nos. of each type / DB 2 Nos. of each rating/DB 2 Nos. of each rating/DB 2 Nos. /DB 2 Nos. of each type/DB
CONTROL DESK/ AMMETER CONTROL PANEL 1. 2. 3. 4. ILLUMINATION 1. 2. 3. 4. C. Lamps Fittings Control gear complete Timer 4 Nos. of each type 2 Sets of each type 2 Sets of each type 1 No. Ammeter Indicator Lamp Assembly Control switch Push button 1 No. of each range 5 sets 1 no. of each type 1 no. of each type
VENTILATION, AIRCONDITIONING & DRY FOG DUST SUPPRESSION SYSTEM SYSTEM / EQUIPMENT DESCRIPTION Air Washing type Ventilation Systems. Centrifugal Fans & Filters V -Belt Bearings Flexible Connection Filter element QUANTITY 1 set of each type 1 set of each type 1 set of each type 20% of requirement
Page 14 of 62
Water Pump
Impeller 1 set of each type Coupling 1 set of each type Bearings 1 set of each type Gland Packing 2 sets of each type Nozzles Nozzles 10% of requirement Valves Valves 1 set of each type Exhaust Fans Bearings 1 set of each type Dry Fog & Plain Water Sprinkling type Dust Suppression Systems Water Pump Impeller 1 set of each type Coupling 1 set of each type Bearings 1 set of each type Gland Packing 2 sets of each type Nozzles Nozzles 10% of requirement 20% Nozzle tips of requirement Sprinklers Nozzles 10% of requirement Solenoid Valves Solenoid Valves 10% of requirement Pressure gauges Pressure Gauges 1 set of each type Sensors and Instruments Sensors & Instruments 1 set of each type Valves Valves 1 set of each type Pressure Regulating Units PRU 1 set of each type (PRU) Flow Activation Station FAS 1 set of each type (FAS) Compressor Bearings 1 set of each type Couplings / V Belts 1 set of each type Pulleys 1 set of each type Filters 1 set of each type Gaskets / O Rings 1 set of each type Valves /Safety valves 1 set of each type Piston rings 1 set of each type
Page 15 of 62
Annexure-III INFORMATIONS TO BE FURNISHED BY THE BIDDER ALONG WITH A SOFT COPY 1.0 Check List for Bid submission
1. 2. 3. 4. 5.
6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17 2.0
All drawings and documents duly signed as per TS submitted along with Bid Clause wise list of deviations from TS furnished Time bar chart and level of PERT network furnished as per the TS Separate price bid submitted Necessary particulars to establish the possession of technical know-how and facilities available furnished as per TS Reference list for supply of similar equipment along with users certificate furnished as per the TS Write up of testing facilities available at works furnished as per the TS Brief scope of collaboration for collaboration agreement furnished as per the TS Clause wise list of deviations / exclusions furnished as per the TS Delivery schedule indicated as per TS Bought out items conforms to TS Location and size of MCC & control room indicated List of tools furnished as per TS List of commissioning spares furnished as per TS List of spares for two years operation along with item wise price furnished as per TS List of insurance spares with price furnished as per TS Erection plans furnished as per TS
- Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No
- Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No - Yes/ No
Questionnaire The Bidder shall fill in this questionnaire and submit in hard as well as a soft copy with their Bid. This data shall form a part of the contract with successful Bidder.
2.1
General 1. 2. Name and address of the Bidder Previous experience of the Bidder
Page 16 of 62
3. 4.
5.
6. 7
List of similar equipment supplied Whether the Bidder has any technical collaboration with any other company / organization for his equipment If answer to question 4.0 is yes, furnish the following details. a) Name and address of the collaborator b) Nature of the collaboration in detail c) Previous experience of the collaborator List of drawings literatures enclosed with the offer Is it the Bidder's intention, if awarded the contract, to comply fully in all respects with owners specifications covering the work? If not, he shall state specific exception in details
A. WAGON TIPPLER GENARAL Type: Designed capacity Guaranteed capacity Make: Capacity: Angle of tipping: Drive: Tippler drive: Side arm charger: Indexer: Clamping: Wt. of the machine Tippling time cycle: Rail Gauge: Drive Rack Assembly Spherical roller bearing SKF ECACK30/W33/Equivalent. CLAMP CYLINDER Bore Rod
NO.24168
Page 17 of 62
Stroke Tippler Ballast-25T at each end frame Made from concrete with steel scrap DRIVE PINION P.C.D Face width No.of teeth Pressure angle Material CYLINDER FOR INHAUL CLICKING STOP Bore Rod Stroke HYD.POWER PACK DETAILS FOR WT Type Oil pump proportional control of capacity Tank capacity Electric motor for WT main drive Electric motor for WT clamp Cooling HYDRAULIC MOTOR DATA FOR WAGON TIPPLER Type Model Displacement Speed Details of Motor Pressure (Max) Torque theoritical Power theoritical (Max) Speed (Max) HYDRAULIC CYLINDER DATA FOR WAGON TIPPLER Bore Rod Stroke SIZE OF WAGON TO BE HANDLED Length Width Height
B.
APRON FEEDER: GENERAL Make: Capacity: Pan width: Length: Motor DRIBBLE CONV. GENERAL Conv.Belt Belt width Belt length
C.
SIZER GENERAL Main Dimensions Total length Total width Total Height Estimated Mass Chamber Dimensions Total length Total width Total Height Frame Dimensions Total Height Shaft Configurations No. Teeth / Segment No. Segment / Shaft Roll Length Roll Speed Bearing Type Bearing Lubrication Gear Box Type Output Torque
Page 19 of 62
Max Peak overload Torque Transmission Ratio No. of Stages Lubrication Type Calculated life time Approx. Mass Recommended Installed power Estimated Absorbed power D. WEIGH BRIDGE GENERAL Make Quantity required Carrying capacity /strength Weighing capacity Type Platform size Mounting Resolution Taring facility Auto tare Purpose Cycle of weighment Duty Power supply required Operating temp.range Platform size Material of construction Load cell Load cell capacity E. SPECIFICATION OF LOAD CELL GENERAL Characterstic Make Type No.of loadcells Capacity of each loadcell Rated output
Specification
Page 20 of 62
Combined error Repeatability CREEP ON LOAD (30min) Zero balance voltage Input resistance Output resistance Compensated temp.range Operating temp.range Temp.effect on span Temp.effect on tare Excitation voltage Safe overload Ultimate overload Insulation resistance Protection Cable F. CONTROLLER GENERAL CHARACTERISTIC Model no. Type Power supply Operating temperature Range Resolution Non - linearity Repeatability Excitaton to transducer Display Input Output Programmable parameters Casing dimension G. SIDE ARM CHARGER GENERAL Type of side arm charger (sac) Sac pulling capacity SAC total travel Max.wagon size that sac can handle
SPECIFICATION
Type of luffing system for sac Track gauge Operating speed of sac in m/s Forward with single wagon Return Type of power supply system for sac Support roller wheel Guide roller wheel Feston support post Electric motor for sac Cooling DRIVE PINION P.C.D Face width No.of teeth Pressure angle Material RACK FOR SAC TRAVEL Total nos Pitch Pressure angle Teeth per rack Material HYD.POWER PACK DETAILS FOR SAC TYPE Oil pump proportional control of capacity Tank capacity Electric motor for SAC Cooling HYD.MOTOR DETAILS FOR SAC Hyd.motor double displacement type Motor model: Displacement: Details of Motor Pressure (Max) Torque theoritical Power Speed (Max) SAC RAISE & LOWER CYLINDER Bore Rod Stroke SAC UNCOUPLING CYLINDER
Bore Rod Stroke SAC DELATCH CYLINDER Bore Rod Stroke H. INDEXER GENERAL Type of side arm charger (sac) Max.rake (Train) size that Indexer can handle Type of luffing system for Indexer Track gauge No.of wagon handled by Indexer Operating speed of Indexer in m/s Forward with rake Return Type of power supply system for Indexer Fixed support roller wheel Guide roller wheel Sprung support roller assembly Feston support post Indexer normal travel DRIVE PINION P.C.D Face width No.of teeth Pressure angle Material RACK FOR INDEXER TRAVEL Total nos Pitch Pressure angle Teeth per rack Material HYD.POWER PACK DETAILS FOR INDEXER TYPE Oil pump proportional control of capacity Electric motor for Indexer
Cooling HYD.MOTOR DETAILS FOR INDEXER Hyd.motor double displacement type Motor model: Displacement: Details of Motor Wt Pressure (Max) Torque theoritical Power theoritical (Max) Speed (Max) INDEXER ARM RISER CYLINDER Bore Rod Stroke INDEXER UNCOUPLING CYLINDER Bore Rod Stroke 2.2 BELT CONVEYORS
Sl. No 1 Description Belt Conveyor System Conveyor capacity, Mt/h a) Rated (guaranteed) b) Design Belt width, mm Belt speed, m/sec Length, centre to centre, m Lift, m Max. angle of inclination, degree Radius of curvature for : a) Concave b) Convex Details of take-up i) Type of take-up a) For Boom conveyor of stacker / reclaimer b) For Intermediate Conveyor of stacker c) For all other conveyors Belting i) Type of fabric ii) Cover grade iii) Cover thickness, mm - Face cover, mm
Page 24 of 62
2 3 4 5 6 7
10
11
12
13
14
15
16
- Back cover, mm iv) No. of plies v) Troughing angle vi) Factor of safety vii) Normal working tension viii) Type of belt joint i) Idler type: a) Carrying (except in case of reversible conveyor) b) Return c) At loading point ii) Idler Spacing a) Carrying b) Return c) At loading point d) Self aligning (carrying side) e) Self aligning (return side) Pulleys : i) Minimum shell thickness ii) End disc thickness iii) Shaft deflection at hub iv) Lagging thickness v) Lagging vi) Pulley Material (For ILMS conveyor) vii) Shaft material Drive Pulleys i) Lagging ii) Diamond pattern groove iii) Minimum angle of wrap iv) Maxm. out of roundness Rubber for pulley lagging i) Type ii) Shore Hardness iii) Elongation iv) Strength v) Abrasion loss vi) Specific gravity vii) Adhesion Strength Emergency Stop Switch & Belt Sway Switch System i) Spacing (Emergency stop) ii) Spacing (Belt Sway Switch) iii) Degree of protection Zero Speed Switch i) Type ii) Mounting location Conveyor Gallery a) Walkways width b) Side windows in staggered fashion
Page 25 of 62
17
18
19 20
21
22
23
24
25
i) Spacing (c/c) ii) Size Deck plates a) Material b) Thickness, mm Seal plates a) Material b) Thickness Stone picking arrangement Chute Jamming Detector (a) Type (b) Degree of Protection Reduction gears a) Type b) Size Fluid Couplings a) Type b) Rating, kW Brakes a) Type b) Rating c) Protection Flexible couplings a) Type b) Rating Drive motors a) Type b) Make c) Insulation class d) Motor nameplate rating, kW at 500 C ambient e) Protection Class
2.3
CHUTES, HOPPERS,SKIRT BOARD

Sl. No 1 2 3 Description Chutes & hoppers construction Minimum valley angle (from the horizontal), degree Material & Plate thickness a) Sliding zones and adjacent sides b) Non striking/ non sliding zones c) Chute with valley angle 80 and above d) In the zone of magnetic field of ILMS e) In the zone of flap gates f) Discharge Hoods over head pulleys g) Location of Inspection door/sealing Skirt board
Page 26 of 62
a) Plate thickness, mm b) Length of each skirt board, m c) Height, mm d) Width, mm e) Top cover plate thickness , mm
2.4
ACTUACTOR OPERATED FLAP GATE

Sl. No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14 15. Description Make Dimensions Material of construction of the gate Liner plate specification Method of fixing of liner plates Type and make of drive and rating Capacity and designation of the equipment Total weight and weight of individual parts Type of actuator and thrust in kg of each actuator Stroke in mm of each actuator Velocity mm per of each actuator Motor: Type, rating, power supply, class of duty, insulation, make number of starts/ hours Make, ratings, type of limit switches Effort required for manual operator, kgf Type of limit switches
2.5
ELECTRIC HOISTS
Sl. No 1. 2. 3. 4. 5. 6. 7. Description Location Capacity Duty classification as per IS:3938-1983 Total weight of hoist including electrical equipment Make of hoist block Speeds with safe working load Lifting height a) Above floor level b) Below floor level Wire ropes a) Type of construction b) Size c) Number of falls d) Factor of safety Rope drum a) Materials b) Diameter
Page 27 of 62
8.
9.
10.
11.
12.
13. 14. 15. 16.
17. 18. 19.
20.
21
22. 23. 24. 25. 26.

Drives a) Type & material of gear box b) Gear & pinion c) Material & hardness Motors a) Type & number b) Kw rating c) Synchronous speed d) Class of insulation e) Pull out torque f) Frame size Brakes a) Type b) size c) Torque rating Type & details of limit switches Type of couplings Type of bearings Lifting hook a) Type b) Material Type & details of control Trolley Speed with safe working load Wheels a) Numbers b) Diameter c) Material & hardness d) Max. wheel load e) Wheel base Drive a) Type & material of gear box b) Gears & pinions c) Material & hardness d) Kw rating e) Synchronous speed f) Class of insulation g) Pull out torque h) Frame size Brakes a) Type b) Size c) Torque rating Type & details of limit switches Type of coupling Type of bearings Type & details of controls Clearance diagram indicating the basic dimensions
Page 28 of 62
27. 28. 29. 30.
Type & lubrication provided Type & size of cables Location & control details of hoist block power feeding Any other information
2.6
EOT CRANE
Sl. No. (a) 1.0 2.0 3.0 Description During participation in technical Bid: G.A. Drawing. VENDER TO CONFIRM Wheel Load Diagram (Wheel Distance & Wheel Load). Sketches showing full details of cranes with dimensions/ end clearances (between centre of LT rails to column face of building), overhead clearance from LT rails, hook approach limits, lift height, Details of Web thickness baffle plates, Stiffeners ,of Girder section , End carriage (Boggies) Trolley Section etc. Vendor to submit appropriate Q.A. Plan. After Receipt of Order: Calculation for Box Girder, End Carriage structural plates/ Web / Stiffener plate, Wheel Load calculation & Calculation for selection of Diameter of Wheel, Motor, Gearbox and Brake etc. 3 - sets of followings documents like G. A Drawings, Structural drawings like Endcarriage, Box Girder, Assembly Drawings/ Sub- assembly Drawings, Gear Box Drawings (specially of Typical Gears having Helix Angle, Pressure Angles, Modules etc.) ,Bracket/ Current Collector System, Hook Block, LT & CT wheel, Main Hook assembly LT machinery, Hoisting machinery, Electrical Drawings comprising Power , Control Circuits , Electronic Circuitry diagram for RRC etc. No fabrication / purchase of BO. Items should be taken up before the approval of the drawings. With the supply of crane: Operating manuals of Crane - 3 Sets. Detailed Maintenance manual of Crane. Spares- part list / concerned drawing of the spares -3 Sets. Maintenance, Interface & commissioning manuals for Controller & drives - 2 Sets along with drive parameterisation software. Catalogues, O&M Manuals of all bought out items including drawings, wherever applicable. Detailed specification of all rubber items like Oil- Seals / O- Rings etc. One Soft copy for the above requisites shall also be supplied in CD.
4.0 (b) 1.0
(c) 1.0 2.0 3.0 4.0 5.0 6.0
2.7
MANUAL HOISTS
Sl. No 1. 2. 3. Description Name of the manufacturer, type & model no Numbers offered & their location Safe working load for each hoist (in tones)
Page 29 of 62
4. 5. 6. 7. 8. 9. 10 11. 12. 13.
Duty class as per IS:3832-1983 Head room, mm Lift, mm Minimum radius of curvature of which this hoist can negotiate (mm) Weight of each hoist Specification of each chain Tools & tackles included in offer Commissioning spares & 2 years Operating spares included in offer Any other information
3.0
DRAWINGS/DOCUMENT TO BE SUBMITTED BY THE BIDDER Drawings /Data along with the Bid 1) Schematic drawings showing flow of materials. 2) Layout drawings of Additional Coal Storage and Handling System showing clearly the Major Equipment, Junction Houses, Conveyor Galleries, Approach Road, Rail Track for Yard Equipment, Yard Drainage Scheme etc. 3) General Arrangement Drawing of Additional Coal Storage and Handling System showing clearly the Major Equipment, Junction Houses, Conveyor Galleries, Belt Conveyor with drive, tail and take up arrangement, hoisting & handling facilities envisaged for maintenance of equipment. 4) Cross Section of Additional Coal Storage Yard showing the coal stock pile, yard equipment, track rail for stacker and reclaimer, yard drainage system etc. 5) General Arrangement of Major Equipment showing plan, elevation, cross sections along with mounting details, with broad dimensions and technical parameters. 6) Basic calculation substantiating selection of all major equipment, motors, gear boxes, couplings, brakes etc. 7) Equipment wise List of commissioning spares and consumables with item wise description and quantity included in the main offer. 8) Equipment wise list of 2 years operational spares (un-priced). The list shall indicate description and quantity for each item. 9) List of special tools and tackles 10) Details /drawings for Civil & Structural Engineering works. 11) Single line diagram of power distribution system.
Page 30 of 62
12) Electrical schematic diagrams 13) Cable specifications, cables schedule and cable layout drawings. 14) Any other structural / mechanical / electrical etc. drawings / data mentioned elsewhere in the technical specification as well as considered necessary by the Purchaser/ Consultants.
15) List of exclusion, if any from Bidders Scope of Work. 16) List of deviations from technical specification. 4.0 4.1 ELECTRICS DRAWINGS/DOCUMENT TO BE SUBMITTED BY THE TENDERER Drawings / Data / Documents along with the Bid 1. Detailed scope of work with general description of the system & equipment offered specifying the important features and detailed design criteria and design philosophy including full details of reference data, assumptions, etc. Description to be accompanied by single line diagrams and equipment layout to enable owner to have proper appreciation of equipment offered and its operation. Bill of Quantities (un -priced) in specified format, with division list of supplies from foreign and indigenous sources. List of specific exclusions, if any, from Bidders Scope of Work. List of deviations from technical specifications, Equipment wise List of commissioning spares and consumables with item wise description and quantity included in the main offer. List of 2 years operation spares, equipment wise (un-priced). The list shall indicate description and quantity for each item. List of special tools and tackles Work Schedule with bar chart indicating all activities for electrics.
2.
3.
4. 5. 6.
7.
8. 9.
10. Phase-wise construction power requirements for erection / testing activities.

11. Questionnaire as asked, duly filled-in. 12. Reference list of similar jobs carried out 13. Dimensional details & weights of each equipment offered (tentative) Technical Data to be submitted with the Bid. 1. 2. 3. 4. 5. Name and capacity of MCC considered List of LT drives of each MCC along with single line diagrams Connected load and Maximum demand of each section of 6.6 kV switchboard/ 415 V PCC Connected load and Maximum demand of each section of MCC. List of motors with ratings ( working+ standby) 6. List of performance tests proposed by the tenderer to demonstrate the guaranteed parameters for the electrical equipments. 7. Specific energy consumption, maximum demand and annual energy consumption. 8. Type test certificates for major categories of equipment, issued by independent testing authority. 9. Technical catalogues of major equipment offered. 10. Services to be provided by owner at battery limit with specification 11. Single Line Diagram of each MCC/ DB 12. Capacity of UPS for stacker & reclaimer 13. Capacity of PLC for stacker & reclaimer 14. Size of HT/LT trailing cables considered 15. Rating of 6.6 kV on load isolators considered
4.2
TECHNICAL PARTICULARS TO BE SUBMITTED BY THE BIDDER ALONG WITH THE BID GENERAL The information /data asked under this section shall be furnished by the tenderer along with the offer. In the event of the contract being awarded , the data/technical particulars furnished here under and accepted by the owner shall be deemed to form a part of the contract. Design Considerations 1. List of Drives/ Mechanism with kW Rating 2. Aux. Power Consumption Spares and tools & tackles 1 .List of commissioning spares 2. List of mandatory spares 3. List of special tools and tackles : : :
: List to be submitted : List to be submitted : List to be submitted
Page 32 of 62
Summary Of Technical Parameters Of Major Electrical Equipment Sl. No. Equipment Description & Qty Make & type Total / Country of Weight manufacture Dimension Rating as Guaranteed per design Tech Data condition of Tender
MOTOR 1. Make, type & applicable standard 2. Furnish following for all drives Working /Standby Speed Enclosure Qty
Sl. No
Application
Rated Parameters kW Voltage
MCC 1. Make, Type & Applicable Standard 2. Rated Voltage, current & Frequency 3. Short time rating 4. Bus bar material & type of sleeving 5. Protection class : : : : :
Components of MCC 1 Air Circuit Breaker 2. MCCB 3. AC Contactor 4. DC Contractor 5. Thermal Relay 6. Control Devices 7. Meters : : : : : : :
Make & Type
Page 33 of 62
MCC WISE DATA Sl. No MCC Designation Rating of Volt, Amps Single Front/ Double Front No. of Connected Max. No. of Overall bus load per load per panels dimension sections section section s
RELAYS 1. 2. 3. 4. METERS 1. 2. 3. 4. Make Type Reference standard Size Make Type Draw out type with built in test facility Relay details
CURRENT TRANSFORMER 1. Make, type & applicable standard 2. Ratio & accuracy class: metering/protection 3. Rated voltage short time rating POTENTIAL TRANSFORMER 1. 2. 3. 4. 5. Type Primary/secondary voltage ratio Method of connection Rated voltage factor Class of insulation
PDB/LDB/SLDB/AUX. PDB (SEPARATELY FOR EACH DB) 1. 2. 3. 4. 5. Make, Type & Applicable Standard Rated Voltage, current & Frequency Short time rating Bus bar material & type of sleeving Protection class
Page 34 of 62
Components of DB 1. 2. 3. 4. 5. 6. DB-WISE DATA Sl. No DB Designation Rating of Volt, Amps Single No.of Front / bus Double sections Front Connected Max. load per load section per section No. of Overall panels dimensions Breaker MCCB/MCB AC Contactor Thermal Relay Control Devices Meters
TRANSDUCER (For each type) 1. 2. 3. 4. 5. 6. Make Output range Accuracy Maximum burden on CT/PT Nominal input/rated I/V Overload capacity without loss in accuracy
LIGHTNING PROTECTION 1. 2. 3. 4. 5. 6. Whether lightning conductors have been envisaged for the lightning protection Angle of protection Whether building is also protected Number of electrodes provided Earthing resistance value Size of down conductors
: Places to be indicated : : Yes/No : : :
EARTHING 1. Material and size of earth strip for the

Page 35 of 62
2. 3. 4. 5. 6.
various places Size of main outer strip Galvanising content on GI strip Value of earthing resistance (proposed to be achieved) Type & size of electrodes Construction of earthing mat, etc as per TS
: : : : : : Included
UPS SYSTEM 1. Make of the system 2. Capacity in kVA 3. Battery back up time 4. Make & type of battery 5. Number of cells per battery 6. Overall dimension(L x B x H) mm of battery 7. Ventilation requirements 8. Make, Rating & type of charger 9. Make, Rating & type of rectifier transformer 10. Make & current rating of SCR & Diode 11. Make & rating of inverter 12. Make & type of static transfer switch 13. Make & rating of manual bypass switch TRANSFORMER 1. Name of manufacturer 2. Service-whether indoor or outdoor 3. Type of cooling 4. Rating a. Rated KVA b. Rated current, amp (rms), HV/LV c. Rated voltage, kV (HV/LV) 5. Temperature rise above 500C ambient a. In oil by thermometer, 0C b. In winding by resistance, 0C c. Hot spot temperature in winding limited to, 0C 6. Insulation class 7. Vector group 8. Type of tap changer with capacity/steps/range 9. Tapping provided on HV side? 10. Losses a. No-load loss at rated voltage and frequency b. Load loss at rated load c. Cooler loss
: : : : : : : : : : : : :
: : : : : : : : : : : : : Yes/No : : :
Page 36 of 62
11. Impedance at rated current frequency : 12. Reactance at rated current and frequency, % : 13. Efficiency at 0.80 p.f lag % at 100%/75%/50% load : 14. Load/p.f. at which max. efficiency occurs, % full load : 15. Maximum efficiency, % : 16. Minimum clearances in mm HV LV a. Between phases : b. Between phase and ground : 17. Withstand time without injury for 3 ph short circuit, sec : 18. Insulation strength a. one minute power frequency test KV rms : b. Impulse withstand voltage, KV : 19. Tap changer provided with i. Tap position indicators ? : Yes/No ii. Operation counter ? : Yes/No iii. Padlocking provisions ? : Yes/No 20. Details of tank i. Material : ii. Maximum internal withstand pressure of tank kg/cm2: 21. Enclosure details (for dry type transformer) i. Material : ii. Thickness : iii. Degree of protection : 22. Details of core material : 23. Insulation material : 24. Details of bushings HV LV LV- Neutral a. Make : b. Type : c. Voltage class, KV : 25. Insulating oil a. Approx volume of oil, liter : b. Whether first filling of oil with 10% excess included ? : c. Oil conforms to IS:335 ? : 26. Marshalling Box a. Weatherproof, suitable for outdoor for oil filled type ?: Yes/No b. Degree of protection : 27. Each transformer with fittings andaccessories : Yes/No 28. Approximate overall dimensions, (LxBxH) mm : 29. Approximate weights, Kg : a. Core and coil : b. Tank and fittings : c. Oil : d. Total weight : 30. List of special maintenance tools and accessories : Furnished
Neutral CT of transformers (for each type) 1. Make, type & applicable standard 2. Ratio & accuracy class: metering/protection 3. Rated voltage short time rating LIGHTING MAST General 1. Make 2. Material of construction 3. Cross section of mast in polygon (No. of sides) 4. Thickness in mm (bottom/middle/top sections) 5. Length of individual sections (mm) 6. Base dia & top diameter (OAF) 7. Type of joints 8. Length of overlap (joint at site mast Section in mm): 9. Thickness of galvanization (minimum) 10. Size of opening door at base (mm) 11. Type of locking arrangement & door construction: 12. Weights in kgs of 30 mtrs high mast 13. Dynamic loading as prevailing actual at site 14. Maximum wind pressure (Basic wind speed) 15. Maximum gust speed time 16. Factor of safety for wind load 17. Factor of safety for other loads Lantern Carriage 1. Diameter of carriage ring (mm) 2. Load carrying capacity 3. Total weights of assembly with fittings 4. Number of fittings Winch 1. Make of winch, number of drums per winch 2. Capacity 3. Operating speed 4. Method of operation 5. Tested load per drum (kg) Wire Rope 1. Grade 2. Number of ropes/thickness 3. Construction 4. Breaking load capacity 5. Factor safety
: : :
: : : : : : : : : : : : : : :
: : : :
: : : : : : : : : :
Page 38 of 62
Cable 1. Type 2. Make 3. Current carrying capacity 4. Cable size Power Supply arrangement 1. Input supply 2. KW rating of motor 3. Speed of motor 4. Reversible / Non reversible 5. Remote control switch type 6. Lifting capacity of torque Limiter 5.0
: : : :
: : : : : :
Ventilation, Air Conditioning and Dust Suppression System. 5.1 Bidders shall furnish all information as stipulated in relevant chapter. Bidders shall also furnish the following information: Process flow, process instrumentation and control diagram and water and compressed air balance diagrams. Dimensioned general arrangement and relevant cross sectional drawings of the pump house, compressed air station etc. with specification and bill of material. Dimensioned general arrangement drawings of all equipment. All relevant basic design calculations supporting the selection of equipment, location of valves, specials and supports along with forces and moments of fixed support.
a)
b)
c) d)
5.2
Ducting including Supply Air Diffusers with Volume Control Dampers a) Duct : Material, thickness & quantity b) Damper: material, thickness, size, quantity c) Supply Air Diffuser: material, thickness, size, quantity
5.3
Ventilation Systems a) b) c) d) e) Type of ventilation system Capacity of each ventilation system Make of equipment Design heat load for each premise Indoor climatic condition to be maintained
Page 39 of 62
f) Power requirement of each system g) Air change/hr h) Any specific design consideration i) Noise level at 1 m distance from the ventilation equipment j) Noise level at served premises 5.4 Centrifugal Fan a) Make & Model No b) Quantity, no. c) Type of blade d) Capacity, m3/h e) Total pressure, mm WC f) Speed, rpm g) Shaft power, KW h) Total Efficiency, % i) Motor rating, KW/ pole j) Fan Characteristic Curve k) Impeller Diameter, mm l) Velocity at inlet & outlet of fan, m/sec m m) Weight of fan and motor, kg n) Coupling details o) Vibration isolator type & quantity p) Thickness of scroll, blade, Back plate, shaft mm q) Noise level at 1m distance r) Overall size s)Drive Motor rating suggested Fan Drive Motor Details a) Type & make b) Voltage, phase & frequency c) Rated power d) Speed e) Starting/ pull out torque f) Line current g) Starting current h) Overall efficiency i) Class of insulation j) Type of enclosure k) Any other information Exhaust fan a) Make & Model b) Capacity in m3/h.
5.5
5.6
c) Total Pressure, mm WC d) Material of construction and its thickness e) Speed in rpm. f) Drive details. g) Shaft Power consumption. h) Wheel diameter i) Efficiency j) Static & Dynamic weight of fan & motor assembly k) Critical speed of fan l) Noise level at 1m distance in dB(A m) Performance curve. n n) Air flow direction. o o) Fixing details. p p) Vibration level. 5.7 Dry Panel type filter a) Make & Model b) Capacity in m3/h c) Pressure drop in mmWC. both in clean & in dirty condition d) Effective cross sectional area in m2 e) Velocity through filter in m/sec. f) Material of filtering panel. g) Cleaning efficiency Vs particle size h) Methods of surface regeneration. i) Filter box construction details. j) Overall dimensions & no. of filters. k) Fixing frame details. l) Total weight. Air Washer Unit a) Make & Model No. b) Type of unit (Horizontal/vertical) c) Overall dimensions (mm) d) Weight (kg) with and without water Capacity in m3/h. e) Total Pressure drop, kgf/ m2 g f) Material, dia and nos. of nozzles g) Make up water requirement h) Details of makeup, overflow, drain, supply & return water pipe lines i) Saturation efficiency j) Amount of water and its pressure at the nozzle k) Casing and tank thickness l) Water tank capacity
5.8
Page 41 of 62
5.9
Centrifugal Pump (indicate separately for ventilation and dust suppression) a) b) c) d) e) f) g) h) i) j) k) Make and model no. Type of pump Capacity in m3/hr. Total head in m WC. Quantity Material of construction Shaft Impeller Casing Pump speed (rpm) Shaft power Drive details a. Motor make b. Motor KW c. Insulation class d. Frame size Bearing type & make Type of coupling Vibration level Noise level at 1 m distance from pump set
l) m) n) o)
5.10 Dry Fog & Plain Water Sprinkling type Dust Suppression Systems a) Technical details and quantity of main equipment including Nozzles, PRU, FAS and Instrumentation for Auto Operation. b) Technical details and quantity of auxiliary equipment including air compressors, pumps, etc. c) Technical details of circular swiveling sprinklers d) Compressed air & water requirement, capacity of compressor, air receiver, capacity of water pump unit etc. e) Total power consumption. Capacity of each motor for pump and compressor. f) Details of air & water pipelines with sizes and quantities. g) Details of valves and fittings h) Details of solenoid valves, sensors, pressure gauges and other instruments. i) Details of tanks j) Details of hood / skirt boards modification k) Size of compressor cum pump house. l) Size of only pump house (In case compressed air is not provided)
Page 42 of 62
5.11 Split Air Conditioner a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) 6.0 Make & Model Quantity Capacity in TR (Nominal / Actual Air Flow m3/h Flow direction and volume control grill Material of construction Compressor type Drive details and total power consumption Overall dimensions Refrigerant type Filter efficiency Weight of unit Noise level at 1m distance in dB(A) Fixing details. Vibration level. Accessories included
Drawings/documents for Fire Protection System Drawings/documents to be furnished with offer The tenderer shall submit the offer along with the following drawings / documents. a) Scope of work with general description of the system and equipment offered specifying the important features. The tenderer has to give a confirmation with respect to the scope of work as detailed in this specification excepting for the deviations, if any, to be listed in the schedule of deviation. The description to be accompanied by single line diagrams, and equipment layout to enable the Purchaser to have a proper appreciation of the equipment offered and its operation. Specific exclusions, if any, from scope of work . Block Scheme diagram for all fire protection system along with tentative BOQ for major equipments. Specification of equipment along with their makes/catalogues and material of construction. Reference list of job executed for each type of system. List of mandatory spares as per requirement for 2 years operation and maintenance. List of special tools and tackles.
b) c)
d) e) f) g)
Page 43 of 62
h) i) j) k)
Amp. hour capacity of DC battery required for MFAP. Write up with control schematic on working of all fire protection systems. Detector type and Catalogues Linear heat sensing cable details
Page 44 of 62
ANNEXURE - IV Format - 1 1.0 FORMAT FOR GENERAL AND COMMERCIAL PARTICULARS 1. 2. 3. Name and Address of Bidder. Telegraphic Address of Bidder Name and designation of the person to whom all references shall be made to expedite technical coordination Place of Manufacturer Proposal No. & Date Current Registration No. with D.G.S. & D Whether all service facilities available? Whether necessary spare parts available? Has tenderer paid Earnest Money Deposit? Is offer valid for four (4) months from Price bid opening? Has bidder quoted F.O.R site prices? Is price break up given in Price Bid? Are prices quoted FIRM? (Price should be firm.) Is the tenderer agreeable to the terms of payment? If not, has terms of payment acceptable to him been indicated? Does the tenderer agree to the delivery periods indicated? Are the delivery periods guaranteed under penalty clause? Is the tenderer agreeable to pay 10% Security Deposit? Are all schedules for technical particulars and prices filled in? Has tenderer brought out all deviations in schedule of deviations? Warranty period from takeover of plant / equipment. Are equipment guaranteed as per various guaranteed clauses of tender documents? SIGNATURE ___________________ DESIGNATION ___________________ COMPANY ____________________ DATE ____________________ COMPANY SEAL
4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14
15. 16. 17. 18. 19. 20. 21.
Page 45 of 62
Format - 2 2.0 FORMAT FOR BIDDERS EXPERIENCE LIST Sl. No 1 Purchaser Location 2 3 & Customers PO No. and Date 4 Period & Details Year of of work Completion 5 6 7 Capacity of plant 8 Total cost of work done by bidder 9
NOTE: Bidder may also furnish the above details for ongoing assignments.
SIGNATURE ___________________ DESIGNATION ___________________ COMPANY ____________________ DATE ____________________
COMPANY SEAL
Page 46 of 62
Format - 3
3.0 Format for deviations from Tender Document
Sl. No
Clause No
Tenderers Deviations
Amount of variation Reason (+/-) to retain the Deviation tender conditions
for
The Bidder hereby certifies that the above mentioned are the only deviations from the tender documents.
COMPANY SEAL
Page 47 of 62
Format - 4
4.0 FORMAT FOR COMMERCIAL DEVIATIONS
OTHER MODIFICATION AND SUPPLY (BIDDER SHALL INDICATE OTHER MODIFICATIONS AND SUPPLY NECESSARY IN HIS OPINION FOR SUCCESSFUL COMMISSIONING OF THE PLANT BUT NOT INCLUDED IN THE SPECIFICATION)
Sl. No 1
Description 2
Price 3
COMPANY SEAL
Page 48 of 62
Format - 5
5.0 Format for Shutdown Requirement
Sl. No
Description
Duration Shutdown (hours) 3
of Number shutdowns envisaged 4
of Remarks
However, Bidder agrees to carry out the work as and when shutdown will be made available by the purchaser for even lesser duration, matching with total hours of shutdown.
COMPANY SEAL
Page 49 of 62
Format - 6
6.0 FORMAT FOR SCHEDULE OF TESTS
Test as per the specification and IS shall be performed. Detailed list of tests including results of proto type tests shall be indicated in this schedule.
SIGNATURE __________________________ DESIGNATION __________________________ COMPANY __________________________ DATE __________________________
COMPANY SEAL
Page 50 of 62
Format 7
7.0 AMENDMENT SHEET Sl. No. Amendment No/ Sheet No Letter Ref. No. & Date
Page 51 of 62
Format - 8
8.0 LIST OF DRAWINGS ENCLOSED WITH BID Sl. No. 1 Drawings 2 Title 3
COMPANY SEAL
Page 52 of 62
Annexure-V
SCHEDULE OF COMPONENTS IN USE AT NALCOS EXISTING COAL HANDLING PLANT, CPP, ANGUL Components schedule given below are for information to Bidders for standardization and interchangeability with existing Coal Handling Plant only. Bidders must take a note of these components details while selecting a new supply to control the inventory level. A) Conveyor Pulley Schedule Pulley Type Pulley Diameter (mm) Face width (mm) 1150 1150 1150 1150 1150 1150 1150 Shaft Diameter (mm) 125 150 165 175 90 100 115 Bearing Diameter (mm) 115 140 150 160 75 90 100 Shaft length (mm) 1690 2095 2100 2120 1760 1760 1770 Plummer Block Center (mm) 1550 1650 1650 1650 1650 1650 1650
Drive/ Discharge Pulley
630 630 630 800 Non Drive 400 Pulleys 400 500 B)
Bearing & Plummer Block Schedule. Shaft diameter (mm) 65 75 90 100 115 125 140 150 160 Bearing size 22215K 22217K 22220K 22222K 22226K 22228K 22232K 22234K 22236K Plummer Block Schedule Drive Pulleys Non Drive Pulley 1 1328 - AL 1 1328 - AL 1 149 - AL 1 149 - AL M 1034 - BL M 1034 - BL M 1033 - CL M 1033 - CF M 1035 - AL M 1036 - AF M 1036 - BL M 1036 - BL M 1035 - CL M 1036 - CF 1 829 - AL 1 1330 AF 1 1487 - L 1 1488 - F
C)
Gear Box Schedule. Gear box size SZN-200 SZN-225 SZN-250 SZN-280 Reduction Ratio 16 : 1 16 : 1 16 : 1 20 : 1
Page 53 of 62
SZN-320 SZN-250 KDA-200 D) Fluid Coupling Schedule
20 : 1 16 : 1 125:1
Fluid coupling size FCU-16.25 FCU-17.75 FCU-23 FCU-41 E) Idler Schedule The idlers are drop in slot type.
Baffle Ratio 1.5B 1.5B 1.5B 1.5B
Page 54 of 62
ANNEXURE-VI
LIST OF PREFERRED MAKES 1.1. MECHANICAL SL. NO. 1. 2. 3. 4. EQUIPMENT GEAR BOXES CONVEYOR BELTS MAKE ELECON, FLENDER, SHANTHI, SEW, NAW, GRAEVES DUNLOP, NIRLON, MRF, PHOENIX, NORTHLAND, FORECH, ANIL RUBBERS, ORIENTAL. IDLER ELECON, TRF, KALI, KRUPP, MACMET, HINDUSTAN UDYOG PULLEY ELECON, TRF, KALI, HEC, HINDUSTAN UDYOG, McNALLY BHARAT, HITECH, MASYC, KRUPP, SIMPLICITY, ARUDRA, MACMET. BEARINGS SKF, FAG, NTN, NBC, NORMA, TATA, EAST EUROPIAN, ZKL SLEW RING BEARINGS ROTHE ERDE, TITANUS, LYC-CHINA FLEXIBLE COUPLING FMG, DAVID BROWN, HICLIFF, CONCORD, ROMA, WELLMAN INCAD. GREAVES LTD., NAW, GBM, ALLFLEX FLUID COUPLING PEMBRIL, FLUDOMAT, VOITH, ELECON FASTENERS GKW, SUNDERAM, PRECISION FASTENERS MANUAL HOISTS WH BRADY, KANUBHAI, HERCULES, TRACTEL TIRFOR, REVA ENGG. MM ENGRS, BRADY&MORRIS OIL SEALS VACCA, RUBBER EQPT. & ENGG. CO. L TD LUBRICATION TECALEMIT, SURMAC, LUBCON, PRAKASH, AFMC, HELIOS PROTOS, LINCOLN HELIOS POWER PACK REXROTH, PARKER, ETON, YUKEN, VICKERS, HAGGLUNDS HYDRAULICS REXROTH, YUKEN, CARTER, VELJAN CYLINDERS UTL, MONTECH, WIPRO, OSCAR, HAGGLUNDS, PARKERCALZONI HOSES AEROLEX, GATES INDIA PVT. LTD a) BELT CLEANERS a) HOSCH, KAVERI,TECHNOFAB, PROMAC, BMH CONCARE b) SKIRTS AND SKIRT b) UNITED TECHNO MECH, TEGA, KAVERI, HOSCH SEALING ARRANGEMENT ACTUATOR OPERATED UNITED TECHNOMECH, PREPEC, PEBCO FLAP GATES IN LINE MAGNETIC ELECTRO-ZAVOD, MBIL, ELECTROMAG, POWER BUILD, SEPARATORS MCI, ELECTROMAGNETIC INDUSTRIES BELT WEIGH SCALES SCHENK-JENSON, TRANSWEIGH, IPA, SARTORIUS BELT SWITCHES JAYSHREE, SCHNEIDER, TELEMECHANIC, INDUSTRY
Page 55 of 62
5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
15. 16.
17. 18. 19. 20.
SYNDICATE, PROTO CONTROL 21 BRAKES BCH, INDUSTRIES SYNDICATE, STORM KRAFT, ELECTROMAG, SPEED O CONTROL, STROMAG 22 ELEC. HOISTS ARMSEL, SHIVPRA, WH BRADY, BRADY & MORRIS, GRIP ENGRS., HI-TECH, CENTURY CRANE, TUOBRO FURGUSON, UNITECH In case the Tenderer/ Contractor intends to substitute any particular make of equipment / components/ materials by their/ his own make other than that listed in this document, the Tenderer shall clearly bring out the same in his tender along with justification and indicate the makes offered by him. It will be prerogative of the Purchaser to accept or reject the tenderers own makes so offered. 1.2. ELECTRICAL
Sl.No 1. ITEM 415 V MCC/ (Drawout type) APPROVED SUB VENDORS 1. ABB 2. GE Power Control Ltd 3. L&T 4. Siemen Ltd 5. Schneider Eectric India Pvt.Ltd 1. Control & Switchgear Co. Noida 2. GE Power Control Ltd 3. L&T 4. M.K.Engineers & Controls 5. Schneider Eectric India Pvt.Ltd 6.ABB 7.SIEMENS 1. Alstorm 2. BHEL 3. Crompton Greaves Ltd 4. ABB 5.SIEMENS 1. Alstorm 2. Asea Brown Boveri Ltd, Faridabad 3. Bharat Bijlee 4. Kirloskar Electric Co.Ltd, Banbalore & Hubli 5. Siemens 6. CGL 1. Bhartiya Industries 2. Baliga Lighting Eqpt(p)Ltd 3. Ex-protecta 4. Electrical Equpt.Corporation 5. Flexpro Electricals Pvt.Ltd 6. Prompt Engineering Works 1. ABB,Bangalore 2. Bhartiha Industries 3. L&T 4. Siemens 5. Schneider Eectric India Pvt.Ltd 1. ABB,Bangalore 2. Bhartiha Industries 3. Control & Switchgears Contactors Ltd.
Page 56 of 62
2.
415 V PDB/DB (Fixed type)
3.
HV Motors
4.
. LV Motors
5.
Local Control Stations (Weather Proof)
6.
Bimetal Relays
7.
Contactors
Control Switches/Selector Switches
9.
Fuse Switch
10
Timers
11
Fuse
12
ELCBs
13.
MCBs
14
MCCBs
4. GE Power Control India Ltd 5. L&T 6. Siemens Ltd 7. Schneider Electric India Pvt.Ltd 1. Alstom Ltd 2. Havells India 3. Hotline Switchgear &Controls 4. Kaycee Industries 5. L&T 6. Reliable Electronic Components Pvt. Ltd 7. Siemens Ltd 8. Switron Devices 1. ABB Ltd, Bangalore 2. Control & Switchgears Co Ltd 3. Havells India 4. Indo Asian Fuse Gear 5. L&T 6. Siemens Ltd 7. Standard Electricals 8. Alstom 9. Schneider Electric India Pvt.Ltd 1. Bhartiha Industries 2. Concord Controls 3. Electronic Automation Pvt Ltd 4. L&T 5. Siemens Ltd 6. Schneider Electric India Pvt.Ltd 1. GE Power Controls 2. Indo Asian Fuse Gear 3. L&T 4. Siemens Ltd 5. Ferraz 6. Bussman 1. Datar Switchgear Pvt Ltd 2. Indo Asian Fuse Gear 3. Legrand India 4. ABB 5. Siemens 6. Schneider Electric India Pvt.Ltd 7. GE 1. Datar Switchgear Pvt Ltd 2. Havells India 3. Indo Asian Fuse Gear 4. Indian Current Control 5. Legrand India 6. Standard Electricals 7. ABB 8. Siemens 9. GE 10.L&T 1. GE Power Controls 2. L&T 3. Schneider Electric India Pvt.Ltd 4. Siemens 5. ABB
Page 57 of 62
15
Meters
16
Push Buttons & Indicating Lamp
17
Lighting & Power panels
18 19
Lighting Fixtures Terminal Blocks
20
Switch socket outlets
21 22
Transducer LT Transformer
23
PLC
24
UPS
25
Control Desk
27
VVVF Drive
1. Automatic Electric 2. Meco Instruments Pvt Ltd 3. Nippen Electrical Instruments Co 4. Risabh Instruments Pvt.Ltd 5. Industrial Meters(P) Ltd 1. Bhartiha Industries 2. Concord Controls 3. Control & Switchgears Co Ltd 4. Hotline Switchgears & Controls 5. L&T 6. Precifine Products Pvt. Ltd 7. Siemens 8. Shri Tulsi Switchgears 9. Teknick Controls 10. Schneider Electric India Pvt.Ltd 11. Binoy Opto Electrics,Kolkata 1. Control & Switchgears Co Ltd 2. Havells India 3. Indo Asian Fuse Gear 4. Legrand India 5. Standard Electricals 1. Bajaj Electricals 2. Comptron Greaves 3. Philip India 1. Essen 2. Connect well 3. Elmex 1. ALSTOM 2. CGL 3. B & C 4. ESSEN 1. ABB 2. MECO 1.CGL 2.KEC 3.BBL 4.BHEL 5.AREVA 6.BMCC 7.T&R 8.VIJAY ELECTRICAL 1.GE-FANUC 2. ALLEN BRADLY 3.SCHNEIDER 1.EMERSION 2.HI-REL 3.NUMERIC 4.TATA LIBERT 5. AMAR RAJA 1. SIEMENS 2. ALSTOM 3. L&T 4. ABB 1. ALSTOM 2. BHEL 3. DANFOS
Page 58 of 62
29.
6.6 K V Isolator
30
Trailing Cables
4. L&T 5. NELCO 6. ROCKWELL 7. SIEMENS 8. ABB 9. SCHNEIDER 10. YASKAWA 1. PANICKER 2. BOND STRANDS 3. DRISCHER 1. KEI 2. NICCO 3. UNIVERSAL 1. BHEL 2 Siemens 3. ABB 1. BHEL 2 Siemens 3 TELK 4 ABB 5 AREVEA
31
HT Switch gear
32
HT Transformer
1.3.
AIR CONDITIONING, VENTILATION & DUST SUPPRESSION SYSTEM Ventilation system Dust Suppression System Air Conditioning system Note: 1. Makes indicated above shall also be read with preferred makes as listed elsewhere in this specification. 2. For make of any item, not appearing in the above list, specific approval shall be taken by the bidders from Purchaser. - EFE, C. Doctor, Voltas - TPS, Kaveri, F. Harley - Blue Star, Voltas, Carrier
Page 59 of 62
Annexure-VII
1.0 LIST OF TOOLS AND TACKLES S.NO 1. 2. DESCRIPTION Manually operated Hydraulic Jack i) 50T X 150 mm stroke Bastard (Rough Cut) Files 250 mm size i) Flat ii) Round iii) Half Round iv) Triangular Fine Cut Files 250 mm size i) Flat ii) Round iii) Half Round iv) Triangular Adjustable Outside Micrometer Interchangeable Anvil Type i) 0-150 mm ii) 150 600 mm Inside Micrometer i) 50 150 mm Vemier Calipers i) 0-150 mm size ii) 0 300 mm size Feeler Gauge i) 10 mm thk. 6 inch ii) 10 mm thk. 12 inch Sprit Level i) 150 mm Torque Wrench with socket 75 150 kg.m Standard Ring spanners (Upto 32 mm ) Standard D.E. spanners (Upto 32 mm ) Adjustable spanners (Upto 50 mm each set of 3 Nos.) Socket Head Spanners (Box Spanners 10 to 32 mm ) Sledge Hammers i) 5 kg. QUANTITY 2 Nos
1 No. 1 No. 1 No. 1 No 1 No. 1 No. 1 No. 1 No
3.
4.
1 No. 1 No 1 No 1 No. 1 No 1 No. 1 No 2 No 1 set 1 set 1 set 1 set 2 set 2 Nos.
5. 6.
7.
8. 9. 10. 11 12. 13. 14
Page 60 of 62
15. 16. 17 18. 19.
20
21.
22.
23 24 25. 26. 27 28. 29 30. 31 32
33 34. 35.
36. 37 38 39
ii) 10 kg Nylon Faced Hammers (4 Sizes) 4 dia portable motor operated grinding m/c with flexible grinder Ball Pein Hammers in different sizes. Dial Gauge 0-10 mm LC-0.01 mm with mag. Stand Steel Tapes i) 3 m Size ii) 6 m Size Steel Scales i) 0.3 m Size ii) 0.5 m Size Internal Calipers i) 150 mm Size ii) 300 mm Size External Calipers i) 150 mm Size ii) 300 mm Size Hand operated Hacksaw Frame with 1 Doz. Blades (12) Tri-square (6 x 12) Screw Operated Coupling and Bearing Puller 300 mm Size Grease Gun with hose & adopter (Manual) Bucket Grease Gun (Manual) Self supporting, extendable aluminum ladder with maximum height of 6m Hydraulic flange puller of reputed make Pipe Wrenches 6 & 12 Digital Tachometer (0 3000 rpm) Screw Drivers i) 150 mm Size ii) 300 mm Size Sling with Eye Bolt and D-Shackle of 2,3,5 &10 tonnes Plum Bobs All types of Pliers of different size of reputed make to suit the eqpt. i) Cutting pliers ii) Internal Circlip iii) External Circlip Adjustable Pliers Marking Punches Scribers Insulation resistance Tester (Megger)
2 Nos 1 set 2 Nos 6 Nos 2 Nos
1 No. 1 No 1 No. 1 No 1 No. 1 No 1 No. 1 No 1 Set 2 Nos 2 Nos 2 Nos 1 No 2 Nos 2 Sets 4 Nos 2 Nos 2 Nos. 2 Nos 2 Sets 2 Nos
2 Nos. 2 Nos. 2 Nos 2 Nos 2 Sets 4 Nos
Page 61 of 62
40. 41. 42. 43. 44. 45 46 47 48. 49 50 51 52 53.
i) 500 V ii) 1000 V Tong Tester Portable Emergency Light (Hand Torch with Dry Cells) 100 W Hand Lamp with 50 M Flexible Wire Hand drills (pistol) Digital Multimeter Digital Clamp meter Hand drill Electrical & 1 Crimping Tool ( Hand Operated) - 5 mm2 to 16 mm2 Crimping Tool ( Hand Operated) -16 mm2 to 240 mm2 Milli Ohm Meter Combination Plier Nose Plier Earth Megger Phase Sequence meter (0 415V)
1 No. 1 No 2 Nos 2 Nos 2 Nos 2 Nos 1 No 1 No 2 Sets 1 Set 1 Set 1 No 2 Nos 2 Nos 1 No 1 No.
2.0
LIST OF TENDER PURPOSE DRAWINGS FOR BIDDERS REFERENCE SL. NO. 1 2 3 4 5 6 7 DESCRIPTION DRAWING NO Layout of Coal Storage Yard & Handling 1034/Q6Q3/A-02A/LO-001 Rev 05 System Coal Flow Diagram General Layout of CPP, NALCO G.A. & Marking of Conveyor BC-115 G.A. & Marking of Conveyor BC-103 G.A. of Junction House JH-1 (Set of three drawings) FD-CHP 6-08-0-07734-01 02728-M-BM-CS-GA-0027 Rev C CKIH-3901-M0-B057 Rev D CKIH-3901-M0-B004 Rev C
G.A. of wagon tippler & receiving RITES/PORTS/NALCO/FS/L-01 conveyor (Set of five drawings)
Page 62 of 62

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NATIONAL ALUMINIUM COMPANY LIMITED

BID DOCUMENT No. : WT/01/2011/RITES/NALCO-ANGUL

PAGE NO 1-5 1-18 1-12 1-66 1-29 1-77 1-26 1-62

Technical Specification: General

Technical Specification: General

Additions to existing system currently under development:

Technical Specification: General

Technical Specification: General

Technical Specification: General

Technical Specification: Intent of Specifications

Technical Specification: Intent of Specifications

Technical Specification: Intent of Specifications

Technical Specification: Intent of Specifications

Technical Specification: Intent of Specifications

Technical Specification: Intent of Specifications

Technical Specification: Intent of Specifications

Technical Specification: Intent of Specifications

5.4.2 5.4.3 6.0 6.1

Performance Requirement Guaranteed parameters of the major equipments shall be as follows:

Technical Specification: Intent of Specifications

Technical Specification: Intent of Specifications

Equipment Wagon Tippler

Guaranteed parameter 20 Tips /Hour

Conveyors (R1 & R2)

Technical Specification: Intent of Specifications

Technical Specification: Intent of Specifications

Technical Specification: Intent of Specifications

Technical Specification: Intent of Specifications

Technical Specification: Instructions To The Bidders

Technical Specification: Instructions To The Bidders

Technical Specification: Instructions To The Bidders

Technical Specification: Instructions To The Bidders

Technical Specification: Instructions To The Bidders

Technical Specification: Instructions To The Bidders

Technical Specification: Instructions To The Bidders

Technical Specification: Instructions To The Bidders

Technical Specification: Instructions To The Bidders

Technical Specification: Instructions To The Bidders

Technical Specification: Instructions To The Bidders

Technical Specification: Instructions To The Bidders

Technical Specification: System Parameters, Operation & Control Philosophy

Technical Specification: System Parameters, Operation & Control Philosophy

Technical Specification: System Parameters, Operation & Control Philosophy

3.2.2 3.3 3.3.1

Technical Specification: System Parameters, Operation & Control Philosophy

Press Accept PB. Ann. Window Status indication Buzzer

: Steady glow. : Fast blinking : Off.

Technical Specification: System Parameters, Operation & Control Philosophy

Technical Specification: System Parameters, Operation & Control Philosophy

6.0 6.1 6.1.1

Technical Specification: System Parameters, Operation & Control Philosophy

Technical Specification: System Parameters, Operation & Control Philosophy

: RCC Construction. : To accommodate atleast 2 nos. 8 wheeled wagons. : One (1)

: 37 : 50 mm thick guniting. : 350 mm x 350 mm : 200 mm x 36 mm thick flats.

Technical Specification: System Parameters, Operation & Control Philosophy

8.4 8.4.0 8.4.1

Technical Specification: System Parameters, Operation & Control Philosophy

Technical Specification: System Parameters, Operation & Control Philosophy