MAKNAN CONSULTANCY PRIVATE LIMITED

TECHNICAL SPECIFICATION

(1155-RMLC-TS-MECH-03, REV. 1)

FOR

DESIGN, ENGINEERING, SUPPLY, SUPERVISION OF ERECTION AND

COMMISSIONING

OF

TWO (2) SETS FUME EXTRACTION SYSTEM (FES)

IN

STEELMELT SHOP-2

AT

RUNGTA MINES LIMITED,

CHALIYAMA PLANT, CHAIBASA, JHARKHAND

SEPTEMBER, 2017

MAKNAN CONSULTANCY PRIVATE LIMITED

AE 767, SECTOR-I, SALT LAKE
KOLKATA 700064

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TECHNICAL SPECIFICATION
OF
FUME EXTRACTION SYSTEM
(1155-RMLC-TS-MECH-03)

1.0 INTRODUCTION

Rungta Mines Limited are operating a DRI based steel plant at

Chaliyama near Chaibasa, Jharkhand. Major facilities of the plant
consists of 8 x 100 tpd DR units along with WHRB based Power Plants
and a Steelmelt Shop (SMS-1) having 4 x 15-ton capacity Induction
Furnace and 1 x 3-strand, 6/11 m radius billet caster. Construction of a
Bar & Rod Mill is under progress.

RML now intend to set up another Steelmelt Shop (SMS-2) and 2 x 350
tpd DR kilns along with WHRB based Power Plants to augment the
production of the Chaliyama plant. SMS-2 will also have 4 x 15-ton
Induction Furnace and 1 x 3-strand, 6/11 m radius Billet Caster. A 35-T
Ladle Treatment system is also under consideration.

Plant and equipment of the Fume Extraction System (FES) will be

provided with state-of-the-art features which will enable operational and
maintenance flexibility and assist in increased output and ensure
maximum availability of the plant and equipment

This Technical Specification is issued for design, manufacture, supply,

supervision of erection and commissioning of Two (02) sets of Fume
Extraction Systems (FES) for Induction Furnaces at Chaliyama plant.
Drawing no. 1155-RMLC-LAY-003 indicating the preliminary layout of
SMS-2 is enclosed for information.

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2.0 TECHNICAL SPECIFICATION OF INDUCTION FURNACE

Four (04) nos. Induction Furnaces will be located in the Steelmelt

Shop-2 in two groups, each group comprising two x 15-ton capacity
Furnaces. LRF will be located adjacent to one group. Each furnace
will have two crucibles. FES will be provided to draw out fumes
generated during charging and melting operations of the Induction
Furnace, clean the fumes in bag filters and then let out clean air to
the atmosphere through a tall stack.
Separate FES will be provided for each group of two furnaces and
the system will be complete in all respects and will comprise fume
hood over each furnace, swiveling mechanism from one crucible to
another, ducts, spark arrestor, bag filter, ID fan, chimney etc along
with necessary electricals and controls. Duct from each group of
furnace will be laid underground within the shop and then raised
to about +6.0 m outside the shop and join to spark arrestor, bag
filter and then to chimney. It may be noted that each system will be
identical and also independent in all respects. Provision will be
made in one of the system for connecting LRF fume duct in future.
Chimney to be fabricated as per IS:6533-1995.

Typical design features of the FES is envisaged as follows :

Capacity of Induction Furnace Nom-15 ton, Maxm-17 ton

No. of Furnace Four (4)
No. of crucibles/furnace Two (2)
Crucible diameter 1.2 m (To be confirmed)
Furnace charge-mix 80% DRI, 10% scrap, 10% pig iron
No of heats/day/furnace Avg-10, Maxm-12
Capacity of LRF 35-ton
No. of FES Two (02) sets
Design gas volume of each system 80,000 nm3/hour
Gas temperature at inlet of Filter 130 0 C maxm.
Inlet dust loading 150 gm/Nm3
Guaranteed Emission at stack <50 mg/Nm3
Gas cleaning arrangement Bag Filter
Air to cloth ratio of Bag Filter 1.4 m2/min/m3
Bag material Polyester needle felt
Bag cleaning arrangement By Pulsejet air, On-line cleaning
Dust removal By rotary air lock valves
Height of chimney 30 m minimum

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Capacity of ID Fan and motor to be 10% more than the gas volume
entering the Bag Filter.

Safety emergency dilution damper will be provided in the system in case

high temperature rise is observed in the gases.

3.0 UTILITIES AND SERVICES

The following utilities will be provided by the Purchaser at the

battery limit at the nearest shop column to be mutually agreed
upon.

3.1 Electric power

Electric power available at the plant is as follows:

a) 11 kV, 3-phase, 50 Hz power supply for furnace

transformer.

b) 415 V, 3-phase, 4-wire, 50 Hz for all other equipment

including motors up to 200 kW rating.

c) The expected voltage and frequency variation will be in the

range of 10% and 3% respectively.

If any equipment is designed for a voltage different from the

above, necessary transformer and conversion equipment shall
be included in the tender.
Power supply to LT MCC will be made available at 415 V from
the shop load-centre substation.
The tenderer shall indicate the emergency power
requirement for operation during power failure for safety of
equipment.

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3.2 Compressed air

Tenderer to indicate the requirement of plant grade

compressed air for general purpose use. If instrument grade
air is required, the tenderer should include the necessary
equipment in his offer.
Compressed air shall be supplied by the Purchaser at the
battery limit at desired pressure.

3.3 Other facilities

If any utility services other than those mentioned above are

required for the equipment, the tenderer shall indicate the
technical parameters (temperature, pressure, quality etc) and
quantities required in the offer.

4.0 SCOPE OF WORK

The scope of work of the Tenderer will include design,

manufacture, supply, supervision of erection and
commissioning of the FES.

Scope of supply of FES shall be complete in all respects

including mechanical, electrical, instrumentation, utility and
services equipment.

Division list of scope of supply is broadly indicated in Annex-1. It

may be noted by that all equipment and accessories required for safe
and satisfactory operation of the FES are to be included in scope of
supply, even if not specifically mentioned in the Annex-1.

All commissioning spares will be included in the main scope of

supply.

An itemized list of 2 years’ spares along with price shall be

submitted by the Tenderer.
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Supply of initial consumables and operating supplies will be in

the scope of the Tenderer.

5.0 REQUIREMENTS FOR SUBMISSION OF OFFER

The offer shall contain the following information/documents:

 Technical parameters of plant and equipment offered
 Make of equipment and accessories
 Division list of supplies of the Tenderer and Purchaser
 List of exclusions, if any
 Break-up of price for the plant and equipment offered
 Supervision charges for Erection and Commissioning
 List of essential spares with item-wise price
 Performance guarantee parameters
 General arrangement drawings of FES (plan and elevation)
 Delivery period and commercial terms and conditions
 Reference list of similar projects
 Any other information relevant to the project

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ANNEXURE-1 : DIVISION LIST OF SCOPE OF SUPPLY S SUPPLIER

OF FUME & DUST EXTRACTION SYSTEM P PURCHASER

Detailed Design

Supervision of

Supervision of
Basic Design
Basic Data

Erection

Erection

Comm.
Supply
Sl.
No. Item Qty.

Complete mechanical and electrical design &

1. S S S - - - -
engineering services
1
2. Ducting comprising:
set
2
i Swivelling hood with bearing arrangement S S S S S P S
sets
1
ii All Ducting with matching flanges S S S P S P S
set
1
iii Supports for ducting S S S P S P S
set
1
iv Emergency bleed air damper with actuator S S S S S P S
set
1
3. Self-supported chimney comprising: S S S S S P S
set
1
i Chimney with platform, ladder & hand railings S S S P S P S
set
1
ii Aviation lamp & lightning arrestor S S S P S P S
set
1
4. Spark Arrestor comprising: S S S S S P S
set
1
i Complete equipment S S S S S P S
set
1
ii Inspection door S S S S S P S
set
1
iii Support structures S S S P S P S
set
1
5. Bag filter unit comprising:
set
1
i Raw gas casing S S S S S P S
set
1
ii Hopper S S S S S P S
set
1
iii Inspection door S S S S S P S
set
1
iv Clean air plenum with top cover S S S S S P S
set
v Pulse header incl. fittings 1 S S S S S P S

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set
1
vi Blow tubes incl. fittings S S S S S P S
set
Compressed air piping with fittings within 2 m of Bag 1
vii S S S S S P S
Filter set
1
viii Bag cage with venturi S S S S S P S
set
1
ix Filter bags S S S S S P S
set
1
x Solenoid operated valves S S S S S P S
set
1
xi Rotary air lock valve with motor S S S S S P S
set
1
xii U-tube manometer S S S S S P S
set
1
xiii D.P. Switch S S S S S P S
set
1
xiv FR unit with pressure gauge S S S S S P S
set
1
xv Pressure switch for compressed air line S S S S S P S
set
1
xvi Supporting structure with foundation bolts S S S P S P S
set
1
xvii Maintenance platform with staircase and railings S S S P S P S
set
6. ID Fan comprising:
1
i Fan with inspection cover and drain plug S S S S S P S
set
1
ii Fan inlet damper S S S S S P S
set
1
iii Inlet/outlet flexible connection S S S S S P S
set
1
iv Pedestal for fan and motor S S S S S P S
set
Flexible coupling with guard 1
v S S S S S P S
set
1
vi Drive motor S S S S S P S
set
1
vii Foundation bolts S S S S S P S
set
7. Compressed air system
1
i Compressor with motor and all accessories S - P P P P P
set
1
ii Compressed air piping up to 2 m from Bag filter unit S - P P P P P
set
8. Electrical Equipment
1
i Drive motors for all equipment S - P P P P P
set
1
ii Starters for all drive motors, actuators S - P P P P P
set
1
iii MCC panel for FES S - P P P P P
set

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1
iv Incoming/outgoing power cables & cable trays S - P P P P P
set
1
v Earthing materials S - P P P P P
set
1
vi Electrical accessories S - P P P P P
set
1
vii Termination and laying of cables S - P P P P P
set

NOTE : Above scope of supply is for One (1)

set of FES serving two Induction Furnaces,
each furnace having two crucibles.
Two (2) such sets to be supplied by Tenderer