acl_ep_gu _part vi b2 laboratory equipments technical specification

Project : Nagpur Grinding Unit 16/12/2011

Part : Technical Specification For Laboratory Equipments Rev - 0

ANICPL Engineering & Procurement Tender Document Page # 1

CONTENTS

1.0 INTRODUCTION

2.0 BASIS OF DESIGN

3.0 DESIGN STANDARDS

4.0 SCOPE OF SUPPLY

5.0 DESIGN DATA & TECHNICAL SPECIFICATION

5.1. LABORATORY AUTOMATION

5.1.1. X-RAY ANALYSER

5.1.2. ON-LINE PARTICAL SIZE ANALYSER

6.0 INSPECTION AND TESTING SCHEDULE AT MANUFACTURER'S WORKS

7.0 SUBMITTAL OF DRAWINGS/DOCUMENTS AND ENGINEERING ACTIVITIES

8.0 TRAINING OF PLANT PERSONNEL

9.0 PERFORMANCE GUARANTEES AND PENALTIES

10.0 DELIVERY SCHEDULE




1.0 INTRODUCTION

M/s Abhijeet New India Cement Pvt.Limited, are setting up a 1.5 MTPA Green Field Cement grinding Plant at Nagpur (Maharashtra). For Site Conditions & other information “General Conditions of Supply” shall be referred. General condition shall be furnished to selected Bidder. 2.0 BASIS OF DESIGN

2.1 CONTINUITY OF POWER SUPPLY FACILITIES FOR INSPECTION, TESTING, MAINTENANCE, CLEANING AND GENERAL REPAIRS WILL BE OF PRIME IMPORTANCE IN THE DESIGN.

2.2 STANDARDISATION OF EQUIPMENT AND ITS COMPONENTS TO REDUCE THE NECESSARY STOCK OF SPARE PARTS.

2.3 ALL ELECTRICAL EQUIPMENT SHALL BE DESIGNED FOR OPERATION AT THE REQUIRED CAPACITY IN AMBIENT AIR TEMPERATURES (49 ºC) IN A DUSTY PLANT ENVIRONMENT.

2.4 THE DESIGN SHALL INCLUDE THE NECESSARY PROVISIONS FOR THE SAFETY OF MAN, MACHINE AND ENVIRONMENT.

2.5 THE VOLTAGE, FREQUENCY AND SYMMETRICAL SHORT CIRCUIT LEVELS FOR SUPPLY AND DISTRIBUTION SHALL BE AS FOLLOWS: -

2.5.1 INCOMING POWER (GRID POWER) : 3 PH, 220 KV ± 10%, 50 HZ ± 3%

2.5.2 MEDIUM DISTRIBUTION VOLTAGE : 3 PH, 11 KV ± 10%, 50 HZ ± 3%

2.5.3 MV FAULT LEVEL : 40 KA AT 11KV

2.5.4 MV SYSTEM OF EARTHING : NON-EFFECTIVELY EARTHED

2.5.5 LV DISTRIBUTION VOLTAGE (TN-S) : 3 PH, 415 V ±10%, 50 HZ, ±3%,

50 KA MIN.

2.5.6 LIGHTING, PLUGS SOCKET AND AUX. EQPT. : 230V, 1 PH + E + N , 50 HZ

2.5.7 WELDING OUTLETS : 415 V, 3PH + E + N, 50 HZ

2.5.8 EMERGENCY POWER : 415V, 3 PH +E + N, 50HZ

2.6 AUXILIARY CONTROL VOLTAGE

2.6.1 HV & MV SWITCHGEARS : 110 V-DC & 220 V-AC + E + N, 50HZ

2.6.2 MCC : 220 V AC 1 PH. + E + N, 50HZ

2.6.3 CONTROL SUPPLY

2.6.4 (ACTUATORS, SOLENOIDS, AND PROXIMITY ETC): 220 V AC, 1PH. + E + N, 50HZ

2.6.5 AUTOMATION CONTROL

2.6.6 DIGITAL INPUT / OUTPUT : 220 V AC 1 PH. + E + N, 50HZ

2.6.7 DIGITAL INPUT / OUTPUT : 220 V AC 1 PH. + E + N, 50HZ

2.6.8 ANALOGUE INPUT / OUTPUT : 4-20MA

2.6.9 UNINTERRUPTIBLE VOLTAGE : 220 V, 1 PH, 50 HZ.

2.6.10 ALL VARIABLE SPEED MOTORS SHALL BE SQUIRREL CAGE WITH VVVF DRIVE.




2.7 ENVIRONMENT CONDITIONS

2.7.1 DESIGN TEMPERATURE FOR INDOOR EQUIPMENT : MIN. 06°C

Max. 49°C

2.7.2 DESIGN TEMPERATURE FOR OUTDOOR EQUIPMENT : MIN. 06°C

MAX. 49 °C

2.7.3 DEGREE OF PROTECTION FOR INDOOR EQUIPMENT : IP4X

2.7.4 DEGREE OF PROTECTION FOR OUTDOOR EQUIPMENT : IP55

2.7.5 DEGREE OF PROTECTION FOR FIELD INSTRUMENTS : IP65

2.7.6 DEGREE OF PROTECTION FOR PUSH BUTTON STATIONS: IP65

2.8 SIGNAL COMMUNICATION AND INTERFACE WITH PLANT PLC

1.1.1. MV Switchgear Meters & Relays : Profibus/Field Bus (Profibus is preferred)

1.1.2. Switchgear Meters & Relays : Profibus/Field Bus (Profibus is preferred)

1.1.3. LV Switchgear (PCC) Controls : Hardwire/ Profibus

1.1.4. Motor Control Centre (MCC) Controls : Profibus

1.1.5. Process Monitoring Instruments : Profibus/ Hardwire

1.1.6. Machine Safety Instruments : Hardwire

1.1.7. Sub Control Systems : Profibus/ Hardwire

3.0 DESIGN STANDARDS:

In general, the equipment/components shall conform to the latest edition of relevant Standards of the Indian Standards Institution.

Wherever the Indian Standards do not exist, the equipment/ components shall be designed, assembled and tested in accordance with the latest editions of the Standards of the International Standard Institutions, Institution of Electrical & Electronics Engineers, USA (IEEE), National Electrical Manufacturers Association, USA (NEMA), International Electro-Technical Commission (IEC) or National Standards Institution of the country where they are manufactured.

The equipment shall also conform to the latest International Standard Institutions as regards safety, earthing and other essential provisions specified therein for installation and operation of electrical plants.

4.0 SCOPE OF WORK

The scope of supply and services shall include design, engineering, manufacturing, software development, testing, documentation and handing over the complete Laboratory Equipments.

The detailed scope of work is as per Annex-IV-B-4 enclosed with the specifications.




5.0 TECHNICAL CONCEPT & FUNCTIONAL REQUIREMENT OF LAB EQUIPMENTS

GENERAL

01 The System shall include suitable compact instruments, incorporating latest technology with solid-state modular plug-in construction.

02 The Scope shall include necessary companion flanges and other accessories to make the system complete and operational. Any device not included in the specification but considered necessary for proper erection, mounting and operation of the equipment shall be deemed to be within the scope of supply under this specification.

03 To reduce inventory, as far as possible, standard equipment in standard sizes and ratings shall be supplied. The purchaser reserves the right to select the equipment of a particular manufacturer and the Supplier shall supply equipment of that particular make, if so required.

04 The openings for ventilation and forced draft etc. shall be suitably protected with screens. When screens are provided on top of the equipment, means shall be provided to protect them from falling objects.

05 The equipment should be designed so as to ensure safety of operating and maintenance personnel. Aspect of ease of maintenance, testing and repair should be given due consideration while designing the equipment.

06 The equipment shall be sturdy and continuous duty type. The instruments must retain their guaranteed accuracy / sensitivity / repeatability under the conditions existing in a cement plant.

07 The equipment shall be tropicalised and given protective dips to prevent any damage due to fungus, mildew etc.

08 Power shall be made available at 415V + 10%, 3 phase, 50 Hz + 5%. For other voltages, adequately rated step down transformers / power supply units shall be provided by the supplier. 220 V AC UPS supply for Electronics & other critical items shall be provided at one point.

5.1 TECHNICAL FEATURES

5.1.1 X-RAY ANALYSER

01 The X-Ray fluorescence spectrometer will be applied for off-line chemical analysis of raw materials like fly ash, gypsum, clinker, cement etc.

02 The facilities for sample preparation, pressed powder tablets shall be included

03 X-Ray Fluorescence Spectrometer

• .A high standard of accuracy is required.




• Multi channel spectrometer for simultaneous determination of following key elements Si, Al, Fe, Ca, Mg, S, K, Na, (8 elements) with one Goneometer.

• Optionally Multi channel spectrometer for simultaneous determination of following key elements Si, Al, Fe, Ca, Mg, S, K, Na, Cl & C (10 elements) with one Goneometer.

• - X-ray tube of suitable wattage, without sacrificing sensitivity of detection preferably X-ray Tube wattage should be 2.2 to 2.5 KW.

- External air/water or water/water cooler system for close circuit water cooling X-ray spectrometer.

- Spare part kits for spectrometer and cooler.

- Operational supplies such as counter gas, sample rings etc. for approximately 2 years.

04 Standard samples for calibration for X-ray analyser shall be the part of the supply.

5.1.2 ON-LINE PARTICLE ANALYSER

The system shall be based on Laser diffraction principle for rapid reproducible means of measuring the whole particle size distribution i.e. both size by size classification as well as average diameters & surface area.

Measuring principle : Laser Diffraction

Particle size range : 0.3 to 300-1000 micron (dry) without changing the calibration or optic system

The resolution of the results to be divided in > 30 classes

Dry : Suitable to operate in air suspension. Compressor air will be supplied by ANICPL necessary moisture separator to be considered by supplier.

Calibration : Suitable for automatic calibration and must use international standards. An option should exist to use any other standards in case of any specific need

The particle analyser shall be applied for particle size analysis of cement.

The particle size range analysed with the instrument shall be 0.3 micron to 300-1000 micron. The instrument shall be fully automatic. The switchover shall be in less than a minute.

The measurement shall be displayed on a computer. The computer shall be with the following minimum configuration:

• Intel Pentium IV processor 2.66 GHz. or better

• 512 MB RAM




• 256 KB cache memory

• 80 GB HDD

• SVGA graphics

• Ethernet adapter

• Keyboard with mouse

• Windows 2000/ XP operating system

• 22” TFT colour monitor

• All related system software

• DVD writer

• Laser printer with auto sheet feeder

The measurement time shall be less than 1 min.

The results of the analysis shall be displayed on the computer screen in the following ways:

• Curves of percentage by weight, cumulative “undersize” or “oversize”

• Graphically by weight, Area, no. of particles

• Possibility of processing measurements for values of any diameters as specified by user

• Possibility of processing by different proven laws

Software configuration

The software shall be Windows2000/XP based to be compatible with plant DCS. The complete instrument operation and control should be simple along with full range of analysis and data interpretation facilities. The system software shall have compatibility to integrate with QCX Lab Automation system.

The software measurement control should have operator alarms of incorrect actions/conditions. It should have controlled access providing the security of operation.

Sampler

• Auto sampler for fully automatic sampler to measure samples online.

• Automatic cleaning of lens assemblies.

5.1.3 DCS

A suitable designed process controller shall be provided for operation and control of X-ray analyser, particle size analyser. The process controller shall be modular and open in architecture. The details of process controller shall be furnished

6.0 INSPECTION AND TESTING SCHEDULE AT MANUFACTURER'S WORKS




The equipment shall be Inspected/Tested which may be witnessed by the Purchaser/Purchaser's representatives. The Supplier shall be responsible for providing instruments of correct accuracy that may be required for carrying out these tests. All tests shall be carried out as per relevant Indian Standard Specifications or other approved International Standard Specifications.

7.0 SUBMITTAL OF DRAWINGS/DOCUMENTS AND ENGINEERING CTIVITIES:

The drawings/documents in six (6) sets shall be submitted for scrutiny /approval. Six sets of final approved drgs./documents including up dated and as built shall be provided to the purchaser. Three sets of complete documentation as mentioned above including as built drawings and documents should be provided as soft copy. All drawings, GA, circuits, loop diagrams, system architecture etc. shall be in Auto cad format and other documents in PDF/ HTML / XML as applicable

8.0 TRAINING OF PLANT PERSONNEL:

The Supplier shall provide the following training to the two engineers for trouble free operation and maintenance of the equipment.

8.1 AT MANUFACTURER'S WORKS/DESIGN OFFICE

01 Acquaintance with the inner details of system being supplied.

02 Acquaintance with the hardware and software used

03 Programming, incorporating changes in the programme, optimisation of control loop etc.

04 System and component faultfinding

05 Minor repairing of the defective equipment/components at site.

06 Erection and commissioning procedures

07 Preventive maintenance of the equipment supplied.

08 Also refer to section 2.5 above regarding training

8.2 ON JOB TRAINING AT PLANT SITE

1 Plant personnel will be associated actively with software

Development erection and commissioning

2 All the pre-commissioning and commissioning tests and the set

Values will be made available to the plant personnel.

3 All the commissioning problems will be discussed and explained to the plant personnel.

8.3 TRAINING SCHEDULE

The training at the Manufacturer's Works/design office / OEM’s works shall be arranged for two engineers.




The training schedule shall be worked out in consultation with the purchaser's representative that the personnel are mobilised for training at the appropriate stage of manufacturing and design.

9.0 PERFORMANCE GUARANTEES AND PENALTIES:

The successful Bidder shall guarantee the performance of. In case of trouble/ problem with the equipment, the Bidder shall have to make suitable modifications, repairs, replacement at his cost as may be called for to bring the equipment up to the desired/specified level of performance, failing which the equipment shall be deemed to have failed to perform and is liable for rejection and the Purchaser shall have the right to modify/replace the equipment at the risk and cost of the Supplier.

10.0 DELIVERY SCHEDULE

In order to maintain the overall time schedule for the project implementation, the Bidders shall confirm to supply and complete the erection, testing, commissioning and handing over of the x-Ray analyser within 8 months from the date of issue of Letter of Intent.

acl_ep_gu _part vi b2 laboratory equipments technical specification

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