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DESIGN, SUPPLY, ERECTION, TESTING AND

COMMISSIONING OF

HAMMER MILL , DUST COLLECTION SYSTEM AND

SUBSYSTEMS

Satish Dhawan Space Centre SHAR

Indian Space Research Organization

Sriharikota -524 124, A.P

Hammer Mill, Dust Collection System & other subsystems SDSC SHAR, ISRO

PREPARATION OF BIDS- INFORMATION TO BIDDERS

1.1. VALIDITY OF OFFERBid shall remain valid for acceptance for a period of 4 (Four) months from the due date of submission of

the Bid. The Supplier shall not be entitled during the said period to revoke or cancel his Bid or to vary the

Bid except and to the extent required by Purchaser and communicated in writing. Bid shall be revalidated

for extended period as required by Purchaser in writing. In such cases, unless otherwise specified, it is

understood that validity is sought and provided without varying either the quoted price or any other terms

and conditions of Bid finalized till that time.

1.2. COST OF BIDDINGAll direct and indirect costs associated with the preparation and submission of Bid (including clarification

meetings and site visit, if any), shall be to Supplier's account and the Purchaser will in no case be

responsible or liable for those costs, regardless of the conduct or outcome of the Bid process.

1.3. SCHEDULE OF PRICESThe schedule of prices shall be read in conjunction with all the sections of proposal document. For

lumpsum contract, the lumpsum prices quoted by the Supplier shall be firm and fixed for the completion of

the work, unless stated otherwise. The price must be filled in the online bid with the ‘Schedule of Prices’.

The price bid format is given in Annexure – IV.

1.4. DOCUMENTS COMPRISING THE BIDPART – I TECHNICAL AND UNPRICED COMMERCIAL PART

Technical bid shall be submitted online in the format ‘documents solicited from the vendor’ and the

following documents shall be attached along with the technical bid. If sufficient space is not available for on

line submission, the same in hard copy form shall be send to Department by courier/ post to reach before

the tender opening date, failing which the on-line bid will not be considered for evaluation. No attachment

with price information shall be attached along with the technical bid.

i. Submission of bid letter along with one set of proposal document duly signed and stamped as token

of acceptance.

ii. All the annexures and scope enclosed in proposal (Section -2) duly filled, signed and sealed.

iii. Unpriced copy of schedule of prices with all other commercial terms and conditions duly filled (Prices

to be kept blank), signed and stamped.

iv. Data sheets for all the equipment & checklists enclosed in proposal duly filled, signed, & stamped.

(Annexure-I , Section-2).

v. Technical details, equipment general arrangement drawings with part list, catalogue, layout drawings,

P & I diagram, catalogues etc as applicable and any other drawing, document as mentioned in the

proposal.

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Hammer Mill, Dust Collection System & other subsystems SDSC SHAR, ISROvi. Audited balance sheet including profit and loss account for the last three financial years showing

annual turnover.

vii. Latest income tax clearance certificate.

viii. Latest solvency certificate from a scheduled bank.

ix. List of projects in hand & completed during the last 3 financial years indicating the name of client,

contact person, contract value, nature of work, work completed, work balance, name of Consultant,

month & year of commencement & completion etc.

x. Schedule Bar chart.

xi. Execution Plan.

xii. Any other relevant document, Supplier desires to submit.

xiii. The bidder shall furnish a list of all critical items / sub-assemblies along with offer which are bought

out by the bidder and proposed to be used , along with necessary details such as manufacturer’s

name, brand, model no etc

PART – II PRICED COMMERCIAL BID Commercial bid shall be filled in on line ‘price bid format’ and no scanned copy should be attached along

with the technical bid. No deviations, terms and conditions, assumptions, conditions, discounts etc. shall be

stipulated in price bid. Purchaser will not take cognizance of any such statement and may at their discretion

reject such bids.

2. BID EVALUATION2.1. Vendor shall submit the details in vendor evaluation criteria mentioned in Annexure-III along with

technical and unpriced commercial part to evaluate the same.

2.2. The offer shall be for complete scope of work as specified in tender document. Part/Spilt offer is NOT

acceptable.

2.3. During evaluation, purchaser may request Supplier for any clarification on the bid upon additional

documents which is to be complied with; otherwise offer will be deemed incomplete.

2.4. Techno-commercial discussion shall be arranged with Supplier, if needed. Supplier shall depute his

authorized representatives for attending discussions. The representatives attending the discussions shall

produce authorization from his organization to attend the discussion and sign minutes of meeting on

behalf of his organization if required. The authorized representative must be competent and empowered

to settle/decide on all technical and commercial issues.

2.5. The complete scope of work is defined in the Proposal document. Only those Suppliers who undertake

total responsibility for the complete scope of work as defined in the Proposal document shall be

considered.

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Hammer Mill, Dust Collection System & other subsystems SDSC SHAR, ISRO2.6. In case Bid does not fully comply with the requirement of Proposal document and the Supplier stipulates

deviations to the clauses of the proposal in Schedule of deviations, which are unacceptable to the

Purchaser, the Bid will be rejected.

2.7. Performance of Supplier on similar works executed/ under execution shall be taken into consideration

before selecting the Supplier for opening his price bid.

2.8. Purchaser reserves right to visit client’s site for verification/validation.

2.9. The time schedule for completion is given in the Proposal document. Supplier is required to confirm the

completion period unconditionally.

2.10. Purchaser reserves the right to accept a bid other than a lowest and to accept or reject any bid in full or

part without assigning any reasons. Such decisions by the Purchaser shall bear no liability on the

Purchaser whatsoever consequent upon such decision.

2.11. Purchaser shall not be obliged to furnish any information / clarification to unsuccessful Suppliers as

regards to non-acceptance of their Bids.

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Section – 1General Terms and Conditions of

Contract

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Hammer Mill, Dust Collection System & other subsystems SDSC SHAR, ISROGENERAL TERMS AND CONDITIONS OF CONTRACT

1 INTRODUCTIONSDSC SHAR invites tenders in sealed covers from reputed firms with proven ability for DESIGN, SUPPLY, ERECTION, TESTING AND COMMISSIONING OF HAMMER MILL, DUST COLLECTION SYSTEM AND ITS SUBSYSTEMS AS PER TECHNICAL SPECIFICATIONS for SDSC SHAR, Sriharikota.”

2 SCOPE OF WORK AND TECHNICAL SPECIFICATIONS

The scope of work is given below and technical specifications are given in the enclosure to this document. The general terms and conditions are given below.

The details of scope of work:1. Detailed design/scheme shall be submitted to the Department and any suggestion or modifications

shall be incorporate. Clearance shall be obtained before realization.

2. Realization of the system as per the technical specifications and approval of the Department

3. Required handling systems for transportation and erection at site.

4. Submission of detailed work break-up structure with schedules and resources.

5. Supplier shall carry out inspection at identified stages and the copies of such reports after inspection shall be forwarded to Purchaser. The original copies of certificates shall be submitted along with other documents at the time of acceptance testing.

6. Supply of List of essential spare as per this document. Any other critical spare not mentioned in list has to be suggested by the supplier. The supplier has to ensure the supply of all essential spares and material for trouble free operation of the equipment for ten years. The scope of the work is not limited to the above but also includes all the requirements for the fully functioning the system and to meet all the requirements regardless of whether they are explicitly mentioned or not.

7. Acceptance tests are to be worked out in mutual consultation with Department .

3. WORKS UNDER PURCHASER’S SCOPEi. Overall layout of equipment and sub systems and its dimension.

ii. Design Review and clearance: The design report will be subjected to the review by Purchaser experts committee.

iii. Approval of Quality Assurance Planiv. Clearance for manufacture of interfaces v. Stage inspections or third party inspection.

vi. Pre-delivery / dispatch inspection.vii. Inspection of fully commissioned system

viii. Supply of PLC , SCADA based Control systems and CCTV systems.

4. SUPPLIER’s OBLIGATIONS & FUNCTIONS4.1 SPECIFICATIONS AND DRAWINGSThe Supplier shall execute the works in compliance with the provisions of CONTRACT, good engineering

practices and code requirements.

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Hammer Mill, Dust Collection System & other subsystems SDSC SHAR, ISRO4.2 APPROVAL OF TECHNICAL DOCUMENTS / DRAWINGS

Supplier shall prepare and submit the following Documents to SDSC SHAR from the award of Purchase order for clearance.

4.2.1 Party shall produce the schedule of drawings and documents to be submitted for review, approval and information with submission date.

4.2.2 Party shall produce the configuration drawings for SDSC SHAR approval.4.2.3 Party shall convey Quality Assurance Plan (QAP). The QAP shall list down various stages of

inspection and inspection agency namely supplier quality Control agency & 3 rd party inspection agency, if engaged. Elaborate Quality Assurance Plan (QAP) is to be prepared& furnished for review & approval.

4.2.4 Detailed equipment list, design details and bill of materials.

4.2.5 General arrangement (GA) drawings shall be submitted for approval. 4.2.6 Instrument data sheets and mounting sketches for erection and bill of materials. Measurement

Sensors mounting details shall be provided in detail.4.2.7 Instrument list & Sensors Details with Makes and Model Nos.

4.2.8 Cable Schedule and Interconnection Schedule. 4.2.9 Electrical wiring diagrams showing interlocks, controls, wiring sizes, rating of each electrical

component etc. and logic diagrams.4.2.10 Dimensioned general arrangement and section drawings of switchgear panel.

4.2.11 Detailed description of operating sequence and control and interlock system.4.2.12 No activity shall be executed unless Purchaser’s approval is obtained. The above documents /

drawings shall be submitted in a format approved by Purchaser. Quality Assurance Plan shall be strictly in accordance with Quality Control Manual and Formats to be provided after the award of CONTRACT.

4.3 DESIGN& SUPPLY OF HAMMER MILL, DUST COLLECTION SYSTEM AND ITS SUBSYSTEMS.

4.3.1 Design, Supply, Testing, erection, Integration and commissioning of Hammer Mill, Dust Collection system and its sub systems shall be as per Section 2.

4.3.2 Any item which may not have been specifically mentioned herein but are needed to complete the equipment / system shall also be treated as included and the same shall also be supplied and erected at no extra cost, unless otherwise specifically excluded as indicated.

4.3.3 All these goods or material shall be supplied or used shall be new and of first quality. Where imported or partly imported goods or material are offered or intended to be used, the fact must be specifically stated and brought to the notice of Purchaser.

4.4 INSPECTION AND TESTING4.4.1 As per the procedures detailed in Section 2.

4.4.2 The supplier shall identify and inform various stages of inspection including sub systems, components and bought out items etc., to SDSC SHAR. The approved QAP shall be followed during course of Supply, Erection & Testing.

4.4.3 Purchaser reserves the right to inspect all phases of Supplier’s operations through its representatives and/or third party inspection agency approved by the Purchaser. Therefore it is the responsibility of the supplier to provide the necessary support for the inspection agency and get the works inspected at all stages of work as identified in quality assurance plan. The presence or absence of a Purchaser’s representative does not relieve the Supplier of the responsibility for quality control in all phases of the work. In the event that any of the work being done by the Supplier or any Sub-Supplier is found by Purchaser’s representatives to be unsatisfactory or not in

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Hammer Mill, Dust Collection System & other subsystems SDSC SHAR, ISROaccordance with the drawings, procedures, specifications and standards, upon verbal notice of such discrepancy or deficiency, the Supplier shall take immediate steps to revise the work in a manner to conform to the relevant drawings, procedures and specifications. The Supplier shall carry out required supervision and inspection as per Quality Assurance Plan and furnish all assistance required by the Purchaser in carrying out inspection work during this phase.

4.4.4 The authorized inspectors of the purchaser shall have access to the premises of the supplier and its sub-contractors at all reasonable times. All the equipment, instruments, tools that are necessary for the inspection shall be provided by the supplier on demand by purchaser’s own inspectors or a third party authorized by purchaser. Inspection by purchaser’s own inspectors or by third party authorized by purchaser shall not absolve the responsibility of the supplier from proper performance of the system and from the guarantee/warranty clauses stipulated in the contract.

4.4.5 Pre – delivery Inspection: As per the procedures detailed in Section 2.

4.5 DELIVERY AND STORAGE 4.5.1 Dispatch Instructions given in the Contract shall be strictly followed. Failure to comply with the

instructions may result in delay in payment apart from imposing any other charges as may be deemed to fit.

4.5.2 The Supplier shall be responsible for transporting all the equipment to site, unloading and storage. No equipment shall be delivered without obtaining dispatch clearance from Purchaser. All the equipment shall be properly packed to avoid any damage during transportation / handling / storage.

4.5.3 Party shall undertake the responsibility of the system and its components during transportation to Sriharikota and during erection, testing and commissioning of the same at suitable location identified by SDSC, SHAR and until handing over the system to SDSC, SHAR after its acceptance.

4.6 INSTALLATION4.6.1 Supplier’s staff shall include adequate number of competent erection engineers with proven

experience on similar works to supervise the erection works and sufficient skilled, unskilled and semi-skilled labour to ensure completion of work in time.

4.6.2 Supplier’s erection staff shall arrive at site on date agreed by Purchaser. Prior to proceeding to work, Supplier shall however, first ensure that required/sufficient part of his supply has arrived at site.

4.6.3 Certain material handling equipment are available with purchaser and the same shall be extended free of cost for carrying out unloading and erection at purchaser’s site. However party shall convey the list of material handling equipment needed for the above purpose. If the required material handling equipment is found unavailable, the supplier shall has to arrange the same by its own.

4.6.4 Erection of equipment may be phased in such a manner so as not to obstruct the work being done by Other Suppliers and / or operating staff that may be present at that time.

4.6.5 During erection, Purchaser’s engineer will visit site from time to time with or without Supplier’s engineer to establish conformity of the work with specification. Any deviations, deficiencies or evidence of unsatisfactory workmanship shall be corrected as instructed by Purchaser.

4.6.6 Supplier shall carry out work in a true professional manner and strictly adhere to the approved drawings. Any damage caused by Supplier during erection to new or existing building shall be made good at no extra cost to Purchaser.

4.6.7 Supplier shall provide the list of spares required for hassle-free operation of the equipment with cost and probable suppliers. Any special tooling used during erection and commissioning is to be supplied at the time of hand-over without any additional cost.

4.7 RECORDS4.7.1 Supplier shall maintain records pertaining to the quality of erection work in a format approved by

Purchaser. Whenever erection work is complete, Supplier shall offer erected equipment for

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Hammer Mill, Dust Collection System & other subsystems SDSC SHAR, ISROinspection to Purchaser’s engineer who along with Supplier’s engineer will sign such records on acceptance.

4.7.2 The complete project, right from component level till the complete system performance tested including sub – assembly shall be properly documented with drawing, configuration drawings, Test certificate etc.

4.7.3 There shall be time to time submission of information /clearance / approval by the purchaser and all comments shall be duly incorporated.

4.7.4 All such drawing will become part of PRODUCTION MASTER FILE which shall also contain as built drawing, Final Erection, Testing & Commissioning report done at site. 5 copies of PRODUCTION MASTER FILE shall be supplied.

4.8 EQUIPMENT ERECTION4.8.1 Supplier shall carry out the works in accordance with the specific instructions given on the

approved drawings/ documents or as directed by Purchaser.

4.8.2 Supplier shall take utmost care while handling instruments, delicate equipment, panels etc., and protect all such equipment on erection.

4.9 DRAWINGS AND O&M MANUALS4.9.1 Supplier shall submit 5 hard copies & three soft copies of all the approved

drawings incorporating any modification / changes made during the execution of CONTRACT. All these drawings shall be marked as ‘As Built’.

4.9.2 Supplier shall submit 5 hard & 3 soft copies of the following documents.4.9.2.1 Operations manual of the machine.4.9.2.2 Programs manual.4.9.2.3 Maintenance manual with drawings, circuit diagrams, interfacing

instructions, trouble shooting and maintenance instructions and spares list with source of supply.

4.9.2.4 Submission of the drawings and manuals shall be a precondition for releasing of any final payment due to Supplier.

4.9.2.5 Manuals and mounting instructions for all the Sensors, transmitters, Load cells and control valves.

4.10 TRAININGSupplier shall organize training for purchaser authorized persons by covering

operation and maintenance of the machine, comprehensive programming at supplier’s premises prior to dispatch as described in detailed in Section 2.

5. SCHEDULE OF PRICE 5.1The quoted price shall include all costs of “DESIGN, SUPPLY, ERECTION, TESTING AND

COMMISSIONING OF HAMMER MILL, DUST COLLECTION SYSTEM AND THEIR SUBSYSTEMS AS PER TECHNICAL SPECIFICATIONS”. Shop floor testing, packing, forwarding, transport to site, unloading, storage, all risk coverage, erection, commissioning, training, testing & evaluation of equipment including any other cost for proper and complete execution of the CONTRACT.

5.2CONTRACT prices shall also include all third party inspection, travelling expenses, living expenses, salaries, overtime, benefit and any other compensation for engineers, supervisors, skilled, semiskilled workmen, watch and ward staff, laborer and other staff employed by the Supplier, cost of tools and tackles required for erection and other consumable material required, and all taxes, duties, and levies as applicable on the date of submission of bid.

5.3 Price shall be firm & fixed.8

Hammer Mill, Dust Collection System & other subsystems SDSC SHAR, ISRO5.4The taxes applicable for supply and erection & commissioning shall be indicated

separately in terms of percentage in the price bid. If the offers submitted by the suppliers are silent on taxes, it will be presumed that quoted rates are inclusive of taxes & duties and no claim in this regard will be entertained later.

6 DELIVERY TERMS6.1The rate quoted shall be on FOR SDSC SHAR, Sriharikota basis. 6.2In case of foreign suppliers the prices shall be quoted on CIP, SRIHARIKOTA basis.

Supplier is responsible for clearing the consignment, transport of equipment to destination and erection & commissioning at site and all the necessary works till the equipment is commissioned and accepted by Purchaser.

7 MODE OF PAYMENT7.1Supplier can submit the banker details and payments will be made through Electronic

Clearance System (ECS). 7.2In case foreign suppliers LC will be established for supply portion and erection &

commissioning portion separately. The agency commission shall be paid in Indian Rupee based on the suppliers authorization. Any other mode of payment shall be stipulated by the tenderer.

8 TERMS OF PAYMENTSOur standard payment term is 100% within 30 days after receipt and acceptance of individual items at SDSC SHAR.

9 DELIVERY SCHEDULESupplier shall follow the following schedule for executing the contract

S. No Mile Stone Expected date of completion

T1 Letter of Intent / Purchase order date T

T2 Submission of Configuration and G.A. Drawings T1+ 4 weeks

T3 Date of clearance of Configuration and G.A. Drawings T2+ 2 weeks

T4 Submission of final drawings T3 + 2 weeks

T5 Submission of fully configured system for pre delivery inspection at party’s site T4 + 12 weeks

T6 Installation, Testing & Commissioning T5 + 4 weeks

Tentative foundation details of the equipments such as areas where civil works are to be commenced for the foundation in the building plan, depth of foundation required for each of the item shall be submitted by the party within three weeks from the date of receiving the purchase order. The party shall submit detailed foundation design, layout drawings and other civil requirements along with the Configuration and GA drawings.

10 Earnest Money Deposit (EMD)The Earnest Money Deposit(EMD) of Rs 1,00,000/- (Rupees One Lakh Only), refundable (Without interest), should be necessarily accompanied with the Technical Bid of the agency in the form of Demand Draft/Pay Order/Banker's Cheque drawn in favour of

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Hammer Mill, Dust Collection System & other subsystems SDSC SHAR, ISROAccounts Officer, SDSC SHAR ,Sriharikota failing which the tender shall be rejected summarily.The details of DD/PO/BC towards EMD shall be entered in the online bid at appropriate places and the instrument shall be sent to Department before the tender opening date. In case, if the instrument is not received in time, the offer will not be considered.The EMD in respect of the agencies which do not qualify the Technical Bid (First Stage)/Financial Bid (Second competitive stage) shall be returned to them without any interest. However, the EMD in respect of the successful tenderer shall be adjusted towards the Security

11 RISK COVERAGEDepartment will not pay any insurance taken by the supplier. The Supplier shall include the cost of comprehensive risk coverage at his own cost covering the value of equipment including transportation to the site from manufacturer’s works, storage at site, fabrication, erection, testing and commissioning at site. The period of such coverage shall be up to contractual completion period or any extension granted by Purchaser thereof.

12 SECURITY DEPOSIT 12.1 The supplier whose tender is accepted will be required to furnish by way of Security

Deposit for the due fulfillment of the contract such a sum as will amount to 10 % of the contract price of the work awarded in the form of Bank Guarantee valid till the satisfactory execution of the contract and acceptance.

12.2 The security deposit (bearing no interest) shall be held by the Purchaser as security till satisfactory completion, testing and handing over of all the system and for the due performance of all suppliers’ obligations under the contract as per delivery period or extension granted thereof by the Purchaser.

12.3 Within 10 days from the date of receipt of Letter of Intent, supplier shall deposit the security deposit to the Accounts officer, Satish Dhawan Space Centre SHAR, Sriharikota as detailed above by any of the following modes.

(a) By a crossed demand draft in favor of Accounts officer, Satish Dhawan Space Centre SHAR drawn on SBI and payable at Sriharikota.

(b) By an acceptance bank guarantee. The bank guarantee shall be from a reputed international/nationalized/schedule bank.

12.4 In case of breach of contract, the Security deposit shall stand forfeited in addition to other relief available to the Purchaser under this contract.

13 PACKING AND FORWARDING13.1 The Supplier shall arrange to have all the material suitably packed as per the

standards & statutes and as specified in the contract. Unless otherwise provided for in the contract, all containers (including packing cases, boxes, tins, drums, and wrappings) used by the Supplier shall be non-returnable.

13.2 All packing and transport charges, transit handling costs, transit risk coverage and transport fees of agents employed at the place of delivery or elsewhere, shall be deemed included in the price to be paid to the Supplier.

14 WARRANTY The supplier shall provide twelve months warranty for the entire system for a defect liability, after final official handing over. During this period supplier has to provide and adhere to the following:

14.1 This period shall include maintenance; replacement of defective/failed parts at free of cost.

14.2 Supplier has to attend to unlimited breakdown calls.

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Hammer Mill, Dust Collection System & other subsystems SDSC SHAR, ISRO14.3 Purchaser will not provide any transport/accommodation for this purpose.14.4 Upon oral or written notification of defects in or malfunctioning of the goods during

the warranty period which require corrective action, Supplier shall send the necessary personnel to job site to supervise and assume responsibility for repairs and/or replacement, if necessary, of the defective goods or material at his own cost. If Supplier does not, within seven (7) days after receipt of notification, take steps to correct the breach, Purchaser may do so at the cost and expense of Supplier. Supplier shall reimburse Purchaser all expenses incurred by Purchaser to repair or replace malfunctioning or non-conforming goods.

14.5 Where defects items are replaced by new ones, the full warranty period stipulated in the contract shall apply to such replacement items as from the date of their delivery.

15 GUARANTEES:The Supplier shall guarantee that the equipments furnished by him are in conformance with the requirement of the specifications. Goods covered by the contract shall be free from defects in design, materials or workmanship for a period of twelve months from the date of successful commissioning & acceptance by Purchaser.

16 PERFORMANCE BANK GUARANTEE The supplier shall guarantee for the performance of the contract by providing bank guarantee in favour of the Purchaser for an amount equivalent to 10 %( ten percent) of the total value of this contract valid till the warranty period of the contract. The performance bank guarantee shall be submitted by the supplier with in fifteen days from the date of accepting the equipment as per the CONTRACT. The format for the performance bank guarantee shall be obtained from Purchaser.

17 DISCLOSURE AND USE OF INFORMATION BY THE SUPPLIERSupplier shall take all necessary steps to ensure that the requirements of the contract or any specification, plan, drawing, pattern, sample or information supplied by, or on behalf of, the Purchaser in connection therewith shall not be disclosed to any person other than a person employed or engaged by the Supplier, whether under sub-contract or otherwise, for the performance of the contract.

18 APPLICABLE LAW AND JURISDICTIONThe laws of India shall govern this contract for the time being in force. The Courts of Andhra Pradesh, India only shall have jurisdiction to be with and decide any legal matters or disputes what so ever arising out of the contract.

19 FORCE MAJEUREShould a part or whole work covered under this agreement be delayed due to reasons of Force Majeure which shall include legal lockouts, strikes, riots, civil commotion, fire accident, quarantines, epidemic, acts of God and Government, embargoes, the completion period for work, equipment referred to in this agreement shall be extended by a period not in excess of the duration of such Force Majeure. The occurrence shall be notified by either party within reasonable time.

20 SAFETY AND SECURITYSupplier shall follow the safety regulations / codes or safety instructions issued by PURCHASER and shall take necessary measures at his own cost. The contractor personnel have to undergo security checks by security force i.e. CISF. All the working personnel shall comply with code of conduct during their stay inside the SHAR campus.

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Hammer Mill, Dust Collection System & other subsystems SDSC SHAR, ISRO21 GENERAL21.1 SITE DETAIL

21.1.1 The indented “Hammer mill, Dust collection system and its subsystems” is to be erected inside a facility in SDSC SHAR, Sriharikota, The place ”Sriharikota” is 20 km East of Sullurupeta (nearest town ) which is 80 km North of Chennai, Tamilnadu, INDIA.

21.1.2 SDSC SHAR, Sriharikota is prohibited place. Hence, no contractor, working personnel will be allowed to stay and they have to be accommodated in Sullurupeta by his own arrangement.

21.1.3 The contractor may have to transport working personnel on day to day basis by his own arrangement. Location of the site is worked out to be 32km(Approx.) from Sullurupeta.

21.2 POWER SUPPLYElectrical power provided by the purchaser during installation is NOT chargeable subjected to availability & approval. Reasonable quality of normal power will be made available at one point (415V, 3 phase, 50 Hz). However, onward distribution shall be done by the supplier. All electrical installation by the supplier shall be as per safety regulation & standard and will be subjected to purchaser inspection & approval.

21.3 WORK RULESGenerally, NO work shall be carried out during night or public holidays unless a written permission is obtained from Purchaser.

21.4 SITE CLEARANCEUpon completion of work, Supplier shall remove all his equipment and material from the site within one month or time mutually agreed. Supplier at all times shall keep site in clean condition and remove all unwanted material at regular intervals. In case supplier fails to remove all his equipment and material within the mutually agreed time it is deemed that Purchaser will arrange to remove the same at the supplier’s cost besides imposing penalty for failure.

21.5 ACCOMMODATION Very limited accommodation may be provided by Purchaser to senior supervisory staff of the Supplier on chargeable basis subject to availability. Supplier shall make his own arrangement for accommodation & canteen facility for all its staff, technicians, labor & workers. Transportation shall be arranged by Supplier at his own expenses for entire staff.

21.6 MEDICAL FACILITIESNo medical facilities will be provided by Purchaser at site for Supplier's site personnel. Supplier shall make his own arrangement at his own expenses for medical facilities for site personnel.

21.7 WORK PROGRAMMEThe supplier along with proposal shall give a preliminary programme schedule for executing the contract as per the scope of work. Upon award, supplier shall prepare a detailed programme schedule for review / approval by Purchaser. Supplier as per exigencies of work shall revise and update programme periodically. Monthly progress review meeting will be conducted alternatively at purchaser / supplier site

21.8 SUB-CONTRACTS21.8.1Whole of the work shall not be subcontracted. 21.8.2The portion of the work for which the supplier is not expert, shall be sub -

contracted to proven / reputed OEM in that field. Such sub- contract if any shall be given with prior approval of the purchaser including choice of subcontractor.

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Hammer Mill, Dust Collection System & other subsystems SDSC SHAR, ISRO21.9 CHANGES AND MODIFICATION TO SPECIFICATIONS, DESIGNS, DRAWINGS

AND QUALITATIVE / QUANTITATIVE REQUIREMENTS.21.9.1Supplier shall obtain approval for the designs and drawings from the Purchaser

before initiating the action for procurement / fabrication.21.9.2Change in make/model for bought item is NOT allowed unless approved by

purchaser. 21.9.3Purchaser is free to modify the designs or drawings during design review. Party

has to carry out one time modifications at each stage without any extra cost and obtains the approval from Purchaser.

21.9.4Any amendment to the contract, which may be necessary in this respect, will be established within a reasonable time in the form of an Amendment to Contract to be signed by both parties.

21.10CANCELLATION The Purchaser shall have the right at any time to cancel a contract either wholly or in part by giving one month written notice. From the time of receipt of the written notice the Supplier shall undertake to observe the instructions of the Purchaser as to the winding up of the contract both on his own part and on the part of his sub-suppliers.In the event of such cancellation, the Purchaser shall unless otherwise specified in the contract, only pays.

- In the case of a fixed-cost contract for the supply of equipment or material. The contractual value of items delivered and accepted under the contract before receipt of notification of cancellation, or to be accepted under the special conditions of cancellation.

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Section – 2 Technical Specifications of Hammer mill,

Dust collection system and its subsystems

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2.1 IntroductionIndian Space Research Organisation (ISRO) is planning to set up a new grinding facility for solid propellant oxidizer at SDSC SHAR. The oxidizer material is explosive and hygroscopic in nature. The oxidizer material is ground to fine powder with wide Particle Size Distribution (PSD) to use for subsequent processing. Hammer mill is used to grind coarse particles of oxidizer into fine particles. The feed material of Average Particle Size (APS) 280 – 330 µm is obtained from our production facility. The material is ground by using the hammer mill to product size of APS 45 -55 µm.

The feed material is obtained in FIBC (Flexible Intermediate Bulk Container) from production facility and will be unloaded into master hopper placed at elevated location (First floor of the facility) using crane. The master hopper is fitted with a valve (electrically/ pneumatically operated proportional orifice control gate valve with manual override) that can be controlled from control room. The valve and actuators shall be ATEX approved. The status of valve shall be acquired at the control room. The master hopper is placed on 4 active load cells to measure the weight locally and the same will be acquired using a PLC and SCADA system in control room for regulating the flow based on weight of the material. The feed material is fed at controlled feed rate into the hammer mill using screw feeder system.

The hammer mill is run at desired RPM to obtain product material of required PSD. The ground material is collected at the bottom outlet of hammer mill. A negative suction is applied through connecting ducting from bottom outlet of hammer mill and dust collection system. The dust collection system is a bag house with a set of filter bags. The negative suction is operated through filter bags allowing material to lodge on them. A timed reverse jet is applied with use of compressed air, timer and solenoid valves to un-lodge the material on filter bags. Differential Pressure transmitter should be mounted so as to measure the pressure difference across the baggage system. Air fail switch has to be provided in the blower duct, provision has to be made to measure air pressure in blower duct. The product material is collected at the bottom of dust collection system into a FIBC via rotary air lock valve. This document provides the specification of hammer mill, dust collection system, and its subsystems.

2.1.1 Details of handled material:

Name of Material: Ammonium PerchlorateUN Number of feed material: UN1442UN Number of product material: UN0402Hardness of material: 2-3 on MohsScaleAPS of feed material: 280 – 330 µmAPS of product material: 45 – 55 µmDensity of material: 1.95 gm/cm3.Bulk density of feed material: 1.12 gm/cm3.Bulk density of product material: 0.6gm/cm3.

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Feed material in FIBC

Unload material into hopper

Screw feeder hopper hoperhopperHopper HooperhopperScrew feeder

kjkvhkhjkfeederfeederFeederGrinding in Hammer Mill

Conveying material from mill room to collection room

Collection of material in dust collector

Conveying material from first floor to ground floor

Final product in 1 ton FIBC bag


2.1.2 The process flow chart is given below:

Process Flow Chart

First floor – Feeder room

Ground floor - Mill Room

Ground floor - Collection Room

2.1.3 Grinding system consists of the following elements:

a) Major Equipment:1. Master hopper with valve (electrically/ pneumatically operated with manual override – shall be

operated locally and remotely)& load cells 2. Ducting from first floor to ground floor3. Screw feed hopper (integrated to screw feeder)4. Screw feeder (shall be operated remotely with VVVF drive)5. Hammer mill (shall be operated remotely with VVVF drive)6. Ducting from hammer mill to dust collection room7. Reverse jet pulse dust collection system 8. Centrifugal Blower

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The grinding system includes the feeding system, hammer mill and product collection system which is dust collector coupled with reverse pulse jet system and centrifugal blower. The RPM of screw feeder is monitored / controlled to give controlled feed to hammer mill. The RPM of hammer mill shaft is monitored / controlled to achieve desired PSD.

b) Control and monitoring system:The control and monitoring panel is used to control and monitor all the process parameters. The panel is situated in a control room about 200 m from the hammer mill, dust collection and subsystems. The control system shall monitor all the process parameters, interlocks, CCTV, weight of feed hopper, collection and status of valves. However, the supply of SCADA / PLC based control and monitoring system is not the scope of the supplier. All the necessary cables from sensors, transmitters, Status & Command signal shall be brought to instrumentation Marshalling chamber in safe area via concealed cable trays with proper ferruling for identification is in the scope of supplier. Termination at the Marshalling chamber is not in the scope of the supplier.

c) Safety System:The material is highly explosive, hence the grinding system includes all possible interlocks and safety measures to avoid hazards. In pure form, exposing the material to more than 75OC is dangerous. The contamination with finely divided or pure metal dust is potentially hazardous even at room temperature. The systems shall ensure that the material is not subjected any kind of high temperatures or contamination.

d) System readiness:The handling of material is carried out in batches. 4-15 batches constitute a program schedule. To prevent contamination of material from different batches, the whole system that is prone to contact with material (AP), is water washed to remove any material stuck to it. This includes chamber of hammer mill, dust collection system, feeding system and ducting from feeding system to dust collection system. All the parts of the system are dissembled and water washed. They are allowed to dry for required time and once dryness is ensured, the system will be re-assembled. Hence all instruments / sensors mounted on the Grinder / subsystem shall be with IP 65 protection or better.

2.2 Working, operational sequence, control philosophy and Interlocks2.2.1 Working of AP Grinding System

a. Components of hammer mill will be cleaned dry, assembled and sealed.b. All necessary checks like oil level in hammer mill, intactness of bolts & nuts will be carried out.c. Hoppers will be inspected and cleaned if required.d. A magnet (ERIEZ make) is placed in screw hopper to prevent accidental entry of ferrous

material.e. The dust collection system will be cleaned dry, assembled and sealed.f. A collection FIBC is connected to discharge port / flange of rotary air lock valve of dust

collection system.g. A no-load trial run for 15-30 min will be carried out. Post trail-run checks will be carried out for

final assurance. h. Feed material, 1000kg is received in a FIBC to the receiving bay of facility in a trailer. i. The FIBC is transferred from receiving bay to feeder room through flap door.

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j. The FIBC is moved to top of master hopper and material is unloaded into master hopper through discharge sprout of FIBC.

k. The building will be vacated and all the further operations till the end are unmanned only.l. It will be ensured that the compressed air line pressure is above 6.5 ksc. This shall be

monitored using Pressure transmitter of suitable range.m. The process will carried out in operational sequence mentioned in next section.n. Material is transferred from feed bin to hammer mill in controlled fashion using screw feeding

mechanism. In case of accumulation of materials in screw feeder hopper, the feed bin valve is switched off till material is consumed.

o. The weight of ground material collected in collection FIBC is monitored continuously on mobile balance. If the material is found less than required further grinding is continued to achieve required batch size.

p. The ground material is weighed exactly by using another balance and will be sealed and dispatched to next process facility.

q. During grinding occasionally mill will be stopped, samples of material will be collected for PSD analysis. The RPM of mill may be adjusted to get desired PSD.

r. Factors like Mill RPM, feeder RPM, suction velocity, size of feed material, moisture content and thickness of material lodged on filter bags affect the PSD of collected product.

2.2.2 Operational Sequencea. All the necessary checks will be carried out for running the equipment.b. The compressed air line pressure shall be more than 6.5ksc. (Pressure shall be monitored using

SMART pressure transmitters of suitable range)c. The building will be vacated and operation will be carried out remotely.d. The panel will be turned on, followed by reverse pulse-jet timer.e. The centrifugal blower and pneumatic vibrators timers are turned on.f. After a while, confirming that blower is turned on and timed reverse jet is observed, the mill

motor will be switched on and RPM will be set to desired value.g. The screw feeder will be turned on and set to desired RPM.h. After confirming that the system is running normal, feed bin valve will be opened in controlled

manner to allow material to be fed.i. Always maintain optimum level of feed in screw feeder hopper to get required PSD j. The impact of fed material on hammers and other housing surfaces break them into small

particles. The retaining sieve at the discharge port of hammer mill will ensure that oversized particles are retained and ground further to reach desired size.

k. The equipment is turned off in reverse order as it is turned on. Master Hopper valve is shut off, followed by switch off of screw feeder, hammer mill, blower and reverse jet timer in that order.

l. The power to control panel will be terminated.m. The collection FIBC will be removed and weighed on platform/trolley balance.n. If material is found less than required, additional material will be ground as mentioned above in

this section. o. A sample will be collected for PSD analysis. The remaining material will be sealed in FIBC and

sent to next processing facility. p. During processing all the monitoring and controlling operation will be carried out using control

and monitoring panel only.

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2.2.3 InterlocksThe following interlocks are necessary to carry out smooth functioning of Hammer mill and Dust Collection system. Provision should be made to access all the below mentioned equipment and instruments from SCADA. SCADA and PLC system will not be in the scope of supplier. However the supplier has to supply all necessary sensing elements with proper interfaces that are to be interfaced with Data Acquisition System.

a. The reverse jet pulse shall be ON. b. The negative suction carry over the material from hammer mill and prevents piling up or

choking in ducting of mill to dust collection system and any material pile up is dangerous. c. When feed is operated without hammer mill running, the material will get accumulated in

hammer mill chamber even when the negative suction is operative.d. Hence, the hammer mill/feed should not be operated when blower was shut off.e. The feed should not be operated when hammer mill was shut off.f. The master hopper valve should not be operated when feeders were shut off.g. When the ducting is chocked with ground material, leading to poor negative suction, an air fail

switch should be activated to stop feed system and hammer mill.h. When the power to the panel is turned on, it should turn on “Yellow” LED cluster indication

lamps placed one near approach road and another on the top of the building.i. When the operational sequence is initiated, it should turn on “Red” LED cluster indication

lamps and turn off “Yellow” LED cluster lamps placed one near approach road and another on the top of the building.

j. The system should remain shut down when any of the Emergency Push button station positioned in feeder room, mill room, collection room and control room panels is activated.

k. Proper interfaces shall be provided (sensors / through drives) to monitor the ON/OFF/TRIP status and line currents of all motors.

2.3 Scope of the Supplier

This section covers the general requirements for design of system, supply of materials, preparation of detailed drawings, manufacture, testing & inspection of contractor’s works, packing, forwarding, transportation, transit insurance, unloading at site, erection, testing & commissioning of hammer mill, dust collection system and their subsystems as per specifications detailed in Annexure I ( Table- 1 to 19)

2.3.1 Design, testing, supply, erection and commissioning of hammer mill, dust collection system and their subsystem as per given specification. The scope includes installation of all necessary equipment, instrumentation and electrical components in feeder room, mill room, collection room and control room.

2.3.2 Supply, erection and commissioning of process, control and automation related sensors / transmitters etc. as per the specifications given in this document for grinding of oxidizer.

2.3.3 Any other equipment/ parts/ components, which are not mentioned in specification but required for smooth operation of the system shall be considered included and to be supplied and installed without additional cost. The list of such equipment/ parts/ components shall be submitted for department approval. Any other equipment/ parts/ components that are

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suggested by vendor as optional for safe and smooth running of system may be submitted along with offer.

2.3.4 A Drive cum switch gear Panel (DSG panel) as per the detailed specification mentioned in Annexure-1 is to be realized. The DSG Panel should be fabricated and assembled by a panel manufacturer from the authorized panel manufacturer in the list. The supplier should engage the panel manufacturer, obtain and submit GA drawing, Power drawing, control drawing and get it approved by department. The panel should undergo functional tests, HV test, Dielecric strength and other qualification tests as per standards at Panel manufacturers works in presence of department engineer.

2.3.5 The systems control and data acquisition is through PLC & SCADA is in Purchaser’s scope . The PLC envisaged for this automation is dual redundant with criss cross configuration. The DSG panel should use PROFINET Protocol and all feeder elements including VFD drive should be configured suitable to this dual redundant configuration. All feeder currents, speed (VFD), on/off/trip status, On/Off commands, run status, feeder protection (EL,SC,OC,winding temp) should be communicated through profinet cable. Profinet cable (main & redundant -2 runs) should be laid from DSG panel to control room with sufficient length including extra loop. However individual feeders in DSG panel should be controllable locally from DSG panel pushbutton stations at service room apart from control room PLC mode and even without availability of PLC & SCADA system. This may be achieved by local Drive programming or through a small PLC incorporated in DSG panel. This local operation should have enable/disable provision with removable key. Individual feeder ON/OFF buttons to be interfaced with VFD/Contactor to meet discreet operation of each feeder element in local nodes.

2.3.6 Authorized Drive engineer shall be deputed for integrating DSG panel with SCADA & PLC as per automation system requirements. They should carry out all required Drive parameterization and demonstrate necessary Drive functionality and protective features. They should also be available for first live trial process operation of the system after integration with SCADA & PLC automation systems.

2.3.7 All, drive licensed software, drive parameters with suitable communication cables and interfaces (required to connect to PC) to monitor and modify the drive parameters and drive codes & parameters to be provided. In case PLC is used PLC licensed software and code also to be provided.

2.3.8 All cable laying and suitable termination, loop checking, interfacing and trial runs is in scope of supplier. Necessary works like clamping, crimping, ferruling etc is in supplier’s scope.

2.3.9 Installation of all the sensors/ transmitters and control valves with mounting structures, wherever is deemed necessary by the purchaser.

2.3.10 Calibration certificates for all the sensors/transmitters installed should be provided at time of commissioning.

2.3.11 Guidelines or supply of routine test certificates and FLP test certificates for all flameproof equipments.

2.3.12 Submission of necessary GA drawings, piping layout, wiring diagram, panel drawings etc after award of contract to department and obtaining approval before commencement of fabrication is in scope of supplier.

2.3.13 Party shall submit project execution plan along with their offer, detailing the methodology of contract execution.

2.3.14 Factory Acceptance tests (FAT) & Site Acceptance tests (SAT) to meet the design specifications & functional requirements.

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2.3.15 Power wiring with suitable rating armoured cables as per load details a. PCC to DSG panel (Incomer)b. DSG panel to Mill motor, Screw feeder, control valve, blowers, and compressor.

The cables shall comply with LT voltage level 1100V, Armoured with XLPE insulation as per IS: 7098. The minimum size of cable shall be 4 sq. mm copper conductor for all power wiring. All feeders shall be with copper conductor cables. The power wiring shall be carried out with necessary saddles, clamps, cable tags, glands, etc. The termination of flame proof stations in Mill room, collection room, feeder room and receiving bay shall be with Double Compression Glands.

2.3.16 Cable laying:

a. Power, Control and Communication cables shall be laid in trenches and cable trays as applicable.b. Medium voltage and control cable shall be separated from each other by adequate spacing or by

running through trenches or cable trays.c. The lengths indicated in the cables schedule are only approximate. The contractor shall

ascertain the exact length of cable for a particular feeder by measuring at site. All cable routes shall be carefully measured and cables cut to the required lengths, leaving sufficient lengths for the terminations of the cable at both ends.

d. Cable shall be laid in RCC trench (underground trench) or in surface tray. RCC ground level Trench will be provided by department & internal required cable Tray mounting is in scope of the supplier.

e. Cable installation shall be provided minimum cable bending radii as recommended by manufacturer.

f. Cables shall be nearly arranged in the trenches/trays in such a manner that criss-crossing is avoided and final take off to the motor/switchgear is facilitated.

g. All cables shall be identified close to their termination point by cable tags.

2.3.17 Termination:

a. Double compression type flameproof glands shall be used for termination carried out at FLP items.

b. Where copper to aluminum connections are made, necessary bimetallic washers shall be used.c. In case of control cables all cores shall be identified at both ends by their terminal numbers by

means of PVC ferrules for core size. Wire numbers shall be as per schematic wiring/inter-connection diagram. All unused spare cores of control cables shall be nearly bunched and ferruled with cable tag at both ends, for future use. All spare cores shall be terminated in TB.

d. Contractor shall drill holes for fixing glands wherever necessary. Gland plate shall be of used wherever more number of cables is terminated .Gland plate shall be of non-magnetic material/aluminum sheet in case of single core cables. All unused cable entries on equipment/panels shall be plugged or sealed.

e. The cable shall be terminated at electrical equipment/switchboard through glands of proper size.

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2.3.18 Before energising, the insulation resistance of every circuit shall be measured from phase to phase, phase to neutral and from phase/neutral to earth.

2.3.19 The approximate cable length requirements are listed in table below :

Control wiring: The control wiring shall be armored with minimum copper conductor size of 2.5 sq. mm of XLPE/PVC insulation, voltage grade 650V/1100V as per IS: 1554/7098. The control wiring shall consist of following:

a. Master Emergency OFF at Control room shall be hardwired with DSG panel MCCB trip circuit.

b. DSG panel to Control room

The Power & control cable requirements to meet various interfacing field elements are specified below. The details are indicative and vender shall meet extra cable requirements in case of requirement.

Cable schedule Cable type Anticipated Length

1 PCC to DSG panel (Incomer) Armoured XLPE insulated 3 ½ C 95Sq.mm copper cable , 25 m

2 DSG panel to Mill motor Armoured XLPE insulated 3 ½ C 50Sq.mm copper cable 25 m

3 DSG panel to screw feeder motor

Armoured XLPE insulated 3 ½ C 16Sq.mm copper cable 25 m

4 DSG panel to control valve Armoured XLPE insulated 3 ½ C 16Sq.mm copper cable 25 m

5 DSG panel to blower motor1 Armoured XLPE insulated 3 ½ C 25Sq.mm copper cable 25 m

6 DSG panel to blower motor2 Armoured XLPE insulated 3 ½ C 25Sq.mm copper cable 25 m

7 DSG panel to compressor Armoured XLPE insulated 3 ½ C 50Sq.mm copper cable 150 m

7Feeder room to DSG panel

(Emergency off) Armoured control cable 12 pair

1.5sq.mm copper cable25 m

8 Mill room to DSG panel (Emergency off)

Armoured control cable 12 pair 1.5sq.mm copper cable 25 m

9 Mill room to DSG panel (Local on/ off)

Armoured control cable 12 pair 1.5sq.mm copper cable 25 m

Collection room to DSG panel (Emergency off)

Armoured control cable 12 pair 1.5sq.mm copper cable

25 m

10 DSG panel to Control room Armoured control cable 24 pair 1.5sq.mm copper cable 200 m

11 DSG panel to Control room Profinet cable(2 runs) 200 m

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2.3.20 INSTRUMENTATION SYSTEM FOR HAMMER MILL AND SUBSYSTEMS

a) The vendor has to supply suitable sensors / transducers to monitor the various parameters mentioned in Technical Specification. The mounting details of the sensors shall be provided with P&ID during design review phase.

b) The mounting of all sensors, transmitters, control valves etc. at the required locations to monitor various process parameters is in the scope of the suppliers. Mounting of all sensors / transducers / Instruments by selecting suitable mounting arrangement, piping, fittings required between equipment and routing of Sensor/transmitter cables(with ferrules for proper identification) via concealed cable trays up to instrumentation Marshalling chamber is in the scope of the supplier. Terminations are not in the scope of the supplier. All sensor / transmitter cables shall be minimum of 25m length. However actual length has to be arrived at by considering the cable routing plan.

c) All the sensors, transmitters and actuators shall be ATEX approved/ intrinsically safe to suit the environment of the process. All sensors/transmitters are to be 24V DC loop powered. The supplier has to provide calibration certificates and ATEX/intrinsic safe certificate from standard agencies for all items supplied. The speed of the screw feeder and hammer mill has to monitored using P&F make RPM sensor by providing suitable mounting and sensing arrangements. There shall be provision to set the timer for pulse air and pneumatic massagers through SCADA. The status of the solenoid valves need to be interfaced with the SCADA system through micro switches

c) Humidity transmitter shall be provided to measure the humidity and temperature of feeder room and collection room. All transmitters shall be with PROFIBUS-PA interface wherever available. If PROFIBUS-PA interface is not available it shall be 4-20mA loop powered SMART transmitters. All transmitters shall be with local display. They shall be mounted at accessible locations. All control sensors and actuators are to be provided with redundancy.

d) Any other sensors/ equipment/ components, which are not mentioned in specification but required for monitoring / control operation of the system shall be considered included and to be supplied and installed without additional cost. Since the control system is planned with redundancy at I/O level itself, there shall main and redundant sensors for each parameter to be monitored.

e) List of parameters to be monitored is given below along with required makes of sensors are specified below. Minimum of 20 % spares has to be provided for each type of sensor. The supply of any of the item with Makes other than those specified in the list requires approval from the purchaser.

Sl No: Parameter Sensor Make

1 Control Valve for Master Hopper with manual override

Orifice Proportional Control Valve / equivalent

VORTEX / Equivalent (ATEX approved)

2 Weight of material in the Master Hopper 4 active load cells Mettler

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3Sensing of pressure wherever mentioned including Differential Pressure

Pressure transmitters ROSEMOUNT 3051 with PROFIBUS PA

4 RPM monitoring of screw feeder and mill Inductive Proximity Sensors P&F

5 Motor Line Currents

Current Sensor with 4-20mA output. Where ever drives are available, line currents and trip status can be obtained from drives.

LEM/IFM/ M-systems

6 Humidity Sensor Humidity Transmitter Emerson /Honeywell7 Pulse Air Solenoid Dual coil solenoid valve ASCO NUMATICS8 Solenoid Driver P&F

2.3.21 Quality Acceptance Plan

Supplier has to meet the following Quality Acceptance Plan (QAP) and provide necessary documents/ records whenever necessary for approval of department, prior to commencement of works. An execution plan shall be submitted by supplier in concurrence of QAP for department approval. Any deviations shall be reported in written format immediately.

2.4 Factory Acceptance Test (FAT)Factory Acceptance Tests (FAT) will be carried out by department personnel at supplier’s site before dispatch of material to SDSC SHAR. It is supplier responsibility to carry out FAT to department satisfaction and obtain clearance for dispatch.

2.4.1 Dimensional checks of hammer mill, dust collection system, blower and their components.2.4.2 Measurement of clearance between hammers and housing, retaining screen and other chamber

components using putty test / suitable method.2.4.3 Measurement of clearance between screw feeder blades and trough using putty test / suitable

method.2.4.4 Measurement of clearance in vanes and housing of Rotary Air Lock valve using putty test /

suitable method. 2.4.5 Verification of following documents

a. Flame proof certificate of all the electrical components to be housed in mill room, feeder room, collection room and receiving bay, complying IS 2148 & IS 325 and issued by approved agencies like CMRI / ERTL.

b. All motor routine test certificates complying IS:325.c. Dynamic balancing certificate of hammer mill shaft and impeller of centrifugal blower.d. Blower performance curve certificates.e. Material test certificates.f. Dimension measurement certificates of all couplings like gears, belts, pulleys etc.g. Radiography test certificates.h. Hardness test certificate for hammers.i. Calibration Test certificates for sensors/transmitters.

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j. ATEX certificates for sensors/transmitters.k. Panel test certificate for HV & dielectric tests

2.4.6 Quality control test which shall be carried out to assure quality of all components.2.4.7 Measurement of current and IR value for all motors.2.4.8 Functional and interlock checks of electrical systems.2.4.9 The panel should undergo functional tests, HV test, ielectric strength and other qualification

tests as per standards at Panel manufacturers works in presence of department engineer.2.4.10 Visual check of all instruments, IS isolator/multiplier, etc. mounted in the panels.2.4.11 High voltage test for all panels2.4.12 Insulation resistance test before and after HV tests for panels.2.4.13 Complete trial assembly of setup and examining of interfaces, gaps, intactness etc of system. 2.4.14 Measurement sensors mounting location 2.4.15 Functional testing of hammer mill along with dust collection system and centrifugal blower. A

no-load trial shall be carried out at minimum (1000 to 3000) RPM of hammer mill shaft for 4-6 Hours and data shall be logged and presented. Another no-load trial shall be carried out at maximum (5000-7000) RPM of hammer mill for 2-4 Hours. All data shall be logged and presented. Possibility shall be explored by the supplier for the mill to be operated at constant feed rate both at low and high speed with dummy material to know the material feed and product properties. Hammer mill also shall be operated with minimum flow rate and maximum flow rate with constant mill speed to know dummy material feed and product properties

2.4.16 Functional testing: This shall include the simulation of each item in the Control Panel supplied & wired by the Supplier and achieving the functional requirements as called for in the specifications.

2.4.17 After the Contractor has performed the tests satisfactorily, the Contractor shall perform tests on the Control Panel to be witnessed as per approved QAP. Contractor shall notify to the department at least one week prior to Factory Acceptance Test.

2.4.18 All test certificates for testing instruments shall have calibration certificates from approved test house, valid for minimum 6 months.

2.5 Site Acceptance Tests (SAT)

After successful completion of FAT, material shall be dispatched to SDSC SHAR, unloaded, stored and installed. After successful installation of all systems at site, the site acceptance tests includes the following:

2.5.1 Physical verification of hammer mill, dust collection system and their subsystem for any damages and their interfacing. All equipment shall be properly grounded using suitable GI/ Aluminum strips, GI/Copper strips of appropriate size.

2.5.2 Measurement of current and IR value for all motors.2.5.3 Functional and interlock checks of electrical systems2.5.4 No load trial of system including checks for abnormal running, interlocks and control systems. All

parameters of operation shall be recorded as per department defined format. Any abnormalities found shall be reported and rectified.

2.5.5 Live trials with Ammonium Perchlorate. All parameters shall be recorded and reported. Any abnormalities shall be reported and rectified. System qualification includes obtaining qualified ground product.

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2.5.6 Physical verification of hammer mill, dust collection system and their subsystems for any damages and interfacing after no-load and live trial.

2.5.7 The supplier has to ensure proper interfacing of all sensors / transmitters / Drives with Data Acquisition and Control System.

2.5.8 Interlocks Checking and Remote Operation through SCADA Console.2.5.9 Establishing communication from IMCC/DRIVE to SCADA. This part will be executed after

erection of PLC/SCADA System by the department. Party shall provide provision for all the motor currents along with their status to SCADA.

2.5.10 Verification of all certificates.2.5.11 Submission of installation report.

2.6 Training & Documentation

2.6.1 Training for department personnel, regarding operation, maintenance and troubleshooting of system

2.6.2 Three engineers from department shall be trained in VVVF drive & Motor management system from drive manufacturer and Motor management system supplier.

2.6.3 Contractor shall provide soft copy (3 nos.) and hard copy (5 nos.) of the catalogues, and manuals of all the components and systems and as built circuit diagrams. Supplier shall provide 5 no’s of lubrication and maintenance documents, list of spare with order number.

2.6.4 Soft copy & hardcopy of drive parameterization shall be provided.2.6.5 Manual and software for VFD drive shall be provided.2.6.6 3 engineers shall be trained in VVVF drive system.

2.7 Department Scope:

2.7.1 Building and cable trenches2.7.2 Supply of PLC & SCADA for remote monitoring and control operations2.7.3 CCTV System

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Annexure – I

Technical Specifications

Table 1Specifications of Hammer Mill

Description Essential Specification Compliance (Yes/ No)

Quantity 1 NoModel / Type 2DH (Double Hammer)Sets of Hammers 12 SetsHammers per set 2 NosHammer Type LFS Hammers with tip hardness 50-58 on Rockwell C

scale and material to be specified Retaining Screens 9- no’s

Herring bone type Number -020 (opening size : ~ 500 microns) – 3 no’s 027 (opening size : ~ 680 microns) – 3 no’s 035 (opening size : ~ 890 microns) – 3 no’s

Type of Oil – Plummer block Krytox GPL 106 (M/s. Dupont) Liner Multi Deflector typeMOC Housing SS304Base Plate SS304 Base Plate dimension to be specified by supplierRotor RPM 1500 – 7000Grinder capacity 300 – 600 kg/HrFeed Mechanism Screw feeder typeFeed Rate 300 – 600 kg/HrSpares One set of recommended spares for hassle free

operation for 10 yearClearance between liner and hammers 2-4 mmClearance between retaining screen and hammers

2-4 mm

Clearance between base and hammers (Drive end)

3-4mm

Clearance between base and hammers (Non-drive end)

4-5 mm

Clearance between shaft and base 0.65-0.85 mmClearance between hammers Max. 4 mmThickness of components To be specified by supplierWeight of each components To be specified by supplierWeight of hammer system To be specified by supplierSafety Mechanism The system shall be provided with necessary safety

mechanisms like air fail, choke, over heating etc.Monitoring Parameters 1. Motor RPM of Hammer mill

2. Rotor Shaft RPM of Hammer mill

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Table 2Specifications of Screw Feeder


Quantity 1NoMOC SS304Feed rate (kg/Hr) 300 – 600 Clearance between screw and trough

1- 2 mm

Inlet not less than 150 mm x 150 mm with suitable mating flange to mate the hopper

Outlet Closed type connected to hammer mill chamber Monitoring parameter

RPM of Screw feeder

Table 3Specifications of Drive System for Mill Motor

An FLP induction Electric Motor with suitable transmission system is to be designed for rotating the Mill rotor.

The motor should be 3000 rpm (syn) with suitable transmission system (pulley) to achieve 1500-7000 rpm at shaft.

The Electric motor is powered through VVVF drive for fine end rpm control however the operating frequency of drive should be kept above 15Hz towards achieving 1500-7000 rpm at shaft.

The motor capacity should be selected such that motor shall draw only 80% of rated current at full load.Specification of motor & transmission is given below

Compliance (Yes/ No)


Quantity 1NoELECTRICAL SPECSMOTOR Make Kirloskar/Crompton Greaves/Bharat Bijili/CEMP/MarathonRPM of Motor) 3000 rpm (syn)Capacity The motor capacity should be selected such that motor shall draw only

80% of rated current (or less) at full load. Design calculations to be submitted towards arrival of motor power rating and approval to be obtained.

Operating Voltage 415 V ± 10% , 3 phaseOperating Frequency 50 Hz ± 5 %Hazardous zone operation

Zone I, Group IIA, Group IIB compatible

Duty Class ContinuousProtection IP 54 or better (IP 65 preferable)

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Temperature Classification

T4 or better

Insulation Class F and temperature rise limited to Class BThermistor/KTY84 Sensor

Two nos. embedded in windings to monitor winding temperature and trip system upon high winding temperature. KTY84 is preferable

Connector Armoured copper conductor cable terminated using double compression flameproof gland

Motor inverter duty requirements

Motor Voltage rise time shall be more than 0.1µs, Peak insulation voltage minimum 1400 V.Suitable for VFD operation considering factors like voltage rise time, peak insulation voltage and bearing currents caused by VFD.

MECHANICAL REQUIREMENTSRPM at the end of transmission

1500 – 7000 using suitable transmission system

Table 4Specifications of Drive System for Screw feeder

A FLP induction Electric Motor with suitable transmission system is to be designed for rotating the screw feeder motor.

The motor with suitable transmission mechanism to achieve 5-50 rpm at shaft. The Electric motor is powered through VVVF drive for fine end rpm control however the

operating frequency of drive should be kept above 10Hz towards achieving required rpm at shaft for feed rate of 300 – 600 kg/Hr

The motor capacity should be selected such that motor shall draw only 80% of rated current at full load.Specification of motor & transmission is given below



Quantity 1 NoELECTRICAL SPECIFICATIONSMotor Make Kirloskar/Crompton Greaves/Bharat Bijili/ CEMP/ MarathonRPM of motor 1500rpm(syn)Capacity The motor capacity should be selected such that motor shall draw

only 80% of rated current (or less) at full load. Design calculations to be submitted towards arrival of motor power rating and approval to be obtained.

Operating Voltage 415 V ± 10% , 3 phaseOperating Frequency 50 Hz ± 5 %Hazardous zone operation

Zone I, Group IIA, Group IIB compatible

Duty class ContinuousProtection IP 54 or better (IP 65 preferable) Temperature classification

T4 or better

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Insulation Class F and temperature rise limited to Class BThermistor/KTY84 Sensor Two nos. embedded in windings to monitor winding temperature

and trip system upon high winding temperature. KTY84 is preferable

Connector Armoured copper conductor cable terminated using double compression flameproof gland


Motor Voltage rise time shall be more than 0.1µs, Peak insulation voltage minimum 1400 VSuitable for VFD operation considering factors like voltage rise time, peak insulation voltage and bearing currents caused by VFD. All termination shall be made using proper flameproof glands

MECHANICAL REQUIREMENTSRPM at end of transmission

5 – 50 using suitable transmission system

Table No: 5Specification of VFD for Mill motor


Quantity 2 Nos (working+spare)Make Siemens / ABB with PROFIBUS/PROFINET interfaceMain voltage 380-480 V ± 10 %, 3 PhaseInput Frequency 48-63 HzOutput rating One size higher standard Drive rating of selected motor full

load ratingOverload capacity 150 % for 60 sec Digital inputs 6 Nos programmable (minimum)Analog inputs 2 Nos programmable (0-10 V, 0-20 mA, and -10 to +10 V) (minimum)Relay outputs 3 Nos programmable (minimum)Analog outputs 2 Nos programmable (0-20 mA) (minimum)Safety guidelines IEC 61800Ambient Temperature 50 Deg CCommunication interface

Profinet or other protocol with Profinet converter

Choke or filter Choke/Filter of suitable rating to limit THD as per IEEE519Protections Protection against input/output phase loss/phase short circuit,

under/over voltage , di/dt, inverter protection, heat sink protection etc.,

Operator panel Advanced Operator panel (AOP)mounted on panel cubicle door

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Table 6Specifications of VFD for screw feeder motor

Description Description Compliance (Yes/ No)

Quantity 2No’s (working+spare) each ( Total – 2 nos)Make Siemens / ABB with PROFIBUS/PROFINET interfaceMain voltage 380-480 V ± 10 %, 3 PhaseInput Frequency 48-63 HzOutput rating One size higher standard Drive rating of selected motor full

load ratingOverload capacity 150 % for 60 sec Digital inputs 6 No’s programmable (minimum)Analog inputs 2 No’s programmable (0-10 V, 0-20 mA, and -10 to +10 V) (minimum)Safety guidelines IEC 61800Ambient Temperature 50 Deg CCommunication Interface

Profinet or other protocol with Profinet converter

Choke or filter Choke/Filter of suitable rating to limit THD as per IEEE519protections Protection against input/output phase loss/phase short circuit,

under/over voltage ,di/dt, inverter protection, heat sink protection etc.,


Table 7Specifications of Hopper (Screw Feeder)


Quantity 1MOC SS304Capacity Min 60 lts Other specifications SS 304 removable perforated mesh jacket to fit into hopper to depth

of min 100 mm. Hole size not more than 1 mm with triangular pitch. The distance between two holes shall not more than 2 mm.

Table No: 8 Specification of Master Hopper with valve


Quantity 1 NosType Cylindrical with conical bottomMOC SS304Capacity 1500 ltsSWL 2000 kg

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Half cone angle max 45O with verticalDischarge min 100 mmOverall Height Not more than 1.5 mtsBottom clearance from the end of the valve 500 mm Width Max 1.6 mts IDScreen SS 304 removable perforated mesh jacket to fit into master hopper

to depth of max 100 mm. Hole size not more than 3 mm with triangular and the distance between two holes shall not more than 2 mm.

Other specifications Shall be designed, supplied and commissioned by party along with necessary fasteners. The hopper shall be associated with weighing system with flame proof local display and remote display in control and monitoring panel to indicate weight of master hopper with readability of minimum 100 gm.

Control Valve Control valve with manual override shall be operated from control room to regulate the flow. Valve shall comply to operation in Zone I, Group IIA, IIB hazardous area.

Table 9Specifications of Mill base plate


Quantity 1 NosMOC SS304Capacity To sustain weight of hammer mill and damp vibrations during

operationOther specifications Shall be designed, supplied and commissioned by party along with

necessary fasteners Safety factor 6:1

Table No: 10Specification of RPM Sensors


Quantity 6 NosMake Pepperl & FuchsType Namur induction proximity switch along with suitable frequency to

current converter, current repeater, current to voltage converter and necessary subsystems

Model No NCB8-18GM40-NO-VI along with all of its accessories & Necessary cable from RPM Sensor to P&F Frequency to current converter in panel. Supply of P&F Freq to Current Converter is in the scope of Supplier.

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Hazardous zone operation

Ex Proof, Zone I, Group IIA, Group IIB compatible

Table 11Specifications of Dust collection system


Quantity 1 NosMOC SS304Type Reverse jet pulse with timer based system with filter bag setupFilter Bag material Polyester needle felted epitrophic antistatic filter bag along SS304

bag retainers and clamps. Clamps shall have provision for quick fixing and removable type.

Filter Area , No. of bags , bag dimensions & bag retainers

To be specified

Maximum pressure drop across the unit

Maximum. 120 mm WCG

MOC Venturi SS304 Assembly No loose parts like screws, bolts, nuts which have risk of falling into

product are not allowed inside dust collection chamber. Alternative safe fastening technique shall be specified by supplier

Suction source centrifugal blower inletPulse mechanism Ex-proof dual coil solenoid valves with micro switch for providing

status operated through programmable timers through SCADA.(For testing during SAT, discrete sequential timers may be used)

Pulse duration On: 50 – 150 milliseconds - AdjustableOff: 3 -60 seconds – Adjustable

Access door The size of door shall be suitable designed to safe, quick and easy access and maintenance of filter bags.To be designed to facilitate removal of the whole set of filter bags as an integral set for cleaning/ replacement. There should provision to change/ replace individual bag. The best possibility may be suggested.

Half Cone angle of hopper Should not be more than 50OC with verticalExplosion vents 2 Nos. and min. 450 x 900 mm sizeDischarge 330 -450 mm. A suitable coupling method to attach FIBC shall be

providedBottom clearance From bottom of discharge/ Rotary air lock valve to floor shall not be

less than 1200 -1500 mm and will be reviewed in GA drawingsInlet position The inlet to dust collection system shall be connected from outlet of

hammer mill, with slope angle not more than 10O with horizontal. The connecting duct from hammer outlet to dust collection system should not have any sharp bends.

Pneumatic Vibrators Pneumatic vibrators positioned at hopper as per standard. Total collective force shall not be more than 2kN using four vibratory

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hammers. A timer should be used to energize a set of only two opposite vibrators and alternatively. Capacity of pneumatic vibrators and their position details shall be submitted in the technical bid. Pneumatic vibrators shall be of approved make.

Support and platform structure

Suitable support structure to bear the weight and with required clearance shall be made using SS 304. Suitable platform structure shall be provided for accessing the access doors, solenoid valves etc. Design shall be submitted to department for approvalAt the discharge, there shall be four hooks mounted on legs, which can be movable up and down using suitable mechanism and shall not give any friction or exposure to material dust. These hooks will be used to mount collection FIBC.

Pressure indicators Two differential pressure transmitters with local display and a u tube manometer shall be provided along with dust collection system to indicate differential pressure between suction and collection using SS tubing.

Suction By Centrifugal Blower (Two centrifugal blowers , one in working and other redundant , using a single duct provided with a damper)

Discharge Teflon lined rotary air lock valve with min clearance of 500-750 microns and it should be suitable to discharge the product of average particle size of 45-55 microns. All contact parts of the discharge material shall be Teflon including blade and housing. The valve shall be driven by a Ex proof motor complying to operate in Hazardous Zone I, Group IIA, IIB areas

Monitoring Parameters i. Air Pressure in blower ductii. One Air fail switches in blower ducts

iii. Compressed air pressureiv. Pulse durationv. Pneumatic Vibrators - Time duration

vi. Differential pressure

Table 12Specifications of VFD for blower


Quantity 2No’s (working + spare)Make Siemens / ABBMain voltage 380-480 V ± 10 %, 3 PhaseInput Frequency 48-63 HzOutput rating One size higher standard Drive rating of selected motor full

load ratingOverload capacity 150 % for 60 sec Digital inputs 6 Nos programmable (minimum)Analog inputs 2 No’s programmable (0-10 V, 0-20 mA) (minimum)Relay outputs 3 Nos programmable (minimum)Analog outputs 2 Nos programmable (0-20 mA) (minimum)

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Safety guidelines IEC 61800Ambient Temperature 50 Deg Ccommunication Profinet or other protocol with Profinet converter Choke or filter Choke/Filter of suitable rating to limit THD as per IEEE519protections Protection against input/output phase loss/phase short circuit,

under/over voltage ,di/dt ,inverter protection, heat sink protection etc.,


Table 13Specifications of Centrifugal Blower


Quantity 2 No’sDrive type VVVF Drive system MOC of blower SS 304, min 3 mm thickMOC of dampers SS 304, min 2 mm thickMOC of base frame SS 304MOC of impeller SS 304, min 2 mm thickMOC of ducts and flange SS 304, duct min 2 mm thick; flange min 6 mm thickBlower suction To mate with dust collection systemBlower discharge To be specified by party, open into mill roomOperation temperature Max 50OCDrive type Direct driveBlower capacity Min 1250 CMH @ 600 mm WCDynamic balance As per standardMounting of motor SS pedestalELECTRICAL SPECSMOTOR Make Kirloskar/Crompton Greaves/Bharat Bijili/CEMP/MarathonRPM of MOTOR 3000 rpm (syn)Voltage 415 V ± 10% , 3 phaseFrequency 50 Hz ± 3 %Motor capacity The motor capacity should be selected such that motor shall draw

only 80% of rated current (or less) at full load. Design calculations to be submitted towards arrival of motor power rating and approval to be obtained. Min 7.5 HP

Motor typeFlameproof induction motor, Ex-d, suitable for operation in Zone I, Group IIA, IIB hazardous areas. Two sets of embedded thermister in motor winding.


Voltage rise time shall be more than 0.1µs, Peak insulation voltage minimum 1400 V.Suitable for VFD operation considering factors like voltage rise time, peak insulation voltage and bearing currents caused by VFD.

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Motor temperature classification

T4 or better

Ingress of Protection IP 54 or better (IP 65 preferable)Drive type Direct driveHazardous zone operation Zone I, Group IIA, Group IIB compatible

Table 14Specifications of Compressor


Quantity 1 NosCapacity Min. 100 CFM at 7 kscType Reciprocating, Non lubricantMake Kirloskar / Chicago Pneumatic / Boge / Ingersoll-rand Air dryer Shall be equipped with refrigerant type air dryer. Pressure dew point shall be

3-5 deg C.Receiver min 1000 ltsRemarks Compressor will be positioned in compressor room, approximately 200 m

from equipment and necessary piping as per standard shall be designed to transfer compressed air to the grinding equipment

Monitoring parameters

Compressor ON/OFF/Trip status

Table 15Pipe lines and valves


Quantity Pipe lines from compressor to the dust collection system Length Approximately 150 to 200 meter length MOC SS-304Valves Flanged Valves shall be provided of make : BDK / L & T / UnisonAnalog gauges Analog gauges shall be provided for pressure measurement at dust collection

system inlet apart from digital sensorsTesting Standard Pressure Test: IS2825

Flanges & Joints: IS131589, Class 150, SORFAdditional Remarks

All the necessary pipe welding, fabrication and erection, DP testing, screws, bolts, clamps, mounting brackets, tools, consumables, etc is scope of supplier. Material test certificates shall be provided. Compressed Asbestos Fibre (CAF) gasket of 3 mm minimum thickness shall be used for flange joints

Table 16Specifications of Hopper magnets

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Quantity 4 NosMake Eriez or equivalentModel IR54168 of Eriez or equivalentMOC SS304Size Shall be suitable to place in perforated sheets of master hopper and screw

feeder hopper

Table 17Specifications of Drive cum switch Gear Panel(DSG panel)


The DSG panel should be with following feeders with compartmentalized cubicles separated from each other, with bus bars and bottom cable entry

Construction 1. DSG panel shall be floor mounting, free standing, totally enclosed and dust, damp and vermin proof.

2. MCC enclosure shall have minimum degree of protection - IP 52 (as per IS 2147).

3. Sheet steel used for fabrication shall be cold rolled, cold annealed. Minimum thickness of various members shall be as follows :-

Base frame / Channel / Gland plate : 3 mm Load Bearing Members / Doors : 2 mm Internal Partitions : 1.6 mm

4. Construction shall be rigid and robust. All steel work shall be flawless and have a smooth finish. Stiffener shall be provided where required for sufficient rigidity.

5. Clearance between phases and between phase and earthing as well as the insulation levels shall be in accordance with relevant standard.

6. Hooks shall be provided for lifting the DSG panel. 7. Panel should have undergone 7 tank process, powder coated

with Siemens grey colour RAL7028.8. Cable Entry is bottom entry. 9. All feeders to be housed in separate compartments. 10. Busbars shall be of high conductivity electrolytic copper or

aluminium, suitable for carrying the rated and short time current without overheating. Busbars shall be adequately supported on insulators to withstand dynamic stresses due to short circuits.

11. MCCB’s shall be 3 pole or 4 pole conforming to as IS-13947 (Part2)

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12. MCCB’s shall have thermal over current and magnetic short-circuit adjustable releases.

13. Contactors shall be magnetic, air break type generally as per IS 13947 Part-4 suitable for Type 2 co-ordination.

14. All power contactors shall be rated for 125% of feeder full load current. Minimum rating shall be not less than 9 Amps.

15. All control wiring inside the DSG panel shall be carried out with 1100 / 650 V Grade PVC insulated wires of grey colour.

16. Minimum size of conductor for power circuits shall be 4.00 sq. mm copper.

17. Front operated.18. Height of panel should not be more than 2.0 meters.

Make : RittalIncomer feeder Motorised MCCB with adjustable short circuit, earth fault and overload.

PAC meter with Profinet connectivity for local display and remote data logging.

Outgoing feeder 1

Mill motor feeder: VVVF drive (detailed specification for drive given in table-5) with input and output filters and suitably rated MCCB for the feeder Incomer.

Outgoing feeder 2

Mill motor feeder (redundant): VVVF drive (detailed specification for drive given in table-5) with input and output filters and suitably rated MCCB for the feeder Incomer.Out going will be connected only when feeder 1 fails

Outgoing feeder 3

Screw feeder: VVVF drive (detailed specification for drive given in table-6) with input and output filters and suitably rated MCCB for the feeder Incomer.

Outgoing feeder 4

Screw feeder (redundant): VVVF drive (detailed specification for drive given in table-6) with input and output filters and suitably rated MCCB for the feeder Incomer.Out going will be connected only when feeder 3(Main)fails

Outgoing feeder 5

Blower1: VVVF drive (detailed specification for drive given in table-12) with input and output filters and suitably rated MCCB for the feeder Incomer.

Outgoing feeder 6

Blower2: VVVF drive (detailed specification for drive given in table-12) with input and output filters and suitably rated MCCB for the feeder Incomer.

Outgoing feeder 7

Flap door : Suitably rated MCCB with adjustable short circuit, earth fault and overload protection, DOL starter (or starters) for motors of flap door. The contactors should be suitable for inching duty.

Outgoing feeder 8

Compressor :Suitably rated MCCB with adjustable short circuit, earth fault and overload protection

Ratings 1) All MCCB rating should be selected based on maximum current possible with 20% margin. Ics for incomer 50kA(min) and outgoing feeders 35kA(min)

2) All contactors should be selected such that one step higher rating than the rating based on maximum current flow.

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3) Bus bars shall be copper or aluminium with tinned end connection area rating should be with 80% cushion.

4) Cables minimum 4 Sqmm copper cable with 80% cushion.Drive

communication/Motor

management system

All the feeders of the Panel are with VVVF drive except compressor feeder and incomer feeder. All drive feeders should be connected through PROFINET communication to remote SCADA&PLC arrangement for control as well as status and parameter monitoring. If drive is not having PROFINET interface suitable converter should be used for connecting to the Profinet network. Incoming feeder and compressor current should be measured with suitable transducer and given to profibus network along with on /off/trip status using suitable converter.The communication protocol should be with Profinet only.

Motor winding temperature trip

/monitoring requirements

The PTC/ KTY 84 temperature sensor shall also be interfaced with motor winding temp relay with display of motor winding temp apart from trip arrangement from motor management temp module. The requirement to have two independent chain of motor winding monitoring/trip mechanism is to meet hazardous area safety guide lines for mandatory requirement of trip mechanism when Flameproof motor is driven by VFD to limit surface temperature not exceeding T4 temp class .The winding temp sensing by PTC/ KTY 84 sensors should be interfaced for tripping and monitoring through external winding temperature relay of M/S Siemens make only.

Control requirements

The systems control and data acquisition is through PLC & SCADA and is in a third parties scope which will be realized later. The PLC envisaged for this automation is dual redundant with criss cross configuration. The DSG panel should use PROFINET Protocol and all feeder elements including VFD drive should be configured suitable to this dual redundant configuration. All feeder currents, speed(VFD), on/off/trip status, On/Off commands, runstatus, feeder protection (EL,SC,OC, winding temp) should be communicated through profinet cable. Profinet cable (main & redundant -2 runs) should be laid from DSG panel to control room with sufficient extra length. However individual feeders in DSG panel should be controllable locally from DSG panel pushbuttons, potentiometer (for speed) and Drive AOP at service room apart from control room PLC mode and even without availability of PLC & SCADA system. This may be achieved by Drive programming or through a small PLC incorporated in DSG panel. This local operation should have enable/disable provision with removable key. All controls in Hazardous area such as ON/OFF, emergency off are to be interfaced to DSG panel through intrinsic safe barriers of P&F make. This intrinsic safe barriers to be provided where ever required(4Nos). Local pushbuttons stations in metal enclosure to be provided where ever required and to be interfaced through above IS barriers.

Marshalling cubicle

Ethernet (CAT-6) cable and remote control connections wires should be brought to instrumentation marshalling cubicle with proper ferruling for identification.

Test & Acceptance

The panel should be designed, manufactured and tested in accordance with IS 8623(Pt1), IS 13947(Pt4/Sec1) and as per the above specifications. Type

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tests and routine tests shall be conducted in accordance with IS 8623(Pt1) and certificates in this regard should be provided. The panel should undergo functional tests, HV test, dielecric strength and other qualification tests as per standards at Panel manufacturers works in presence of department engineer.

Design approval Party to submit GA drawing, Power drawing, , including selection of switchgear ratings, control drawing ,Drive interface diagram, bill of material and get it approved by department before fabrication.

List of DSG panel manufacturer

M/s Siemens ; M/s Kasa Anlagen, Chennai ; M/s Chemin controls , PondicheryNote: Any Panel Manufacturer with experience of MCC with drive fabrication ,in this case proof of experience(MCC with more than 4 Feeders and rating above 50kw,with profibus / profinet communication interface)to be furnished

Table 18Specifications of Power and control cables


Type Armoured copper conductorSIze Power cable – 4mm2.

Control cable – 2.5mm2.PROFINET cable-M/S Siemens make only

Insulation XLPE insulation as per IS 7098 suitable for LT insulation class 1100 V. Inner and outer sheath shall be HR/FRLS/ZHLS

Make HAVELL/ POLYCAB/ FINOLEX/ LAPP/ INCAB/ CCI/ RPG/ TORRENT/ GLOSTER/ UNIVERSAL/ HVPL/ RALLISON

Table No. 19Grounding and Earthing


System Grounding and Earthing

Grounding of panels, junction boxes, power distribution boards & field instruments shall be as per Grounding Scheme.Separate instrument signal and body earthing shall be provided for each field instrument. Single point earthing configuration shall be followed for the cable shields i.e. all data and control cables shields shall to be grounded at one end only to avoid ground loop.Control Panels shall be provided with a safety ground bus & system ground bus made of copper securely fixed along the inside base of the panels. These buses shall be typically of 25 mm wide and 6 mm thick of copper. The safety ground bus shall be properly secured to the plant safety earthing. All metallic cases/frames of relays, instruments, other panel mounted equipment shall be connected

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to the safety ground bus and shields & drain wires of signal/control cables shall be connected to the system ground bus by independent copper wires of not less than 2.5 sq. mm. The system ground bus shall be electrically isolated from AC mains earthing bus. The insulation colour code for earthing wires should be green with yellow bands.There should be different earths for Instrumentation and Electrical equipment.All motors and panels shall be provided with double earthing with suitable earth strip or wire as applicable.

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Annexure - II

List of sparesEquipment Description Quantity Compliance

(Yes/ No)Hammer Mill Rotor assembled with 12 sets of hammers

Helical screwsRotor bearingsDrive belt Others recommended by supplier

1 Set2 Nos2 Nos1 No

Dust collection system Filter bagsClamps for fixing the bagsVenturiesOthers recommended by supplier

2 Sets2 Sets1 Set (set is equivalent to no. of filter bags)

Electrical Systems 1. One VFD each with preloaded software for Mill, screw feeder and centrifugal blower

2. One set of Switch gears incomer MCCB, OLR, Contactor etc3. RPM Sensors – 2 Nos4. One set each of Frequency to current converter, current to

voltage converter 5. One Flame proof push button station each for Mill, screw

feeder and blower.6. One flame proof motor each for Mill, screw feeder and

blower.

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Annexure - III

VENDOR EVALUATYION CRITERIA

The pre-Qualification criteria shall be filled by supplier, duly signed and submitted along with technical bid for review by purchaser.

Sl. No CRITERIA

Vendor Compliance(YES*/NO)

1 Tenderer shall have at least 10 years of experience in the field of design, supply and erection & commissioning of Hammer mill, dust collection and subsystems for grinding of hazardous materials. Tenderer shall submit the documentary proof of previous order along with quotations

2 Should have Configured, Designed, Manufactured and Erected & Commissioned Hammer mill (2 DH type), dust collection and its subsystems at least capacity of 350 kg/hr during last 10 years. Proof to be enclosed.

3 Copies of the completion certificate/performance certificate and contact details from your client organization to whom similar size of the Hammer mill (2 DH), dust collection and sub systems was supplied shall be furnished. Performance demonstration of similar kind of machine supplied by tenderer at client site shall be arranged.Department reserve right to evaluate vendor & its sub-contractor capability to supply indented Hammer Mill and its sub systems to this tender specification and reject, if not capable

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Annexure – IV

Schedule of Prices

S. No Description Unit

Cost

(in Rs/foreign currency as applicable.)

1

DESIGN, SUPPLY, ERECTION, TESTING AND COMMISSIONING OF HAMMER MILL , DUST COLLECTION SYSTEM AND ITS SUBSYSTEMS (Without Spares and AMC).

Lump sum

1.1 VAT/CST on items in S.No.1 %

2Packing forwarding and Transportation charges for total system

Lump sum

2.1 Service tax on Item in S. no.2 %

3Installation, Testing and Commissioning charges for

one machineLump sum

3.1 Service Tax on Item in S.No.3 %

Total Cost (Sum of S.No. 1+1.1+2+2.1 + 3+3.1)

4.Cost of Spares (Listed in Annexure II of technical

specifications)Lump sum

4.1. VAT/CST on items in S.No.4 %

Total Cost (sum of S.No 4 +4.1) of system

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Annexure –VEXCEPTIONS AND DEVIATIONS

In line with Proposal Document, Bidder may stipulate Exceptions and deviations to the Proposal conditions if considered unavoidable.

SL.NO

Reference in Specification Dept. Spécification Offered

Spécification DEVIATION

PAGE NO

CLAUSE NO

NOTE :

Only deviations are to be written in this Annexure – V.

Any deviations taken by the Bidder to the stipulations of the Proposal document shall be brought out strictly as per this format and enclosed along with the bid.

Any deviations not brought out as per this Proforma (Annexure – V) and written elsewhere in the Proposal document shall not be recognized and the same is treated as null and void.

Any willful attempt by the Tenderer to camouflage the deviations by giving them in the covering letter or in any other documents that are enclosed may render the Bid itself non-responsive.

(SIGNATURE OF BIDDER)

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