3045 tsr3

BHILAI STEEL PLANT

DALLI MECHANISED MINE

UPGRADATION OF DRY SCREENING FACILITY AT CRUSHING

SCREENING WASHING PLANT

TENDER SPECIFICATION

STEEL AUTHORITY OF INDIA LIMITED CENTRE FOR ENGINEERING & TECHNOLOGY

RANCHI - 834 002

OCTOBER 2010 CET/01/RN/3045/TS/RM/01/R=3

BSP : DALLI MECHANISED MINE CONTENTS CET/01/RN/3045/TS/RM/01/R=3

UPGRADATION OF DRY SCREENING FACILITY PAGE 1 OF 2

CONTENTS - CHAPTERS

Chapter

No. Description Page no.

1 Introduction 1.1-1.2

2 Scope of Work 2.1-2.11

3 Technical Specification 3.1-3.27

4 Performance Guarantee Test 4.1

5 Special Instruction to successful Bidders 5.1-5.4

BSP : DALLI MECHANISED MINE CONTENTS CET/01/RN/3045/TS/RM/01/R=3

UPGRADATION OF DRY SCREENING FACILITY PAGE 2 OF 2

CONTENTS - DRAWINGS

Sl.

No. Drawing No. Description

1 CET RN 3045 RM1 00 001 R=0 Existing Flow Diagram of Dalli Washing Plant.(4 sheets)

2 CET RN 3045 RM1 00 002 R=0 Existing Flow Diagram of Dry Screening Section

3 CET RN 3045 RM1 00 003 R=0 Proposed Flow Diagram of Dry Screening Section

4 CET BH 3045 ME1 00 001 R=1 Scheme of Dry Screening Facility (750 TPH Rated capacity)

BSP : DALLI MECHANISED MINE CET/01/RN/3045/TS/RM/01/R=3

UPGRADATION OF DRY SCREENING FACILITY PAGE 1.1

1 INTRODUCTION

1.1 Five captive mines of Bhilai Steel Plant feed iron-ore to 2(two) Ore Processing Plant (OPP) located at Dalli & Rajhara. The OPP of Rajhara has dry process & that at Dalli has wet process. There is provision of dry processing at Dalli OPP also.

1.2 Bhilai Steel Plant receives iron ore from Dalli -Rajhara group of mines. Dalli Rajhara iron ore complexes were developed in phases. Rajhara open cast mines came into operation in October 1960. The Crushing & Screening Plant has two parallel dry circuits.

1.3 Dalli started as semi mechanised mine in 1965. At 4.0 Mt stage of BSP to meet the additional requirement Dalli mine was added with wet circuit installed in 1979. Later on an additional dry circuit plant was added to achieve ROM capacity.

1.4 Dalli Rajhara mines are located 95 km south of the BSP in southern Madhya Pradesh and well connected with Durg by high way. It is also well connected with Durg and Bhilai by broad gauge railway which transport ore to Bhilai Steel Plant.

1.5 The process plant of Dalli mechanised mine was originally designed for processing two lines in wet operation and one line with combination of various screens for dry operation to accommodate non washable ore. Dry circuit operation is closed since 1993.

1.6 Now, because of exposure of high grade ore in the mine and filling of tailing pond to its capacity and increased requirement of fines, it has become necessary to utilise this system for recovery of more fines. It will save the water and electricity in handling of tailings.

1.7 It has been decided to modify the screens with single screen of 750 tph rated capacity(minimum) from 200/250 tph rated capacity (3 nos at top & 3 nos. in bottom totalling 6 nos) existing which will eliminate the operation of some equipment like tripping trolley, three feeding conveyors and vibrators which will require less manpower. This will require replacement of existing feeders (in-feed arrangement) and modification of existing feeding/delivery chutes and minor civil work.

1.8 Intent of the specification

1.8.1 The intent of this Tender specification is to furnish the required technical details & drawings to enable the bidder to submit best



offers for this package as per “Scope of Work” mentioned at Chapter 2, “Technical Specifications” covered in Chapter 3, “Performance Guarantee” given at Chapter 4 and “Special Instructions to the Bidder” given in Chapter 5.

1.8.2 This Tender Specification shall be read in conjunction with other documents enclosed by the Employer with this Tender. The provisions given in these documents shall be complementary to one another.

1.8.3 The package shall be implemented on turnkey basis within 7 months after signing of contract.

1.8.4 Relevant details necessary for preparation and submission of best offers are included in the subsequent sections of this Tender Specification.

1.8.5 This Tender specification shall be read in conjunction with Invitation to Tender (ITT) and Standard Bidding Documents (SBD). The provisions given in these documents shall be complimentary to each other. However, in case of any conflict between provisions of these documents, the priority of adopting the provisions from the documents shall be in the following order:

i) Invitation to Tender

ii) Standard Bidding Documents

iii) Tender Specifications



2 SCOPE OF WORK

2.1 GENERAL

2.1.1 The scope of work for this package shall cover design, engineering, preparation of general arrangement and marking drawings, fabrication / erection drawings, fabrication, manufacture / supply and transportation to site of the plant, erection and commissioning and performance guarantee for all items of mechanical, civil , structural and electrical as elaborated in the subsequent clauses of this TS on Turnkey Basis within 7 months after signing of contract.

2.1.2 All works envisaged in this package shall generally be carried out by the Successful Bidder based on indicative drawings furnished in the TS. The Successful Bidder shall prepare all necessary general arrangement drawings including fabrication / erection drawings of above proposed equipment and facilities.

2.1.3 Site cleaning, preparation, transfer of benchmarks, checking & fixing, aligning of structures, final cleaning of site after completion of the work will be under the scope of the successful Bidder. No separate payment will be made towards this and the cost, if any, will be deemed to be included in the total contract price.

2.1.4 The Bidder, before submitting his tender, shall visit the site and ascertain the local conditions, labour rules, availability of construction materials, traffic restrictions, and all obstructions in the area and also ascertain all site conditions including the sub-soil conditions and shall allow for any extras likely to be incurred due to all such conditions in his quoted prices. After the award of work no additional claims will be entertained on these accounts under any circumstances.

2.1.5 The successful Bidder shall set out and level the work and will be responsible for the accuracy of the same. He shall provide all instruments and proper qualified staff with labour for getting his work checked by Engineer in charge, if so desired. Such checking, if any, shall not relieve of the responsibility for correct setting out.

2.1.6 The successful Bidder shall keep the site clean as an ongoing process of all rubbish, which may arise out of the work, executed



by him and dispose them as directed by the Engineer in charge within a lead of 5 km.

2.1.7 The successful Bidder shall protect all benchmark and reference pillars / lines from damage or movement during progress of work. In case of any damage the Bidder shall have to restore the same to its original condition.

2.1.8 The successful Bidder will coordinate with other agencies if any working at the site for the successful and timely implementation of the work.

2.1.9 The successful Bidder will make all necessary arrangement for crane, hoisting equipments & transportation of materials (raw and or fabricated) at site of work. Dalli Mines will not provide cranes or other equipment to the successful Bidder for any site work.

2.1.10 The successful Bidder will abide by the safety rules of the Dalli Mines and all rules imposed by State Government & Central Government as in force.

2.1.11 Spares for Two years Operation / Maintenance

The successful Bidder shall furnish spares for two years normal operation/ maintenance of the offered equipment to ensure availability of the equipment. Price of such spares shall be quoted separately.

2.1.12 Consumables

The successful Bidder shall confirm the supply of all consumables required for erection, testing and successful commissioning of the system.

2.1.13 Initial Fill

Supply of the initial fill is in the Successful Bidder’s scope.

2.1.14 Special Tools & Tackles

The Successful Bidder’s shall confirm the supply of all special tools and tackles required for erection, testing and successful commissioning of the system.



2.1.15 Following drawings / documents shall be submitted by the Bidder along with the offer in six sets:

1) Clause wise confirmation of the TS.

2) List of exclusions & deviations.

3) Technical specification and data sheets of equipment.

4) Manufacturer’s catalogues / brief technical descriptions of offered equipment and brought-out items.

5) Any other detail, which may be felt necessary

2.1.16 The Successful Bidder shall furnish a plan of quality assurance and quality control, both in respect of site works as well as supplies, which he proposes to follow for the purposes of assuring the quality of supply and workmanship at various stages. The Quality Assurance Plan (QAP) shall be mutually discussed and approved by the Employer. The same shall thereafter form part of the contract

2.1.17 Any other related job, not specifically mentioned herein but necessary for the successful completion of the project and safe, efficient and smooth operation of the system / equipment will also be under the scope of work of the Successful Bidder.

2.2 MECHANICAL

2.2.1 Dismantling Work

The following existing equipment/ facilities shall be dismantled completely including accessories etc. and transporting it to suitable place within 5 Km as directed by Engineer In charge.

1) Dismantling of existing dry screen complete with connecting chutes, supporting system etc.

2) Dismantling/ modifications of existing concrete floor if required.

3) All discharge and receiving chutes along with skirt board of the existing conveyors shall be dismantled/ modified to suit the proposed material transportation.

2.2.2 Proposed New facilities

Bidders are requested to visit the site before quoting and give certificate of visit .



1) The existing flow sheet of Dalli Ore processing plant Drawing No CET RN 3045 RM1 00 001(4sheets) is shown and also existing and proposed flow sheet of material conveying system from mid bunker to conveyor 9 & 10 of Dalli Crushing Screening Washing plant (CSW plant) are shown in the, Drawing Nos CET RN 3045 RM1 00002 & 003, R=0 respectively.

2) One no. of screen for segregating iron ore in two different sizes ie,+10mm as lump and – 10 mm as fine, 750 tph rated capacity(minimum) of feed , complete with deck, side skirt plate, cardan shaft, isolation frame, springs, drive arrangement, under size chute with liner integral with screen etc shall be part of Screen. The screen shall be provided with four no. wheels. Wheel Guage shall be 3400 mm & wheels shall be travelling on billets (50x50 mm size). The screen shall be provided with wheel lifting & lowering mechanism, so that during operations screen shall be mounted on foundations (lifted wheels position)& during maintenance wheels shall be lowered so that screen can travel over billets. Also, connecting chutes to the screen shall be removable type. Screen shall be installed after dismantling of one existing dry screen not in working condition . The existing screen platform shall be modified to accommodate the higher capacity screen (Rated 750 tph in place of 200-250 tph screens) if required, otherwise new platform to be erected. .

3) All discharge and receiving chutes shall be modified to suit the existing conveyors as shown in the Drawing no. CET BH 3045 ME1 00 001 R=1.

4) The drives, gearboxes, couplings etc. of drive units for the proposed Screen shall be new as per supply.

5) Required Maintenance platforms and approach walkways.

2.2.3 Requirement of Drawings and Technical Document

The following drawings / documents shall be submitted by the Bidder along with the offer:

1) General layout drawing of the proposed system

2) General arrangement drawing showing elevation of all systems with overall dimensions

3) Basic technical parameters of the equipment/ facilities



provided new

4) Manufacturer's catalogues, leaflets for various bought-out components of mechanical and other services, brief technical description of offered equipment and bought-out items

5) Any other details, which may be felt necessary

2.2.4 Following drawings/ data/ documents shall be submitted in a phased manner as per no. of copies furnished in the SBD to the Employer for approval / reference by the Successful Bidder within one month of placement of order and prior to commencement of fabrication:

1) General layout drawing of existing lump and fine ore conveyor in that area i.e. conveyor 9 & 10.

2) General arrangement drawing of individual conveyor as mentioned above giving dimensions, profile, lift, idler spacing, take-up arrangement,

3) Motor kiwi, drive and pulley arrangement etc. along with chutes, scraper, skirt boards, switches and other items as applicable

4) General arrangement of dry screen, with all necessary information.

5) Foundation/ mounting details of motors

6) Guaranteed data sheet for motor/motors

7) General arrangement drawing of dry screening plant indicating overall dimensions

8) General arrangement of electrical equipment and layout drawing

9) Cable layout drawing

10) Single line diagram of all MCC, PDB, LDB etc.

11) Control schematic with write-up

12) Earthing scheme

13) PLC details

14) General arrangement drawing of all other major equipment

15) Quality assurance plan (QAP) of motors



16) Manufacturer's catalogues of all bought out items

2.2.5 Construction Methodology and Sequence of Erection

The successful bidder shall submit the construction methodology to be adopted by him with respect to space management, erection sequence, testing and commissioning within one month after placement of order.

2.2.6 For procurement of mechanical bought out items, the successful bidder shall adhere to BSP’s preferred make.

2.3 CIVIL WORKS

2.3.1 Design, engineering, preparation of general arrangement and marking drawings, supply of all labour, materials, mobilization of resources to sites, site handling, execution of civil works required for the Revival of Dry Screening facilities at Dalli CSW Plant, Dalli and performance guarantee for all civil works as elaborated in the subsequent clauses of this TS on TURNKEY BASIS.

The scope of work shall be as follows and shall be studied in conjunction with attached with this document. The scope covers the entire job for the civil works including the design, Engineering, construction / dismantling and any other activity as necessary for the execution of project on turnkey basis.

2.3.1.1 The new screen of increased capacity is to be installed at +5.53m level. Existing RCC floor and beams shall be dismantled in floor and beams for making opening of increased size. The dismantling is to be carried out at +5.53 m level, between axes (A/B) and B, and axes (6) and (7). The dismantling work should be carried out giving utmost care not to disturb the adjoining structures. The debris of the dismantled portion shall be removed from the site carefully so as not to hamper with the smooth functioning of the other two present screens. Due care shall also be taken to avoid accidents due to fall of debris by providing proper protection around the work site.

2.3.1.2 Construction of RCC beams including inserts, bolts and making good the dismantled floor between axes (A/B) and B, and axes (6) and (7) at +5.53m level. It is proposed to make new beams in such a manner, that they rest on top of the existing beams in between the above mentioned axes by drilling holes and taking out dowels, so as to make the new beams monolithic with the



old beams. The dowels will be grouted using a non-shrinking epoxy grout.

2.3.1.3 The bidder should check the stability of the structure considering the new loading as per the new screen.

2.3.2 The Bidder shall prepare all general arrangement drawings including reinforcement drawings of the above proposed work as per Clause no. 3.3.2.4.3.

2.3.3 The Bidder, before submitting his tender, shall visit the site and ascertain the local conditions, labour rules, availability of construction materials, traffic restrictions, and all obstructions in the area and also ascertain all site conditions including the sub-soil conditions and shall allow for any extras likely to be incurred due to all such conditions in his quoted prices. After the award of work no additional claims will be entertained on these accounts under any circumstances.

2.3.4 The Bidder will make all necessary arrangement for any hoisting equipments & transportation of all materials at site of work. Dalli Mines will not provide any equipment to the bidder for any site work.

2.3.5 Site cleaning, preparation, transfer & setting up of permanent benchmarks & geodetic lines, checking & fixing, final cleaning of site after completion of the work shall be under the scope of the successful Bidder.

2.3.5.1 The successful Bidder shall set out and level the work and will be responsible for the accuracy of the same. It may be noted that the Bidder shall deploy qualified and experienced surveyor all through the execution of work at site for checking / maintaining the centre-lines / levels, preparing schemes showing hindrances at site, if any, from time to time as per the direction of Engineer–in–charge. No separate payment shall be made towards this and the cost if any shall be deemed to be included in the contract price.

2.3.5.2 The successful Bidder has to ensure the deployment of unskilled manpower for doing jobs like area cleaning, dressing, levelling, removal of debris, shifting of materials, cleaning of drains etc. as per the direction of Engineer-in-charge. No separate payment shall be made towards this and the cost if any shall be deemed to be included in the contract price.



2.3.5.3 The successful Bidder shall keep the site clean as an ongoing process of all rubbish, which may arise out of the work, executed by him and dispose them as directed by the Engineer in charge within a lead of 7 km.

2.3.5.4 The successful Bidder will abide by the safety rules imposed by State Government & Central Government as in force.

2.3.5.5 The successful Bidder shall protect all benchmark and reference pillars / lines from damage or movement during progress of work. In case of any damage the Bidder shall have to restore the same to its original condition.

2.3.5.6 The successful Bidder shall also be responsible for co-ordination with other agencies working for the successful and timely implementation of the work.

2.3.5.7 Any other related job, not specifically mentioned herein but necessary for completion of the project and safe, efficient and smooth working of the screen and its auxiliaries/equipments will also be under the scope of work of the bidder.

2.3.5.8 The proposed size and arrangement of the screen on the existing floor shall be indicated by the bidder along with the offer.

2.3.5.9 The successful bidder may refer to the drawings for planning the modifications in the structure. The drawings can be obtained from BSP as and when required

2.4 STRUCTURAL WORKS

2.4.1 Design, engineering, preparation of general arrangement and marking drawings, supply of all labour, materials, mobilization of resources to sites, site handling, execution of structural works required for the Revival of Dry Screening facilities at Dalli CSW Plant, Dalli as elaborated in the subsequent clauses of this TS on turnkey basis.

2.4.2 The complete steel structural work as per requirement within the battery limits shall include design, drawings, supply of all materials, fabrication, painting, delivery at site, and storage at site, fabrication, dismantling, erection, testing and commissioning, complete in all respects.

The proposed work will involve



� The structural steel work involved in the project under study consists of all launders and chutes work as per requirements, necessary steel structures required to support feeding launder and discharge chutes, necessary maintenance platforms and approach walkways etc.

� Dismantling of existing structures such as maintenance platforms, staircases, bunkers etc.

� All structural fabrication work shall be as per IS 800-2007.

All structural work shall be carried out as per relevant latest IS codes.

2.5 ELECTRICS

2.5.1 Design, engineering, manufacturing, assembly at manufacturer’s works, packaging, transportation, supply, unloading, storage at site, erection, testing and commissioning of the major equipment/ items broadly under the scope of work of the successful bidder/s on turnkey basis for electrical system required for Dry Screening Facilities of Screening and Washing Plant, Dalli.

2.5.2 The major electrical items/ equipment in the scope of supply and other work are as given below :

Sl.

No.

DESCRIPTION QTY.

1. Electrical Components i.e. MCCB ,Earth Leakage Relay Contactor, auxiliary

contactor, O/L relay etc. for Screen Motor. Proposed electrical components shall be installed in place of the electrical components of existing screen motor. Location: Open type switch board of Control Room no-6.

1 set.

2. Disconnection and removal of electrical components for existing screen on Switch board of Control room no-6

Lot

3. Local Control Station along with emergency switch.

1 set

4. Supply, routing, laying and termination of LT Power cables and control cables for Screen Motor including MS ladder type cable tray, GI pipes, supports etc. as required .

Lot

5. Earthing : Lot



Power earthing including earthing materials for proposed equipment of plant. Earthing of equipment is to be connected to existing earthing network of the plant.

6. Drawings and documents:

Preparation of all necessary drawings and documents required for the complete system.

Lot

2.5.3 The installation shall have to be approved by statutory Government Authority like Electrical Inspector, DGMS, etc. Any modification in the equipment or installation that may be demanded by them will be carried out by the successful Bidder at no extra cost to the Purchaser. The successful Bidder will take all necessary steps to get the installation approved by above authorities for the equipment supplied by him.

2.5.4 Battery Limits

Battery limit for the successful Bidder /s shall start from the following:

Tapping LT power supply, including supply of cable, at 415 V from existing Control Room.-6

Onward Scope of Work for power supply, transformation, distribution, cabling , earthing as explained in the various clauses of this TS shall be within the scope of work of the successful Bidder.

2.5.5 Purchaser’s Obligation

1) The Purchaser shall provide the site for storing the equipment/ material within a reasonable distance from the proposed site.

2) The Purchaser shall provide 3 phase, 415 V 50 Hz, A.C. power feeders as Construction power supply within 50 meter of construction site.



3 TECHNICAL SPECIFICATION

3.1 BASIC DESIGN AND SITE CONDITIONS

3.1.1 General Information of Site

Bhilai Steel Plant is located in Durg District of Chhattisgarh state. The plant is located in the vicinity of Bhilai Railway station of South Central- Eastern Railway which is 856 km west of Calcutta and 280 km east of Nagpur. The average elevation of site is 307 m above mean sea level. Plant is well connected by road net work. Nearest airport is at Raipur, which is 60 km from Bhilai. Nearest seaport is Visakhapatnam, 600 km by rail from Bhilai. Existing ground level at site is +307.5 m (RL).

Bhilai Steel Plant receives iron ore from Dalli Rajhara group of mines. Dalli Rajhara iron ore complexes were developed in phases. Dalli Rajhara mines are located 95 km south of the BSP in central Chhattisgarh and well connected with Durg by high way. It is also well connected with Durg and Bhilai by broad-gauge railway which transport ore.

3.1.2 Climatic Conditions

The climatic data at Plant site is as follows:

The meteorological data for Dalli is as follows:

1) Air Temperature

Maximum 55 0C

Minimum 5 0C

2) Absolute Humidity

Maximum 100 %

Minimum 7 %

Maximum temperature and maximum humidity do not occur simultaneously. Equipment should be designed to work in hot, humid and dusty area.

3.1.3 Battery Limits

Screen shall me placed in the top floor of existing screen floors j with modification of chutes for transporting 1000 TPH Designed capacity of iron ore and 750 TPH rated capacity as described in the clause 3.2 and shown in relevant drawing.



3.2 MECHANICAL

3.2.1 The feed material for dry screening, granulometry in percentage is as follows:

-8 mm 42.22-55.76

-10 mm 45.93-61.27

-12 mm 53.92-71.0

-15 mm 60.96-79.58

-20 mm 66.29-87.03

-30 mm 72.57-93.69

-40 mm 75.61-97.87

-60 mm 98.76-99.6

-80 mm 100

Separation required at 10 mm

Moisture in feed material 4-5%

Bulk Density 2.2t/m3

Capacity (Rated) 750 tph,minimum

Oversize in fines +10 mm 5% Max

Undersize in lump -10 mm 5% Max

Moisture in feed material 4-5%

Bulk Density 2.2t/m3

Ambient Temperature 50 degree centigrade

Capacity (Rated) 750 tph

Screen width to be specified by the bidder

Screen length to be specified by the bidder

Screen inclination to be specified by the bidder

Motor requirement to be specified by the bidder

Type of screen linear,

circular etc to be specified by the bidder

Model to be specified by the bidder

Exciter Model & No to be specified by the bidder

Type of drive to be specified by the bidder



Set of Safety guards/switches to be specified by the bidder

Type of tensioning device

for driven equipment to be specified by the bidder

Screen is required for the above with feeding and discharge chutes (10mm thick MS plate ) with liner (10 mm thick). Screen shall have minimum dynamic force to be transmitted to their site with minimum noise and shall have corrosion protection. Screen should have stable operational behaviour. Influence of material handled should have minimum effect on the screen. Lump and fines to be fed to existing conveyor 9 &10 respectively with modified chute.

3.2.2 For procurement of mechanical bought out items, the eligible bidder shall adhere to the ‘Preferred Make’ as per Bhilai Steel Plant’s list.

3.3 CIVIL WORKS

3.3.1 Design Specifications

3.3.1.1 This specification covers the design criteria for Civil Engineering work for the replacement of the screen at Dalli Mines. The term ‘Design Criteria’ includes loading standards, permissible stresses, functional requirements and quality standards to be adopted as a basis for preparation of designs and drawings by the successful Bidder. These designs and drawings will cover the dismantling of the existing beams, construction of new beams and other miscellaneous civil engineering items of work to be provided to the successful Bidder .

3.3.1.2 The designs prepared by the successful Bidder shall not only provide for the requirements indicated in this specification but also consider the overall process requirements, and service conditions. The designs shall be compatible with the existing and proposed structures at Dalli Mines.

3.3.2 Standards

The design criteria for civil engineering work shall be in accordance with this specification. Detailed instructions on such aspects as are not indicated herein shall be as per the latest standards, codes. In the absence of suitable IS specification and codes of practices other recognised international standards and codes may be followed with the prior approval from Purchaser.

3.3.2.1 In respect of pollution control, safety, sanitary and hygienic requirements the stipulations of the Department of Environment of the Government of India, Chattisgarh Government Safety Rules,



notification of Chattisgarh Government Department of Science, Technology and Environment on Water and Air Pollution and other statutory authorities shall be satisfied.

3.3.2.2 This specification covers design of major Civil Engineering items of work. Other items of work shall be designed according to the relevant standards, recommendations and stipulations referred above. This design specification shall also be read in conjunction with the General specifications for Civil Engineering Work.

3.3.2.3 In case anything mentioned in this specification is at variance with IS or other codes of specification mentioned herein, the provisions of this specification shall prevail.

3.3.2.4 Concrete And Reinforced Concrete For Structures

3.3.2.4.1 Concrete work shall be a dense, homogenous, smooth mass including required finishes, possessing required strength and resistance to weathering and abrasion for the structures and foundations.

3.3.2.4.2 Design of all reinforced concrete structures shall be as per IS: 456–2000.

i) Load Condition

1)All concrete structures shall be designed to resist full operating dead and live loads.

2) Design of the structure should be such that it forms an integral part of the existing building.

3) Permissible Stresses

Allowable stresses for the concrete structure shall be as per IS:456-2000. The structures shall also be checked for dynamic loading as per IS: 2974-1979 (Part- IV).

4) Supporting structures and foundations for screen which may cause vibration shall be designed for the dynamic effect of screen together with the direct loads. The dynamic loads and other relevant data required for analyzing the dynamic effect shall be taken as per manufacturer’s data recommendations.

3.3.2.4.3 Design Calculations, Drawings And Documents

The design calculations shall be submitted by the contractor for approval, prior to submission of construction drawings shall include but not be limited to, the following.



1) Design Calculations

i) The design calculations for all the structures shall be submitted by the bidder. The design calculations shall include static and dynamic design calculations for all structures. Whole RCC Structure supporting the vibrating equipment, which is screen, in this case shall be proportioned to avoid resonant frequencies. The dynamic analysis of whole structure in totality for the new arrangement shall be done to check for any local failures in supporting beams, as per the stipulations as recommended by respective IS codes as well as the stipulations recommended by equipment manufacturer. In case any structural element is experiencing failure then it shall be strengthened / dismantled and new element of modified size shall be provided.

ii) Measures required for the safety of the structures and workers shall also be given.

2) Drawings

i) The contractor shall prepare general layout drawings giving salient levels and dimensions of the whole structure. Detailed working drawings shall be prepared on the basis of the general layout drawings considering overall layout for the building, services, etc. space requirement and clearances as necessary. The contractor shall ensure that no further drawing shall be required to be prepared by any other agency for successful implementation of the project. The successful Bidder shall submit a comprehensive and complete unit wise classified list of drawings in reproducible form.

ii) The successful Bidder shall submit for approval of the Consulting Engineers general arrangement and detailed working drawings for all concrete, reinforced concrete and other civil work, as follows:

• Loading drawings indicating superstructure loading, floor loadings, etc.

• Reinforcement details with bar bending schedules for all reinforced concrete works.

• Drawings for all types of bolts, inserts, embedments, covers, etc.



• Detailed bill of materials of all items of work.

3.3.3 Material Specification

3.3.3.1 General

1) Local conditions

The Bidder, before submitting his tender, shall visit the site and ascertain the local conditions, labour rules, availability of construction materials, traffic restrictions, all obstructions in the area and also ascertain all site and shall allow for any extras likely to be incurred due to all such conditions in his quoted prices. After the award of work no additional claims will be entertained on these accounts under any circumstances, whatsoever, from the Bidder.

2) Setting out and levelling

The successful Bidder shall set out and level the work and will be responsible for the accuracy of the same. He is to provide all instruments and proper qualified staff with labour for getting his work checked by Engineer, if so desired by the Engineer. Such checking, if any, shall not, however, relieve the successful Bidder in any way, of his responsibility for correct setting out.

3) Safety

The successful Bidder shall take adequate precautions to ensure complete safety and preventions of accidents at site and shall be responsible for the same. The safety precautions shall conform to the safety regulations prescribed by the Safety Code for constructions and relevant Indian Standard Codes, some of which are stated below: IS 4014-1967 : Safety Regulations for scaffolding work IS 7923-1985 : Safety Code for working with Constructions

machinery IS 4138-1977: Safety Code for working with compressed air

4) Keeping work free from water

The successful Bidder shall provide and maintain at his own cost, pumps and other equipments to keep the works free from water and continue to do so until the handing over of the works.

5) Rubbish

The successful Bidder shall keep the site clear on a continuous basis of all rubbish etc. which may arise out of the work executed by him and dispose them suitably in allotted areas.



6) Bench Marks, Reference Pillars etc.

The successful Bidder shall protect all bench mark, and reference pillars /lines including ground water gauges from damage or movement during working. In case of any damage the Bidder shall have to restore the same to its original condition at his own cost.

7) Standards

Unless otherwise mentioned in the specifications, all applicable codes /standards as published by the Bureau of Indian Standards on the date of award of contract shall govern the work in respect of design, workmanship, quality and properties of materials, method of testing and other pertinent features. In case of variance between this specifications and IS Codes /Standards, the provisions of this specification shall prevail up to the extent of such variance.

3.3.3.2 Dismantling

1) The dismantling work shall be carried out with utmost care so that the adjacent structures, which are not to be dismantled, do not get damaged. However, if any existing structures get damaged during dismantling, the successful Bidder without any extra cost shall carry the rectification and restoring of the entire structures.

2) The successful Bidder shall assess the entire dismantling work independently and decide accordingly the resource to be employed by him so that the work can be executed in the stipulated time frame.

3) The successful Bidder shall obtain the necessary clearance certificates from Safety department of Dalli Mines for the arrangement of dismantling work at every stage.

4) All debris collected due to dismantling shall be transported and disposed off within the lead of 7 Km within plant boundary as directed by the engineer in charge.

5) All serviceable material shall be stacked and transported to scrap yard/dump yard within a lead of 7 Km.

6) The stacking shall be done for various categories of dismantled items. Such categorization shall be worked out in consultation with engineer in charge.



7) Dismantling shall be done preferably in such piece size length as will facilitate easily transportation and disposal of those items to dumping yard /storage yard.

8) Dismantling of all RCC and PCC work shall be done as per detail dismantling drawing.

9) Pneumatic hammer / breaker in general shall not be used for dismantling of RCC slabs, beams, etc. All the dismantling work shall be carried out manually.

3.3.3.3 Plain And Reinforced Concrete Work

1) Materials

i) Cement

Ordinary Portland cement shall conform to IS 269-1989 / IS 8112-1989 and Portland blast furnace slag cement shall conform to IS 455-1989. Soundness test is to be carried out on cement samples from time to time. Frequency of these tests shall be increased during monsoon period.

ii) Aggregates

All aggregates shall conform to IS 383-1970. Fine aggregates shall be approved river or pit sand. Coarse aggregates shall be approved crushed stone. Aggregates shall be clean and free from any foreign material. Test on aggregate shall be carried out from time to time to ascertain the suitability of the aggregates.

iii) Reinforcement

Reinforcement in general shall be of tested quality. Cold twisted steel bars or TMT bars conforming to IS 1786-2008 as shown in drawings shall be free from oil paint and rust coatings. However, MS round bars conforming to IS 432-1982 or IRC mesh fabric reinforcement conforming to IS 1566-1982 can also be used if specifically required and shown in the drawings. The binding wire shall be 20 SWG approved annealed iron wire.

iv) Shuttering

The material for shuttering shall be steel plates as per IS 2062-1999 or wooden planks as per the requirement.

v) Jointing materials



All rubber and PVC water stops joint fillers, sealing materials etc. used in concrete work shall be of standard manufacture as per relevant IS codes. Usage of these materials shall be in accordance with the manufacturer's instructions.

vi) Admixtures

Admixtures, if required, to be used shall be of approved quality and make and shall conform to relevant IS codes.

vii) Water

Water shall be clean and of potable quality as per clause 5.4 of IS 456-2000.

2) Workmanship

i) Concrete

Production and control of concrete shall be as per IS 456-2000. The grades of concrete shall be as indicated in the drawing. The Bidder shall at his own cost, grade the aggregates and control the water cement ratio, design the different mixes to required strength and workability. The designed mix shall conform to the requirement of IS 456-2000 and recommended guidelines in SP: 23-1982. The minimum cement content and maximum water cement ratio of concrete work shall conform to the requirements of durability of concrete for moderate exposure as indicated in Table-5 of IS 456-2000. All concrete shall be machine mixed, and no hand mixing shall be permitted. The maximum size of aggregates used shall be as indicated in the drawings and IS 456-2000. Where reinforcement is too closely spaced for the maximum size of stone in a range, the largest suitable range shall be used. Before commencement of work, the Bidder shall submit to the Purchaser for his approval complete details of the tests for design mixes together with the grading analysis and mix design calculations. No concrete shall be placed on site until the Purchaser has approved the mix design. Where nominal mixed concrete as defined by IS 456-2000 is permitted by the Purchaser for any specific reason, the proportion of the materials shall be as indicated in IS 456-2000. The water cement ratio shall not exceed those specified in IS 456-2000. If the quantity of water is required to be increased for better workability, the cement content also



shall be increased proportionately so that the water cement ratio as specified in IS 456-2000 is not exceeded.

ii) Mixing

Except where nominal mix concrete as defined in IS 456-2000 is permitted by the Engineer to be used, all components of concrete shall be proportioned by weight using weigh batches for each grade of concrete. Mixing shall be carried out in mechanical mixers and preferably a batch mixing plant shall be used. Batches shall not exceed the capacity, which can be mixed efficiently as determined by the mixer efficiency test, and peripheral speed shall conform to the manufacturer's recommended rate but should not vary by more than ±10%. Mixing shall continue until the mass is uniform in colour and consistency but in no case net minimum mixing time shall be less than 1.5 minutes. Net minimum mixing time shall begin when all ingredients including water is in the mixer. Excessive mixing shall be avoided. Mixers shall be operated only by trained operators. Weigh batches shall be placed level during use and the hoppers shall be loaded evenly.

iii) Consistency

Consistency of concrete shall be controlled as per IS 456-2000 and the Bidder shall carry out slump tests in accordance with IS 1199-1959.

iv) Work tests

Over the full period of construction, the successful Bidder shall carry out works tests of concrete cubes at his own cost. Sampling, making up, curing and testing of specimen shall conform to IS 456-2000, IS 516-1959 and IS 1199 -1959. The number of specimen to be tested and their criteria for acceptance shall be according to IS 456-2000. Frequency of work tests shall be as indicated below:

v) Reinforcement

Workmanship shall conform to IS 2502-1963. All reinforcement shall be free from loose mill scale, rust, oil, grease and paint, etc. Reinforcement shall not be bent or straightened in a manner that will injure the material, and all bars shall be bent cold. Reinforcement bars shall be placed and maintained accurately in the position as shown in the drawings. The



correct cover to the reinforcement shall be maintained by use of pre-cast concrete blocks. All intersections of longitudinal and transverse bars of stirrups and all laps shall be securely tied together with approved binding wire. The binding wire shall be so placed that it touches all the four corners of the intersection and the two ends shall be looped with pliers and the end should be turned into the body of the concrete. Welded joints may be used in cases of important connections tests shall be made at the cost of the Bidder to prove that the joints have reached the strength of the bars connected. Welding shall be done in accordance with IS 2751-1979 and special precautions shall be adopted for cold worked bars. Butt-welding between the ends of a rod in line, whereby stress is transferred across the section may be adopted only for mild steel bars. In case of tack welding for fixing reinforcements in their position, no special precautions need to be taken.

vi) Embedments

All embedment shall be accurately set and rigidly fastened. Anchor bolts shall be set to template and firmly secured in vertical and horizontal line at required positions. Water stops shall be secured against displacement during the placing of concrete. The joints for G.S. sheet water stops shall be soldered watertight and those of PVC and rubber shall be joined by cementing and vulcanizing. Expansion joint fillers shall be for the full depth of slabs or full width in walls and shall be cemented with bituminous cement against previously placed concrete. The ends shall be butted tight and the upper edge set flush with finished slabs.

3) Placing of concrete

i) Transporting concrete

Concrete shall be transported from the mixing plant to the forms as rapidly as possible by means that will prevent segregation or flash set in the concrete during hot weather. The containers shall be such as to prevent large evaporation. At the time of placing concrete in very hot weather, care shall be taken to see that the temperature in wet concrete does not exceed 38°C. Before placing the concrete, all formwork, embedment and reinforcement shall be checked for completeness, location, dimension, square and plumb. All



chips and sawdust or other foul matter shall be removed from within the forms. The base surface shall be well moistened and puddles wiped out. Placing equipment and accessories shall be kept clean and free of partially set grout and concrete, and maintained in proper working order. Suitable walk cradles shall be placed over the reinforcement when the concrete is placed by manual transportation.

ii) Placing

Concrete shall be placed within a maximum period of 25 minutes of its removal from mixer. No concrete shall be placed until the place of deposit has been inspected and approved by the Engineer. In general, placing shall be direct, by transporting buckets. Where it is necessary to deposit the concrete at level differences of more than 1.5 m, short chutes shall be used. Short chutes and hoppers shall be so designed and installed that segregation will not take place. In cases where chutes are impracticable due to excessive drop to placing level, hoppers and sectional tubes (elephant trunks) shall be used. Concreting in open shall not be allowed during rains unless all precautions have been taken by the Bidder and permission has been given by the Engineer.

iii) Construction joints

Construction joints shall be located such that they do not impair the strength of the structure. In walls and columns, height of each lift shall not generally exceed 1.5 m unless otherwise specified in the drawings. Method of forming all construction joints shall conform to the provision of IS 456-2000. All construction joints in the underground structures shall be provided with rubber or PVC water bars. The surface of previously placed concrete at the construction joint shall be thoroughly hacked to expose the coarse aggregates of previously placed concrete and cleaned with wire brush and water to remove all laitance. Immediately before placing fresh concrete, such prepared surface shall be coated with a thin layer of cement slurry.

iv) Expansion joints

Expansion joints shall be provided at locations as shown in drawings or as per IS code. Details of expansion joints shall be as shown in the drawing and all materials like bitumen impregnated fibre board, PVC water bar, aluminium foil etc.



shall be of approved make and quality. Bidder shall ensure that all expansion joints are 100% watertight. If concrete is found to leak at construction/ expansion joints or at other places, the Bidder shall carry out necessary remedial measures at his own cost such as pressure grouting etc., immediately to make the structure watertight.

v) Compaction

Concrete in general shall be consolidated by vibration using high frequency mechanically driven vibrators. Concrete shall be placed in layers at least 300 mm deep in walls and approximately 450 mm in mass pours. Vibrators shall not penetrate more than 50 mm into the surface of previously placed layer but shall completely vibrate the working layer. Care shall be taken not to over vibrate any concrete and especially those with higher slumps. Under no circumstances vibrator shall be attached to or allowed to touch reinforcement. Spare vibrators in good operating condition shall be in hand during placing operations.

4) Grouting

i) Grouting:

• Before placing the grout, the concrete surface shall be thoroughly cleaned, preferably with compressed air and the surface shall be thoroughly wetted with water for several hours. Grout concrete shall be of non-shrink stranded ready mixed cement-based grout of approved make as per item of work/drawing. The grouting shall be prepared and placed as per manufacturers’ instructions. Before placing the grout all free water shall be removed and the flat surface shall be coated with thin cement slurry.

• The quantity of mixing water shall be minimum commensurate with the workability, compaction, and filling of the grout in all corners and crevices. The grout shall be evenly spread and compacted by rodding or a vibrator until the whole of the space is completely filled with concrete. The grout shall be carefully observed for initial settlement. If any settlement is observed, further grout is to be poured and rodded.

ii) Non-shrinking grout: Non-shrinking grout where required shall be used in accordance with the method specified by the



manufacturer. Material shall be as approved by the Engineer.

5) Curing

The grout must not dry out after it is placed in position. The surface shall be kept moist with wet sacks for at least seven days.

6) Curing and protecting

Curing of concrete with water shall comply with IS 456-2000. The Bidder shall keep the exposed surfaces of concrete in a constantly wet condition for at least 7 days from the date of placing the concrete. Curing compound may be used subject to approval by the Engineer. Finished floor and concrete shall be protected carefully until completely set. Protection of concrete against extreme weather conditions shall comply with the Code.

7) Repairing and patching

Pockets honey combing and other defects, which may be formed due to segregation, improper vibration and any other reason whatsoever shall be completely repaired to the satisfaction of the Engineer. The voids, if any, shall be properly keyed and reinforced, if necessary. The face shall be tightly formed and arranged for providing a head in the concrete. The cavities shall be filled with the same concrete as used for the structure and thoroughly rodded or vibrated where possible. The filled hopper shall be left in place until shrinkage has taken place and the concrete sets sufficiently to stay in place. While still `alive', the upper part of form hopper shall be removed and excess concrete struck off and finished with wooden flat or trowel to match existing concrete. Any fins or unsightly grout runs or bulges shall be removed from the surfaces exposed to view. The rod holes shall be finished with cement or grouted to match the existing surface as closely as possible. No cement wash shall be used unless particularly called for in the drawings.

8) Tolerances

Tolerance is a specified permissible variation from lines, grades or dimensions given in drawings. No tolerances specified for horizontal or vertical building lines or footings shall be construed to permit encroachment beyond the legal boundaries. Unless otherwise specified, the tolerance shall be as per the relevant IS codes.

9) Form Work



i) Shuttering For Concrete

• The term `shuttering' shall include all centering and form work required to support the concrete during the process of laying, compacting and setting and all items such as planking, lagging, walling, moulds, covers, cross bearer, struts, props, bracing, etc., shall be covered by the term `shuttering'.

• Shuttering shall be strong and constructed rigidly so that there shall not be any deformation under weight and pressure of wet concrete, constructional loads, wind and/or other forces. It shall be constructed in such a manner that it can be easily removed afterwards.

• The shuttering shall have smooth and even surface and so constructed as to remain sufficiently rigid during the placing and compacting of concrete and shall be sufficiently tight to prevent loss of liquid from the concrete.

• Devices shall be provided in the shuttering for forming openings, holes, pockets, chases, recesses etc., wherever required.

• Cutting of holes etc. in the concrete after casting shall be avoided. Corner fillets shall be provided in the formwork to obtain chamfered edges to beams, columns, etc. wherever required.

• Shuttering shall conform to IS 456-2000. Forms shall be of pre-fabricated standard or shop-built panels or built-in-place units, stiffened and braced. A smearing of oil shall be given on the faces of the shuttering in contact with the concrete. Care shall be taken so that oil does not come in contact with the reinforcement. Forms shall be cleaned from all dust and loose materials before applying oil over it.

• The shuttering shall be such that after its removal, the exposed concrete shall be smooth and even. If any unevenness is found, The Bidder shall chip the bulged portion of the concrete and plaster with 6 mm thick cement plaster (1:4) at his own cost, after obtaining Engineer's approval.

• The minimum period for removing form work from various concrete members when normal Portland cement is used



shall be as per the provision of IS:456-2000, it being assumed that the work shall not be loaded for several days after the period given. All formwork shall be removed without any shock or vibration to the concrete.

ii) Supports

Formwork shall be so designed that the side of beams and slabs can be removed without disturbing soffit forms and their supports. Props and supports shall allow accurate adjustment of the formwork to line and level and be capable of being removed in an approved sequence without causing any injury to the concrete. Provision shall be made for removal of formwork without disturbing props required for supporting hardening concrete.

iii) Setting

Panels and units shall be set to true dimensions and alignment and rigidly tied, walled and braced to prevent distortion and displacement during concreting. All joints shall be tight and close fitting to prevent leakage. At all construction joints, formwork shall be tightly secured against previously cast and hardened concrete. While fixing formwork for beams and slabs, tight fitting collars shall be provided around the heads of columns and the joints shall be made grout tight. Slip forms where used shall provide smooth and even surface true to dimension and alignment and shall be free of unsightly offsets, fins or bulges.

iv) Ties

Standard form ties, clamps, bolts, inserts etc., shall be of adequate strength. Spreader, either removable or embedded type, shall be used to maintain the wall thickness. The material and position of any tie passing through the formwork shall be as approved by the Engineer. All ties, which will remain embedded in the concrete, shall be fixed in a manner that will provide a minimum cover of 12 mm at both the ends. Any holes left after the removal of the ties shall be filled with concrete or mortar as approved by the Engineer. Provision shall be made for forming holes and chases for services and for providing pipes, conduits and other fixtures as shown in the drawing and/or as directed by the Engineer.

v) Cleaning and treating of forms



All rubbish shall be removed from the interior of the formwork, and inside of the formwork shall be wetted with water before commencing the concreting. Mould oil or other approved release agent shall be used at all panels. Care shall be taken to prevent contact of release agent with reinforcement.

3.4 STRUCTURAL WORKS

3.4.1 Structural

3.4.1.1 All the structures pertaining to the scopes shall be designed with IS-800-2007 or any other international code and practices relevant to the standard design. Apart from equipment and dead load, a live load of 300 kg/cm2 on the platform and walkways shall be taken into consideration. Stairs shall be minimum of 800mm width. All walkways shall have standard handrails of 1000mm height. Toe guard of 160mm x 6mm thick shall be provided. Material of construction shall be structural steel conforming to IS-2062-2006, GR A & B.

3.4.1.2 The structure shall be painted with 2 coats of primer and 2 coats of anticorrosion paint. If it is exposed to heat then 2 coats of heat resistant paint shall be applied. Thickness of painting shall be minimum 100 microns for each coat.

3.4.2 Painting

3.4.2.1 All equipment, technological structures covered in the scope of the Bidder shall be painted with two coats of primer followed by two coats of finish coat.

3.4.2.2 Paint shall generally be applied by brushing. All surfaces shall be cleaned of loose substance and foreign materials such as dirt, rust, scale, oil, and grease, welding flux etc. so that the prime coat adheres to the original metal surface. Paint shall be applied only on clean and dry surface when the temperature of the surroundings is 50C or higher. Each coat of paint shall be allowed to dry sufficiently before application of the next coat.

3.4.2.3 Surfaces to be painted shall be applied with two coats of red oxide zinc chromate primer conforming to IS 2074:1992 or aluminium zinc oxide primer conforming to IS 2931:1964 as per requirement. Two coats of finish paint shall conform to synthetic enamel conforming to IS 2932:1993 or aluminium paint conforming to IS 2339:1963.

3.4.2.4 Items, which have received their finish coat already, shall have their injured spots levelled up, smoothed, primed and finish coated to match the original colour. The Bidders, free of cost, shall supply such touch up paint.



3.4.2.5 Each coat of primer and finish paint shall not be less than 30 microns and a minimum 120 microns dry film thickness, after finish coats, shall be ensured.

3.4.3 Inspection and Testing

3.4.3.1 The Bidder shall submit Quality Assurance Plan (QAP) for the offered equipment giving details of all tests proposed during manufacturing, assembly at works & at site after erection.

3.4.3.2 The inspection/ testing of offered equipment shall be carried out as per approved QAP. All the tests shall be carried out in the presence of Purchaser for which intimation shall be given two weeks in advance.

3.4.3.3 Checking/ Inspection/ Testing of all the offered equipment shall include the following:

1) Material test certificates for important parts/ component of bought out items of the equipment/ internal inspection report.

2) Visual inspection including dimensional checks

3) Checking of vibration level

4) Checking of noise level

5) Temperature rise in winding of motor and bearings

6) Operation of drives for equipment at no load

3.4.3.4 The maximum noise level of the drives etc., shall not exceed 85 db (A) at one meter from the source

3.4.3.5 The Successful Bidder shall maintain required quality during manufacturing/ installation and shall also guarantee the equipment/ facilities supplied by him against all defects whatsoever. In case any defect is found, the Successful Bidder shall immediately rectify/ make good such defects without sacrificing quality. If rectification is not possible, the Successful Bidder shall provide free replacement at no additional cost to the Employer.

3.5 ELECTRICS

3.5.1 Basic Design and Site Conditions LT Power Supply:

1) 415 Volts + 10%, 3 phase, 4-wire, 50 Hz + 5%

2) Fault level 50 kA for 1 second.

Control Voltage:

230 AC + 10% for 415 V LT switchgear



3.5.2 Standards The electrical equipment/ items shall be designed, manufactured, installed and tested in accordance with latest IS/ IPSS/ IEC, as applicable to respective equipment.

All equipment/ items shall generally comply with the latest revision of the following:

1) Indian Electricity Rules, 1956 (latest revision) 2) Indian Electricity Act, 1910 (latest revision)

All equipment/ items shall also comply with the statutory requirements of the Government of India, the Government of Chhatisgarh and DGMS

The successful Bidder shall follow the safety rules of Dalli Mechanised Mine and shall take clearance before starting the work from Dalli Mechanised Mine to ensure compliance to rules and extant practice.

Design and selection of equipment/ items shall be done taking into consideration of easy inspection, testing, maintenance, cleaning etc. to be carried out at site without disrupting process or taking prolonged shutdowns.

3.5.3 LT Motors

Technical Particulars for LT motors are given below:

1) Reference Standard IS 325: 1996- Three Phase induction motor.

IS 4722: 1992- Rotating Electrical machine

IS 1231: 1974- Dimensions of three phase foot mounted motor

IS 6362-1971- Designation of methods of cooling for rotating electrical machine

IS 4029-1967- Guide for testing three phase induction motors

IS 2253-1974- Designation of types of construction and mounting arrangement of rotating electrical machine



2) Type of motor Energy efficient Squirrel Cage Induction Motor

3) Rated voltage 415 V

4) Variation in Rated voltage (%)

+ 10%

5) Rated frequency 50 Hz

6) Variation in rated frequency (%)

+ 5%

7) Duty S1

8) Speed (RPM) To be matched with the driven equipment

9) Mounting Horizontal mounting / as required.

10) Type of enclosure TEFC

11) Cooling designation IC-411

12) Degree of protection IP 55

13) Class of insulation F

14) Temperature rise (over ambient temp. of 50oC).

70oC

15) Method of starting DOL.

16) Ratio of starting torque to rated torque

To be provided by the bidder

17) Starting current in percentage of rated current (Ist / Ir)

600 % (Max),

18) Power factor at rated voltage and load

0.9 or better

19) Safe stall time at 100% rated voltage at Hot condition

5 –10 Sec more than locked Rotor withstand time

20) Minimum permissible voltage at terminal for starting (with full load)

85% of rated voltage

21) Permissible running time with full load at minimum

5 min



(75%) allowable voltage.

22) Transient recovery after temporary system disturbance for 0.2 Sec and sudden restoration to 70% of rated Voltage

The motor shall be capable to accelerate with load to rated operating point from such condition.

23) Fault withstand current and time for terminal box

50 kA (rms) for 0.25 sec.

24) Torque /Speed Characteristics of Motor and Load

The Torque / Speed characteristics of motor shall match with the same characteristics of driven equipment for desired starting and acceleration

25) Direction of rotation Bi-direction

26) Winding Material Copper

27) Winding Insulation type Non-hygroscopic, oil resistant and resistant to flame propagation

28) Winding connection Delta

29) Whether windings have adequate tropical protection against fungus, corrosion etc. provided.

Yes

30) Motor terminal box type It shall be suitable for termination of actual no. and size of cables as per kW rating of the motor considering derating due to site ambient temp. as well as method of installation.

31) Degree of protection for terminal boxes

IP - 55



32) Earthing of motor body Each motor frame shall have two distinct grounding pads, one on each side, complete with tapped hole and bolt

The size of the earth connection of the motors to the shop earth grid shall be as per IS: 3043-1987.

33) Space heater To be provided for motor rating 37 kW and above

3.5.4 LV Switchgear and Control gear

Technical Particulars

1. Reference Standards IS 13947 (Part 1-5): 1993- Low Voltage Switchgear and Control gear

IS 8623 (Part 1-3): 1993- Low voltage switchgear and control gear assemblies

2. Supply system & variation

Voltage 415 V+10%

Phase 3 φ & Neutral

Frequency 50 Hz + 5%

3. Neutral system Solidly grounded

4. System Fault level 50 kA (RMS) for 1 second

5. Rated Insulation Voltage

2.5 kV for 1 min

8. Component Details

8.1 MCCB :

a) Draw out type No

b) Rated Interrupting capacity (symmetrical)

50 kA (RMS)

c) Current limiting type

Yes



d) Capacity to protect downstream equipment

Type 2 Co-ordination IS13947 (Part 4/Sec 1): 1993

8.2 Earth Leakage Relay

Sensitivity 100 mA to 500 mA ( Selectable type)

Time Delay 0.2 to 5 Sec ( Selectable type)

Test Push Button Yes

Reset Push button Yes

Core Balance Transformer Type

8.3 Contactors (Power)

a) Utilisation Category

AC3 for non reversible feeders

AC4 for all reversible feeder

b) Coil voltage (VR) 240 V

c) Drop out voltage 50 %VR

d) Pick up 85-110 % VR

e) Auxiliary Contacts & rating

2 NO + 2 NC, 10A, 240V AC.

8.4 Wiring

a) Power Circuit Insulated (1.1 kV) Flexible Copper Wire / strip

b) Control circuit Copper 2.5 mm2 multi strand PVC wire, insulated

8.5 Control Supply 240 V ac , single phase 50 Hz

8.6 CT Yes

8.7 Ammeter Yes

8.8 Overload relay EMPR

3.5.5 Local Control Push Button Station (LCS)

Local control push button station for the drive will be provided.

LCS will have two push buttons, viz., Lockable stop push button and start push-button. The stop push-button will be of red colour, mushroom



headed with ‘press to lock” and Lockable type feature. The start push-button will be of green colour and shrouded spring return type.

The local control station will be in line with the following specifications:

Enclosure: Degree of protection will be IP-55. Enclosure will be of die cast aluminium or cold rolled sheet of thickness not less than 2.5 mm.

Push Button contact Utilisation Category

AC 11

Insulation Voltage 600 V

Contact combination 2 N0 + 2 NC

3.5.5.1 A detachable gland plate at bottom or a suitable knockout will be

provided for cable entry from bottom. The LCS will have industrial type heavy-duty terminal block and the terminals will be suitable for termination 2.5 mm2 copper conductors. Each terminals-block will have 2 nos. terminals as spare terminals. “Drives ON”, “Drive OFF” and control station inscription will be marked on corrosion resistant metal strip. Identification label on each push-button will be etched / engraved on corrosion resistant metal strip or plastic sheet of 3 mm thick and will be fixed on the front side of individual local control station with few threading screws.

3.5.6 LT Power & Control Cable and cable laying

Sl

No.

Specific aspect of

Cable

Specification

1. Grade 1.1 kV grade for aluminium power cable and 1.1 k V/650V grade for copper control cable.

2. Type XLPE insulated

3. Conductor conductor made of stranded and compacted electrical grade aluminium wires (tinned copper wire for Control Cable) as per IS 8130 - 1984

4. Maximum conductor temperature with

90 deg C



rated current

5. Insulation High quality XLPE applied by extrusion process.

6. Inner Sheath Extruded PVC inner sheath with non-hygroscopic fillers for suitably holding the cores in circular configuration as per table 4, in IS 1554 (Part-I,-1988)

7. Armouring Flat strip armoured.

8. Outer Sheath Extruded type/ PVC outer sheath (type ST1 as per IS 5831-1984)

9. Maximum conductor temperature withstanding ability during short circuit.

160 deg C

3.5.6.1 The LT power and control cables would be laid along existing

structures/ galleries etc. on MS fabricated & painted cable trays. At specific locations and as per site condition cables shall also be taken through galvanised steel conduit.

3.5.6.2 All cables shall be tested for proper insulation before laying. Cables

shall be laid in a proper manner so that there shall not be any damage to the cable, no kinks or twists in the cable during cable laying. All spare cores of the control cables shall be neatly bunched and taped at both ends.

3.5.6.3 Cable Termination

Termination and jointing of cables shall be made with double compression type brass cable glands and crimping type cable lugs. Aluminium conductor power cables shall be terminated with aluminium lugs and copper conductor cables shall be terminated with tinned copper lugs.

No cable joints are envisaged in the intermediate point in the through run of cable unless the length of the run is more than the length of the standard cable drum.

3.5.6.4 Cable identification tags shall be provided as per the norms.

3.5.7 Earthing



Earthing shall be provided for all new electrical equipment. Earthing shall be connected to the existing earthing. Earthing shall conform to IS: 3043-1987. All joints shall be made with pressure type fitting or welded

3.5.8 List of preferred make of electrical bought out items shall be as per BSP’s preferred make list:



4 PERFORMANCE GUARANTEE TEST

4.1 Performance tests shall be carried out by the Successful Bidder to establish the performance for individual equipment and equipment in combination for different streams in association with the Employer / Consultant.

4.2 After the equipments are completely erected at site, each item / equipment shall be thoroughly inspected for correctness and completeness of the installation. They shall be subjected to final tests for performance, to be carried out by the Successful Bidder or his authorised representative, in the presence of Employer / Consultant. These tests shall be carried out to demonstrate that the performance of the equipment conform to relevant standards and specifications and meet the requirements as given in this specification.

4.3 For each equipment, the load test shall be conducted in stages. The equipment shall be run for 72 hours continuously at no load and at load for time duration as per mutually agreed upon between Bidder and the Employer / Consultant.

4.4 The Successful Bidder shall demonstrate the actual speed /tonnage with oversize and undersize(as per TS) of the equipment to be supplied by him, e.g., screen and its rated/designed capacity. Material will be supplied by client.

4.5 Proper operation of all safety switches shall be demonstrated by the Bidder in the presence of the Employer / Consultant.

4.6 During operations of the equipment at no load and at load, performance of all the drives shall be checked in respect to vibrations, noise and heating etc. as mutually agreed between Employer and the Bidder.

4.7 If during the test runs, there is an interruption, the test run shall be discontinued and fresh date shall be decided mutually by the Employer and the Successful Bidder.

4.8 If any equipment fails during performance test, the Bidder shall rectify it, free of cost, to restore the same within the contract period.

4.9 The Successful Bidder shall stand responsible for satisfactory performance of each equipment for a period of 12 (twelve) months from the date of commissioning or 18 (eighteen) months from the date of complete supply, whichever is earlier. If any equipment fails during period, the Bidder shall rectify it, free of cost, to restore the same.



5 SPECIAL INSTRUCTIONS TO BIDDER

5.1 GENERAL

5.1.1 1 no. soft copy of complete offer shall be submitted along with the Bid with hard copies.

5.1.2 All materials / equipment / machinery / fabricated items used in the subject package shall be according to the specification given herein and any deviation should be clearly brought-out in the offer. No mention of deviation will mean that the bidder has accepted the specification given herein.

5.1.3 The Bidder shall include in his supply a complete new and unused set of all special tools & tackles required for operation and maintenance of the plant/ equipment offered.

5.1.4 The equipment broadly described under the scope of work shall be located generally as per General Layout Drawing enclosed with the bid. The scope of TS as described in Chapter 2 & 3 covers mainly principal items for the guidance of the Bidder.

5.1.5 The plant and equipment supplied shall be new and best of its kind and of latest technology. All materials and equipment shall comply with latest codes and standards, applicable nationally / internationally. A consolidated list of all codes and standards followed or adopted for design, manufacture and testing shall be submitted. Preferably, all equipment and accessories shall confirm to the latest Indian Standards and IPSS wherever applicable. All electrical equipment supplied shall be designed, manufactured, tested & erected as per the latest revision of Indian Electricity Rules, Statutory requirements of the Govt. of India, Govt. of State. In the event of requirement of TS exceeding the requirement of corresponding standards, regulations & safety codes, the specification provided in the TS shall govern. In the event of conflict between standard regulation & TS, the most stringent shall be applied.

5.1.6 All equipment as may be necessary shall conform to the provision of Statutory and other Regulations in force such as Indian explosives Act, Indian Factories Act, Indian Boiler Regulation, State Factories Act, Central Pollution Control Board, Indian Weights & Measures Act, etc. The Successful Bidder shall take necessary steps to get all the installations within his scope of supply approved by the concerned legal authorities.

5.1.7 The Bidder shall use new, good and tested quality materials. The workmanship shall be of high quality.

5.1.8 Layout of plant and equipment shall have provision for easy and safe movement of operation / maintenance personnel for



operation / inspection of the running plant. Adequate space for dismantling / removal of equipment / parts for repair shall also be built in the layout. All working parts of the equipment shall be easily accessible and maintainable. There should be a proper arrangement for convenience of operation, inspection, maintenance, replacement & repair. Fast wearing parts shall be accessible for replacement/maintenance without necessitating removal of other parts. All like parts of the equipment supplied shall be inter-changeable.

5.1.9 After erection, all equipment, pipes, structures, etc., shall be thoroughly cleaned and painted with one coat of primer and two coats of approved colour paints. Paints shall be of good quality and shall be strictly as per instructions and recommendations of the paint manufacturer and to the approval of Employer. Painting in damp or foggy weather shall not be resorted to. Painting specification and procedure shall be subject to the Employer's approval.

5.1.10 Execution of entire work shall be carried out in such a manner that normal working of the existing running conveyor line is not interrupted. Shut downs, for mutually agreed periods shall be arranged by the Employer for interconnections / modifications / extensions of existing facilities.

5.1.11 Testing shall be done as per relevant latest Indian Standards/ International codes or practices and shall include electrical, mechanical and chemical tests including performance tests and test certificates for the same shall be submitted for Employer's approval prior to dispatch.

5.1.12 The Successful Bidder shall obtain written approval/clearance from the Employer at each stage or before start of the next stage of site work. The Bidder with the approval of the Employer shall decide the stages.

5.1.13 The Successful Bidder shall ensure deputation of well experienced engineers and technical staff from various disciplines including mechanical, technology, refractory electrical, instrumentation, automation and process control (as per requirement) for erection, testing and commissioning of plant and equipment.

5.1.14 All the manufacturing / fabrication works shall be carried out only on the basis of approved drawings and schemes or as directed by the Employer. It is solely the responsibility of the Successful Bidder to ensure that all working drawings prepared by him bear the stamp of approval of the Employer / his consultants prior to start of work. All other drawings shall bear the acceptance stamp of Employer / his consultant for execution of the project.



5.1.15 For issue of steel from Employer, kindly refer commercial terms and conditions.

5.2 DRAWING/DOCUMENTS/DATA TO BE FURNISHED

5.2.1 The offer shall be accompanied with various layout drawings showing the major equipment and auxiliaries, details of services & facilities.

5.2.2 The Bidder shall submit along with the bid, 10 sets of the drawings / documents / data and 1 nos. soft copies as per the following details:

1. General arrangement drawings of all units, equipment and systems with overall and relevant dimensions.

2. All schedules duly filled in as mentioned in this TS and enclosed herewith

3. Manufacturers' catalogues/ brief technical descriptions of offered equipment and bought-out items.

4. Schedule of quantity of equipment

5. Delivery/ commissioning schedule (Bar chart/PERT Network).

6. List of exclusions, deviations and reference list

7. Weight and mounting arrangement of each critical item/ equipment

8. Details of technical capability of Bidder.

9. List of two years operational and maintenance spares

10. Drgs/data listed at various clauses at Chapter 3.0 and elsewhere mentioned in this Tender Specification.

11. Any other details which may be felt necessary.

12. The Bidder shall note that above drawings & documents listed are minimum requirement only. The Bidder shall ensure that all other necessary write-ups, curves and information, required to fully describe the equipment and system offered, are submitted with this offer.

5.2.3 The drawings/ document submitted by the Successful Bidder shall be reviewed & commented (or approved) by Employer within 14 days of receipt of such drawings/ document. Successful Bidder shall incorporate all the comments and resubmit in 10 copies to the Employer within 15 days time from the date of Employer's comments. In order to expedite the approval of drawings discussion shall be held with the Bidder at Plant location/Ranchi.

5.2.4 Approval given by the Employer shall not relieve the Bidder of his obligations under the contract



5.2.5 Drawings/Document submitted by the Successful Bidder shall be thoroughly checked and signed by him before submission. All reference drawing numbers, including Employer's existing drawing number if any, must be mentioned in each drawing submitted for approval. The drawings shall be complete with Bill of Material.

5.2.6 Editable format soft copies on CD/DVD of all approved drawings, “As-Built” drawings and manufacturing drawings of critical parts, spares and fast wearing parts shall be supplied.

5.3 TIME SCHEDULE/PROJECT COMPLETION

5.3.1 Level-III Network (to be submitted as activity on arrow) shall be updated by the Successful Bidder every month and detail status/ delay analysis shall be submitted to the Employer along with the Monthly Progress Report. The software for preparation of network shall be discussed and decided mutually.