JVML Sms Ts Belt Conv System r1

JSW VIJAYNAGAR METALLICS LIMITED (JVML)
VIJAYNAGAR WORKS
KARNATAKA
5 MTPA SMS COMPLEX
TECHNICAL SPECIFICATION
FOR
CONVEYOR SYSTEM & AUXILIARY SYSTEM
MECON LIMITED
RANCHI – 834002
TS NO. MEC/11/17/Q7NX/02/TS-052R1 December, 2021

JSW VIJAYNAGAR METALLICS LIMITED
(JVML)
VIJAYNAGAR WORKS
TECHNICAL SPECIFICATION OF
CONVEYOR SYSTEM & AUXILIARY EQUIPMENT
FOR NEW SMS
CONTENT
Chapter Description Page No.

No.
01.00. Introduction 3 of 96
02.00. Intent of Specification 4 of 96
03.00. Instructions to Tenderer 5 to 11 of 96
04.00. Scope of Work 12 to 14 of 96
05.00. Technical Specification 15 to 39 of 96
06.00. Performance Tests and Guarantee 40 to 41 of 96
07.00. Delivery Schedule 42 of 96
08.00. Information to be furnished by the tenderer 43 to 50 of 96
09.00. Documentation 51 to 52 of 96
10.00. List of Drawings enclosed 53 of 96
Annexure-I Electrical 54 to 83 of 96
Annexure-II Format for Deviations from Tender Document 84 of 96
Annexure-III Amendment Sheet 85 of 96
Annexure-IV Make of Bought Out items 86 to 87 of 96
Annexure-V Performance Test & Guarantee 88 to 96 of 96
© 2021, MECON Ltd. All rights reserved Page 2 of 96

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01.00 INTRODUCTION
JSW Vijaynagar Metallic Limited, (JVML) is setting up a New Steel Melt Shop of
approx. 5 MTPA capacity at a green field site at Toranagallu, Karnataka.
Basic Oxygen Furnace process route has been adopted for steel making.
The following main technological units have been considered for the new Steel Melt
Shop:
1. 1 X 350t moveable KR (desulphurization unit)
2. 2 X 350t Basic Oxygen Furnace with Dry GCP
3. 2 X 350t LHF
4. 1 X 350t RH Degassing Unit
5. 2 X Twin strand Slab Caster
MECON Limited (MECON) has been appointed by JVML for providing engineering and
consultancy services for the above project.

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02.00 INTENT OF SPECIFICATION
The intent of this specification is to prescribe the complete work for supply of Conveyor
system as required for M/s JVML at their Vijayanagar Plant, which the Tenderer shall
undertake with full compliance with the contract documents. The various specific
technical details elaborated in this technical specification are meant for fair bidding
purpose. Although every required item of work may not be explicitly mentioned in the
specification, the Tenderer shall supply all items necessary to complete the specified
work with the exception of those items of work listed under ”Exclusion”. The Tenderer
are required to make their own checks regarding correctness/ sufficiency of the details
before quoting.
All equipment shall be designed, fabricated and selected as per relevant Indian
Standard/ International Standard and upto date engineering practices and necessary
inspection/ test certificates shall be submitted along with equipment supply to certify the
quality and genuineness of critical components.

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03.00 INSTRUCTIONS TO TENDERER
03.01 This specification covers the design, engineering, manufacture, assembly, shop testing,
finish painting at manufacturer’s shop, transportation to site of conveyor system
complete with their electrical equipment and standard accessories with attachments as
covered under this specification and drawings enclosed with the TS.
03.02 Tenderer shall quote for full scope of work as covered under Chapter 04.00 of this
specification. The Purchaser reserves the right to award the full scope of work either to
one contractor or more than one contractor.
03.03 The tender shall be accompanied with General arrangement drawing for each
equipment showing to scale the elevation, side view and plan along with all the
information and duly filled questionnaire to enable the purchaser to assess important
technical features of the equipment offered. Other documents and drawings as
covered under chapter 09.00 of this TS shall also be furnished along with the Tender.
Tenders may be rejected if compliance with this clause is not ensured while tendering.
The Tenderer shall also clearly specify any request for deviation from technical
specification in the format enclosed as Annexure-II. Deviation indicated elsewhere
other than enclosed format will not be considered. Generalized statements like “the
equipment shall be manufactured as per I.S. standard, our specification” may result in
rejection of Tenders.
03.04 The Tenderer shall submit a time bar chart along with the Tender indicating starting
and completion dates showing break up of time required for raw material procurement,
engineering, various shop activities, order placement for bought out items and their
delivery to shop, assembly, testing, inspection and dispatch to site.
If the Tenderer feels that any dimension and / or design data for the equipment
described in the technical specification is to be modified, he shall indicate 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.
03.05 The Tenderer shall visit site in order to fully satisfy himself about the condition of the
site before quoting particularly at areas which requires modifications & alterations. For
this purpose, the Tenderer shall contact with the Purchaser and take prior appointment
from them.
03.06 Since erection of all equipment, components, technological structures, frames, chutes
etc, covered in this package shall be erecrted by other agencies all parts shall be
properly marked so as to ensure easy assembly and erection at site.

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03.07 The Tenderer shall ensure that minimum amount of assembly at site is necessary for
early commissioning of the equipment after delivery. Site welding shall be avoided as
far as possible. The Tenderer before proceeding with design details shall take care of
the site condition so as to avoid any difficulty in erection arising out of design.
03.08 Metric system & English language shall only be used throughout the tender and in the
drawings.
03.09 The supplier shall submit test certificates for all electrical equipment, cables and all
parts used in handling as for instance wire ropes, chains, load hooks etc.
03.10 All the equipment shall be of reputed make and proven quality with regard to their
performance. The make shall be as per approved list of Purchaser/ Consultant.
03.11 Some of the equipment parts, if specified, shall have to be manufactured as per
Purchaser’s specifications and drgs. Purchaser’s preferred make of equipment if any,
shall be adhered to.
03.12 The tenderer shall note that to expedite the commissioning of project, engineering of all
junction houses shown in the tender drawings are completed. Tenderer shall strictly
adhere to the size of junction houses indicated in specification.
03.13 The Tenderer shall check the size of Junction Houses for accommodation of drive
components. If any junction House size is found not adequate by tenderer provided
with normal helical gearbox drive to achieve the maintenance space, the tenderer shall
consider bevel helical drive for those conveyors in his offer. No commercial claim shall
be entertained after placement of order and during detail engineering drawing approval
in this respect. However, engineering of providing additional secondary members/insert
plates to accommodate their equipment, shuttle Conveyors, Diverter gates/flap gate
support platforms, local maintenance platform if required and other necessary
accessories in junction House floors shall be in tender’s scope of work.
03.14 The tenderer shall also note and confirm that they shall design their equipment in such
a way that the equipment can be erected in the junction House without any
modification being done in the junction Houses which is being engineered by others/
has already been engineered. The insert plates, fixing details, openings planned in the
junction houses for their equipment shall be strictly adhered to. The tenderer will inform
with proper drawings location, sizes and fixing details of secondary members for
support of equipment under their scope of supply within three months of the placement
of order. The structural drawing of buildings showing beaming arrangement, inserts,
openings etc. shall be handed over to successful tenderer.
03.15 The equipment shall be designed as per design criteria given below:

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I. Hierarchy of Specifications
a) Technical Specification
b) Indian Electricity Rules & statutory requirements of Central Govt. and State Govt.
Equipment complying with other recognized Standards such as IEC, BS, VDE, and
IEEE will also be considered if it ensures performance equivalent to or superior to
Indian Standards.
The components and materials used and the equipment supplied shall conform to high
standards of design, engineering and workmanship and shall be suitable for efficient
operation and reliable service in steel plant conditions.
Technical parameters of conveyors are indicated in Technical Specification drawings.

However, after the placement of order and during detailing, if there is change of profile
made by the Purchaser, the following shall be adopted:
1. For changes of +/-2% of conveyor length without change in drive kW rating there will
not be any price variation.
2. For changes beyond +/-2% of conveyor length the Tenderer shall indicate
a) Per meter cost of conveyor.
b) Per kW rate for change in the drive rating.
II. Design Basis
 Utilisation of cross sectional area - 80 % of theoretical cross sectional area

indicated in IS 11592-2000 (for computation of belt speed)
 Design capacity of belt conveyors- 20% more than rated capacity to be
considered while calculating motor power
 Idler Troughing angle – 35 deg
 Idlers –As per idler schedule enclosed with the TS.
 Friction factor (for kW calculation) of belt conveyors- 0.03
 Friction Co-efficient between Drive Pulley and Belt- 0.275
 Belting – N/N,EP

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Duty Conditions
Belting will be designed for heavy-duty condition and will be suitable for 24 effective
working hour operations per working day and 365 working days per year. It will be
suitable for installation over conveyor systems having 35° troughing angle. It will have
sufficient resistance against exposure to open sunlight so that its qualities do not
deteriorate while working in open sun. It also may have to work in rain and/or in
conditions where relative humidity goes up to 100%.
 Carrying idler spacing -1000 mm. Spacing in the convex curve position of
conveyor shall be limited to half the normal spacing of carrying idlers
 Return idler spacing - 3000 mm spacing

 Training Idler spacing
a) Carrying side - 15 m
b) Return side - 30 m
 Impact idler spacing - 500 mm or less - (min. 6 Nos.)
 Deck plate - 3.15 mm thick entire length.
 Drive pulley –12 mm thk. vulcanized natural rubber lagging with diamond groove,
minimum durometer hardness of 60º shore A scale. Pulley Shell thickness 20 mm
minimum.
 Tail/ Bend/take-up pulley – 10 mm thk vulcanized natural rubber plain lagging,

minimum druometer hardness of 40o shore A scale, and shell thickness 16 mm
minimum. (20 mm (minimum) thick for 18J5C1)
 Pulley face width - As per IS 8531-1986, Reaffirmed in 1993 or as mentioned in

clause No. 06.02.01 of the specification.
 Pulley Shaft – major shaft diameter upto 160mm- steel, class - 4 as per IS
1875-1992 (Reaffirmed 2004). More than 160mm- forged steel, class-4
normalized as per IS: 2004-1991(Reaffirmed 2001).
 Pillow blocks
a) Material - cast iron / cast steel
b) Bearing - Self aligning spherical roller bearing
c) Life - 50,000 working hrs min
d) Construction - Horizontal split type (one end fixed and the other end
expn. type)

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 Reducer
a) Service rating of 1.75 times the calculated shaft kW and thermal
capacity of gear box shall be better or equal to that of motor.
Gearbox size shall be selected that no artificial air/water cooling is
required.
b) Material - fabricated or cast steel
c) kW rating shall be not less than 1.25 times the motor kW. Higher
value of `a’ or `c' will be considered
 Brakes
D.C. electromagnetic brakes on conveyors wherever required Where
stopping time regulation is required & brake shall be considered for Conv. FARC1
 Roller type hold back device -To be provided on all inclined conveyors to prevent
roll back. Rating minimum 1.5 times the maximum calculated torque.
 Take up
Screw take up - up to 40 m (with protected thread) in general
Automatic take up travels as per I.S.
 High speed coupling - gear coupling/ resilient coupling less than 30 kW
 Delay filled chamber type fluid coupling for 30 kW & more
 Pin bush coupling - Not Applicable.
 Low speed coupling - gear or resilient.
 External scraper:
Multi sprung blade type.
Material scraped shall fall into main chute.
Blade material – metallic blade with tungsten carbide tips
 Internal scraper
V shaped, mounted on carrier assemblies with elasto-mount and non-

metallic polyurethane blade.
 Belt sway switch - At both ends and at 50 m interval (Approx.) (with Minimum 1

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Pairs)
 Belt slip and snap switch - away from the drive (1 No.)
 Pull cord switch - at 30 m interval on both sides for each conveyor, starting from
the drive end. (with Minimum 1 Pairs)
The Supplier shall make his own calculation in respect of belt speed, motor
kilowatt, belt tension etc. of belt conveyors to ensure satisfactory performance of
the system as a whole. The drive train component selected shall not be of lesser
than what is indicated in the specification and the belting chosen shall not be of
inferior quality than what is specified. The starting torque of drive motor and the
high speed coupling shall be so chosen as to allow soft start condition. The
selected belt speed shall be suitable for the material being handled. Indication of
drive KW or belt rating etc. given in specification shall be treated for guidance and
the supplier shall take full responsibility for guaranteed performance for the
components supplied by him
All bought out items shall be as per JSW preferred makes.
For Design basis of elctrics and electrical components refer Electrical

Specification Annex. I.
03.16 Painting:
All parts of the equipment shall be thoroughly cleaned of loose mill scales, rust or foreign
matters.
1.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 in
accessible after assembly shall be painted and assembled while the paints are wet.
2.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 coice of the Purchaser.
3.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:

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a) Primary coat : 30 –40 micron per coat (2 coats)

b) Intermediate coat : 70 –80 micron per coat (1 coat)
c) Final coat : 40 –50 micron per coat (2 coats)
Colour scheme shall be approved by the Purchaser.
03.17 Preparation Of General Arrangement Drawings:

The structural/Civil drawings of conveyor gallery & Junction House & building will be
made available to successful bidder. The equipment & conveyors to be provided matching the
structural & civil drawings.

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04.00 SCOPE OF WORK
04.01 Scope of work of the Tenderer shall consist of design, manufacture, fabrication,
procurement, inspection, shop testing, assembly, final painting, supply and
transportation to site of conveyor system along with other equipment & all connected
chute works with liners at transfer points complete with mounted electrics and standard
accessories and other equipments complete with their electrical equipment and standard
accessories with attachments as per technical parameters indicated in enclosed TS
diagrams.
04.02 The scope of work of the Tenderer for conveyors shall include
i) Motors
i) Gear boxes with integral holdback
ii) Couplings
iii) Pulleys with bearing blocks – head, tail, snub, bend and take-up
iv) Idlers – carrying, return, impact, self-aligning and transition
v) Idler frames
vi) Chute Jamming Detectors with connector cables
vii) Belt cleaning devices
viii) Electro-magnetic brakes if applicable
ix) Pull-cord switches with mounting frame, pull cord rope, rope clamp, rope
hooks.
x) Belt sway switches with mounting frames
xi) Zero-speed switches with sensors, sensor connecting cable, Zero Speed
Switch Encloser Box size 300(h)x200(w)x 155(d) mm
xii) Intermediate frame with short post, stringer and deck plate. Deck Plates
shall be provided as defined in detail specification.
xiii) Conveyor hoods all along the length except shuttle conveyors and belt
feeders.
xiv) Take up pulley frame with take up guides, Take up hardware like sheave,
rope, clamps, take up weight.
xv) Head, Bend, Tail pulley frame
xvi) Drive base frame
xvii) Guards – tail pulley, bend pulley, coupling
xviii) Skirt Boards
xix) Chutes with discharge hoods– leading to/ coming from conveyor with
liners
xx) Belting
xxi) HGTU/VGTU/Screw Take Up
xxii) Shuttle Conveyors/ Mobile Tripper with all electrics of Tripper including
festoon cable arrangement/ drag chain arrangement and end limits
switches, position sensors, position sensor connecting cables, Tripper
control panel etc.

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xxiii) Motorized Flap Gates with end limit switches, fixing brackets
xxiv) Reversible Belt Conveyors
xxv) Limit switch for belt rupture dectectors (1 No. for Less than 100 Mtr.
Conveyor and 2 Nos. for More than 100 Mtr.) Mechanical detector system
is not in scope.
xxvi) Motorized Slide Gates
xxvii) Vibro Feeders with electrics
xxviii) Rod Gates
xxix) High Angle Conveyors
xxx) Level Sensors
xxxi) Belt Weigh Scales including all electrics and cables
The scope of the Tenderer shall be deemed to include all such items which
although are not specifically mentioned in the specification, but are needed to
make the equipment complete in all respect for its safe, reliable, efficient and
trouble free operation.
04.03 System Description
04.04 The scope of supply and services of the Tenderer shall include the following:
Sl.No. Conveyor/EQUIPMENT Capacity(TPH) Belt Belt C/C (m) Lift(m)

No. Rated/Design Width Speed
(mm) (m/s)
1. BOFC1/C2 700/840 1200 1.3 380 48.42
2. BOFRSC1/RSC2 700/840 1000 1.5 33.1 0
3. FAC1 300/360 650 1.3 288 18.5
4. FARC1 80 3.5
5. FAC2 300/360 650 1.3 168 11.7
6. FAC3 300/360 650 1.3 73 0
7. FARC2 300/360 650 1.3 15 3.5
8. FARSC1/C2 300/360 650 1.3 7.5 0
9. * FAC4 300/360 650 1.3 463 22
10. * FAC5 300/360 650 1.3 463 32
11. DRIC1 300/360 650 1.3 60 12.85
12. DRIRC1 300/360 650 1.3 10 0
*-The drive, belting etc shall be based on above parameters considering future
provisions, however the conveyor to be supplied based on the attached TS drawing

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04.05 BATTERY LIMITS
a) From Skirt Board of BOFC1-C2 (Dicsharge chute from Belt Conveyor SMS JH1C1/C2 not
in scope)
b) Up to Top of BOF bulk Material bunkers including level indicators, slide gates.
c) From Bottom of Ground Hoppers for Ferro Alloy Feeding
d) Up to Top of BOF Ladle Addition bunkers, LF & RH Bunkers including level indicators.
e) From Bottom of Underground hoppers (DRI Feeding system) upto Feeding chute to Scrap
Box.
f) Exclusions
Following equipment and services are excluded from the scope of supply of the
Tenderer. These components shall be procured/ manufactured by the Purchaser
separately.
 Design, Engineering, fabrication, erecton of building structures

 Civil Works
04.06 For scope of work and exclusions of elecrics refer Electrical Specification Annexure I.
04.07 All fixing bolts and nuts including foundation bolts shall be included in the scope of
supply of Tenderer.
04.08 Statutory approval wherever required shall be taken by the Tenderer for the equipment
being supplied by them from relevant state/ central authorities.
04.09 Since the erection of the equipment is excluded from the scope of this package, the
Tenderer shall furnish necessary technical supervisory personnel to supervise the
erection; testing, commissioning & PG test and required to quote separately for this
alternative. The assembly of the equipment shall be made in such a way that no
problem is encountered while handling/erection of the equipment at site. Erection mark
of such assembly shall be clearly marked to facilitate the erection of the equipment.

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05.00 TECHNICAL SPECIFICATION
05.01 General
01. This specification covering broad parameters and technical requirement shall be
applicable for the design, manufacture, supply, erection, testing and commissioning of
belt conveyors, Reversible Belt Feeders, Reversible Shuttle Conveyors, Flap Gates, all
connected chute works with liners at transfer points complete with mounted electrics and
standard accessories. All equipment shall be designed, manufactured, supplied, erected,
tested and commissioned in accordance with relevant Indian Standards, IPSS and
International Standard where applicable in addition to the requirement mentioned herein.
02. The components of the belt conveyors/ Reversible Belt feeders/Shuttle Conveyors shall
be designed, manufactured, assembled and tested in accordance with IS:11592 and shall
be of standard make.
03. All working parts requiring replacement or inspection or lubrication shall be easily
accessible without the need for dismantling of other equipment or structure.
04. Adequate no. of locating pins and match marking shall be provided for easy assembly
and dismantling.
05. The Supplier shall make his own calculation in respect of belt speed, motor kilowatt, belt
tension etc. of belt conveyors to ensure satisfactory performance of the conveyor
components and system as a whole. But in any case the parameters should not be less
than indicated in the T.S.
06. All equipment shall be designed such that all components are easily accessible for
inspection, repair and maintenance.
07. Junction Houses and Galleries are not included in the scope of supply of the Tenderer.
08. Steel frames carrying machinery shall be machined to true surface.
09. All gears and bearings shall be lubricated by splash lubrication/ grease as required. All
greasing points shall be easily accessible.
10. Junction Houses and Galleries are not included in the scope of the tenderer.
05.02 Belt Conveyors
01. Conveyor Pulleys

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All pulleys shall be of welded steel construction, stress relieved before boring and
machining and statically balanced. Solid end discs shall be designed and provided to
give maximum strength. Pulleys shall be designed as per relevant Indian Standard and
IPSS where applicable. Pulleys shall be connected to the shaft preferably through
keyless friction grip connections unless otherwise agreed. However, the discharge and
drive pulleys of Conveyors with more than 160KW motor power shall be designed
with turbo-diaphragm construction and fitted on shaft through key-less friction
grip only.
Drive pulleys shall be covered with minimum 12mm thick herringbone/ diamond rubber
lagging. Tail, bend and take-up pulleys shall be covered with minimum 10 mm thick
diamond rubber lagging. The depth and width of the grooves in the lagging shall be 6
mm spaced at 30mm interval. The eccentricity of pulley shell shall not be more then +
0.5% of the diameter prior to lagging. Drive pulleys shall be machined at steel faces
prior to lagging. Shore hardness of rubber for drive pulleys shall be not less than 60oA
and for other pulleys shall be not less than 40oA.
Rolled steel may be used for pulley shafts of diameter up to 160 mm. Forged steel shall
be used for shafts above 160 mm diameter. The deflection slope of pulley shaft at
bearings shall be restricted to 1/2000 under rated load condition and at hub centre the
same shall be restricted to 1/1200 under starting load condition. The combined shear
stress in the drive pulley shaft based on the normal torque of driving motor shall not
exceed 500Kg/Sq.cm. Both these aspects shall be considered for selection of shaft
diameter and higher of these two aspects shall be taken into account.
The Plummer block shall be preferably made of Cast Steel (In case of Cast Iron, min
FG-260 grade shall be used). The Plummer blocks shall be dust tight with double
labyrinth seals. Conical head shape nipples confirming to IS: 4009, suitable drain plug
and eye bolt shall be provided. Side covers of Plummer blocks shall be heavy duty
metallic sheets. No plastic components shall be used.
Bearing centers of the pulleys shall be as follows:
- 1800 mm for 1200mm Belt Width

- 1150 mm for 650mm Belt width
Pulley shafts shall be supported on self-aligning double row spherical roller bearings
with adequate sealing and external lubrication arrangement in plummer blocks. Life of
pulley bearings shall be minimum 50000 hours.
Welding on the pulley shell shall be tested radio graphically or by ultrasonic method.
Pulley shafts shall be ultrasonically tested. Checking of out of roundness and static
balancing tests shall be carried out before dispatch of the pulleys.

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All the Drive pulleys of Conveyors shall have Horizontal split Type Plummer Block with
split type bearings.
02. Idlers
Three roll inline troughing idlers of equal length shall be used throughout. The angle of
inclination of side rollers to horizontal shall be as per drawings. Troughing as well as
return idlers shall be of reputed make and manufactured out of heavy duty ERW tubes
as per IS:9295-1983. Idlers shall be of “drop-in-slot” type.
The eccentricity (diametrical run out) of troughing and return idlers shall not exceed +
0.8 mm. Minimum shell thickness of idler tube shall be 5.0 mm. All idlers shall be fitted
with either heavy duty deep groove ball bearings or seize resistant ball bearings. The
bearings shall be held positively on the shafts. Multi-labyrinth seals shall be used for
retention of grease. All bearings shall be greased and sealed for life against ingress of
dust, water and escape of grease. All bearings shall be rated for minimum 40,000
working hours.
Self-aligning troughing and return idlers with vertical guide rollers (supported on ball
bearing of minimum 25 dia with vertical guide rollers) shall be of above specified
construction. All self-aligning idlers shall be provided with grease lubricated anti-friction
bearings at pivot points. Transition idlers at 10º and 20º troughing at both head end and
tail end of each conveyor shall be provided.
Impact cushioned idlers shall be of above specified construction. The rings or disc for
impact idler shall be made of rubber. The minimum number of impact idlers at each
loading point shall be six. The first impact idler shall be placed approx. 150 mm behind
the loading point. Conveyor with multiple loading points shall also be provided with
impact idlers at each loading points. The thickness of rubber shall be minimum 25mm
and shore hardness shall be minimum 55Aº.
Conveyors with belt width of above 1200mm shall be provided with 2 roll- 10º ‘V’ return
Idlers.
Transition idlers of above specified construction shall be used adjacent to head and tail
drums to permit proper support of loaded belt near the head and tail pulleys without
excessive stress and stretch of the belt edges.
Training idlers shall not be used close to belt-weighing scales.
Idler shaft shall be made of class -4, IS-1875 or EN-8, BS-970 or bright bar of equivalent
grade suitable for the duty requirement. Idler frame shall be made of rolled/ formed steel
with provision for securely bolting to the stringers of the conveyor frame. All fixing bolts
shall have spring washers.

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Clearance, gap etc. for the carrying and return idlers shall conform to the relevant
IS/IPSS Standard to extent possible. All idler rollers shall be painted with 2 coats of red
oxide primer and 2 coats of enamel finish paint.
03. Belt Cleaners
a) External belt cleaners
2 Nos. of External belt cleaners (One Pre- scrapper & One Main Scrapper) shall be
provided at the discharge pulley of the conveyors. For Primary Scrapper, the cleaner
shall have Multi – Sprung polyurethane blades in segments & secondary Scrappers, the
cleaner shall have sprung metallic blades (in segments) with Tungsten carbide tips,
mounted on carrier assemblies with flexible mountings to take care of belt
flapping/jerks/joints.
Polyurethene deflector skirts shall be provided below the tips to prevent materials build
up on the unit. The cleaners shall be mounted on an elastomount system to facilitate
automatic blade adjustment on wear. The inclination of the blades should be such as to
effect efficient scrapping of the belt. The spring action of the individual metallic blades
should ensure constant contact with belt during operation and suitable sprung deflection
of contact with uneven surface of the belt. The blades shall be in segments for ease of
replacement and mounting on the head pulley frame. The material scrapped should fall
inside the discharge chute directly.
b) Internal scraper
One no. each `V' shaped internal scraper shall be provided on the upper side of the
return belt near the tail end, fitted with wear resistant non-metallic scraper blade to
remove spilled materials on the belt. The blade shall be adjustable after the wear.
However, for reversible conveyors, 2 Nos diagonal scrappers shall be provided at both
ends.
04. Gear Boxes
Conveyors shall be driven through totally enclosed oil-cooled reduction gearing having
anti-friction bearings with oil seals at shaft projection. Worm gear or chain drive shall not
be used.
The reducers shall be selected with a service rating of 1.75 times the calculated kW.
The transmission efficiency of the gearing shall not be less than 0.98 per stage. The
material of gears, profile and geometry shall ensure high power/weight ratio with low
volume. Gears and pinions shall preferably be solid forged. Where forging is not
possible, forged steel gear rims shall be fitted on steel centers to withstand shock loads.

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All reducers shall have permanent magnet plugs, oil level indicators, inspection window,
breather cap etc. The gear box housing shall be made of fabricated steel or cast steel
confirming to IS: 1030.
05. Couplings
Flexible couplings shall be used between motor and gear-box and geared couplings
shall be used between gear-box and drive pulley. The hub and sleeves of the geared
coupling shall be of forged C-40 steel and bolts shall be of alloy steel. Traction type fluid
coupling shall be used between motor and gear-box for drives of 30 kW and above
capacities in combination with flexible connecting coupling. For motor KW above 30KW
delayed fill chamber type fluid coupling shall be used. All coupling bolts shall be
replaceable without shifting of drive components.
06. Hold Back and Brakes
All inclined conveyors shall be provided with suitable roller type hold back devices (other
than brakes) to prevent belt from running back in case of conveyor stoppage due to
power failure or otherwise. Holdback rating shall be minimum 1.5 times the maximum
calculated torque.
DCEM brake shall be provided on all conveyors in case coasting time is more than 6
seconds. For Conveyor FARC1 brake shall be considered irrespective of coasting time.
Brake shall have min 1.5 times the maximum calculated torque rating.
07. Take Up
All conveyors/ Belt feeders up to 40 meter in length shall have screw take - ups having
protected threads generally. Take-up travel shall be minimum 500mm. The screw of the
screw take-up shall be of square thread type and stainless steel construction with brass
nut. Automatic counterweight gravity take up shall be provided for conveyors above 40
meters in length. HGTU/VGTU shall be provided wherever feasible. Take-up shall be
complete with pulley carriage suitable for guide structure made of pipe. Counter weights
shall be metallic and they shall be held by a winch arrangement to arrest fall on failure of
the belt. A safety cage of wire mesh minimum 1500mm high from the ground shall be
provided all around the Take Up Tower. 4 Nos. of spring buffers with fixing arrangement
shall be provided for each conveyor whose take-up tower is terminating at intermediate
structural/ civil floor levels. Counter weight box shall be located 2000mm above ground
after full stretch of belt by means of wire rope sling/ turn buckle arrangement.
Take- up tower are not in the scope of this package. However, the guide posts of all the
towers and take up hardware shall be in the scope of this package.
08. Chutes

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All transfer points shall be provided with non choking chutes made of minimum 10 mm
thick mild steel plates and shall be constructed in small segments for easy dismantling.
Hinged type sealed inspection doors and flanged poking holes with bolt cver shall be
provided at suitable height and location. The size of the door shall allow replacement of
liners without any dismantling.
Snub pulley near discharge end shall be covered by the chutes.
Chutes shall be designed such that impact of the material on the conveyor is minimum.
They shall be designed to ensure continuos flow of material to the centre of the belt with
minimum spillage, noise and dust emission. The bottom part of chute may be formed
semi-circular section to ensure central discharge of materials.
Minimum valley angle of the chute shall be 60 deg. to the horizontal wherever feasible.
Minimum angle of slope of chute plate shall be 60 deg. The valley angle and slope angle
shall be suitably increased for handling wet or sticky material.
Adjustable stone box shall be provided at discharge end of chute for arresting the free
fall of material and to form a natural bed of material for protecting the parent plate.
Chutes shall be oriented as far as possible so as to ensure discharge of material in the
direction of travel of receiving belt
Liners:
All chutes shall be provided with 40mm thick Rubber liners in impact zone and 20 thick
UHMWPE in sliding zones.
09. Discharge Hoods
Hood shall be made of 5mm thick mild steel plates. The hood shall be in segments
bolted to each other for ease of maintenance. The hood shall cover discharge opening
for the chute as well as pulley. Rubber curtain and guard shall be provided at the entry
of belt in the discharge hood. No direct impact of material on hood wall shall be allowed.
Baffle plates shall be designed in such a manner that discharge material fall centrally on
belt / hopper. Baffle plates shall be lines with 40thk natural rubber having shore
hardness-55 deg.A to take care of impact.
Hinged inspection door shall also be provided in the hood. The door shall preferably be
located within a height of 1400 mm from the floor. Adequate opening shall be provided
in the hood for withdrawal and adjustment of belt scrapers.

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10. Guards
Safety guards shall be provided on the conveyor and shall comply with the relevant
IS/IPSS Standard. The guards shall be of expanded metal conforming to IS: 412
(current)
Safety guards shall be provided for all couplings, pulleys, tensioning devices, brakes etc.
Vertical take up pulleys shall be effectively guarded against spilled materials. Adequate
wind guards shall be provided along the whole length of the conveyors on outdoor
installation. All plates and angles used for guards shall be min 3.15mm thick. Wire mesh
guards shall be made of min 4mm dia wires. All VGTU towers shall be guarded with wire
mesh fencing upto minm 2500mm height from ground from all sides for safety. Fencing
shall be provided below the conveyors where return belt is more than 1000 mm above
the floor, to prevent people from crossing below the conveyor.
11. Conveyor Frames
Conveyor frames shall be made of joists and/or channels suitably stiffened and braced.
The spacing of supports shall not exceed 3000 mm. Frames shall be connected to floor
beams/civil foundation of junction house by bolting/welding. Size of posts and stringers
for the conveyors shall be ISMC 100 for 650 belt width. Size of posts and stringers for
the conveyors shall be ISMC 125 for 1000 & 1200 belt width
12. Deck Plates
Deck plates of minimum 3.15mm thickness shall be along entire length of conveyors, .
13. Skirt Boards
Skirt boards of minimum 4000mm length shall be provided at the loading points of all
conveyors/ Belt feeders/ Shuttle conveyors. Wherever the loading points are nearer to
each other, the skirt board shall be made continuous between them. Minimum length of
skirt boards from the beginning of loading area in the chute shall be 4000 mm in the
direction of belt travel. Skirt boards shall flare out in the direction of Belt travel. Skirt shall
be totally covered with MS plates. The thickness of skirt plate shall be minimum 10 mm.
The top cover plate where provided shall be minimum 2 mm thick. Flanged openings
shall be provided in skirt board top plate for fixing DE hoods.
Skirt plates shall be provided with minimum 10mm thick replaceable Mn steel liners.
Back plates with liners and rubber seals shall be provided wherever single discharge
point is envisaged. Double Lip apron type sealing shall be provided as skirt sealing
arrangemnt. The arrangement for fixing rubber curtain and rubber on skirt boards shall
be such as to ensure quick adjustment. The thickness of rubber curtains shall be
minimum 10 mm. Skirt rubber shall be in segments and the design shall ensure

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automatic flexing of rubber for proper sealing. Shore hardness of skirt rubber shall be
min. 55o A. Skirt rubber shall be minimum 10 mm thick. The height of the skirt above the
belt top shall be minimum 500mm. Flanged openings shall be provided in skirt board top
plate for fixing DE hoods.
14. Drive Base Frame
The drive unit consisting of motor, gear-box, coupling and brakes along with protective
guards shall have a common base frame and shall be fabricated form heavy structural
sections and plates. Suitable bracing should be provided wherever necessary on the
drive unit base frame and structure to make it rigid. Proper arrangements shall be
provided with gearboxes and motors to maintain correct alignment with finish pads for
mounting. The drive base frames shall be bolted to the structural floor beams/civil
foundation of junction houses provided by the Purchaser. Necessary load data and
foundation details shall be furnished by the successful Tenderer to facilitate design of
the structural / civil floor for accommodating the frame by the Purchaser.
15. Pull Cord switches
Pull Cord Switches shall be provided on both sides of Conveyor for emergency
stoppage of conveyor. The first switch shall be about 4000 mm away from the driving
drum and subsequently at not more than 30 M interval. The pull wires shall run along
the entire length of each conveyor on both sides. Where Mobile trippers are used on
conveyors, the pull wires shall run along the hand railings on conveyor walkways.
16. Belt Sway Switches
Belt sway switches shall be provided on each conveyor for protection against excessive
sway of the belt. Totally enclosed dust and vermin proof belt sway switches shall be
provided on both sides of the conveyor length for protection against excessive sway of
the belt. A pair of switch shall be installed near the head end and a pair near the tail end
and hereafter they shall be placed at an interval of 50m. A pair of these switches shall
also be provided before the belt weighing scales
17. Zero Speed Switch
Zero Speed (Belt slip) switches shall be provided for each conveyor to stop the drive in
case of excessive slippage or breakage of the belt or incase the belt speed falls below
80% of the rated speed. Provision shall be made such that preceding conveyor does not
start unless the running conveyor picks up 80% of the rated speed. These switches shall
serve as interlocking to ensure that all belts are started sequentially.
18. BELTING

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Belting shall be designed for heavy-duty condition and will be suitable for 24 effective
working hour operations per working day and 365 working days per year. It will be
suitable for installation over conveyor systems having 35° troughing angle, it will have
sufficient resistance against exposure to open sunlight so that its qualities do not
deteriorate while working in open sun. It also may have to work in rain and/or in
conditions where relative humidity goes up to 100%.
Specification for N/N & EP Belting-
Constructional Features:
The belting shall consist of a carcass having rubber covers. The carcass will consist of
number of plies. The specified construction of ply type belting will be full width ply only.
Fabric shall be of Nylon-Nylon or Polyester Polymide as relevant.
The belting shall be with pre-stretched, straight ply, skim coated with open ends. It will
have sufficient strength as specified else where, to give required tension at safety factor
of 10 and utilisation factor as 80% (maximum).
The belt shall have sufficient lateral flexibility so that it suits the troughing angle
requirements even when it is empty. It will have sufficient lateral stiffness. The belt will
have sufficient longitudinal flexibility so that it can easily flex around different pulleys of
the conveyor system. The belt shall have sufficient impact resistance to withstand
impact at the loading points. Rubber cover when removed from the belt and tested as
described in relevant IS, /ISO-3400 the minimum tensile strength shall be 24 Mpa and
minimum elongation at break will not be less than the 350% as specified in the IS. After
ageing as per provision of IS the variation in the original values of tensile strength and
elongation should not exceed the value as specified in the IS. The grade of cover shall
be M-24 Type.
The edges will be of cut edge construction. The percentage of elongation shall be limited
to 2% of belt length for EP belts.
The top and bottom cover thickness shall ne 6/3mm genrally. However the same shall
be 8/4mm for shuttle conveyors, reversible conveyors.
On the carrying surface, at interval of maximum 12 Meters. the belting will be marked as
follows:-
(a) Manufactures name and trade mark, if any

(b) Fabric designation as N/N.
(c) Belt designation i.e. KN/M.
(d) Grade of rubber cover shall be as per IS-1891 (part-5);1993.

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(e) Last two digits of the year of manufacturing say -04 for 2004 and 05 for
2005.
(f) BIS Code reference i.e. 1891 (Pt-I)-1994.
Specification for Steel Cord Belting
Constructional Features
The rubber conveyor belting of steel cord shall be with Skim coated, open end and edge
protected construction.
The belt shall have sufficient lateral flexibility so that it suits the troughing angle
requirements even when the belt is empty. It shall have sufficient lateral stiffness.
The belt shall have sufficient longitudinal flexibility so that it can easily flex around
different pulleys of the conveyor. The belt shall have sufficient impact resistance to
withstand impact at the loading points.
The steel chords to be provided in the steel belt shall have characteristics of high
strength in longitudinal direction, high flexibility for increased fatigue resistance, less
elasticity for minimum elongation and galvanizing for better adhesion of cords to rubber
and toughness and protection against corrosion. This shall be made of high quality
carbon steel (0.65 to 0.75 carbons) specially developed for use of belt with standard
wires having the diameter of 0.2 to 0.5 mm wire of strength 220 Kg/Sq. cm. The steel
cords shall be painted with brass or zinc.
Belt shall be designed to protect against longitudinal/through cut. The contractor/

manufacture should design the belting to protect against any longitudinal cut due to
foreign material. The rip protection shall have transverse breaker fabric.
The belt cover shall be made of natural/ synthetic rubber as main material so that it is
excellent in abrasion, impact and flexing and working suitable for surface operation. It
shall have 8 mm (Top) and 4 mm (Bottom) thickness for protecting belt against damage
and provide good protection. The grade of cover shall be M-24 as per IS.
The surface and edges of the finished belting shall be free from blisters, pattering and
other surface defects and will be completely sealed against ingress of moistures. The
belt shall be suitable for vulcanized joints.
Packing
Belt will be packed in a wooden drum. This packing will enable the easy unreeling of the
belting. On the body of the wooden drum the direction of belt and the location of end of
the belting should be indicated so that belting can be properly placed while unreeling.
Each belting will have separate rake / number of reels.

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19. Chute Jamming Detectors
Chute Jamming Detectors shall be provided on each chute. The detectors shall be so
located or protected that they do not come in contact with the regular flow of the
material. The detector shall, also be protected against deposit of fines particles causing
false alarm or stoppage of the conveyors. The position of each detectors shall be
decided based on the braking time of the delivery conveyor at rated capacity and the
holding capacity of the chute. Two nos of detecors shal be provide on each leg of
bifurcating chute.
05.03 Reversible Shuttle Conveyors
Shuttle conveyors will have independent drive for travel motion through geared motor
with brakes. Stringer frame for the conveyor shall be in segments independently
supported on wheels and connected together through hinged pins. Screw take - up
arrangements for the belt conveyors shall be positioned at tail end.
Double flanged parallel tread wheels shall be provided. The Rails will be 60 Kg/m.
Cleaners shall be provided to sweep the rail from spilled material. Anti-friction bearings
will be used throughout. The travel drive will be so designed that no part of equipment
shall project below rail level.
The belt conveyor will be driven through motor and bevel-helical gear box. All other
stipulation for conveyor component as detailed above will be applicable for the shuttle
conveyor also.
All the mounted electrics for Reversible Shuttle Conveyor including, Flexible cable, Drag
chain etc. shall be in the scope of bidder.
Technical Characteristics of Shuttle Conveyors
S.N Description Reversible Shuttle Reversible Shuttle

Conveyor Conveyor
BOFRSC1/C2 FARSC1/C2
1. Quantity (Nos.) 2 2
2. Capacity(TPH) 700/840 300/360
(Rated/Design)
3. Belt Width(mm) 1000 650
4. Belt Speed (m/sec) 1.5 1.3
5. Travel Speed (m/min) 10 10

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6. Length (m) 33.1 7.5

7. Length of Travel (m) As per drawing As per drawing
8. Rail Centre (mm) 1500 1150
9. Type of Rail (kg/m) 50 SQ BAR 50 SQ BAR
*The Length and Travel length of the shuttle Conveyors mentioned above is
tentative and may change during Detail Engineering.
05.04 Reversible Conveyor
The technical specification of components of feeder will be in line with components of

the conveyors.
The shortpost and frames of belt feeders shall be of bolted and segmented to allow
mounting of endless belts
Technical Characteristics of Reversible Belt Conveyor

S.N Description Reversible Conveyor Reversible Conveyor
FARC1 FARC2
2. Capacity(TPH) 300/360 300/360
(Rated/Design)
Belt Width(mm) 650 650
Belt Speed (m/sec) 1.5 1.5

4. Length (m) 80 14.75
6 Belt Cover Thickness 8/4 8/4
7 Material Ferro Alloy Ferro Alloy
05.05 High Angle (Side Walled) Conveyor
The Side wall conveyors shall be complete with drive system including motor, bevel-
helical gear box, couplings and drive tail/take-up frames, all pulleys, all idlers, skirts,
curve rollers with frames, Bell guiding wheels, belting, deflection disks, cleaners, all
technological structures, casings etc, head and tail end structures, hoods, take up. All
mounted electric like pull cord switch, belt sway switch, zero speed switch along with
pull cord shall also be included in scope of work.
Conveyor frames shall be made of joists and/or channels suitably stiffened and braced.
The spacing of supports shall be as per TS drawing. Frames shall be connected to floor

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beams by bolting / welding. Tube Housing shall be 5 mm thick MS circular construction

with lower half supported at bottom structure and upper half at building structure.
Deck plates of minimum 2 mm thickness shall be provided throughout the horizontal

portion of conveyor to avoid spillage of materials from the carrying side of belt on to the
return side.
Drive and tail pulleys shall be minimum 800 mm diameter with shell thickness
minimum 12 mm. Drive pulleys shall be covered with minimum 16 mm thick
herringbone rubber lagging. Tail pulleys shall be covered with minimum 12 mm
thick plain rubber lagging.
Diameter of the deflection disc shall be minm. 1200 mm and shaft diameter shall be 110
mm at the bearings and 130 mm at locking.
Flat carrying and Return idlers shall be used throughout. Carrying as well as return
idlers shall be of reputed make and manufactured out of heavy duty ERW tubes as per
IS:9296-1983.
The eccentricity (diametrical run out) of carrying and return idlers shall not exceed + 0.8
mm. Minimum shell thickness of idler tube shall be 5.0 mm.
Minimum diameter of idlers shall be –
- Carrying idlers-139.7mm with 25 mm diameter bearings
- Return idler stub-127.0 mm with 25 mm diameter bearings
- Impact idlers-165 mm over 114.3 pipe with shaft diameter as 30 mm
Suitable guiding wheel shall be provided in vertical portion of sidewall conveyor at both
side to prevent potential damage to the edge of the belt. Fixing of the guide wheel shaft
shall be adjustable by 50 mm. Pitch of the guide wheel shall not be more than 2 times
the actual belt width. These wheels shall be made of high precision rubber moulding.
Suitable openings shall be provided in vertical casing near the guide rolls for regular
inspection. Purchaser will provide suitable access to these openings.
Screw take up having protected threads with stainless steel shafts and nut of minimum
32 mm diameter shall only be used.
All other design aspects shall be same as belt conveyors
Technical Characteristics of High Angle Conveyor

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S.N Description HAC1 HAC2
2. Capacity(TPH) 300/360 300/360
(Rated/Design)
Belt Width(mm) To be finalized By Bidder To be finalized By Bidder
Belt Speed (m/sec) 1.5 1.5
3. Length (m) To be finalized By Bidder To be finalized By Bidder
5. Belt Cover Thickness To be finalized By Bidder To be finalized By Bidder
6. Material Ferro Alloy Ferro Alloy
05.06 Flap Gates-
Mechanical
01. The motor operated 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.
02. The flap gates shall be used to divert the flow of material received from feeding conveyor
to the receiving conveyors. The gates shall be operated by an electromechanical linear
actuator. The artuators will be mounted on the chute body/ or on a working / maintenance
platform. The exact mode of support will be intimated to the successful Tenderer.
03. The gate shall be fabricated out of 10 mm thick MS plates with 10 thick MN Steel wear
resistant, replaceable liners. The liners will be bolted by counter sunk bolts. The thickness
of the liners shall be adequate so as to give minimum 3 years operating life.
04. 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 the requirement.
05. The actuator shall be rated for 2500 kg thrust for operation of the flap gates against the
moving weight of material and/or flap gate and the motor shall be rated suitably.
06. The flap gate travel shall be in the range of 60° to 70°. Limit switches shall be provided to
indicate extreme positions. Lever arm shall be provided between actuator and flap gate

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shaft for obtaining required thrust. Each gate shall be provided with a shaft, a hand lever
and self aligning type antification bearings with adequate sealing for dust proofing.
07. The actuators shall be capable of preventing any over travel. Suitable travel dependent
limit switches controlling the travel; of the flap gates on either direction shall provided.
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 to total length of travel of the gates.
08. Suitable thrust dependent limit switches shall be provided. This shall trip off the actuator
motor in case of excessive thrust due to jamming the gates during its travel in either
direction.
09. Provision for alternative manual operation shall also be made using declutchable hand
wheel. The diameter of hand wheel shall be selected considering a 25 kg (max.) force to
be applied by a single operator.
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 flap gate shall rest on a suitable
projected surface from chute to prevent leakage of material through the available clearance
between chute and flap gate.
11. Suitable self aligned double row ball bearings in dust tight housing shall carry the gate
shaft. Suitable provision for regreasing shall be provided.
12. For standardisation purposes, only one standard type of actuator (of 2500 kg thrust load) of
flap gates shall be provided. Flap gate actuator as a whole and individual component wise
shall be completely interchangeable for all locations.
13. The material of shaft shall be EN-8 or equivalent material. The diameter of the shaft shall
be suitable for motor stalled conditions and associated twisting.
14. No cast iron part shall be used.
Technical Characteristics of Flap Gates
S.No. Equpt Material Density Size Location Qty Rated Cap/ Belt Belt
No. (T/Cum) mm Designed Width Speed

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capacity,Tph (mm) m/
Sec
1. FG- FERRO 3.0 -55 In 3 300/360 650 for 1.5
1,FG- ALLOY mm Junction FARC- For
2,FG-3 House 1 for HAC-1
SMS JH- HAC- &
2, BOF 1,HAC- HAC-2
SHOP 2 & 1.3
bidder for
to FARC-
decide 1
05.07 Vibro-Feeders
Vibrating feeders shall be of electro-mechanical type. The vibrating units of the feeders
shall be of unbalanced motor type. The vibrating feeders and their mounting
arrangement shall be properly designed to suit the scheme shown in the TS drg. It shall
be ensured that no vibration is transmitted to the supporting/surrounding structures from
springs/ Rubber cushions. The troughs of the feeders shall be of tray type construction
and shall be made out of minimum 8 mm thick MS plate (IS:2062-1992). Minm. 10 thk
liner (Sail Hard) shall be provided inside the trough along its length and side wall for
entire cross section. The trough liner shall be provided with adequate side guard to
avoid spillage. The trough shall be covered with dust tight hoods with provision of cut out
and flange for dust extraction. The equipment will be provided with enclosed dust proof
vibrators (un-balanced masses).
The feeders shall be of suspended type. Each suspension type vibrating feeder shall be
supplied complete with four numbers of suspension rods/ropes and turn buckles etc.
Design and supply of the supporting structures from bunkers for suspension type
feeders shall be under the scope of the Tenderer. Purchaser shall provide plate insert/
suitable structural member free for suspension of feeder as per requirement furnished
by Tenderer. In no case the feeders shall be suspended from any gate or other
equipment fitted with bunker.
Each vibrating feeder shall be supplied complete with supporting structures, feed
chutes, manually operated feed control gates, hood cover, electrics, plates and fixing
nuts and bolts, suspension rods, turn buckles etc. Anchor bolts for base mounting
connection for base mounted feeders, if any, to the floor are also included under the
scope of supply of the Tenderer.
The successful Tenderer shall ensure that minimum amount of assembly will be
required for erection and commissioning of equipment at site. Site welding etc. shall be
avoided as far as possible.

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The feeders shall be of robust construction and of balanced design.
Technical Characteristics of Vibro feeders

S.No. Equpt Material Density Size Location Qty Rated Cap/ Control Type
No. (T/Cum) mm Designed
capacity,Tph
1. VF- FERRO 3.0 -55 In Ferro 4 300/360 VVVF Capacity
1,2,3,4 ALLOY Alloy variation shall
Shed & be 20% to 120
2. VF-5,6 FERRO 3.0 -55 BOF 2 300/360 % of rated
ALLOY SHOP capacity
3. VF-7 DRI 1.7 -70 BOF 1 300/360
SHOP
05.08 BELT WEIGH SCALES
Belt scales shall be provided for continuous weighing of the material being conveyed by
the belt conveyor so as to indicate the rate of flow of material and to integrate and
display the material passing through the belt over a period of time.
The belt scale shall be complete in all respects to meet the requirement of auto logging
facilities as described elsewhere. The weighing cells shall also have the provision of
preventing the load cell from getting overloaded beyond its safe margin. The equipment
shall be so designed such that no error in measurement or reading occurs due to
unevenness of the belt. The carrying idler spacings are at 1meter whereas the return
idler spacings are at 3meters.
The belt scales will be capable of giving recording within +/- 0.5 % variation of actual
weight of material conveyed by the belt conveyor. The equipment will be designed such
that no error in measurement or reading occurs due to uneveness of the belt. The sway
of belt or non-uniform loading of material on belt will not have any effect on the accuracy
of belt scale.
The belt scale will be load-cell type microprocessor based modular design. The unit will
be of latest microporocessor technology well tried in continuous weighing system. The
belt scale will be complete in all respects to meet the various requirements.
The equipment will be provided with direct weight as well as electronic calibration
facilities. In electronic calibration facility, the belt scale will be automatically calibrated
from remote control station by pressing calibration switch.

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For belt scales separate control and weighing panel (CWP) shall be provided which will
be housed in the corresponding MCC room from where the related belt conveyors are
fed and incoming power supply for related belt scale has been allocated. The MCC
room, where control and weighing panel will also be installed, is provided with filtered
pressurized ventilation without any control of ambient temperatures (maximum 55oC
and 50oC (average over 24 hours).
Isolated 4 - 20 mA DC analog signal proportional to flow rate will be given to the remote
I/O rack of the PLC system from the control and weighing panel (CWP) of the belt
scales. The remote I/O rack (under purchaser's supply and scope) will be installed in the
same MCC room where CWP will also be installed. This isolated 4-20 mA, DC analog
signal will be used for automatic data logging, for the quantity of material conveyed, in
the central control room. Over load indication, in case of conveyors carrying more
materials, will be depicted in the HMI at Central control room.
Necessary boosting arrangement, if required, will be provided for hooking up the belt
scale signal to PLC by the Tenderer.
A local control and monitoring post (LCMP) for each belt scale shall also be provided for
displaying rate of flow and total material conveyed for a particular period. This LCMP will
be mounted suitably at site near the corresponding belt scales on belt conveyor. The
degree of protection of enclosure of LCMP will be IP-55.
The equipment offered shall be of sound engineering and proven quality and these
should be capable of using in steel plant and also meeting complete environmental and
ambient conditions as specified.
All accessories, and auxiliary equipments, as required, will be supplied by the Tenderer
for trouble free, efficient, smooth running operation and guaranteed performance of the
tenderer's equipment and system.
Identification ferrules shall be fitted on wiring at all terminals in conformity with

concerned drawings. All panel wirings shall be done with wire of copper of 1.5 sq. mm
minimum. Panel numbers shall be indicated in the panels.
Load cells
- The load cells shall be magnetoelastic type or high precision strain gauge.
The transducer inside the load cells shall be fully protected by a hermetically sealed
casing conforming to IP-67, Suitable for maximum 70ºC, so that the cell is impervious to
harsh environments with dirt, dust, water, heat etc. requiring practically no maintenance
and cleaning. Accuracy of load-cells/ transducers shall not be affected by variation of

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belt speed and belt tensions, over load, vibration, temperature variation, electrical
disturbances, long measuring cables etc. The load-cells shall be so mounted that
horizontal loads/ side thrust are not transmitted to the same. The output of load-cell with
respect to load applied shall be absolutely linear within its operating range. Each
load-cell shall be designed for 400 % (four hundred per cent) overload capacity and
shall be temperature compensated for range- 40°C to 70°C. The load-cell will be
selected in such a way that the same will not be affected with a variation of 30 - 40 % of
bulk density of materials.
Capacity of the Load cell shall be as per mechanical/technological requirements.

However, final rating of load cells shall be such that load cell can provide for accurate
measurement upto 150% of the rating calculated as per mechanical/technological
requirements.
Complete with excitation source, transmitter, amplifier, junction boxes, special cables,
etc. shall be in scope of bidder
DIGITAL TACHOGENERATORS
It shall be of robust construction and designed to give guaranteed accuracy of feed

rate. It shall generate consistent output pulses of positive or negative polarity as
applicable by accepting shaft rotation. The output pulses shall be suitable for feeding
into high impedance electronic circuit/instrument for digital measurement and control.
The enclosure class shall be IP 67. It shall be provided with ambient temperature
compensating device.
Arrangement of mounting of tachogenerators and its coupling with AC motor shall be

decided considering ease of maintenance.
Specification of major Electrical component and Instrumentation of Belt scales
A suitable cable box shall be provided with load cell unit and also separate suitable
terminal boxes (IP-55) shall be provided at site for wiring from field to control and
weighing panel (CWP).
Control and weighing panel (CWP)
Weighing electronics will be microprocessor based and control system will be suitable
for use with continuous weighing. The panel shall be free standing floor mounted, front
attended provided with a base channel of size 75mm x 40mm (ISMC75), CRCA sheet
steel clad (minimum thickness 2.0 mm), compact, dust and vermin proof and modular in

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construction using standard printed circuits boards. Printed circuit board assemblies will
comprise power supply, processor and buffer memory complete with back-up battery
and charger etc. All operating and calibrating functions will be selected via key boards
with membrane keys. The unit will adopt latest technology, well tried in continuous
weighing system. It will have long term stability of digital measuring, control system,
serial interface capability for connection to PLC system, high reliability by performing
most functions by software, auto-tare facility, integrated test and calibration
programmes, on line self diagnostic and annunciation features etc. Calibration for zero
and span will be fully automatic. It will be capable of handling a number of 4- 20 mA DC
analog input/output and pulse outputs as required. All input and output connections will
be galvanically isolated. 4-20 mA analog signals proportional to the flow rate will be
given to the remote I/O rack of the PLC system from the control and weighing panel
(CWP) of belt scales for automatic data logging in the central control room as described
elsewhere in this specification. Over load indication, in case of conveyors carrying more
materials will be depicted in CRT in the central control room and for this necessary
contacts/ interface will be provided in CWP for connection to remote I/O rack of the PLC.
Following displays shall be provided on the CWP:
a/ Actual flow rate - P
b/ Totalised amount of material conveyed for any particular period.
c/ Belt load - q
d/ Belt speed - V
The height of the panel will be similar to the MCC panel which may be considered as
around 2400 mm. The maximum operating height of devices on the panel shall not
exceed 1900 mm and minimum operating height not less than 400 mm. The panel shall
have minimum depth of 600mm. The cabling will be done from the bottom of the panel.
The degree of protection for the panels (CWP) will be IP-54.The panel will be located in
the MCC room.
The power supply module will be provided in the separate compartment of CWP. All
equipment required for stabilized constant voltage will be supplied. An incoming
MCCB/MPCB of minimum rating 25 A (AC23) will be provided. For panels, where more
than one belt weigher are accommodated, change over incoming switch will be provided
as power from two different MCCs will be given to this panel. Separate points for
portable lamp connection and soldering shall also be provided. The power supply
module compartment shall be fully isolated to avoid any interference with weigh
electronics. The purchaser will provide 415 V,50 HZ, 3 phase power supply as incomer
to CWP and of required rating.
Weigh electronics and control equipment including power supply for more than one belt
scale can be accommodated in one panel each in separate compartment provided the
height of the panel does not exceed the height of the MCC (in the MCC room ) and also

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this arrangement in no way shall affect the performance of the system. The tenderer will
consider this aspect carefully.
Refer Electrical Chapter for Equipment/ Component specification and other details
Technical Characteristics of Belt Weigh Scale

S.No. Equpt Material Density Size Location Qty Rated Cap/ Belt Belt
No. (T/Cum) mm Designed Width Speed
capacity,Tph (mm) m/
Sec
1. BWS- all 2.0 -50 On Conveyor 2 700/840 1200 1.3
1,2 materials maximum mm BOFC-1/C-2
2. BWS- Ferro 3.0 -55 On Conveyor 3 300/360 650 1.3
3,4,5 Alloy mm FAC1,FAC4,FA
C5
05.09 Rod gates:
Frames of rod gates shall be fabricated from rolled steel. All rods shall be of 32mm
diameter from carbon steel bars of class-4, IS:1875. The spacing between rods shall be
decided based on size of material stored in hopper/ bin & direct material load. The
tapered ends of the rod shall rest on min. 50mm square bars placed beyond zone of
discharge. An in-built tray shall be provided on outside part of the hopper for storing the
rods.
Technical Characteristics of Rod Gates
Sl. Equipt no. Material Size Location Qty. Size

No. mm (mm)
1. RG-1 TO 4 FERRO- -55 FERRO ALLO 4 750X750
ALLOY SHED
2. RG-5 DRI -70 BOF shop 1 750X750
05.10 Instrumentation - Level Sensors
For all the material bunkers, radar type level transmitter shall be provided for
continuous level indication in control room.

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For all the material bunkers, vibrating rod type level switches shall be provided for
interlocking purpose. Alarm indication shall also be available in control room. The
level switches shall be inter-locked with succeeding & preceding equipment. For
location & quantity, refer flow diagram.
1. Radar level transmitter
Operating frequency 25 GHz or higher

Type of antenna Horn type or disc type
Beam angle Max. 80
Antenna material SS 304
Process connection Flanged
Flange Material SS 304
Electronics Micro Processor based.
Location of mounting Head mounted
Power supply 24 V DC Loop Powered
Output 4 – 20 mA DC
Electrical connection 2 wire
Communication HART
Detection method Pulse Radar level measurement
Integral Display Yes, Digital for reading, diagnostics
and parametisation
Accuracy ± 0.1 % of span
Enclosure class Explosion proof (ATEX approved)
Cable entry ½” NPT (F)
Housing material Aluminum / Polyester powder
coated
Mounting Top mounting
Cable gland WP, Double compression type, Ni-
plated brass cable gland
Swiveling type arrangement To be provided
Mounting accessories To be provided
Alarm output Yes
2. Vibration fork type
 Vibration fork type level switches shall be insertion type.

 Insertion type Vibration fork level switches shall only be used for solid level
application or high level application or wherever top mounting of switch is
possible.
 Tuning fork type sensor shall be used for liquid or powder or fine material
application. Single Rod type sensor shall be used for bulk solids application.

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 Sensor material shall be considered as SS316L.

 Housing material shall be considered as cast aluminum. Enclosure class shall
be IP 65.
 Cable entry shall be considered as ½” NPTF. Process connection shall be
considered as per the requirement.
 Double compression type Ni-plated brass cable gland shall be used for level
sensors.
Scope of work for the above instruments shall include supply of all types of cables
and erection accessories as required.
05.11 Mobile trippers
1. The tripper shall be designed as per IS: 14386-1996.
2. Travel drive of trippers shall be individual wheel drive, independent of the

main conveyor drive and shall be through electric motor, helical gear box
etc. Chain drive shall not be used. Tripper shall be provided with AC EHT
brake for stopping the same at desired location. Travel speed of trippers
shall not exceed 0.5 m/sec.
3. The traveling tripper shall consist of belt scrapper (refer write up under
conveyor), rubber lagged head and bend pulleys complete with shaft
bearings, chutes, stops and limit switches, brakes etc. The tripper shall
have three-way discharge chute which shall be capable of discharging
material into the bunker openings & final head discharge.
4. Travelling trippers shall be of adequate length with proper slope of

conveyor idlers to match with the flow properties of material being
handled. The maximum inclination of the conveyor belt on the tripper shall
not be more than 12 deg.
5. Vertical and horizontal guide rollers shall be provided to control sway and
uplift of the belt in unloaded condition. The tripper shall run on standard
flat bottom Indian Rails at least of 60 lb/yd. Wheels shall be double flanged
with parallel tread running on anti-friction bearings and shall have min
hardness of 350 BHN. Material of wheel shall be forced steel / cast steel.
6. Traveling trippers shall be equipped with manually operated rail clamps

and rail cleaners and jacking pads.

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7. Flap gates on three way chutes shall be electrically operated.
8. Mounted electrics including Power supply to the tripper through motorized

cable reeling drum with trailing cables, cable trays for resting the trailing
cables, Control panel and end limit switches for protection against over
travel of the tripper etc. shall be in the scope of bidder. The cable reeling
drum and trailing cable of each tripper shall be suitable for the entire
length of the bunker bay. The cables shall have copper conductors, proper
insulating material and braided armoring in accordance with IS: 691.
9. Position indicators shall be provided as per requirement of control logic.

Operating push buttons for local control and emergency stop shall be
within easy reach of the operator on the main conveyor walk way.
10. All stipulation regarding belt pulley, belt scraper, idlers, safety guards, wind
guard, access for maintenance etc. specified for belt conveyors, diverter
gates and discharge chutes shall be applicable for the traveling tripper.
11. The rating of tripper travel motor shall be adequate to move the tripper
smoothly either in forward or opposite direction to belt direction under fully
loaded conditions. Coefficient of friction shall be taken as maximum 0.15.
12. Minimum two drive axles shall be provided for tripper travel. Arrangement
shall be provided at the starting point of the tripper to avoid folding of belt.
13. Provision shall be kept for automatic tripping of bunker bay conveyor in
event of travelling tripper getting dragged (.i.e. travel speed in excess of
rated speed).
14. The supporting structures for the rails with necessary end stops shall also
be supplied under this specification. Suitable belt hold down guide pulley
shall be provided over the concave curve of belt over tripper.
15. Separate openings shall be provided on the bunker floor of each bunker to
measure level of material in the bunker. Hinged door/ flaps shall be
provided on these openings.
16. Suitable gratings are to be provided in between bunkers in the tripper

travel zone. Opening size shall be decided during the detail engineering
stage.
17. Suitable dust cover shall be provided over tripper head pulley. Serrated
rubber seal shall be provided at open side to prevent dust nuisance.
Suitable dust tight access doors shall be provided. Counter weighted type

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belt cleaner shall be provided below the tripper head pulley to cleaning the
carrying side of the belt.
18. Suitable access platform of Chequered plate with ladders, hand railings
and walkways on both sides shall be provided for access / maintenance of
equipment on tripper. Also crossover platform shall be provided with
tripper so that operator can cross the belt through the same.
19. Continuous deck plates shall be provided below carrying idlers on the
trippers.
Refer Electrical Chapter for Equipment/ Component specification and other details
Technical Charcteristics of Mobile Tripper
S.N Description MT1 MT-2
1.Quantity (Nos.) 1 1
2. Capacity(TPH) 300/360 300/360
(Rated/Design)
3. Belt Width(mm) 650 650
4. Belt Speed (m/sec) 1.3 1.3
5. Travel Speed (m/min) 10 10
6. Flap Gates 2 Nos 2 Nos
7. Length of Travel (m) As per drawing As per drawing
8. Rail Centre (mm) 1300 1300
9. Type of Rail (kg/m) 60 lbs/yard 60 lbs/yard
05.11 Motorized Slide Gate

Gate shall be fabricated from rolled steel plates and section, it shall be complete
in all respects including gates plate, frame work, motors, thrustor etc. The gates
plate shall have wear resistant liners (minim. 10thk Tiscral / Sailma) and shall
slide over rollers mounted on anti-friction bearings, placed at 250-300 mm apart
(bush shall not be used). The pull required to operate the gate shall not exceed
25 kg when operating under a loaded bin/hopper. The gate shall be mounted
over the DRI bins. The gate plate shall be designed such that bunker opening is
completely sealed during purging operation.

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06.00 PERFORMANCE TESTS AND GUARANTEE
06.01 After erection and commissioning of equipment, performance tests shall be carried out
to prove the performance of the system and equipment. These tests shall be binding
on both the parties of the contract determine compliance of the equipment /system
with the performance guarantee.
All the equipment, tools and tackles required for successful completion of the
performance tests shall be supplied by the successful tenderer. All the instruments for
the performance tests, as required, shall be supplied by the successful tenderer and
shall retained by him till the satisfactory conclusion of all tests at site. All costs
associated with the supply, calibration, installation and return of test equipment shall
be included in the scope of supply. All test instruments shall be as per standards
approved by the Purchaser.
06.02 If the successful tenderer fails to achieve the guarantee and performance parameters,
he shall investigate the causes and shall rectify and/or replace, free of cost to the
Purchaser the defects of the equipment/system within a period of 1 (one) month from
the date of commencement of performance and guarantee tests and again prove the
guarantees. In such cases, the cost of modifications including labour, materials, and
cost of additional testing etc. shall be borne by successful tenderer.
06.03 If even after necessary alteration and modifications are affected, the performance
guarantees are not fulfilled, the Purchaser reserves the right to reject the equipment.
In the event of exercising this right, the successful tenderer shall replace the defective
equipment/system with the equipment/system that meets the performance guarantee
parameters. The cost of replacement inclusive of labour, materials and repeat testing
to prove compliance with the performance guarantees shall be borne by the
successful tenderer.
06.04 For each equipment, the load test shall be conducted in stages. The equipment shall
be run for 8 to 10 hours continuously at no load, 25%, 50%, 75%, 100% of the
rated capacities or at rate mutually agreed upon between Contractor and
Purchaser. The intervening period shall be available for making adjustments and
arrangements by the Contractor as may be required.
06.05 All the specified speeds of the equipment shall be measured under full load
conditions.
06.06 Proper operation of all positional limit switches for shuttle Conveyor and gates and all
safety switches for cable reeling drums, limit and safety switches/ alarm for
conveyors like pull cord switch, zero speed switch, belt sway switch etc. shall be
demonstrated by the Contractor in the presence of Purchaser / MECON or his
representative.

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06.07 During operations of the equipment at no load and at full load, performance of all the
drives shall be checked in respect of current drawn by the motors, temperature rise,
vibrations, gear box noise and its heating, bearing heating etc. consumption of power
and various consumption like lubricants etc. shall also be measured and compared
with the respective rated values.
06.08 The equipment shall be considered to have performed satisfactorily when

i) Rated capacity of equipment is demonstrated with all its drives and
accessories functioning properly over a minimum period of eight (8) hours.
ii) It runs successfully for a continuous period of 15 days at the rated
capacity.
iii) Successful reversing of reversible shuttle Conveyors (if any) on load.
06.09 Performance guarantee values and penalty for non fulfillment of the same shall
be as follows:
Sl. Description Performance Acceptance Limit with Rejection

No Guarantee Penalty Point
Value, tph
1. Conveyors & a)Rated Rated Capacity Below Rated
other capacity in Capacity
equipments t/hr
and
b) Design in Below Design

t/hr for 10 Design Capacity Capacity
minutes
The following basic performance parameter tests shall be concluded:
a) All equipment shall operate at rated capacity without undue vibration and undue
noise etc.
b) Measurements of power consumption of various drive motors while operating at
performance guarantee levels.
c) Continuous run system performance test. All other parameters of the equipment or
system indicated in the specification.
06.10 The following performance guaranty parameters shall be taken into consideration for
Belting-
The design, construction, testing and performance of the belting will comply with all
applicable codes and as per IS 1891/1994 or equivalent. International standards.

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07.00 DELIVERY SCHEDULE
07.01 Delivery of all the equipment shall be completed within 6 months from the letter of intent
issued to successful Tenderer. However delivery schedule of the equipment shall be
finalized during the tender discussions. As indicated earlier, Tenderers shall submit a
time bar chart along with the tender indicating starting and completion dates, schedule
of erection, testing and commissioning of the equipment etc.
07.02 Timely completion is the essence of this T.S. The Tenderer must satisfy himself about
his ability for completing the work as per delivery schedule, before submitting his offer.

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08.00 INFORMATION TO BE FURNISHED BY THE TENDERER:
08.01 The Tenderer shall furnish the following questionnaire and submit with his offer.
- All drawings and documents as per clause no.

09.02 of TS submitted along with Tender? - Yes/ No
- Clause wise list of deviations from TS furnished - Yes/ No
- Time bar chart and PERT network furnished - Yes/ No
- Copy of Tender drg. signed and submitted ? - Yes/ No
- Delivery schedule furnished? - Yes/ No.
- Bought out items conforms to T.S. ? - Yes / No.
- List of exclusions from Tenderer’s scope - Yes / No.
08.02 The Tenderer shall also furnish the following questionnaire and submit with his offer.
This data shall form a part of the contract with Successful Tenderer.
08.02.01 General
01 Name and address of the Tenderer :
02 Previous experience of the Tenderer :
03 List of similar equipment supplied :
04 Whether the Tenderer has any technical :

collaboration with any other company/
organisation for his equipment.
05 If answer to question 04 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
06 List of drgs./ literatures enclosed with :

the offer.

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07 Is it the Tenderer's intention, if awarded :

the contract, to comply fully in all respects
with owner's specifications covering the
work ? If not, he shall state specific
exception in details.
08.02.02 EQUIPMENT DETAIL (To be filled up & submitted along with the bid)
A) BELT CONVEYOR/BELT FEEDER/HIGH ANGLE CONVEYOR
The detail information of individual components as asked for in the following

questionnaire shall be indicated for each conveyor separately wherever the details are
not identical.
i). Conveyor/Feeder no. :

ii). Carrying capacity (t/h) :
iii). Centre to centre horizontal (m) :
iv). Lift (m) :
v). Belt width (mm) :
vi). Belt speed (m/s) :
vii). Pulley details (for Head / Tail / Takeup/ Bend/ Snub individually):
a). Pulley diameter (mm) :
b). Shaft dia at Brg. :
c). Bearing type & No. :
d). Shell thickness & end disc thickness:
e). Lagging thickness & shore hardness:
viii). Idlers (to be furnished for each type of idlers conveyor –wise)
a). Make :
b). Roll diameter (mm) :
c). Roll thickness (mm) :
d). Tube specification with thickness :
( ERW / Seamless )
e). Max. Roll eccentricity (mm) :
f). Bearings :
a). Make :
b). Number & type :
c). Bearing life (hrs) :
d). Life sealed : Yes / No
e). Size of transverse member of main frame :
ix). Motors ( Separate for Main Drive & Shuttle Drive) conveyor-wise

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i) KW rating :
ii) RPM :
iii) Type :
iv) Duty :
x). Gear Boxes ( Separate for Main Drive & Shuttle Drive)
a). Make :
b). Type & no of stages :
c). Reduction ratio :
d). Torque rating (kg-m):
e). Mechanical/Thermal
f). Overall efficiency :
g). Wt. of Gear box :
h). Hold back : yes / no
i). Material of Housing :
xi). Couplings ( Separate for Main Drive & Shuttle Drive)
a). Make, rating and type of high:

speed couplings
b). Make, rating and type of low speed :
couplings
xii). Take-up type

xiii). Belt cleaners – blade type (for Pre / Main / Internal) & Nos
xiv). Pull chord switches (addressable) :
(no. of pairs )
xv). Belt sway switches (addressable) :
(no. of pairs )
xvi). Zero speed switches(nos) :
xvii). Brakes
a). No and location :

b). Brake drum diameter (mm) :
c). Torque rating (kg-m) :
xviii). Hold Back
a). Type :
b). Make :
c). Lubrication arrangement :
xix). Take-up Winches

a). Capacity :
b). Rope dia :

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c). Operating effort :

xx). CONVEYOR FRAMES / STRUCTURES
i) Size of supporting posts :
ii) Size of stringers :
iii) Spacing of supporting posts :
iv) Deck plate thickness (mm) :
v) Deck plate arrangement :
vi) Intermediate frame details :
vii) Wt. of frame for running :
meter (kg)
xxi). SKIRT BOARD
i) Arrangement | furnish typ. drgs. for

ii) Cross section | various conv. Widths
iii) Thk. Of mother plate / cover plate / liner
v) Dust sealing system
xxii) BELTING
i) Grade of Belt :
ii) Belt material, construction and type:
iii) Number of piles and breaking strength
iv) Weight of belt/metre length [kg]
v) Length of belt required for replacement including jointing allowance [m]
vi) Thickness of covers
a) Top [mm]
b) Bottom [mm]
vii) Belt rating offered for each conveyor
viii) Belt tension offered for each conveyor [allowable] kg
ix) Belt manufacturer
x) Whether Breaker Ply provided
xi) Roll diameter with length of belt in each roll, its weight for handling at site
xii) Melting point of material of carcass
xiii) Weight of rolls with maximum permissible length of belt in a roll.
xiv) Cleats type & Height ( For High Angle Conveyor )
xv) Cleats length & Pitch ( For High Angle Conveyor )
B) Reversible Shuttle Conveyors

a/.Belt Conveyor No.
a Designation
b Capacity (ton/ hr)
c Nos off
d Belt width (mm)
e Belt speed (m/ min.)

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b/ Belt Position
a. Length between centers (m)

b. Toughing angle (deg)
c/ Belt Specification
a) Grade of belt cover
b) Belt material, construction and type
c) No. of Plies & braking strength
d) Weight of belt /meter length (Kg/m)
e) Materials of construction of different parts
f) Length of belt required for replacement
including jointing allowance (m)
g) Thickness of cover
- top (mm)
- Bottom (mm)
h) Details of chain i.e. materials composition

etc.
I) Belt tension (actual) (Kg)
j) Belt tension (allowable) (Kg)
k) Belt manufacturer
d/ Idler
a) Manufacturer and type
b) Roller material
c) Diameter with rubber disc & length of
roller (mm)
d) Shell thickness (mm)
e) Thickness of rubber disc (mm)
f) Spacing (mm)
g) Dia, & Type of bearings (mm)
h) Estimated weight/unit (Kg)
I) Method of lubrication
j) Toughing angle (deg)
e/ Pulleys
a) Manufacturer
b) Dia as per IS : 1891 (mm)
c) Lagging material & thickness & how
secured to pulley (mm)

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d) Fixture of pulley to shaft

e) Make and type of bearings
f) Pulley shaft
- Material of shaft
- Dia of shaft at bearing (mm)
f/ Take up
a) Type
g/Speed reduction units
a) Manufacturer
b) Type
c) Minimum service factor considered
d) Mechanical efficiency (%)
e) Type of primary couplings
f) Type of secondary couplings
h/ Belt Cleaner
a) Type & No of external cleaner
b) Type & No of internal cleaner
i/ Skirt Plates
a) Manufacturer and thickness of side plates
(mm)
b) Material and thickness of covering plates
(mm)
c) Length of skirt boards for each feeding
points (mm)
d) Type and thickness of seals at skirt plates
(mm)
j/ Brakes
a) Type and make
b) Size
k/Frame work
a) Size of stringers
b) Walk way width (side or central) (mm)
c) Chequered / grating plate thickness (mm)
d) Material and type of belt covering
e) Thickness of deck plates (mm)

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l/ Electrical switches
a) Made and type
b) Spacing
c) Rating (Volts amps break)
d) Location of zero speed switch
e) Drive arrangement of zero speed switch
m/ Power required at drive pulley shaft (Kw)
n/ Drive motor details
a) Rating (KW)
b) Speed (rpm)
c) Starting torque (Kg/m)
d) Duty cycle
o/ Track length (m)
a) Track type considered C to C of rail
(mm)
p/ Travel drive
a) Motor rating / RPM
b) Quantity
C) FLAP GATE
i. Capacity and designation of the :

equipment
i. Materials of construction of different parts :
ii. Total weight and weight of individual :
parts
iii. Type of liner and thickness :
iv. Type of actuator and thrust in kg of each :
actuator
v. Stroke in mm of each actuator :
vi. Velocity mm per of each actuator :
vii. Motor at ------- type, rating, power :
supply, class of duty, insulation, make
number of starts/ hours
viii. Make, ratings, type of limit switches :
ix. Effort required for manual operator, kgf :
x. Type of limit switches :
D) VIBRO FEEDER

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i. Rated Capacity :
ii. Type :
iii. Make :
iv. Dimensions (LXW) :
v. Material of construction of the tray & Thk :
vi. Liner & thk :
vii. Method of fixing of liner plates :
viii. Drive Details( type, make, motor rating, gear box rating):
E) MOBILE TRIPPERS
i. Type :
ii. Nos. :
iii. Capacity, tph :
iv. Gate (2/3 way) :
v. Track rail size :
vi. Travel Wheel Details :
Wheel material :
Vii. Duty :
viii. Power supply :
ix. Length of travel :
x. Rail Gauge :
xi. Maxm. Wheel load :
xii. Travel speed :
Travel Drive :
xiii. Any other special features:
F) BELT WEIGH SCALES
i. Make :
ii. Designation :
iii. Type :
iv. Rated Capacity :
v. Belt width & speed :
vi. Accuracy :
vii. Weighing range :
viii. No of m/ced idlers t be provided :
ix. Control System :
G) LEVEL INDICATORS
i. Make :
ii. Type :
iii. Quantity :

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09.00 DOCUMENTATION
09.01 The Tenderer shall submit six sets of following technical drawings & technical data/
information with tender for equipments without which the tender shall be considered
as incomplete & may not be considered for acceptance.
List of drawings /data to be submitted along with tender
01. General Arrangement of conveyor equipment showing overall dimensions and weight
as well as GA of drive system with its component lists.
02. Supplier's name for conveyor components (like idlers, pulleys, motors, and gearbox)
catalogues for these items shall be furnished.
03. Delivery schedule in the form of a bar chart covering periods of design and
engineering, procurement of raw material, manufacturing, assembly, transportation,
erection testing and commissioning.
04. List of imported components in the equipment, if any.
05. If the drawings and other particulars are returned by the Purchaser/ Consultant,
because they are incomplete or incorrect, the Supplier shall not be given any extension
of time on this account.
09.02 List of drawings to be submitted for approval
01. Drawings listed hereinafter shall be submitted to the Purchaser / MECON in stages for
approval, starting within one month of issue of letter of intent and prior to the
commencement of fabrication.
The load data/ drawing must be submitted within one month to enable the Purchaser /
MECON to start the civil / structural / electrical works.
Following design data, calculations and drawings shall be submitted by the Successful
Tenderer to the Purchaser / MECON in stages for approval starting within fifteen days
of issue of letter of intent and prior to commencement of manufacture/ fabrication.
- All the drawings/ data listed in 09.02.01 and 09.02.02 giving all the details,
loads/ power requirement etc.
- Details of head end, tail end, drive base frame etc. of the conveyors such
as bolt location, sizes, chute opening etc. required for engineering the
junction houses by the Purchaser.
- Motor data sheet & GA of motors.
- GA, Bill of materials, wiring diagrams, termination diagram for brake
rectifier panels.
- GA & data sheet for limit switches, belt protection switches.
- GA of junction boxes.
- In addition to the above, the Purchaser/ Consultant reserve the right to

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insist on submission of calculations/ drawings/ data for any mechanical,

structural or electrical equipment/ component as required.
02. Drawing/data/calculation for reference
- Load data and foundation pedestal plan for head end, tail end, drive base
frame etc.
- Any other load data/information required by Purchaser / MECON for design of

building/ structures.
- All drawings and documents approved by Purchaser/MECON.
- Erection specification and quality assurance plan during erection. This shall
also be furnished in soft copy.
- Procedure for testing and commissioning. This shall also be furnished in soft
copy.
- Spare part list and drawings
- Instruction for storage /erection, testing & commissioning.
- Catalogues/literatures
- Operation and maintenance manual.
- Final test certificates
- As built drawings

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10.00 LIST OF DRAWINGS ENCLOSED
Sl Drg. No Description
no.
1. MEC/11/17/Q7NX/TS/55/001, R0 Flow Diagram for Material handling system inside new
SMS
2. MEC/11/17/Q7NX/TS/55/002, R0 Tender drawing of Junction House SMSJH-1
3. MEC/11/17/Q7NX/TS/55/003, R0 Tender drawing of Conveyor FAC1,C2 & BOFC1, C2
4. MEC/11/17/Q7NX/TS/55/004, R0 Tender drawing of Conveyor BOFC1 & C2,
(2 sheets) BOFRSC1 & C2 inside new SMS
5. MEC/11/17/Q7NX/TS/55/005, R0 Tender drawing of Conveyor FAC1 & C2, FARSC1

&C2, FARC1 & future LF Conv inside new SMS
6. MEC/11/17/Q7NX/TS/55/006, R0 Tender drawing of Conveyor FAC3, FARC2, FAC4 &

FAC5 inside new SMS
7. MEC/11/17/Q7NX/TS/55/007, R0 Tender drawing of Conveyor FAC4 for Ferro Alloy

feeding to LF inside New SMS
8. MEC/11/17/Q7NX/TS/55/008, R0 Tender drawing of Conveyor FAC5 for Ferro Alloy
(4 sheets) feeding to RH inside New SMS
9. MEC/11/17/Q7NX/TS/55/009, R0 Tender drawing of Ferro Alloy Shed

(2 sheets)
10. MEC/11/17/Q7NX/TS/55/010, R0 Tender drawing of Junction House SMSJH-1
11. MEC/11/17/Q7NX/TS/55/011, R0 Tender drawing for feeding DRI to Scrap Box
12. MEC/11/17/Q7NX/TS/55/012, R0 Technical Particulars of conveyors of new SMS

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ANNEXURE: I
ELECTRICAL
This Annexure covers the scope of work & technical specifications of electrical
equipment for this package.
01 Scope of Work
Scope of work of tenderer for electrics will include supply of field electrics &
safety switches etc for conveyor i.e Motors, Brake Panel, all types of safety
switches, electrics of Belt Weigh scale and electrics for Tripper electrics for Vibro
feeder.
02 Exclusions
Cables, Starter panel, Local Control stations, Junction boxes (except for JBs of
Brake panel) for conveyors, Earthing, Electrical buildings are excluded from
scope of tenderer.
03 Standard voltage levels & variations

The following standard voltage levels shall be adopted.
Sl.No Description Data

HT supply 6.6 KV, ± 10% (Resistance
earthed), 50 Hz, 3 Phase,
Fault Level 450 MVA/ 40KA
for 3 sec
1. LT AC power supply 415V ± 10%,

50 Hz, 3 Phase, 4 wire,
solidly earthed
Fault Level 50KA for 1 sec
2. AC control voltage 110V +10%

3. Electro-magnetic brakes 220V, DC, obtained through
individual rectifiers
4. Solenoid valves 24V,DC, unearthed
5 Control voltage for Field 24V,DC, unearthed
devices i.e PCS, BSS, Chute
jam switch
6 Zero speed switch 110V +10%

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04 Permissible Variations In Power Supply:
The equipment shall be designed so as to be suitable for the following variations

in voltage and frequency unless specifically indicated and agreed by Purchaser in
writing.
Description Voltage Frequency
Permissible variations with For LT system :- +3 & -

rated performance, rated For LT system:- ± 10% 5%
current and control
For HT system :- ± For HT system :- +3 & -
effectiveness maintained
10% 5%
05 Criteria for selection of voltage levels for motors
For Fixed Speed Process Application

Motor rating up to and including 200kW (DOL) : 415V, ±10%
Motor rating above 200Kw (DOL) : 6.6kV, ±10%
06 Electrics for Tripper:
a. Battery Limit:
Purchaser shall terminate 415V power supply in Power JB near Tripper.
Control Cable for interfacing with PLC shall be terminated in Control JB near Tripper.
The scope of bidder shall start from Power JB and Control JB.
All power cable and control cable from JB to Tripper Control Panel / motor end shall be
in scope of bidder
Any other voltage if required shall be generated in Control Panel in the scope of bidder.
b.Scope of work shall include the following:

1. Control Panel of Tripper
2. All power Cable, Control cable, flexible cables
3. Motorized cable reeling drum with trailing copper cables EPR insulated, CSP
sheathed
4. All Mounted electrics

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5. All safety switches, Limit switches, with minimum IP65 enclosure class, having
2NO +2NC contacts
6. All interfacing signal shall be terminated to Control JB
07 Electrics for Belt Weigh Scale:

a. Battery Limit:
The scope of bidder shall start from out-going terminals of MCC. Cables from MCC to
Belt Weigh Scale panel and further routing shall be in the scope of bidder.
415V power supply shall be given for Belt Weigh Scale.
Other voltage, if required, shall be generated in panel
b. Scope of work shall include the following:

1. Control and Weighing Panel
2. Local Indication Box/ Local Display Panel
3. All Junction Boxes
4. All safety switches,
5. All power Cable, Control cable, flexible cables, special cable
6. All the Load Cell cables, Tachogenerator cables, cables to JB, Cables to MCC
Room, to JB, Cables to Control Panels, Cables to Local indication panel shall
be in the scope of Bidder
c. Belt Weigh Scale Panel Construction features.

- Floor mounted, free standing
- Dust and vermin proof.
- CRCA sheet steel clad.
- Minimum 2.0 mm thick for panels.
- Suitable to withstand vibrations to be encountered in steel plant applications.
- 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.
- Power wiring-Min 2.5 sq.mm. Cu
- Control wiring – Min 1.5 sq.mm. Cu
- The panel door shall be provided with toughened glass in front of controllers for viewing
of display units without opening the panel door. All control devices and indicators shall

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be mounted on the front. Two numbers earthing studs shall be provided with the panel
for external earthing. All power, control, and signal terminals of different voltages shall
be segregated. 20% spare terminals shall be provided in the panel.
d. LOCAL INDICATION BOXES FOR BELT WEIGH SCALE.
Each belt Belt weigh Scale shall be supplied with a local box with following features:
- Sheet steel (2.0mm thick) construction.
- Wall/ structure mounted type.
- Hinged door, dead front type.
- Enclosure class IP-55.
- To be painted as per standard procedure agreed.
- Internal wiring with 1.5 sq.mm copper conductor.
- The box shall be wall/structure mounted type and be complete with
cable glands and lugs.
- The LCB shall be provided with Feed rate actual (TPH meter – digital
type).
e. A suitable cable box shall be provided with load cell unit and also separate suitable
terminal boxes (IP-55) shall be provided at site for wiring from field to control and
weighing panel (CWP).
08 Electrics of Vibro Feeder:

a. Battery Limit:
The scope of bidder shall start from out-going terminals of MCC.
b. Scope of work shall include the following:

1. VFD Panel
2. Local Control Station
3. All Junction Boxes
4. All safety switches,

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09 SPECIFICATION OF ELECTRICAL EQUIPMENTS:
I. 415 V Squirrel Cage Induction Motor
Sl.No. Parameters Description
1.0 Standard IPSS 1-03-001 / IS 12615/ IEC 34 & IEC 72
2.0 Constructional Features
(i) Frame size & rating As per IS 1231. However, kW ratings of

continuous (S1) duty motors shall be selected
from Standards motor ratings as indicated in
Appendix-1 (Table-1A)
(ii) Motor body Grey iron casting as per IS:210
(iii) Motor Feet Integrally cast with the stator
(iv) Protection for Motor & IP – 55 (with canopy for motor if installed
Bearing outdoor)
(v) Shaft ends & Extension Cylindrical as per requirement
Proper drilling and tapping shall be provided for

mounting of tachos for speed feedback (if
required )
(vi) Bearings - For motor of rating upto7.5 kW, ball bearings

shall be used for both DE & NDE end.
- For ratings above 7.5 kW the DE shall be

provided with roller bearing and NDE shall be
provided with ball bearing.
- Bearings shall be suitable for running of

motor in either direction.
- Motors above 280 frame size shall be

provided with grease nipples for in situ
greasing.
(vii) Hazardous Area safety As per Hazardous area classification

design requirement conforming to latest Indian
Standard.

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(viii) Greasing point At DE & NDE sides .
3.0 Terminal box
(i) Location RHS viewed from DE / On top
(ii) Suitability - 4 Core Al/Cu Cable
- Extension shall be done to receive the

aluminium cables to avoid cramping of the
cables in the terminal box .
(iii) Rotation 4 X 90 deg.
(iv) Earthing stud Inside Terminal Block for termination of 4th core
4.0 Cooling - TEFC (IC-411)
- Effective irrespective of direction of rotation
5.0 Quality of operation
(i) Vibration intensity Shall be limited as per IS 12075
(ii) Noise level As per IS: 12065-1987
(iii) Balancing Motors shall be dynamically balanced with

full/half key on the shaft- end and fan
6.0 Electrical design
(i) Power Supply Motor Upto 200kW : 415V
Motor Above 200kW : 6.6kV
(ii) Starting& Rotation Starting- DOL, Rotation suitability – Bidirectional

Vibro feeder motors shall be inverter duty,
however it shall also be suitable for DOL Start
(iii) Min Voltage for Start & Run 85 % of rated voltage at terminal
(iv) Starting Torque >= 160 % Rated Torque
(v) Breakdown or pullout Minimum 200 % of the rated torque

torque
(vi) Starting current Shall be as per latest edition of IS 12615.

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(vii) Duty S1/ as specified in TS/ As perprocess

requirement
(viii) Starts/Hour permissible 3 in quick succession from cold or twoin quick

succession from hot start, under rated load
condition..
(ix) Max speed permissible 120% over speed for 2 minutes
(x) Overload capacity Capable of withstanding 160% Overload for 15

sec.
IE-3 as per IS-12615-2011
(xi) Efficiency
(xii) Derating Motor designed at 40 deg.C shall be derated

suitably for mentioned ambient temperature .
(xiii) Motor connections Motor with frame size 90 shall be connected in

star and of frame sizes more than 90 shall be
connected in delta
For delta connected motors 6 leads shall be

brought out .
(xiv) Insulation Class F
(xv) Permissible temperature Limited to class 'B' (120 deg absolute)

rise
(xvi) Torque Type Normal / High / High slip type / Stall Torque type
(as required for the specific application)

Out door motors above 45 kW
(xvii) Space Heater
Indoor Motors above 110 kW
(xviii) No. of Poles 4 pole
(unless specific drive requirement or economics

call for other poles).
(xix) Testing As per approved QAP during engineering stage.
(xx) Mounting Normally horizontally foot mounting.
Other type of mounting as per specific

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requirement.
(xxi) Earthing 2 nos. on the body on the opposite side and one
inside the TB.
II. Terminal box of Motor

- The terminal box shall be amply dimensioned to receive EPR/PVC/XLPE
insulated and Unarmoured power cables with
aluminium/Copperconductors. Terminal box shall be provided with
additional cable gland for entry of power supply cable for brake rectifier
panel. The cable sizes shall be as given below:-
Motor rating Minimum size of Power cable
(Aluminium) termination in sq.mm.
Up to 3.7 (DOL) 4x4 Cu.
Up to 3.7 (RDOL) 4X4 Cu.
5.5 4X6 AL
7.5 4X6 AL
11 4X10 AL
15 4X16 AL
18.5 4X35 AL
22 4X35 AL
30 3.5X50 AL
37 3.5X50 AL
45 3.5X95 AL
55 3.5X120 AL
75 3.5X185 AL
90 2(3.5X120) AL
110 2(3.5x120) AL
125/132 2(3.5x120) AL
160 3(3.5x185) AL
180/200 3(3.5x185) AL
250 3(3x240) +2 (1x240) CU
400 3(3x240) +2 (1x240)
Above cable sizes are indicative & final size shall be informed to supplier
during approval of Motor Data sheet.
- The terminal box shall normally be provided on the top.
- A suitable earthing stud shall be provided inside the terminal box.
- It shall be possible to rotate the terminal box by 90 degrees.

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III. CONTROL PANEL:
A. General
1.0 Type Metal clad. Non drawout type
2.0 Construction Modular construction. Fully

compartmentalized with metal / insulating
material partition.
3.0 Enclosure class IP54.
4.0 Type of execution Single front.
5.0 Mounting Floor mounting/ Structure mounting
6.0 Installation Indoor.
B. Constructional Features :-
1.0 Sheet steel
Thickness 2.0 mm for load bearing members.
1.6 mm for non load bearing members.
Material CRCA
2.0 Cable entry Incomer :- Bottom cable entry.
Outgoing :- Bottom cable entry.
3.0 Design Separate enclosed/isolated cable alley

(minimum 275mm wide) for each vertical.
Cable alley & module doors shall open

opposite to each other.
4.0 Interlocking & protection Module door interlocked with main power
isolating devices with defeat facility.
Power circuit isolation device to have pad

locking in the OFF position with door closed.
5.0 Operating height Minimum :- 300mm.or as per type tested

design conforming to IEC 61439
Maximum :- 2000 mm.

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Minimum 200mm vacant space shall be

provided throughout the panel at bottom.
6.0 Gland plate Undrilled removable bottom gland plates (3

mm thick).
7.0 Miscellaneous Neosprene rubber gasket shall be provided

for all the doors, removable covers &
between adjacent covers.
Lifting hooks for all the shipping sections.
Doors shall have concealed hinges.
8.0 Labelling Clear legible identification labels (anodized

aluminium with white letters engraved on
black background ) with letter sizes of:-
25-50 mm for MCC panel in front and back

side of the panel.
5 mm for components and module name

plates.
Danger board on front and rear sides in

English, Hindi & regional language.
9.0 Earthing Two separate earthing terminals shall be

provided.
Bolted joints with tooth spring washers for

good earth continuity.
Earth bus to run in all cable alley of the

panel.
10. Panel space heater In each panel with thermostat, DPMCB,

switch.
C. Busbars
(i) Main horizontal & vertical busbars
1.0 Arrangement Three phase & neutral. Bus Bar chamber on

the top.
2.0 Material High conductivity electrolytic aluminium

alloy confirming to grade E91E as per IS-

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5082 -1981.
3.0 Phase Busbar Rating Shall be able to carry continuously the

connected load (considering diversity factor)
plus a 25% margin. Minimum rating shall be
same as incomer ACB/MCCB rating.
Max. current density shall be:-
0.8 A/sq.mm for Aluminium.
1.5 A/sq.mm for Copper.
4.0 Neutral Busbar Rating 50% of phase busbar rating.
5.0 Short circuit rating 50 kA for 1 sec.
6.0 Busbar configuration Red-yellow-blue from front to back or top to

bottom or left to right as viewed from front.
7.0 Busbar insulation Heat shrinkable PVC.
R,Y,B coloured sleeves for phases.Black for

neutral.
8.0 Busbar supporting insulators Non-hygroscopic, Flame retarded.
Track resistant.
High strength.
Sheet moulded compound or equivalent

polysterfibre glass moulded type.
9.0 Max. temp. rise of bus Not to exceed 40 deg. C. above ambient of
50 deg.C.
10. Air clearance for bare busbar Phase to phase :- 25.4 mm (minimum)
Phase to earth :- 19.0 mm (minimum)
11.0 Joints and tap off points Busbar joints and tap off points shall be
shrouded and bolted ( with cadmium coated
bolts with plain and spring washers and
locknuts).
Bimetallic connectors for connection

between dissimilar metals.

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Anti oxide grease for all bus connections.
12.0 Neutral bus isolation Through disconnecting link.
13.0 Vertical busbar Rear side.
(ii) Earth bus
1.0 Material GI / Al.
2.0 Size Minimum 50 x 6 mm at bottom of panel with

extension at both ends.
(iii) Control bus
1.0 Material Copper. (Control Bus on top Busbar

chamber front side).
2.0 Size Minimum 25 x 3 mm or equivalent.
3.0 Segment Control bus shall be sectionalized and each

bus shall be fed from control trafo of
respective section. However selector switch
in one module shall be available to select
the feed of both sections of control bus from
either of control trafo also.
4.0 Selector Switch 25A, 4 position ( Trafo -1, Trafo -2,

Individual, OFF) and as described above.
D. Insulation level
1.0 Rated insulation voltage 1100 V.
2.0 Impulse withstand voltage 4 kV as per IS-13947 (Part I) 1993.
3.0 One minute power frequency 2.5 kV for power circuit & 500 V for control
withstand voltage circuit.
E. Pollution Degree
1.0 Pollution Degree Pollution Degree 3
As per IS-13947 (Part-1) : 1993;unless

otherwise stated
G. Feeder arrangement

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Incomer
1.0 Isolating Equipment 3 Pole MCCB upto 630A..
2.0 Quantity One incomer
3.0 Indication Lamps LED cluster type indicating lamps for:-
Incoming Power ON: R / Y / B.
MCCB-ON/OFF/TRIP
4.0 Meters and selector switches 96 sq.mm size voltmeter with 4 position
selector switches.Analog/Digital
96 sq.mm size ammeter with 4 position

selector switches.
5.0 Current transformer 3 numbers for metering.
H. Outgoing feeder arrangements
(i) Motor Starter feeders
1.0 Circuit breaker Three pole Motor protection MCCB or

MPCB (upto 45 KW).
2.0 Power contactor AC3/AC4, 3 pole, Minimum 25 A at AC-3

duty.
Contactor coil rating for 110 V AC, 2NO +

2NC auxiliary contacts.
Electrically & Mechanically interlocked for

reversible drives.
3.0 Auxiliary contactors Required nos. as per scheme.
4.0 Protection EOCR for all motor feeders
5.0 Control supply isolation device DP MCB
6.0 Test PB Inside module for testing of power

contactors when the module incoming
power breaker is OFF.
7.0 Space heater power provision For motor feeders of 45 KW and above:-

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Through separate DP MCB and interlock

with main power contactor.
8.0 Indication lamps (LED) ON/OFF/TRIP for DOL, F-ON/R-

ON/OFF/TRIP Open/Close/Open
Torque/Close Torque for valves etc. for
RDOL/Valve as applicable.
9.0 Selection of Power Components As per Type-2 co-ordination chart, however

minimum rating of Power Contactor shall be
25A
(ii) Power supply feeders
1.0 Circuit breaker 3 Pole with neutral link MCCB,

microprocessor based with LSIG release. In
case earth fault release is not available with
smaller rating MCCB, same shall be through
external CBCT.
2.0 Indications ON/OFF/TRIP indication lamp.
I. Panel wiring
1.0 Power / current transformer circuit 1.1kV grade single core, black colour PVC
insulated, stranded copper conductor of
minimum size 2.5 sq.mm.
2.0 Control and potential circuit 1.1kV grade single core., Black colour PVC
insulated.
Stranded copper conductor of minimum size

1.5 sq.mm.
3.0 Ferrules Numbered plastic/ceramic ferrules.
Self locking type.
Ferrule numbers of wires connected to

Terminal shall have same as TB number.
4.0 Marking Wiring shall be properly marked as per

relevant IS.
5.0 Spare contacts All spare contacts of relays, selector

switches & contactors shall be wired upto
the terminal block.

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Each components shall have at least one

potential free spare contacts.
6.0 Terminals Power & control terminals shall be

segregated by insulating material like
hylam/bakelite sheet.
Power terminals shall be stud type.
Control terminals shall be single tier, non-

breakable Clip On type suitable for
connecting two cores of 2.5 sq.mm wires.
Minimum 20% spare terminals shall be

provided.
The minimum rating of control terminal shall

be 10 Amps.
CT Terminals shall be disconnecting type

with shorting links.
Ferrule numbers shall be same as TB

Numbers.
7.0 Cable glands Double compression cable glands for

receiving external power and control cables.
J. Control Supply
1.0 Control transformer 1 number of 415V/110V control transformer
Secondary unearthed.
Control supply for each module shall be

through DP MCBs inside respective module.
Control supply ON lamps with earth fault
test PB to be provided.
2.0 Input and output side isolation device Input side :- MCCB/MPCB
Output side :- DP MCB
K. Space Heater Supply
1.0 Space Heater Power supply 240/110V AC power supply for Space
heater/panel illumination shall be arranged
by tapping from phase & neutral side of both

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incomers by providing MPCB at incomer

side, auto-change over arrangement, power
contactor, DP MCBs, thermostat etc.
IV. VARIABLE FREQUENCY DRIVE (VFD)
1.0 Basic design particulars - Digital control technology with flux vector
control/Direct torque drive (with / without PG as
per requirement).
- IGBT based with sine coded PWM control.
- VFD shall communicate to basic automation

system on system communication bus.
- Suitable for variable torque or constant torque

applications. Harmonic control shall be as
defined by IEEE 519-1992.
- VFD shall be provided with dynamic braking

system to avoid DC bus overvoltage during
sudden stoppages unless the application is of
very low inertia
2.0 Reference Standards - IEC 146
- IEC 61800- 2, IEC 61800- 3, IEC 61800- 5
- IEC 61508
3.0 Drive controller - Full closed loop flux vector control shall be
technology available for constant torque applications.
- Operating the drive with motor disconnected.
- Suitable for use on both Constant Torqueor

Variable Torque.
- Multiple programmable stop modes including -

Ramp, Coast, DC-Brake, Ramp-to-Hold and S-
curve.
- Multiple acceleration and deceleration rates.

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4.0 Type of connection - Three full wave diode/IGBT rectifiers supplied

by phase shifted, three phase AC/IGBT/IGCT
to provide a fixed DC voltage.
- DC bus inductor on all ratings
- DC link capacitors
- Insulated Gate Bipolar Transistor (IGBT) power

section, shall be rated for variable / constant
torque applications. The power section shall
use vector dispersal pulsewidth modulated
(PWM) IGBT gate control algorithm and soft
switching IGBT’s to reduce motor terminal
dv/dt and allow longer cable length from drive
to motor without output filters.
- Common control connection for all ratings.
5.0 Overload capacity - 150% of the rated current for 1 minute overload
for constant torque applications .
6.0 Efficiency More than 97% or better at full speed and full load.
7.0 Input power supply - As per design basis clause 1.04 to 1.07
8.0 Voltage variation - Voltage variation of (+/-) 0.1 % with an input

variation as per design basis clause 1.06.
- Steady state regulation of (+/-) 0.25%

guaranteed against 100 to 200 % load
disturbance and input supply frequency
variation as per design basis clause 1.06.
- The drive should be designed to operate on an

AC supply, which may contain line notching,
and up to 10% harmonic distortion.
9 Environmental Conditions
9.1 Storage ambient Upto to 70º C.

temperature range
9.2 Enclosure class - IP42 & above

Operating ambient
temperature range - 0º C to 50º C

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9.3 Relative humidity Upto97% non-condensing.
9.4 Operating elevation Up to 1000 Meters (3,300ft) without derating.
9.5 Shock As per IEC 61800
9.6 Vibrations As per IEC 61800
10 Reference
10.1 Input reference voltage 0 +/- 10 V DC / 0 – 10 V DC / 4 – 20 mA .
10.2 Reference signals The drive should be capable of the following speed
reference signals
Digital MOP
Jog
HMI (Program/Control panel)
Analog Input signals
Preset Speeds
Communication module commands
10.3 Loss of reference The drive should be capable of sensing the

reference loss conditions .
In the event of loss of an analog input reference

signal, the drive should be user programmable to
the following
Fault the drive
Alarm and maintain last reference
Alarm and go to preset speed
Alarm and go to minimum speed
Alarm and go to maximum speed
Alarm and maintain last output frequency
Signal loss detection should be available

regardless of the function of the analog input.

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11 Output
11.1 Output voltage From 0 to rated motor voltage.
11.2 Output frequency 0.5 - 400 Hz.
11.3 Output Waveform The inverter section should produce a pulse width
modulated (PWM) waveform using latest
generation IGBT/IGCTs.
11.4 Output frequency 0.01 Hz.

resolution
12.0 Reflected wave Maximum of 2.25 times the bus voltage or 1600V,
whichever is less, up to cable lengths of 200
metres.
13.0 Starting torque 150 % / 1 Hz. (without PG)
150 % / 0 RPM (with PG)
14.0 Torque accuracy + / - 5 %.
15.0 Speed control accuracy + / - 0.02 %, 0.1% without encoder.
IR compensation to be provided for drive without

PG.
16.0 Ramp rate - Linear acceleration and deceleration adjustable

independently from 0 to 3600 seconds.
- Provision of remotely selectable Accel / Decel

settings should be accessible through digital
inputs also.
17.0 Main power components - ACB / MCCB with 50 KA rating. ACB to be

in incoming AC side considered in case rating is more than 630A.
MCCB to be considered in case rating is 630A
or less.
- Matching input isolation transformer/ line

reactor for harmonic and noise suppression.
For input isolation transformer, the K factor
shall be 4.0 or less.
- AC line surge suppression network.

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- Input contactor.
18.0 Converter –Inverter - Diode / IGBT bridge for AC/DC.

Equipment
- DC link circuit with reactor/capacitor.
- IGBT bridge for Inverter for DC/AC.
- Input isolation transformer / line reactor.
- Input harmonic filter.
- Main PLC to take care of interlocking and

sequencing etc.
19.0 Load side components - Filter network ( du/dt filter or sine filter or Line
reactor based on the requirement).
- Over-load relay for each motor (in case of

group drive).
- Line contactors in input &output side (as per

application requirement.
- Output reactor / terminator (if required).
20.0 Terminal blocks - Separate for control and power wiring.
- Power terminal blocks marked for both inputs

and outputs .
- Ferrule numbers of control wires shall be same

as TB numbers
- 20% spare terminals shall be provided
21.0 By-pass Arrangement DOL By-pass arrangement with selector

switchshall be provided for drives of 415 V motors
where normal operation is possible on rated
frequency of 50 Hz or speed control is not a
process requirement.
22.0 Input / Outputs - Hard-Wired I/O
 Hardwired I/O should be provided via

separate I/O cards
- Standard I/O Card

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 The “Standard I/O board should consist of

both digital and analog I/O. It should be
available in two versions; one for 115/240
VAC digital I/O and one for 24V AC/DC
digital I/O.
- Analog I/O
 Differentially isolated 10V (bi-polar) / 4-

20Ma analog inputs .
- Digital Outputs
 Relay outputs – Minimum 02 nos.
 Contact output ratings should be 240V AC /

24V DC,Maximum 2.0 Amp
23.0 Protective features - AC line surge suppression network and over

voltage protection.
- Under voltage in supply network.
- Phase sequence protection and monitoring.
- Under voltage in DC bus.
- Over voltage in DC bus.
- Over speed protection in the event that the

output frequency exceeds the maximum
reference by a specified amount.
- Over load
- Earth fault
- Instantaneous over current
- Transformer fault ,If applicable
- Cooling fan failure
- Stall monitor for motor alarms
- Controlled shut down, when properly fused,

with no component failure in the event of an
output phase to phase or phase to ground

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VIJAYNAGAR WORKS
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short circuit and annunciation of the fault

condition.
24.0 Annunciations All type of faults shall be annunciated in Control

Panel of the drive which shall be provided and
mounted on Panel front door.
The faults listed below shall be displayed as far

possible.
- AC line surge suppression network and

overvoltage protection .
- Under voltage in supply network
- Phase sequence protection and monitoring
- Under voltage in DC bus
- Over voltage in DC bus
- Over speed monitor
- Over load
- Earth fault
- Instantaneous over current
- Transformer fault ,If applicable
- Cooling fan failure – Stall monitor for motor

alarms
- Motor fault (winding / bearing temperature,

vibration) as applicable
- Loss of frequency command
- Shall be able to store at least 16 previous

faults in memory on FIFO sequence .
25.0 Meters - Input Volt meter with selector switches shall be

provided and mounted on Panel door.
Separate meters with SS shall be provided for

following incase it is not available with control
panel of VFD

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VIJAYNAGAR WORKS
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- Input current
- Output voltage & Current
- Output frequency (digital display)
- KW meter for drive ratings above 200 KW.
26 Other features
26.1 Bus Regulation DC Bus regulation should be available to reduce

the possibility of drive overvoltage trips due to
regenerative conditions.
26.2 Current Limit Programmable current limit from 1 amps to 150%

of drive rated amps. Current limit to be active for
all drive states; accelerating, constant speed and
decelerating.
26.3 Dynamic Braking The drive shall have an internal, built in 7th IGBT
for use as a dynamic braking chopper. This IGBT
shall have enough capacity to handle greater than
or equal to 100% regeneration power from the
output, continuously. The drive shall also have a
“drive mounted” dynamic braking resistor for low
level braking applications and interactive software
to protect the “internally” mounted resistor from
abuse.
27.0 Selector switches Numbers of selector switches shall be provided as

per control requirement during design stage
considering control philosophy.
All the selector switches shall be of 10 A rating .
28.0 Pushbuttons - Trip reset .
- Start if required as per control philosophy
- Emergency stop.
29.0 Lamps Following minimum indication lamps shall be

provided
- R, Y, B phase power ON
- Drive ready.

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VIJAYNAGAR WORKS
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- Drive trip .
- Drive/Motor Run, OFF.
- Control supply ON .
All the lamps shall be of cluster LED type
30.0 Regulation & control - Reference speed setter

facilities
- Ramp generator
- Speed feed back
- Current feed back
- Trigger module
- Pulse transformers
- Logic control module
- Sequence module
- PID control
- Zero speed/ over speed monitor as applicable.
- Momentary power loss restart.
- Auto tuning.
- Current limiter.
- Skip Frequency.
- Counter current/ regenerative braking unit as

applicable.
- Active electronic components used shall be of

industrial grade hermetically sealed.
- Output signals for fault alarm, frequency

arrival, running signal.
31.0 Communication Bus ModBus/ProfiBus-DP/DeviceNet/Ethernet/ Profinet
32.0 Operator panel Shall be mounted on the front door of the unit.

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VIJAYNAGAR WORKS
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- All adjustments to be made with the door

closed.
- Status and Power LEDs viewable through the

cover.
33.0 Membrane keypad - The keypad shall be logically designed for two
operating areas with required number of keys.
- Local operator control like
- local start /stop,
- jog forward / reverse.
- Programming.
34.0 LCD display - Display shall be black lighted, enabling viewing

in extremes of lighting conditions
- Display shall be in alphanumeric (in English

only)
- All the faults stored in memory shall be

displayed by scrolling .
35.0 Construction features - Floor mounted, free standing
- Dust and vermin proof
- Sheet steel clad
- Minimum 2.0 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.

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VIJAYNAGAR WORKS
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36.0 Ventilation - 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.
Resistance boxes shall be floor mounted and shall be preferrably placed on the floor near the
respective MCC/VFD Drive.
V. Brakes
In general, the brakes shall be of heavy duty, DC electro-magnetic type of robust

design and suitable for 220V DC operating coils. These shall be of two shoe, self
aligning, quick acting type with self-lubricating robust bearings and complete with
brake mechanism, brake wheel, shoes, armature/solenoid etc. The brake wheel
shall be of high strength material to prevent flake off the wheel.
The brake mechanism shall be provided with suitable means for adjustment of
residual magnetic gap, brake torque, shoe positioning and shoe adjustment. The
shoe linings shall be made from tough heat resistant material with fixing rivets
adequately counter-sunk to prevent rubbing against the brake wheel.
Alternatively, shoe linings shall be glued with epoxy based fixing compound
having adequate adhesive strength.
The operating coils shall be epoxy filled class ‘F’ insulated and encapsulated in
sheet steel housing for complete environmental protection. The operating coils
shall be terminated to terminal box having enclosure protection of IP65.
VI. Brake rectifier control panel
Power supply (415V AC) to the brake rectifier panel shall be tapped from the
respective motor terminal box. Suitable gland with the motor terminal box shall be
provided for taping the power supply. The brake rectifier panel shall be installed
at field. One number MCB suitable for 50kA fault level shall be provided at the
incoming side of the brake rectifier panel. The panel shall be wired using 4
sq.mm flexible copper conductor. Further, the brake & brake rectifier panel shall
conform to the following:
- DC Electro-magnet type suitable for 220V DC. Necessary transformer
rectifier (selenium bridge rectifier) shall be provided inside the control
panel.

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VIJAYNAGAR WORKS
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- The control panel shall house necessary timers, power contactors,

auxiliary contactors, HRC fuses, indicating lamps, economy resistors,
terminals etc. Economy resistors shall be provided in separate chamber of
the panels and shall be suitable for continuous duty. The enclosure class
of the compartment housing contactors and control equipment shall be IP-
54.
- The panels shall be self-standing, floor mounting and front attended and
fabricated from 2mm CRCA sheet steel with base channel of ISMC 75.
The panels shall be provided with suitable canopy.
VII. Safety Switches
a. Belt Sway Switches

The belt sway switch shall be industrial, heavy-duty type, housed in a dust and
vermin proof cast aluminium /cast iron box. The degree of protection of the
switches shall be minimum IP65. The belt sway switch shall be provided with
indirect acting mechanism such that the belt conveyor does not come in direct
contact with the switches. The operating mechanism shall have a strong reset
spring to absorb high impact of the loaded belt edge which could be as high as
500 kg or more. Further, the belt sway switches shall also be provided with
following facilities/requirements:
a) Switch element with 2NO + 2NC contacts.

b) Action: Self reset type
c) Suitable for ambient temperature 50 deg.C.
d) Resetting sprig mechanism located in a separate built-in housing for easy
replacement at site without disturbing setting.
e) Built-in terminal box incorporating terminal block of required number of
terminals for cable termination (2.5 sq.mm core) and looping at site between
BSS for achieving 2 NO + 2 NC final output contacts with external connection
terminals.
f) Separate cover for terminal box to carryout wiring without opening the main
body cover.
g) The actuating roller provide with stainless steel sleeve.
h) The roller shaft and camshaft to be held in pre lubricated sealed ball bearings.
i) Suitable for mounting in either horizontal or vertical position as required.
j) The design should permit over travel of the operating handle. The
arrangement should ensure that the over travel does not impose additional
mechanical force on the switch element but goes totally absorbed by the reset
spring.
k) Belt sway switch mounting bracket shall be supplied with each switch.

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VIJAYNAGAR WORKS
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b. Pull Chord Switches

The pull cord switches shall be of industrial, heavy duty type enclosed in a dust
and vermin-proof cast iron/cast aluminium box. The degree of protection for the
enclosure shall be IP-65. Further, the pull cord switches shall also be provided
with following facilities/requirements:
a) Switch element with 2 NO + 2 NC contacts
b) Automatic locking arrangement in the operated position and with manually

reset type. The pull cord switch should be capable of getting actuated by a
pulling force around 2.5/3.5 kg.
c) Snap action type for positive operation of contacts.
d) Number of operating position : 1-0-1
e) Provided with separate compartment with cover for built on terminal box
allowing easy termination and looping of cables, (2.5 sq.mm core) between
PCS to PCS for achieving final 2 NO + 2 NC contacts with external connection
terminals without exposing the interior of the switch mechanism.
f) Pull cord wire shall be stranded galvanised steel wire with at least one/two
mm thick PVC cover and having overall diameter 6 to 7 mm. To avoid
preloading and to reduce slackness, the rope shall be supported on hooks
placed at intervals of one meter with first hook one each side at a distance of
about half meter from the switch.
g) Suitable facility shall be provided to identify the particular switch that has been
operated.
l) Pull cord switch mounting bracket shall be supplied with each switch.
c. Zero Speed Switch

Electronic speed switches shall be industrial grade, electronic type with inductive
proximity switch sensor and shall be suitable for 110 AC supply.
Two numbers of speed switches shall be provided with each conveyor. Both
switches shall be installed at tail end/Snub pulleyhowever second switch will act
as standby for the first ZSS.
The unit shall be complete with sensing probes, monitoring unit and
interconnecting special cables between the sensing probes and the monitoring
unit/cabinet. The unit shall work smoothly and trouble free in dusty and corrosive
atmosphere and where lot of unusual vibration shall be present. The sensing
probes diameter shall be minimum 60 mm providing sensing gap of minimum 40
mm.
The unit shall be of multi speed range with setting facilitywith actual speed
display, and shall be provided with output contacts (2 NO + 2 NC), with facility

(JVML)
VIJAYNAGAR WORKS
FOR NEW SMS
for initial by pass adjustable time delay and nuisance tripping delay along with
power supply on LED.
The sensing probe shall be provided with metallic enclosure conforming to IP-67
grade of protection. LED shall be provided for visual indication of correct
functioning of sensing probe.
The monitoring unit shall be structure mounting, and shall have special metallic
enclosure to render the unit suitable for IP-65 grade of protection. The monitoring
unit shall be complete with all components including setting knobs for step less
setting of speed and time and zero setting error, LED lamps for supply and relay
status etc.
VIII. Limit switches
Limit switches as required shall be supplied along with technological/mechanical

equipment for interlocking & control of equipment.
Limit switches for electromechanical sensor shall be suitable for heavy duty, high
impact operation with robust construction and capable of withstanding repetitive
operations. The contacts making and breaking arrangements shall be reliable and
having high mechanical endurance. Number of making and breaking contacts
shall be as per requirement with minimum 2NO+2NC contacts adequately rated
for handling the inductive currents in the circuit. The limit switches shall be
housed in cast metal-clad of robust construction having dust and oil tight
enclosure conforming to IP 65.
The roller shall be made of high grade, wear resistant material with provision for
roller lever to be mounted in steps of 90 deg. Precision limit switches, where
adopted, shall be designed for reliable accurate operation having exceptionally
long life.
Over travel limit switches for moving tripper shall be provided. These shall be
heavy duty, roller lever operated.
IX. JUNCTION BOX

Junction boxes shall be provided by JSW. However JBs if any required for
brake panel are to be included by tenderer in his scope.
Junction boxes (fixed & moving) shall be made up sheet steel of minimum 2 mm thick. It
shall be suitable for wall/structure mounting dust and vermin proof with IP-54 enclosure
class. It shall house suitable numbers of terminals. The door shall be hinged type with
facility to remove the door. The junction boxes shall be adequately sized for termination
of armoured control cables. Removable undrilled cable gland plate shall be provided on
bottom.

(JVML)
VIJAYNAGAR WORKS
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Bidder shall include additionally 10% of all safety switches (Pull cord switches,
Beltsway switches, limit switches, pull cord wire) as 2-years operating spares.
07 DRAWINGS & DOCUMENTS
07.01 Drawings and documents to be furnished along with the Tender
 List of deviations/ exclusions from the technical specification.

 List of Interfacing signal for Tripper
 VFD size / rating for Vibro feeder
07.02 Drawings/ documents to be furnished for approval of Purchaser/ MECON by the

Successful Tenderer
 Sizing calculation for VFD drive selection

 Technical data sheets for LT motors, GA of Motor & TB, Characteristic curves
 SLD, GA & Technical data sheets for VFD drive for Vibro Feeder
 Technical data sheets for load cells, tacho generator etc.
 Catalogue of microprocessor based intelligent weighing controller (IWC).
 GA, wiring diagram, bill of materials for all control panels.
 Individual cable schedules for each Belt Weigh scale including power, control and
special cables. Terminal plans for all items like Belt Weigh scale panels, IWCs, local
control stations, field JBs etc.
 SLD & Control schematic of Tripper, GA Drawing of Control Panel,
 Drawing of CRD, Trailing cable sizing and cable data sheet.
 List of signal for interfacing.
 Cable Schedule for Tripper
07.03 Drawings/ documents to be furnished for reference
 Operation and maintenance manuals, catalogues, calibration procedures, test

certificates, inspection certificates/ reports.
 Interconnections/ external connection diagrams.

(JVML)
VIJAYNAGAR WORKS
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ANNEXURE-II
Sheet 1 of 1
Format for deviations from Tender Document
Sl. Clause No. Tenderer’s Amount of variation Reason for

No. Deviations (+/-) to retain the Deviation
tender conditions
The Tenderer hereby certifies that the above mentioned are the only deviations from the
tender documents.
Signature :
Name :
Designation :
Company Seal

(JVML)
VIJAYNAGAR WORKS
FOR NEW SMS
ANNEXURE - III
AMENDMENT SHEET
Sl. No. Amendment No/ Sheet No. Letter Ref. No. & Date

(JVML)
VIJAYNAGAR WORKS
FOR NEW SMS
ANNEXURE – IV
MAKE OF BOUGHT OUT ITEMS
The preferred makes of JVML for the equipment mentioned shall be adhered to by the Tenderers. In
case of any deviation/ addition, the Tenderer/ contractor shall obtain the prior approval of the Purchaser
in writing. “Equivalent” make if any offered by the Tenderer/ contractor shall not be acceptable.
Motor : ABB / SIEMENS
SIEMENS FLENDER / SEW

Geared Motor :
(Hollow shaft with bake)
SIEMENS FLENDER / SEW
Gear Box :
(Bevel Helical Gear Box)
VOITH / SIEMENS FLENDER
Fluid Couplings :
(Constant fill with delay chamber)
Geared Couplings : FENNER / WELLMAN
SKF / FAG/ TIMKEN

Bearings & sleeves for Pulleys :
(Adapter sleeve type)
SKF / FAG
Bearings for Idlers : (Deep Groove Ball Bearing seized resistance)
6305ZZ C3 / 6306ZZ C3
ORIENTAL RUBBER / PHOENIX YULE/
Conveyor Belting :
CONTINENTAL
Scraper (Internal) : MARTIN / THEJO
Scraper (External) MARTIN / THEJO
SKF/MASTA/NTN/FAG
Plummer Block : ABOVE 140MM DIA- CAST STEEL
BELOW 140 MM DIA- CAST IRON
ELECTRICS
Zero Speed Controller, Sensor,

Pepperl+Fuchs/IFM/Turck
Connector
Zero Speed Switch Controller
Rittal/BCH
Encloser

(JVML)
VIJAYNAGAR WORKS
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Pull cord switches Schmersal/Pepperl+Fuchs/Allen Bradley
Belt sway Switches Schmersal/Pepperl+Fuchs/Allen Bradley
Heavy duty Limit Switches for

Jaibalaji/AG systems
shuttle conveyor end limit.
Heavy duty duty limit switches
Jaibalaji/BCH
for DG
Medium duty limit switches for
Jaibalaji/BCH
Belt Rupture Device (BRD)
Lightning Arrestors Any Standard make
Break rectifier Control panel BCH
Control Panel Siemens, ABB, L&T
VFD Siemens, ABB, L&T

(JVML)
VIJAYNAGAR WORKS
FOR NEW SMS
ANNEXURE IV
PERFORMANCE TESTS AND GUARANTEE
The successful tenderer shall perform the performance guarantee tests for the capacity of the
system for which it is designed.
After erection and commissioning of equipment, performance tests shall be carried out to
prove the performance of the system and equipment. These tests shall be binding on both the
parties of the contract to determine compliance of the designed equipment /system with the
performance guarantee.
If the successful tenderer fails to achieve the guarantee and performance parameters, he shall
investigate the causes and shall rectify and/or replace, free of cost to JSW the defects of the
equipment/system within a period of 1 (one) month from the date of commencement of
performance and guarantee tests and again prove the guarantees. In such cases, the cost of
modifications including labour, materials, and cost of additional testing etc. shall be borne by
successful tenderer.
Sl.No. Description Performance guarantee Remarks

A MECHANICAL
1 Conveyor Belt JSW Scope
2 Carrying Idlers with frame 48 months for bearings
3 Return idlers with frame 48 months for bearings
4 Transition idler c/w Bracket 48 months for bearings
5 Impact idler c/w bracket 48 months for bearings

Drive Pulley c/w Plummer block &
6 24 months In all respect
Bearing
Non Drive Pulley c/w Plummer
7 24 months In all respect
block and Bearing

(JVML)
VIJAYNAGAR WORKS
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8 Drive Base Frame Should With stand the load
9 Drive and Non Drive Pulley Frames Should With stand the load
Take up arrangement (VGTU,
10 Should With stand the load
Screw) excluding counterweights
No spillage from hood &

Discharge Hood & Discharge Chute From Date of
11 chute due to wear out of
with Liner operation
liners for 6 months.
No spillage from hood &
Interconnecting Chute & Coupling From Date of
12 chute due to wear out of
Guards operation
liners for 6 months.
No carry back
13 Internal V plough Belt Cleaner 24 months due to wear of
blades
No carry back
14 External scrapper 24 months due to wear of

blades
Skirt Board Assembly with Liner
15
Plate & Seals
From Date of
16 Deck Sheet & Seal Plate 24 months
operation
17 Motor & Gear Box
18 High Speed & Low Speed Coupling

Stringer Frame & Short Post with
19 Should With stand the load
fasteners
20 Rain Hoods
21 Machine Guards
22 Shuttle Carriage , drive, wheels etc 24 months
B ELECTRICS, CONTROL & INSTRUMENTATION

(JVML)
VIJAYNAGAR WORKS
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Conveyor Safety switches (Zero

Speed, Belt Sway, Pull cord, Limit
1 switch, Belt rupture device Limit

switch) with 2 years’ operating From Date of
24 months
spares as listed in datasheet operation
2 Conveyor & Shuttle Drive Motors

Festoon Trolleys with Flexible
3
Festoon Cables
For each equipment, the load test shall be conducted in stages. The equipment shall be run
for 8 to 10 hours continuously at no load, 25%, 50%, 75%, 100% of the rated capacities or
at rate mutually agreed upon between successful tenderer and JSW. The intervening period
shall be available for making adjustments and arrangements by the Contractor as may be
required.
All the specified speeds of the equipment shall be measured under full load conditions.
Proper operation of all positional limit switches for shuttle conveyor and all safety switches,
limit switches/ alarm for conveyors like pull cord switch, zero speed switch, belt sway switch
etc. shall be demonstrated by the successful tenderer in the presence of JSW site engineers.
During operations of the equipment at no load and at full load, performance of all the drives
shall be checked in respect of current drawn by the motors, temperature rise, vibrations, gear
box noise and its heating, bearing heating etc. consumption of power and various consumption
like lubricants etc. shall also be measured and compared with the respective rated values.
The equipment shall be considered to have performed satisfactorily when

i) Rated capacity of equipment is demonstrated with all its drives and accessories
functioning properly over a minimum period of eight (8) hours.
ii) It runs successfully for a continuous period of minimum 30 days at the rated capacity.
iii) Successful reversing of reversible shuttle conveyors on load.

(JVML)
VIJAYNAGAR WORKS
FOR NEW SMS
Performance guarantee values and penalty for non-fulfillment of the same shall be as follows:
Performance Guarantee Value,
Sl. No Description
tph
1. Conveyors Rated capacity in t/hr
The following basic performance parameter tests shall be concluded:

d) All equipment shall operate at rated capacity without undue vibration and undue
noise etc.
e) Measurement of noise and vibration levels.
f) Measurement of power consumption of various drive motors while

operating at performance guarantees levels.
g) Continuous run system performance test. All other parameters of the
equipment or system indicated in the specification.
DELIVERY SCHEDULE
 Drawings for approval within 1 month from LOI
 Delivery of equipment’s progressively form 3rd month.
 Complete delivery should be completed within 4.5 month only.
Sl.
Description Start week End week
No
Detail engineering & submission of
1 0 2
drawings
2 GA drawing approval 3 3
3 Delivery at site 10 18
Erection
4 13 25
(JSW scope)
5 Commissioning (JSW scope) 26 27
LD for Delivery

(JVML)
VIJAYNAGAR WORKS
FOR NEW SMS
In case of delay in supply of material beyond the contractual completion time due to reasons
attributable to the supplier, LD shall be applicable at 0.5% per week subject to a maximum o0f
XX% of contract price.
However maximum LD percentage shall be decided by commercial department.
Supervision
Supervision man days during installation and commissioning required at JSW site at free of
cost
Electrical engineer: 20 man-days
Mechanical engineer: 40 man-days
Up-Time Guarantee of Belt Conveyors of at JSW Vijayanagar Works
BELT CONVEYORS UPTIME AVAILABILITY DEFINITION
1) Definitions
Year - Year in this paragraph shall mean 365calendar days; from the commissioning date.
Belt Conveyors–Belt Conveyors in this paragraph shall mean any one or more of the Belt
Conveyors Equipment including mechanical and electrical delivered by vendor to JSW
under this contract.
Availability of Belt Conveyors -Availability of Belt Conveyors in this paragraph shall mean
the percent of availability of Belt Conveyors as calculated below.
Failure of Belt Conveyors -Failure of Belt Conveyors in this paragraph shall mean that the
Belt Conveyors is not able to fulfill the specified performance because of any reason
attributable to seller due to faulty design of Equipment, used materials for Belt Conveyors or
bad workmanship in manufacturing, which would prevent electrical or mechanical
functioning of Belt Conveyors in accordance with the specifications.
Downtime of Belt Conveyors -Downtime of Belt Conveyors in this paragraph shall mean the
total time in which the Belt Conveyors is not available for production due to Failure of Belt
Conveyors Equipment.
Regular Production Regular Production in this paragraph shall mean that JSW production
process in the plant proceeds in a smooth and stable manner and that normal production
conditions have been reached.

(JVML)
VIJAYNAGAR WORKS
FOR NEW SMS
Downtime Days of Belt Conveyors -Downtime Days of Belt Conveyors in this paragraph
shall mean the amount of days per Year when the Belt Conveyors is not available for
production due to Failure of Belt Conveyors (Only Equipment supplied by Vendor)
2) Availability guarantee for delivered Belt Conveyors
Based on the following terms and conditions of this paragraph, vendor guarantees to JSW
the availability of Belt Conveyors (Equipment in Vendor scope) shall not be less than 90%
per Year.
Availability guarantee period
The availability guarantee period shall start immediately after the Belt Conveyors is
commissioned to the satisfaction of vendor and JSW.
The availability guarantee period shall end on the date the warranty period ends.
Calculation of Availability of Belt Conveyors.

Availability of Belt Conveyors for one Year is calculated as follows:
No. of days available

Availability of Belt Conveyors = -------------------------------------------x100
350
The guaranteed availability shall be calculated as the average of all individual Availability of
Belt Conveyors in this contract. Only full days, meaning more than 16 consecutive hours of
downtime, shall be counted as Downtime Days of Belt Conveyors. Downtime of Belt
Conveyors less than 16 consecutive hours shall not be calculated as Downtime Days of
Belt Conveyors.
In case a Belt Conveyors is not available for production due to Failure of Belt Conveyors
Equipment, JSW operations management has to inform vendor service crew within 1 hour
after the system is out of operation due to Failure of Equipment. JSW operations
management and vendor service personnel shall inspect the System and fill a report stating
the time of breakdown and the probable cause for breakdown. After the System/Equipment
is repaired, the time when the Belt Conveyors is available for operation and the definite
cause of breakdown shall be added to such report. Both parties shall have a copy of such
report. Based on these reports JSW and vendor will mutually agree on the Downtime Days
of Belt Conveyors for the purpose of calculating Availability of Belt Conveyors.
3) Conditions of Availability Guarantee
General conditions as stated above in this paragraph.

(JVML)
VIJAYNAGAR WORKS
FOR NEW SMS
The Belt Conveyors Equipment are used by JSW personnel or subcontractor / nominated
agency person in accordance with the specified technical capabilities of the Belt Conveyors
Equipment (duty classes, lifting capacities, maintenance schedule etc.)
The Belt Conveyors Equipment are used by JSW personnel in accordance with vendor’s
operator’s manual, the given instructions and training and using spares provided by the
vendor.
Required scheduled time for preventive maintenance will be decided as per O & M Manual.
Required daily, weekly, inspections per O & M manual shall be performed by JSW
personnel. During inspections, an inspection log must document all items required from
O&M manual. JSW must inform vendor within 1 hour of any item that does not pass
inspection criteria established in O&M manual.
Inspections will be used to define timeline for preventive maintenance items such as wear
items; Idlers, Couplings, Gearbox internals etc.
JSW to stock and carry spare parts as outlined in O&M manual. Spares parts and wear
parts shall be procured by recommended vendor.
When Belt Conveyors Equipment fails and Downtime starts, vendor personnel will be
informed within 1 hour after Failure of Belt Conveyors.
The ambient conditions (temperature, humidity, etc.) and power supply where the Belt
Conveyors Equipment are used shall be in accordance with the Belt Conveyors Equipment
specification in this contract.
In case that the above-mentioned conditions are not met, this availability guarantee shall
not apply.
The following cases are not to be regarded as Downtime of Belt Conveyors:
JSW shall grant free access within one hour after the breakdown to vendor service
personnel for carrying out repair works. When the access is hindered or delayed, such time
of delay shall be not counted as Downtime of Belt Conveyors.
Non-availability of Belt Conveyors due to power or network failures or excessive

fluctuations shall not be calculated as downtime. Also, the possible resulting repair of
damages due to such failures shall not be regarded as Downtime of Belt Conveyors.
Scheduled maintenance and repair works shall be not calculated as Downtime of Belt
Conveyors as specified in O &M Manual.

(JVML)
VIJAYNAGAR WORKS
FOR NEW SMS
Non-availability of Belt Conveyors due to repair works, modifications and changes on the
Belt Conveyors Equipment and delivered equipment not carried out by vendor personnel
shall not be calculated as Downtime of Belt Conveyors. Also, the possible resulting
damages or repair of such damages due to such repairs works, modifications and changes
on the Belt Conveyors and delivered equipment not carried out by vendor personnel shall
not be regarded as Downtime of Belt Conveyors.
Non-availability of Belt Conveyors due to misuse or abuse of Belt Conveyors or when Belt
Conveyors Equipment are not used according to the operating instructions and Owner’s
Manuals provided by vendor.
A daily detailed maintenance log, inspection log and Process data log must be provided by
JSW to Vendor on a weekly basis. Incase log is not maintained for a particular day, that day
shall be excluded for the calculation of uptime availability.
Uptime liquidated Damages Calculations:
Uptime % of Belt Conveyors 95 94 93 92 91 90
Penalty % for Downtime 0 0.5 1 1.5 2 2.5
SCOPE MATRIX
O- OWNER , B- BIDDER , BE – BASIC ENGG , DE- DETAIL ENGG , S- SUPPLY , C- CIVIL ,
SF- SITE FABRICATION, E- ERECTION , SS – SITE SUPERVISION
Sl.No. Description BE DE S C SF E SS
A MECHANICAL
1 Conveyor Belt O O O − − O O
2 Carrying Idlers with frame B B B − − O O
3 Return idlers with frame B B B − − O O
4 Transition idler c/w Bracket B B B − − O O
5 Impact idler c/w bracket B B B − − O O
6 Drive Pulley c/w Plummer block & Bearing B B B − − O O
7 Non Drive Pulley c/w Plummer block &Bearing B B B − − O O
8 Drive Base Frame B B B − − O O
9 Drive and Non Drive Pulley Frames B B B − − O O
Take up arrangement (VGTU, Screw) excluding

10 B B B − − O O
counterweights
11 Discharge Hood & Discharge Chute with Liner B B B − − O O
12 Interconnecting Chute & Coupling Guards B B B − − O O
13 Internal V plough Belt Cleaner B B B − − O O
14 External scrapper B B B − − O O

(JVML)
VIJAYNAGAR WORKS
FOR NEW SMS
15 Skirt Board Assembly with Liner Plate & Seals B B B − − O O

16 Deck Sheet & Seal Plate B O O − − O O
17 Motor & Gear Box B B B − − O O
18 High Speed & Low Speed Coupling B B B − − O O
19 Stringer Frame & Short Post with fasteners B B B − − O O
20 Walkway B O O − − O O
21 Electric & Manual Hoist B O O − − O O
22 Belt Vulcanizing Machine B O O − − O O
23 Commissioning spares B B B − − O O
24 PTFE Bearings O O O - - O O
25 Rain Hoods B B B − − O O
26 Machine Guards B B B − − O O
26 Shuttle Carriage , drive, wheels etc B B B − − O O
27 Rail for Shuttle Carriage travel B O O − − O O
B ELECTRICS, CONTROL & INSTRUMENTATION B
Conveyor Safety switches (Zero Speed, Belt Sway, Pull
1 cord, Limit switch, Belt rupture device Limit switch) as B B B − − O O
listed in datasheet
2 Conveyor & Shuttle Drive Motors B B B − − O O
3 Festoon Trolleys with Flexible Festoon Cables B B B − − O O

KEY PLAN
VIEW B-B VIEW A-A

REV. SHUTTLE
CONVEYOR CHUTES TO LD CONVERTER SEE DWG.
700 t/h, 350 m3 /h C.YL1T.SL.14-G/EIZ420
BUNKER SYSTEM SEE DWG. ARGT. ELEVATED BINS - CONV. 1
b = 1000 mm, l ~ 34 m
C.YL1T.SL.14-G/EIZ410 SEE DWG. C.YL1T.SL.153-G/EIZ470
travel length ~ 30 m
+ 62300
PHASE 2
59500
REV. CONVEYOR
300 t/h, 150 m3 /h
02/ 06
04 05 08/ 12
01
03 07 b = 650 mm, + 50000
09
l ~ 78 m
REV. SHUTTLE INCLINED BELT
REV. SHUTTLE + 45800 10/ 01
02/
04 05 06 07 08/ 10/ 12 CONVEYOR CONVEYOR
03
11 09 11 300 t/h, 150 m3 /h
CONVEYOR 300 t/h, 150 m3 /h
300 t/h, 150 m3 /h b = 650 mm, l ~ 7 m b = 650 mm, l ~ 292 m
D C
b = 650 mm, l ~ 7 m travel length ~ 6.5 m h ~ 18 m
travel length ~ 6.5 m
+ 38400
+ 36100
+ 36100 K
+ 32800 C + 32800
ARGT. ELEVATED BINS - CONV. 2 D +31229
SEE DWG. C.YL1T.SL.153.-G/EIZ471

+ 27389
14
+ 22600
+ 24200 + 24200
14
8250 + 22600
INCLINED REV. BELT + 21400 APPROX. 8250 4700 + 21400
CONVEYOR
300 t/h, 240 m3 /h +19008
b = 800 mm, l ~ 20 m
h~4m
ARGT. CHUTES TO LADLE - CONV. 1/2

SEE DWG. C.YL1T.SL.154.-G/EIZ475 INCL. REV. BELT
CONVEYOR
300 t/h, 240 m3 /h
b = 800 mm, l ~ 39 m
h~5m
16000 14000
.00 CONTAINER FOR

DRI EMERGENCY MISPLACED
DRI EMERGENCY FPB435
CONTAINER FOR DISCHARGE PIT MATERIAL 3000
DISCHARGE PIT
MISPLACED MATERIAL 15000 30000 30000 15000 15000 15000 15000 15000 15000 15000 15000 6000 5000 ELEVATION OF CONVEYOR FAC1 & C2 ELEVATION OF CONVEYOR BOFC1 & C2
15 10 9 8 8' 7 6 4 1'
14 12 5 3 2 1
9
122
+3
15 14 12 10 9 8 8' 7 6 5 4 3 2 1 1'
VIEW A - A
TYPICAL GALLERY CROSS SECTION
9
122
+3
VIEW B - B
TYPICAL GALLERY CROSS SECTION
C'
1 1'
16000
8000
B
8500 SECTION C-C
6000 D SECTION D-D

4417
MIN. 1000
C 1.500
0.000 0.000 0.000

GRATING
60 TONNE DRI
(EFFECTIVE CAPACITY)
RAMP GRATING
60 TONNE DRI
(EFFECTIVE CAPACITY)
10 THK SAILHARD LINER

CONICAL PORTION -1700 2 1
10 THK SAILHARD LINER
CONICAL PORTION -1700
D B
-4400
-4400
C B A
A
B
PLAN AT -4.400 M LEVEL SECTION B-B

2 1
6 5 4 3 B
SECTION A-A
30000
5000
A A
B
CRAP YARD CONTROL ROOM
RAMP
15000 15000 15000 15000 6000
6 5 4 3 2 1
6 5 6 5
PLAN AT +8.500 M LEVEL PLAN AT +6.000 M LEVEL
FINISHED FLOOR LEVEL (FFL) AT SMS : +476.5 M = 0,00

FINISHED GROUND LEVEL (FGL) AT SMS : +475.9 M = -0,60
TORPEDO TRACK RAIL TOP LEVEL : +487.9 M = 11,40
02/ 06 07 02/ 07
01 04 05 08/ 10/ 12 01 04 05 06 08/ 10/ 12
03 03
09 11 09 11
FPB435
15 14 12 10 9 8 7 6 5 4 3 2 1
8'
slope 10% slope 10%
slope 10%
VERTICAL GRAVITY TAKE UP

1000 AND LENGTH OF CONVEYOR
SHOULD BE DECIDED BY JSW
BUNKER SYSTEM SEE DWG.

C.FCS0.SL.14-G/EIZ410
63620
system
slope 10%
(GAP)
slope 10%
INCLINED BELT
CONVEYOR
300 t/h, 150 m 3/h
b = 650 mm, l ~ 292 m
h ~ 18 m
850
14 12 10 9 8 7 6 5 4
8'
CLEARANCE
FOR PIPES
BY JSW
30400
C'
C
15 14
12 10 9 8 7 6 5 4
8'
8 8' 7 6 5 4 3 2 1
CONVERTER
CHARGING BAY CONVERTER BAY
2000
30000 1000
B C C' D
C'
C
15 14 12 10 9 8 8' 7 6 5 4 3 2 1
C'
C
15 14 12 10 9 8 8' 7 6 5 4 3 2 1
REV. SHUTTLE
CONVEYOR BUNKER SYSTEM SEE DWG. ARGT. ELEVATED BINS - CONV. 1
CHUTES TO LD CONVERTER SEE DWG.
700 t/h, 350 m 3 /h C.YL1T.SL.14-G/EIZ410 SEE DWG. C.YL1T.SL.153-G/EIZ470
C.YL1T.SL.14-G/EIZ420
b = 1000 mm, l ~ 34 m
travel length ~ 30 m VERTICAL GRAVITY TAKE UP
AND LENGTH OF CONVEYOR
SHOULD BE DECIDED BY JSW
+ 62300 + 62300
PHASE 2
REV. CONVEYOR
300 t/h, 150 m 3 /h
02/ 06 12
01 04 05 08/ b = 650 mm,
03 07 09 + 50000
l ~ 78 m
REV. SHUTTLE INCLINED BELT
REV. SHUTTLE + 45800 10/ 01
02/
04 05 06 07 08/ 10/ 12 CONVEYOR CONVEYOR
03
11 09 11 300 t/h, 150 m 3 /h
CONVEYOR 300 t/h, 150 m 3 /h
300 t/h, 150 m 3 /h b = 650 mm, l ~ 7 m b = 650 mm, l ~ 292 m
D C
b = 650 mm, l ~ 7 m travel length ~ 6.5 m h ~ 18 m
travel length ~ 6.5 m 5056
+ 38400 APPROX.
8
+ 36100 + 36100
+ 36100 K K
+ 32800 C + 32800
ARGT. ELEVATED BINS - CONV. 2 D
SEE DWG. C.YL1T.SL.153.-G/EIZ471

+ 28021
14
+ 22600 + 24989
+ 24200 + 24200
14
8250 + 22600
4700
INCLINED REV. BELT + 21400 APPROX. 8250 + 21400
CONVEYOR
2200
300 t/h, 240 m 3 /h +19008
b = 800 mm, l ~ 20 m
h~4m
37700
ARGT. CHUTES TO LADLE - CONV. 1/2
SEE DWG. C.YL1T.SL.154.-G/EIZ475 INCL. REV. BELT
CONVEYOR
35300
300 t/h, 240 m 3 /h
b = 800 mm, l ~ 39 m
h~5m
32800
16000 14000
0 .00 CONTAINER FOR

DRI EMERGENCY MISPLACED
DRI EMERGENCY FPB435
CONTAINER FOR DISCHARGE PIT MATERIAL 3000
DISCHARGE PIT 3500 1400 3300
MISPLACED MATERIAL 15000 30000 30000 15000 15000 15000 15000 15000 15000 15000 15000 6000 5000
C'
VIEW C-C
15 10 9 8 8' 7 6 4 1'
14 12 5 3 2 1
D
D 38400
+ 36100
00 00 33700
00 61 61
+3
84 +3 +3 M
32800
00
C' L +3
77 00 M
61
+3
L
C'
C 3500 4700
15 14
C'
C VIEW D-D
15 14 12 10 9 8 8' 7 6 5 4 3 2 1 1'
C'
C
KEY PLAN 15 14 12 10 9 8 8' 7 6 5 4 3 2 1 1'
FINISHED FLOOR LEVEL (FFL) AT SMS : +476.5 M = 0,00
FINISHED GROUND LEVEL (FGL) AT SMS : +475.9 M = -0,60
TORPEDO TRACK RAIL TOP LEVEL : +487.9 M = 11,40
VF-1
C'
3 3 12
15 15 15 15 15 15 30 30 15 15 15 15 15 15 15 15 6
SECTION A-A
SECTION B-B
FAC3
Incoming Conveyor to LF
Inclined Inclined
Conveyor LF#2 Conveyor LF#1
1'
SECTION R-R SECTION P-P
1. FINISHED FLOOR LEVEL (FFL) AT SMS : +476.5 M = 0.0

2. FINISHED GROUND LEVEL (FGL) AT SMS : +475.9 M = -0,60
+ 62300
450 2600
4900
2800
+ 36100
+ 34737
+ 31729** +31729**
+ 27389 + 27389
+24500
+21500
H +21500
LF BELT RH BELT
CONVEYOR CONVEYOR
17000 17000 24000 24000
C' D E F G
15000 6000
3 2 1
SECTION A-A
1'
C' D E F G
FLOOR PLAN AT +27389MM LEVEL
SECTION B-B SECTION C-C
1 1 1
1' 1' 1'

F G H F
G G
FLOOR PLAN AT +24500MM LEVEL
FLOOR PLAN AT +21500MM LEVEL FLOOR PLAN AT +21500MM LEVEL
3000
2000
2000
12000
9000
2500 4250
1750 14500 11500
q HOIST
q HOIST
3000 x 2 (=6000) 2500 x 3 (=7500)
27000
1000 3150 5200 3150
4000
1250
5300
1750
750
2000
7000
15000
1150
3000
3000 DN
2450
ROAD
2000
2000
A
3 2 1 1'
8500
53500
C-C (SHT-2) D-D (SHT-2) E-E (SHT-2)
(SHT-2)
7450 7450 7450
7450
4000 5450 F-F (SHT-2)
3000 2
J-J (SHT-2)
7450 4000 1750 9700
5450 2250 7450
2000
25 800 GAP. 2
2 5 4 4 9 MIN.
+31000 +31000 +31000 +31000 +31000

1 +31000
600
1250 1250 1250 1250 +30000
1250 1250 BTM OF BEAM
1800
1800
1800
1900 MIN.
1250 1250
1200
3000 3000 3000 3000 3000 3000
+28750 4000 1000
B-B +28500
1700
4050
4050
4050
3
3900
8
2250
2250
2250
1850 MIN.
8 8 1750 x 4 (=7000)
2700
3000 3000 3000
+26750 6
1745
7 6 12
11 +25500
1750 x 3 (=5250)
1055
875
2200
2200
2200
400
400
400
1750
+24750 +24750 +24750 +24750 +24750
10
1000
1500
1500
1500
+23500
+23200
13 14 BTM OF BEAM 19
1800
1t
22 15 22 18
22 16 22 16
16
500
1700
+21000 +21000 +21000 +21000 +21000 +21000 1150 1500
1000
2450 2450 1550
2450 1550
+18800 2450 1550 20
2450 1550 3000
2000
+18000
2050 2900 21
+16650
25 25
1953
+14500 +14500 +14500 +14500 +14500 +14500
23
1750 9700
+12225 1750 5250
9700
+5075
750 24 2450 2000 2450 2000 2450 2000 2450 2000 2450 2000 2450 2000
7000 4450 7000 4450 2000 7000 4450 7000 4450 7000 4450 7000 4450
H G H G H G H G H G H G
G-G (SHT-1) H-H (SHT-1)
CRANE No.1010 CRANE No.1010

200-20T X 23M Span DG EOT Crane for 200-20T X 23M Span DG EOT Crane for
RH Maintenance in (G-H) Bay RH Maintenance in (G-H) Bay
+38000 +38000 7450

TOP OF CRANE GIRDER TOP OF CRANE GIRDER
CRANE
CABIN 15000
5300 9700
2820 2250 7450
3180 4520
26 25 800 GAP.
MIN.
2 2
+31000
17025 LIFT
+28200
+26830
2000 2000 2000 2000 2000 2000 2000 2000

POSITION
POSITION
12000 15000 12000 15000
27000 27000
H G H G

JVML Sms Ts Belt Conv System r1

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JSW VIJAYNAGAR METALLICS LIMITED (JVML)

5 MTPA SMS COMPLEX

CONVEYOR SYSTEM & AUXILIARY SYSTEM

TS NO. MEC/11/17/Q7NX/02/TS-052R1 December, 2021

Chapter Description Page No.

10.00. List of Drawings enclosed 53 of 96

© 2021, MECON Ltd. All rights reserved Page 2 of 96

© 2021, MECON Ltd. All rights reserved Page 3 of 96

02.00 INTENT OF SPECIFICATION

© 2021, MECON Ltd. All rights reserved Page 4 of 96

03.00 INSTRUCTIONS TO TENDERER

© 2021, MECON Ltd. All rights reserved Page 5 of 96

© 2021, MECON Ltd. All rights reserved Page 6 of 96

Technical parameters of conveyors are indicated in Technical Specification drawings.

II. Design Basis

 Utilisation of cross sectional area - 80 % of theoretical cross sectional area

© 2021, MECON Ltd. All rights reserved Page 7 of 96

 Return idler spacing - 3000 mm spacing

 Impact idler spacing - 500 mm or less - (min. 6 Nos.)

 Deck plate - 3.15 mm thick entire length.

 Tail/ Bend/take-up pulley – 10 mm thk vulcanized natural rubber plain lagging,

 Pulley face width - As per IS 8531-1986, Reaffirmed in 1993 or as mentioned in

© 2021, MECON Ltd. All rights reserved Page 8 of 96

b) Material - fabricated or cast steel

 High speed coupling - gear coupling/ resilient coupling less than 30 kW

 Delay filled chamber type fluid coupling for 30 kW & more

 Pin bush coupling - Not Applicable.

 Low speed coupling - gear or resilient.

V shaped, mounted on carrier assemblies with elasto-mount and non-

© 2021, MECON Ltd. All rights reserved Page 9 of 96

All bought out items shall be as per JSW preferred makes.

For Design basis of elctrics and electrical components refer Electrical

© 2021, MECON Ltd. All rights reserved Page 10 of 96

a) Primary coat : 30 –40 micron per coat (2 coats)

Colour scheme shall be approved by the Purchaser.

03.17 Preparation Of General Arrangement Drawings:

© 2021, MECON Ltd. All rights reserved Page 11 of 96

04.00 SCOPE OF WORK

© 2021, MECON Ltd. All rights reserved Page 12 of 96

04.03 System Description

Sl.No. Conveyor/EQUIPMENT Capacity(TPH) Belt Belt C/C (m) Lift(m)

© 2021, MECON Ltd. All rights reserved Page 13 of 96

04.05 BATTERY LIMITS

 Design, Engineering, fabrication, erecton of building structures

© 2021, MECON Ltd. All rights reserved Page 14 of 96

05.00 TECHNICAL SPECIFICATION

08. Steel frames carrying machinery shall be machined to true surface.

05.02 Belt Conveyors

01. Conveyor Pulleys

© 2021, MECON Ltd. All rights reserved Page 15 of 96

Bearing centers of the pulleys shall be as follows:

- 1800 mm for 1200mm Belt Width

© 2021, MECON Ltd. All rights reserved Page 16 of 96

Training idlers shall not be used close to belt-weighing scales.

© 2021, MECON Ltd. All rights reserved Page 17 of 96

03. Belt Cleaners

a) External belt cleaners

04. Gear Boxes

© 2021, MECON Ltd. All rights reserved Page 18 of 96

06. Hold Back and Brakes

© 2021, MECON Ltd. All rights reserved Page 19 of 96

Snub pulley near discharge end shall be covered by the chutes.

09. Discharge Hoods