SITE CONDITION (LOCATION & TEMPERATURE)

Latitude N 34° 24'

Longitude E 60° 16'

~ 1260 m
Elevation
Above Sea level

Max. ambient air temperature Recorded (ºC) +42

Max. ambient air temperature Design (ºC) +40

Min. ambient air temperature Recorded (ºC) -7

Min. ambient air temperature Design (ºC) -10
Average temperature for design (ºC) +16

Technical Specifications

General
The purpose of using metal detectors is to detect the presence of metallic pieces mixed with product
conveyed by belt conveyors. Aim of metal detection is to prevent damage or excessive wear of
process equipments placed downstream due to transport of metallic pieces.
Data Sheet
Following data sheet should be filled by supplier

Data Sheet for Belt Conveyor that Metal Detector will be installed on

Description Qty./Type Unit Remarks

For installation
Metal Detector (910MD01) -
on belt conveyor 910CV06
Fe content is 41%
Material to Be Handled by Conveyor Crushed iron ore
Fe/FeO ≈ 3
Lump Size 0~300 mm

Bulk Density of Material 2.5 t/m3

Moisture <3 %

Belt Width 1200 mm

Belt Speed ≈ 2.3 m/s

Belt Speed Type Fixed Fixed/Variable

Belt Conveyor Capacity
1287/1609 t/h
(operation/design)
Hazardous/Non
Area Classification Non Hazardous
Hazardous
Inclination 15 degree

Idler Spacing 800 mm

Burden Depth 320 mm

Belt Type EP800/4 8+4 -

Trough Angle 35 deg

For installation
Metal Detector (910MD02) -
on belt conveyor 910CV08
Fe content is 41%
Material to be handled Crushed iron ore
Fe/FeO ≈ 3
Lump Size 0~300 mm

Bulk Density of Material 2.5 t/m3

Moisture <3 %

Belt Width 1200 mm

Belt Speed ≈ 2.3 m/s

 Data Sheet for Metal Detector (continue)

Description Qty./Type Unit Remarks

Belt Speed Type Fixed Fixed/Variable
Belt Conveyor Capacity
1287/1609 t/h
(operation/design)
Hazardous/Non
Area Classification Non Hazardous
Hazardous
Inclination 15 degree

Idler Spacing 800 mm

Burden Depth 320 mm

Belt Type EP800/4 8+4 -

Trough Angle 35 deg

Data Sheet for Metal Detectors (910MD01,02,03,04)

Remarks
Description Qty./Type Unit
Metal Detector
2
(910MD01/910MD02)
Model/Type
910MD01 on belt conveyor 910CV06 &
Installation location 910MD02 on belt conveyor 910CV08
/Outdoor
Mechanism of detection
Detect the metallic pieces among of
conveyed material and transmission of signal
Application to change the position of flap on two way
chutes 910TW01 & 910TW02 (refer to
Appendix 1)
Smallest Size Metallic Pieces to
30 mm In one side
Detect
Hazardous/Non
Area Classification Non Hazardous
Hazardous
Minimum allowable distance of second
metal detector after Tramp Iron Magnet m
Seperator
Power Consumption Watt

Weight Kg

Overall Dimensions mm
4. Electrical Specification

 Supplier's offered equipments shall be capable of operating continues at their nominated load rating
with a combined fluctuation of ±10% for voltage and ±2% for frequency.
 Available Power supply voltage is 230v 1phase AC 50 Hz. Supplier shall provide all necessary
voltages for equipment from the incoming power supply unless otherwise specified and approved by
purchaser.
 Power and Control enclosure shall have at least IEC enclosure degree of protection IP65.
 Control unit shall have a thermostat and anti-condensation heater fitted below the electronics.

Control unit shall have following adjustments and indicators as minimum:

 Sensitivity control and adjustment
 Signal Level Indicator
 Detect indicator
 Coil Fault indicator
 Reset Button
 Selection for OFF, ON and LATCH
 At least two SPDT volt free relay contacts rated 250V/5A shall be provided for fault and Metal detect
Signals. These will be connected to Purchaser’s DCS.
 Search coils shall be suitable for magnetic ores processing.
 Detector operation shall not be influenced by normal electrical interferences present at industrial
plants.
 Control panels should have lock with key.
 All panel parts shall be clearly identified with tag number, wires and terminals shall also have suitable
numbers.
 All incoming and outgoing connections, shall be connected to terminal blocks located in convenient
positions near the gland plate for the incoming cables.
 Interface Signals with Main Control System will be as Follow:

Description Type of Signal

Metal Detected Digital Input for Main Control Sys.

Fault Digital Input for Main Control Sys.

 5- Scope of Work

- The Scope of work comprises the provision of all labor, materials, equipment and services necessary to carry
out the engineering, design, manufacturing, quality assurance, testing, documentation, identification, packing
and supply of the equipments to the point of delivery stipulated in the contract.
- All engineering and design data including technical information of all quotation should be in English with
consistent use of metric units of measurement,
- The metal detector shall be designed, manufactured, erected and tested strictly in accordance with latest
international approved standards and codes, such as DIN, ISO, ASME, IEC, . . . except as modified by this
specification and by project specifications.
- Materials shall be identified in the proposal with the equivalent applicable ASTM, AISI or ANSI number or
by reference to an appropriate International Standard.
- All special tools , required commissioning spare parts, bolts and nuts, internal wiring, one year consumable
material and other related works are in the supplier's scope of work.
- All issue of DRAWINGs shall be supplied in AUTOCAD 2010 format,
- All manuals and documents shall be supplied as electronic files and printed papers,
- All Documentation according to Section 5 and Instrument documents which mentioned in Appendix 1.
- All sensors, instruments, and etc.
 Note: For detail information about control and instrument systems refer to Appendix 1.

6- Attachments

Following drawings have been attached and should be considered as a reference:

- Troughing set section for belt width 1200 Attachment I

- I&C Requirements Appendix 1
 Attachment I

Troughing set section for belt width 1200

 Appendix 1: I&C Requirements

1. GENERAL

1.1. The purpose of this specification is to define the main requirements for the design, manufacturing,
testing documentation and supply of Metal detector magnet unit’s instrumentation and control system
supplied with various mechanical equipments.

1.2. The complete engineering and detail design of the instrumentation, control and safety system for this
unit shall be performed by the supplier/vendor in compliance with this specification. Any deviation
from the present specification at any stage of the project shall be approved by the purchaser.

1.3. The supplier shall supply and install all instrumentation and control system required to enable a fully
operational package unit.

1.4. Metering system shall be Metric.

1.5. Language shall be used in English unless otherwise specified.

2. CODES and STANDARDS

2.1. All of systems and instruments shall be designed, supplied, fabricated and tested in accordance with
the latest revision of all relevant international codes and standards including but not limited to the
following:

 IEC International Electro technical Commission

 DIN Deutchsches Institut für Normung (German Institute for Standardization)
 ISA Instrument Society of American
 BSI British Standard Institution

3. PROTECTION AGAINST ENVIRONMENT

3.1. The system will be designed for installation in non-hazardous (safe) areas.

3.2. Design ambient temperatures shall be considered as follows:

 Outdoor ambient temperature: max:+40 min:-10

 Equipment storing temperature: -5 to +40 ºC
 3.3. All instruments shall be designed to meet IEC 529/IP65-ingress protection.

3.4. All printed circuit boards shall be suitably coated which has proven to be effective in the protecting
of circuits and components.

3.5. vendor/supplier scope of supply:

 All instruments and actuators

 All bulk material for erection/installation (supports, cable trays to junction boxes)
 All tubing and fitting
 All equipment (Local Panels, equipped with all necessary equipment to operate the package (free standing
type), local control box when required, …)
 All junction boxes, (terminals, plugs, ...)
 Cables, inside the skid battery limit and special cable
 package control cabinet (static or electromechanical relays), terminal strips for the multi core cables coming
from the field junction boxes, power supply and other package units necessary auxiliary equipment
 programming devices in accordance with PLC requirements( if PLC based control cabinet)
 Documentation.

4. Instrumentation Requirements

4.1. All instruments shall be of European brands.

4.2. All instrument and devices shall be of industrial use type and tropicalized.
4.3. Accuracy: ≤ ± 0.5%
4.4. Each piece of instrument shall be provided with a 316 S.S. tag nameplate affixed to it. The following marking
as minimum shall be placed on the nameplate made of all instruments.
 Manufacturer’s name

 Model number

 Serial number

 Tag number

4.5. Vendor/Supplier shall perform all necessary calibrations and adjustments for instruments provided
under this contract at his facility and shall provide the instruments ready for installation.
5. CONTROL PANELS

5.1. The cabinets shall generally be self supporting rigid cubicle type units. The control cabinets must be straight
and flat and shall not show distortion.

5.2. The cabinets shall be front access made of steel sheets with thickness not less than 2.5mm thick with IP 54.

5.3. A gland plate shall be incorporated at the bottom of the cabinets for cable entry. Cabinets shall be supplied
with gland.

5.4. Vendor shall ensure that all used components are sized for the load requirements and are positioned in the
panel with regard to accessibility and protection.

5.5. All parts connections and fixing must be easily accessible from the front and removable. Fixing like nuts or
other counter pieces at the backside of the mounting plate are not allowed.

5.6. All panel parts shall be clearly identified with tag number, wires and terminals shall also have suitable
numbers.

5.7. All conductors for internal wiring shall be copper. Supplier shall do all wiring between control terminal blocks
and instruments on the control panels.

5.8. Terminals shall be of the sectional type mounted on rails. 10% spare terminals of each type shall be provided
on each rail.

5.9. Conductors and cables to mobile components (like doors or frames) shall be installed in a suitable way (high
flexible cable conduits) to avoid damages and reduction of the movement.

5.10. Each voltage feed in to a cabinet has to be short circuit and overload protected. Each group has to be
protected separately. All electrical consumers in the field have to be protected separately.

5.11. The terminal and cable layout shall be arranged to provide maximum separation between group of
conductors carrying analog, digital, etc signals.

5.12. All metal parts of the panel not belonging to the current carrying components and equipments, which might
come in contact with energized parts due to failure, shall be connected to earth bus by means of an earth
conductor.
5.13. Protection devices :

AC circuits: Automatic circuit breakers

DC circuits: Fuses with LED

5.14. Control relays shall be of plug-in type and shall have an adequate contact capacity for loads. Relay shall be
provided with gold plate contacts and LED.

5.15. Nameplates:

 Nameplates shall be in the English language.

 Nameplates shall be of engraved with pantograph durable plastic (white background, black lettering).
 Warning and danger signs and nameplates shall be provided if required.

6. SIGNALS

7.1. The transmission signal( From DCS to Metal Detector control panel) shall be as follows:
 Analogue: 4 to 20 mA
 Digital inputs (From DCS to Metal Detector control panel): 24 VDC
 Digital outputs (From Metal Detector control panel to DCS): Free Contact

7. INTERFACE TO PLANT CONTROL SYSTEM

7.1 Alarm initiating devices such as alarm setters and etc shall have a contact which closes at normal
condition and opens at abnormal condition, so that the fail safe concept shall be kept. This means that
cable damage or loss of voltage is detected and handled as faults. For example:
 Contact closed and circuit connected “OK” Signal
 Contact open / cable damaged and circuit disconnected “fault” signal
7.2. Interface terminals installed in the local control panel will be defined into groups as follows:
 Power terminals
 Control input terminals
 Control output terminals
 7.3. All control system signals will be 24 Vdc.

7.4. The following signals shall be made available for all sub control panels as minimum:

 Reset Command:
This signal is supplied from the DCS in 24VDC form, reset the local control panel after detection the
metal.

 Ready:
This contact is provided by the local control panel to DCS. The function “ready” shall signal to the
process control system the readiness of the control panel before remote operation. The following
conditions must prevail to keep this contact closed:
a. Control voltage available
b. No system faults (i.e. overload, emergency trip, etc.)
c. All local/remote switches in Remote mode.
The “ready” circuit will break if any of the above conditions are not met.

 Metal Detected:
This contact is provided by the local control panel to DCS. The “Metal Detected” signal indicated that
metal is detect by metal detector.

8. DOCUMENTATION

8.1. Documents to be submitted with offer:

 Two years spare parts list.

 Commissioning spare parts list.
 A complete list of all deviations from the Specification. A lack of such listing shall be taken to mean
that no such deviations exist.
 Brochures and catalogues containing outline dimensions and drawings for all instruments and control
system.
 Control system parts list and related documents Control system configuration.
 preliminary arrangement drawings of instruments and control panels
 Summary of inspection & testing procedure
 Utility consumption (electricity, instrument air, …) and heat dissipation
  Instrument schedule which shall be listed up all instruments in the Package Vendor's scope of supply
and show their tag numbers, Instrument Types, services, model numbers, characteristic of
input/output signals, characteristic of the medium to be measured and setting points for alarm and
interlocking, etc.
 Data sheet for all of instrument devices that be used in package
 Manuals concerning operation instructions, maintenance, calibration and repair for each type of
instrument and control system
 Installation and commissioning manual for instruments and control system
 Junction Box Wiring diagrams
 Mechanical, electrical hook-ups for each instrument showing connection details and mounting
details.
 Instrument drawings which shows model numbers, detail specification, dimension of major parts
including connections, etc.
 Part lists (three weeks after ordering; for FST approve)
 Erection description.
 Test certificates (FAT).
 List of all documents (For preparing the purchaser document number)

All documentation shall be provided with documentation numbers and table of contents for
the individual document and for complete instrumentation documentation with indication of
issue/revision no.
Language of documents: English
9. TEST & INSPECTION

9.1. Purchaser or his representative reserves the right to witness the work in progress in the vendor's
shop and his sub vendor's shop. In order to check weather their design and manufacturing schedule
is respected together with quality of the product, and inspect the equipment and workmanship.

9.2. Inspection and testing procedure of the items covered by this inquiry document shall be submitted
by the vendor for review and approval by purchaser.

9.3. FAT procedure shall be provided and submitted for approval one month before FAT. Supplier shall
provide all of necessary equipment for FAT in control system construction site.