Belt Weigh Scale.pdf 2m241

ESSAR POWER (JHARKHAND) LIMITED 2X600 MW TORI THERMAL POWER PLANT INTERNAL COAL HANDLING SYSTEM

TECHNICAL SPECIFICATION FOR BELT WEIGH SCALE (ICHS)

ESSAR ENGINEERING SERVICES DIVISION. BANGALORE

TSP NO: 3003-H000-A00032-0016-1615-0014-R00

APRIL-2012

FORMAT NO: EESD (H).PRA.DM.025.F01 Page - 1 -

ESSAR POWER (JHARKHAND) LIMITED

2 X 600 MW TORI THERMAL POWER PLANT INTERNAL COAL HANDLING SYSTEM TECHNICAL SPECIFICATION FOR BELT WEIGH SCALE TSP NO - 3003-H000-A00032-0016-16150014-R00

AEGIS LIMITED ESSAR ENGINEERING SERVICES DIVISION

DETAILS OF REVISION: DATE 03-04-2012

DETAILS OF REVISION

REVISION NO.

INITIAL ISSUE

TSP No.: 3003-H000-A00032-0016-1615-0014-R00 TS for Belt Weigh Scale (ICHS)

R0

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CONTENTS CHAPTER

DESCRIPTION

PAGE NO.

1

GENERAL INFORMATION

5

2

TECHNICAL SPECIFICATION

6

3

SCOPE OF WORK

17

4

INSPECTION & TESTING

18

5

HSE REQUIREMNT

17

6

DELIVERY

18

7

PAINTING

21

8

WORKMANSHIP & PERFORMANCE GUARANTEE

22

9

DOCUMENTS TO BE SUPPLIED

23

I

SITE CONDITIONS

25

II

FORMAT FOR DEVIATION FROM TENDER DOCUMENT

27

NO.

ANNEXURE

QUESTIONNAIRE TO BE FILLED IN AND SUBMITTED III

WITH OFFER

27

IV

TECHNICAL DATA SHEET

28

V

OVERALL SUPPLY & IMPLEMENTATION SHEDULE

30

VI

QUALITY ASSURANCE PLAN

31


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Chapter 01 01. GENERAL INFORMATION

ESSAR POWER JHARKHAND LTD. (EPJL) propose to install a 3 x 600 MW (present units of 2 x 600 MW and future units of 1 x 600MW) coal fired pit head based thermal power station near Chandwa Tehsil, Latehar district, Tori, Jharkhand. The coal for this project would be received from Chakla and Ashok karkata coal fields belonging to Essar’s captive coal mines in Eastern coal field basin. Coal handling system would be installed to meet the coal requirements for the proposed three (3) units receiving feed from the proposed mines. This technical specification is intended to enable the Tenderer to submit a detailed offer for supply of 2 Nos. of 1800BW Belt Weigh Scale for Internal Coal Handling Facility at Tori, Jharkand. The site climatic conditions are given in Annexure I.


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Chapter 02 02.

TECHNICAL SPECIFICATION The scope of supply of Belt Weigh Scales shall consists of design, manufacture, inspection, assembly, shop testing, packing, loading ,transportation, assistance on commissioning , Weighing & Measurement department stamping, warranty for back-up service for 12 months and supply F.O.R Essar Power Jharkhand Limited site as per quantity and specifications mentioned in Annexure - IV.

Belt Weigh Scale: Range -20% to 120% of rated capacity requirement with 100% overload protection Mechanical:

Belt scales shall be provided for continuous weighing of the material being conveyed by the belt conveyor so as to indicate the rate of flow of material and to integrate and display the material ing through the belt over a period of time.

The belt scale shall be complete in all respects to meet the requirement of auto logging facility as described elsewhere.

The weighing frame structure will be very accurately fabricated jig welded and stress relieved. It will be designed such that the load cell output does not get affected by spurious vibrations of belt conveyor and only vertical forces exerted by the material being conveyed by the belt conveyor is transmitted to the load cell. The weighing cell will also have the provision of preventing the load cell from getting overloaded beyond its safe margin.

The equipment will be designed such that no error in measurement or reading occurs due to unevenness of the belt.

The equipment will be provided with direct weight as well as electronic calibration facilities. In electronic calibration facility, the belt scale will be automatically calibrated from remote (central control station) by pressing calibration switch.


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The list and brief particulars of the belt scales as envisaged in the scope of this specification are as per details given in Annexure – IV.

Electrical:

Basic design criteria The belt weigh scales shall be designed as per metrological detail given in Annexure – I. The derating of all indoor equipment shall be done for an ambient temperature of 50°C. All electrical equipment and accessories shall also be designed and supplied conforming to metrological data and site conditions mentioned in Annexure – I. Climate proofing of all equipment and accessories shall be done in accordance with IS: 3202. All outdoor equipment will be derated for 60° Weather proof enclosures having degree of protection IP 55 shall be adopted for outdoor locations. The temperature rise limits will also be complied measured by resistance method over an ambient of 50°C.

with

when

UPS Power supply to be provided for microprocessor based system of belt conveyor. System voltage : AC - Standard voltage: 415 V, 3 phases, 4 wires with system effectively earthed at transformer neutral - Rated frequency : 50 HZ - Voltage variation : +/- 10% - Frequency variation : +/- 5% - Short circuit rating : 50 kA for 1 sec. - Combined variation : +/-10% of voltage and frequency DC supply voltage variation +10% -15%


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Note: If any equipment offered by the contractor / Tenderer is required to operate at a voltage other than the above, then conversion equipment as required will also be provided by the contractor / Tenderer. Standards : The equipment and accessories offered shall be designed, manufactured and tested in accordance with the latest standards and codes of practice published by the Bureau of Indian Standards. The electrical equipment shall also conform to the latest Indian Electricity Rules as regards safety, earthing and other essential provisions specified therein. All electrical s, cabinets, boxes, control post etc. will only be made of minimum 2 mm thick CRCA sheet steel. GENERAL DESCRIPTION OF PLANT CONTROL AND MONITORING A distributed 3 tier hierarchy has been envisaged with MCCs deployed at the bottom of hierarchy. At the second level of hierarchy will be PLC with its necessary I/O including remote I/O for control of various zones. At the third level is the computer system connected to main PLCs through communication bus. The following three modes of operation are being provided in the system: a) Centralized automatic sequential control / operation from the key board of colourographic terminal provided in the control desk located in the central control station (CCS). b) Manual sequential interlocked mode of control through the above key board. Individual drives in a selected path will be operated sequentially. c) Local de-interlocked control from local control station – LCS. A control console with two colourographic terminals will be provided with their processor, memory, control key boards for operation of the system and other units. Each colour CRT will depict the whole system in graphic form on different pages indicating also status of each equipment. CRT and printer will provide status and fault annunciation and data logging of the system. Colour hard copier will be provided which can be hooked up to the PLC / colourgraphic system. Belt scales with auto data logging facility will be provided to ascertain the quantity of base mix stored in stockpiles and also quantity of various materials delivered to base mix preparation system. The above brief description of plant automation and monitoring will enable Tenderer to


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supply belt scales with required auxiliaries and interfacings to hook up the same for centralized monitoring in the central control room over purchaser’s remote I/O rack of the PLC. GENERAL REQUIREMENTS: The belt scales will weigh continuously various materials while being conveyed by belt conveyor on which the weigh scale is installed. The belt scales system will continuously indicate the rate of flow of material as well as continuously integrate and display the quantity of material ed through the belt over a particular period of time. The display of rate of flow and total material conveyed over a particular period will be given in (a) Central control station (b) control and weighing of the belt scale and (c) local control and monitoring cabinet / post (LCMP). The belt scales will be capable of giving recording within +/- 0.25% variation of actual weight of material conveyed by the belt conveyor. The requirement will be designed such that no error in measurement or reading occurs due to unevenness of the belt. The sway of belt or non-uniform loading of material on belt will not have any effect on the accuracy of belt scale. The belt scale will be load-cell type microprocessor based modular design. The unit will be of latest microprocessor technology well tried in continuous weighing system. The belt scale will be complete in all respects to meet the various requirements. The equipment will be provided with direct weight (chain) as well as electronic calibration facilities. In electronic calibration facility, the belt scale will be automatically calibrated from remote control station by pressing calibration switch. Standard weights for the calibration are to be supplied along with the Belt weigher. For belt scales separate control and weighing (CWP) shall be provided which will be housed in the corresponding MCC room from where the related belt conveyors are feed. This control and weighing will be free standing, floor mounted and provided with a base channel of size 75 mm x 40 mm (ISMC 75).The degree of protection shall be IP-54. The MCC room, where control and weighing will also be installed, is provided with filtered pressurized ventilation without any control of ambient temperatures maximum 55°C and 50°C (average over 24 hours). Isolated 4 - 20 mA DC analog signal proportional to flow rate will be given to the remote I/O rack of the PLC system from the control and weighing


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(CWP) of the belt scales. The remote I/O rack (under purchaser's supply and scope) will be installed in the same MCC room where CWP will also be installed. This isolated 4-20 mA, DC analog signal will be used for automatic data logging for the quantity of material conveyed, in the central control room. Over load indication, in case of conveyors carrying more materials will be depicted in the CRT at central control room. Type of Totaliser– Digital, Eight Digits. Totaliser pulses which shall have adjustable multiplier settings (i.e the pulses will be generated for every 1, 10, 100, 1000 Tonnes of materials fed) shall be provided from CWP as input to PLC. Necessary boosting arrangement, if required, will be provided for hooking up the belt scale signal to PLC by the Tenderer. A local control and monitoring post (LCMP) for each belt scale shall also be provided for displaying rate of flow and total material conveyed for a particular period. This LCMP will be mounted suitably at site near the corresponding belt scales on belt conveyor. The degree of protection of enclosure of CMP will be IP-54.The equipment offered shall be of sound engineering and proven quality and these should be capable of using in Power plant and also meeting complete environmental and ambient conditions as specified. Load data to be stored in server. Apart from this there shall be provision of UPS to store load data in case of power disruptions. All accessories, and auxiliary equipments, as required, will be supplied by the Tenderer for trouble free, efficient, smooth running operation and guaranteed performance of the Tenderer's equipment and system. Identification ferrules shall be fitted on wiring at all terminals in conformity with concerned drawings. All wirings shall be done with wire of copper of 1.5 sq. mm minimum. numbers shall be indicated in the s. The maximum operating height of devices on the shall not exceed 1900 and minimum operating height not less than 400 mm.


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SCOPE OF SUPPLY: Load- cells Speed sensors Weigh electronics, instruments, control and weighing s (CWP) interfacings etc. Necessary boosting arrangement if required Local control and monitoring post (LCMP) Suitable cables for wiring and termination (i) from load sensors and speed sensor to local control and monitoring (LCMP) (ii) from CWP to local control and monitoring post. Unit rate / price per km shall be given which shall be applicable for any variation in length. Exact route length of cables shall be indicated during detail engineering. As Belt weigh scale is having Microprocessor based circuitry so it is necessary to keep that / module in controlled environment, same shall has to be taken into consideration while locating Local control and monitoring for Belt scale. Commissioning spares Two year maintenance spares. Separate list and item wise price shall be given separately along with the offer. Tools, tackles, measuring instruments etc. All auxiliary equipment, accessories, mounting and installation materials etc. to make the supply complete in all respects and for efficient, trouble free operation and guaranteed performance of the equipment and system. Any item of equipment not specifically mentioned here-in but essential for proper operation installation and maintenance will be included by the Tenderer/ contractor. OEM shall have to supply model approval certificate from W & M department.


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2 X 600 MW TORI THERMAL POWER PLANT INTERNAL COAL HANDLING SYSTEM


TECHNICAL SPECIFICATION FOR BELT WEIGH SCALE TSP NO - 3003-H000-A00032-0016-16150014-R00


TECHNICAL SPECIFICATION OF MAJOR ELECTRICAL EQUIPMENT AND INSTRUMENTATION Load cells : The load cells shall be magneto elastic type or high precision strain gauge. The transducer inside the load cells shall be fully protected by hermetically sealed casing so that the cell is impervious to harsh environments with dirt, dust, water, heat etc. requiring practically no maintenance and cleaning. Accuracy of load-cells / transducers shall not be affected by variation of belt speed and belt tensions, over load, noise vibration, temperature variation, electrical disturbances, long measuring cables etc. The load-cells shall be so mounted that horizontal loads / side thrust are not transmitted to the same. Load-cells shall be of robust design with hermetically sealed case conforming to IP-68. The output of load-cell with respect to load applied shall be absolutely linear within its operating range. a. Type b. Bridge impedance i. Input ii. Output c. Supply voltage (electrical excitation) i. Required ii. Maximum iii. Rated output iv. Zero balance v. Hysteresis vi. Non-repeatability vii. Non-linearity (should be absolutely linear within its operating range) 1. Temperature effect on output, if any 2. Temperature effect on zero balance 3. Temperature a) Compensated range


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b) Operational range viii.

Over load a) Safe (300-400 %) b) Ultimate

ix. Electrical connection 1. Type of cable 2. No. of cores x. Insulation resistance A suitable cable box shall be provided with load cell unit and also separate suitable terminal boxes (IP-55) shall be provided at site for wiring from field to control and weighing (CWP). Control and weighing for weigh electronics : Weighing electronics will be microprocessor controlled measurement, and control system will be suitable for use with continuous weighing. The unit shall be flush mounted type, CRCA sheet steel (minimum thickness 2.0 mm), compact, dust and water proof housing and modular construction using standard printed circuits boards. Printed circuit board assemblies will comprise power supply, processor and buffer memory complete with storage battery and charger, anaput/ output, frequency digital converter, A/D converter, D/A converter, interface cards. All operating and calibrating functions will be selected via key boards with flexible membrane keys. The unit will be of latest microprocessor technology, well tried in continuous weighing system. It will have long turn stability of digital measuring, and control system, serial interface capability for connection to PLC system, high reliability by assuming most functions by software, auto-tare facility, integrated test and calibration programmes, and on line self diagnostic and annunciation features. Calibration for zero and span will be fully automatic. It will be capable of handling a number of 4-20 mA DC anaput/output and pulse outputs as required. All input and output connections will be galvanically isolated. 4-20 mA analog signals proportional to the flow rate will be given to the remote I/O rack of the PLC system from the control and weighing (CWP) of belt scales for automatic data logging in the central control room as described elsewhere in this specification. Over load indication, in case of conveyors carrying more materials will be depicted in CRT in the central control room and for this necessary s / interface will be provided in CWP for connection to remote I/O rack of the PLC. Following displays shall be provided on the CWP. a) Actual flow rate


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b) Along with a flow rate, Controller should also to provide analog signal for cumulative material conveyed over a period and also an option reset same from the plant PLC. c) Belt load d) Belt speed e) Belt weigh shall capture minimum load in case of coal conveying at lowest weight. The control and weighing (CWP) will be free standing, floor mounted front attended and provided with a base channel of size 75m x 40 mm (ISMC 75). The height of the will be similar to the MCC which may be considered as around 2400 mm. The actual height of the will be indicated to the Tenderer during detail engineering. The will be fabricated from CRCA sheet steel of minimum thickness of 2.0 mm. The cabling will be done from the bottom of the . The degree of protection for the s (CWP) will be IP-54. The will be located in the MCC room. The shall have minimum depth of 600 mm. The power supply module will be provided in the separate compartment of CWP. All equipment required for stabilized constant voltage will be supplied. An incoming switch fuse unit of minimum rating 25 A will be provided. The change over incoming switch will be provided as power from two different MCCs will be given to this . Separate points for portable lamp connection and soldering shall also be provided. The power supply module compartment shall be fully isolated to avoid any interference with weigh electronics. The purchaser will provide 415 V, 50 HZ, 3 phase power supply as incomer to CWP and of required rating. The maximum operating height of the devices on the shall not exceed 1900 mm and minimum operating height shall be not less than 400 mm. Weigh electronics and control equipments including power for more than one belt scale can be accommodated in one each in separate compartment provided the height of the does not exceed the height of the MCC (in the MCC room) and also this arrangement in no way shall affect the performance of the system. The Tenderer will consider this aspect carefully. Speed sensors : The speed sensor shall be either low inertia robust construction photo electric pulse transmitter or low inertial robust construction brush less pulse generator.


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The detector circuit in photo electric pulse transmitter shall be totally enclosed with IP-68 protection. The brushless pulse generator shall be cast aluminium housing conforming to IP-67/ IP68. Local control & monitoring post/ cabinet (LCMP) Indication for rate of flow and total material conveyed for a particular period will be also displayed at local control and monitoring post. Separate LCMP shall supply for each Belt scale. The LCMP will be CRCA sheet steel (minimum thickness 2.00 mm) enclosed having degree of protection of IP-54. This will be wall mounted and located near the belt scale at conveyor.

Cables : Screened cables or other better special cables shall be offered for connection from a/ load sensors and speed sensor to local control and monitoring (LCMP) and b/ from control and weighing (CWP) to local control and monitoring (LCMP). At least two spare cores shall be provided in each cable length. These cables should be suitable for lying along with other normal control cables (used in 240 V, AC control circuit of MCC) on the same tray without any further enhancing of protection over the subject instrument cables. The Tenderer must check this aspect and confirm the same. 415 V, 3 phase normal power supply cables for incoming supply to CWP from the MCC will be supplied by the Purchaser. In the case of long measuring cables and to maintain high accuracy requirements, a cable compensation circuits shall be provided by the Tenderer. Technical specification of the cables shall be submitted by the Tenderer.

Earthing : Necessary earthing terminals and earthing bus shall be provided in the Tenderer's equipment. If any special earthing is required the same shall be indicated by the Tenderer in their offer.


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LOCAL CONTROL S: s/Cabinet shall be of CRCA and sheet material thickness shall be minimum 2 mm for the doors and side s reinforced to provide rigid flat level surfaces, resistant to vibration during transportation and installation. No welds, revert hinges or bolt threads shall appear from outside. Sheet material thickness shall be 3 mm for removable gland plates. In case instruments / lamps/ switches are mounted on the front , then the sheet thickness shall be 2.5 mm as minimum. s / cabinets shall be painted as per colour shade RAL 7035. Interior shall be glossy white. Enclosure protection for Local Indicators, Junction Boxes, Load Cells, Speed Sensors etc., shall be minimum IP-65(Equivalent to NEMA 4X).Tenderer to note that LCMP shall be located in vicinity of Load cells along with Conveyor as wall mounted type construction with IP 65 enclosure protection. CWP shall be located in nearby Control room with free standing constructions with IP- 54 enclosure protections. Preferred dimensions of CWP is 2200 (H) x 800 (W) x 600 (D)

JUNCTION BOXES (JB) FRP type wall/column mounted junction boxes having cable entry only at the bottom and sealed with fire proof compound; Screwed terminal type; the material of accessories will be SS. Min. IP 65 or equivalent degree of protection for enclosure shall be considered. Separate junction box shall be used for analog and digital signal and also for signals with different voltages. Terminal size suitable for 2.5 sq.mm, screwed type terminals of reputed make. Number of terminals shall be suitably selected as per requirement with 20% spares terminals. Documents to be submitted by Tenderer: 1. Operation & control philosophy write up. 2. Integration philosophy of Belt Weigh Scale system with Conveyor System. 3. Wiring & Termination drawing of Belt Weigh Scale system 4. Details of LCMP & CWP with IGA & EGA. 5. Installation drawing of Digital speed sensor 6. Installation drawing of Load cells 7. Installation drawing of JB, LCMP & CWP 8. Power supply requirement of Belt Weigh Scale system. 9. Catalogue of Supplied items.


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Chapter 03 03.

SCOPE OF WORK, BATTERY LIMITS & EXCLUSIONS

a) The scope of work of the Tenderer shall consist of design, Engineering, manufacture, inspection, assembly, shop testing, painting at manufacturers shop, packing, loading and transportation supply F.O.R Essar Power Jharkhand Limited site in completely assembled condition. b) The scope of work shall stand supplement by such details as are given in specification or purchase order or contract or general specifications c) The Tenderer shall submit a dimensional scaled drawing showing all the details, in AutoCAD format and design report immediately on placement of order. The manufacturing shall be taken up only as per client’s approved drawings. d) Erection instructions / manual, Spare parts manuals all other drawings & documents as required by the purchaser / his consultant.


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Chapter 04 04.

INSPECTION AND TESTING

Inspection & testing of equipment shall be carried out by Client or an authorized agent of Client at the works of supplier during manufacturing and on final product to ensure conformity of the same with the acceptable criteria of technical specification, approved drawings, authenticated manufacturing drawings and relevant national / international standards.

Chapter 05 05.

HSE REQUIREMNT Not Applicable


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Chapter 06 06.

DELIVERY

a) The delivery of all equipment covered under this specification shall be FOR M/s. Essar Power Jharkhand Limited site stores at Tori and as per the address and delivery schedule to suit commissioning of plant within 6 months from the date of placement of order. b) Unless requested by Purchaser, supplier shall dispatch equipment with all its attachments, parts, components, spares, documents etc as a single lot with logical identification of packing. c) All equipment shall be packed properly for prevention of damage during transit and deterioration during storage. d) Goods shall be dispatched only on written clearance from Client. e) All equipment should be provided with date of manufacturing, Batch no, QC clearance Identification code as QA/QC plan.


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Chapter 07 07.

PAINTING The following specification shall be applicable for all equipment covered under this document. This specification covers the facilities and quality requirement for surface preparation and painting. The term "painting" referred herein covers rust preventive, preventive and decorative coating along with surface protection.

I.

Surfaces made of aluminum, brass; bronze, stainless steel, cast iron and other corrosion resistant alloys are not required to be painted unless specified except for aesthetic purposes or for identification band. All machined mating surfaces shall be properly cleaned, greased and protected before dispatch.

II.

All surfaces will be sand blasted before applying primer. General compatibility between primer and finishing paints shall be certified by the paint manufacturer supplying the paints.

III.

Areas which become inaccessible after assembly shall be painted before assembly (after painting clearance has been given by the inspecting authority) after requisite surface cleaning as specified.

IV.

The machine finished surfaces shall be coated with white lead and covered before shipment or before being put out into the open air.

V.

The Color code to be followed for the final coat shall be intimated to the successful Tenderer.

VI.

The complete paint system for any item includes the following activities

VII.

i)

Proper surface preparation

ii)

Application of primer coats

iii)

Application of intermediate coats

iv)

Application of finished coats

Surfaces which cannot be painted but require protection shall be given a coat of rust inhibitive grease according to standards. The general guideline followed for painting is follows:


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GENERAL SPECIFICATION FOR SURFACE TREATMENT AND PAINTING

2

3

Equipment with hot indoor or outdoor duty surface (temp. unto 200 deg C)

Equipment with hot surfaces (temp. up to 400 deg C)

SP-Sa 2 1/2

Steel structure and Mechanical equipment (temp. not over 80 deg C) Both static and rotary equipment for indoor or outdoor duty

SP-Sa 2 1/2

1

Description

SP-Sa 2 1/2

Sl. No

Surf ace Pre para tion

Painting scheme At shop

At shop

Tot al DF T

2 coats of two pack air drying, Epoxy polyamide resin based red oxide - zinc phosphate (Epoxy content (% wt.) - 15 to 18, Temperature resistance - up to 120 deg C dry heat, DFT/Coat-30 microns (min)) and One coat of a two pack air drying high build epoxy resin based paint with MIO(Temperature resistance - up to 180 deg C dry heat, DFT / coat 100 microns) 2 coats of a two pack air drying Epoxy polyamide with zinc dust of at least 92% zinc dust on the dry film.{Epoxy content (% wt) - 8 to 10, Air drying time - 10 minutes (touch dry), - 2 hours (hard dry), DFT / coat - 40 microns (min), Temperature resistance - up to 120 deg C dry heat}

2 coats of a two pack air drying epoxy polyamide enamel suitably pigmented.(Air drying time 2 to 3 hours (touch dry - 7 days (full cure)),DFT / coat 40 microns(min), Temperature resistance - up to 130 deg C dry heat)

240

2 coats of a single pack synthetic rubber based aluminum paint. {Air drying time - 2 hours (touch dry) DFT / coat - 25 microns, 24 hours (hard dry), Temperature resistance - up to 200 deg C dry heat, color - smooth aluminum}

180

2 coats of a two pack heavy duty zinc dust rich silicate primer{(ethyl zinc silicate, ezs , based), Total solid (3 wt) - 84 +/- 2, Density- 3.07 +/0.005, Air drying time - 16 hours, DFT / coat - 60 microns, Temperature resistance - up to 450 deg C dry heat}

2 coats of a single pack heat resistant silicon resin based paint with leafing aluminium, Air drying time - 3 to 4 hours (touch dry), 24 hours (hard dry), DFT / coat - 20 microns (min),Temperature resistance - up to 400 deg C dry heat, Colour - smooth aluminium

180


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Chapter 08 08.

WORKMANSHIP AND PERFORMANCE GUARANTEE

a) The material used shall be new and best of its kind available and shall conform to relevant latest Indian and international standards. b) The warrantee shall cover faulty design/ material / workmanship. All rectifications or replacement under the warrantee shall be done by the supplier free of cost. c) The supplier shall warrantee for satisfactory performance of the facilities for a period of 30 months from the date of receipt at site by the purchaser or 18 months from the date of commissioning whichever is earlier. d) The Tenderer shall prepare and submit draft performance test procedure for approval.


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Chapter 09 09.

DOCUMENTS TO BE SUPPLIED BY THE TENDERER WITH OFFER WHICH IS APPLICABLE The following information/documents are to be submitted by the Tenderer along with the offer:

General description of design considerations and all the assumptions made by the supplier.

Capacity, Make and model of equipment /parts /components.

Specifications of materials of construction of parts / component along with standards and chemical composition.

Catalogues / leaflets for all equipment including bought out items. Details of bought out items with makes shall be given separately.

G.A drawings showing overall dimensions and mounting details

Block schematic diagram showing overall disposition of various parts and their mounting arrangements.

Wiring diagrams and terminal wiring diagrams.

Complete details of weigh electronics

a> G.A drawings of i/ Control and weighing s (CWP) and ii/ Local control and monitoring post (LCMP) and number of these s and posts b> Details of stabilized constant voltage power pack with complete protective and signaling elements c>

Complete details and type of load-cells

d>

Complete details and types and speed sensor

f> Complete details and technical details of cables including catalogue g> Earthing details


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h> Details analog signals for hooking up with remote I/O of plant PLC i> Details of signal for over load indication at central control room j> List of exclusions, if any k> Power consumption l> Technical literature and catalogues for all items Standard /special accessories being considered for supply along with the equipment.

Requirement of tools and tackles for erection and commissioning.

List of recommended spares for 2 years normal operation

The deviation list filled in and submitted by the Tenderer as per Annexure-II.

The questionnaire filled in and submitted by the Tenderer as per Annexure-III.

Overall schedule as per Annexure-V.

Quality assurance plane as per Annexure – VI.

Exclusions list indicating all the items with broad specification required to complete the plant and equipment supplied by the Tenderer for the operation and maintenance.

Total weight and weight of components

The following documents to be submitted along with the tendered offer : List of clients for whom such materials/equipment supplied.

Client Performance certificate.

Capacity of their plant and current assignment.

Approval for list of Inspection Agency.

The following documents to be sent in 3 copies and in soft copies, one month supply

before the

All Test reports for the tests conducted.

t Inspection Representative.

Approved Dimensional and cross section drawing with all the details in

report

and

dispatch

clearance

from

Client’s

AutoCAD format.


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ANNEXURE-I SITE CONDITIONS 1.0

Location of the plant

At Village- Angaraha Tehsil Chandwa, District : Latehar, State: Jharkhand.

1.1

Nearest Railway Station & Distance

Tori Railway Station is about 5 km.

1.2

Nearest Airport

2.0

Latitude and Longitude

3.0

Elevation above mean sea level

Ranchi Airport at a distance of about 70 km from site. Latitude : 230 43’ 0” N Longitude : 840 47’ 0” E About 530-550 m

4.0 4.1

Climatic conditions Temperatures : Annual basis Mean Maximum Temperature Mean Minimum Temperature Wet bulb temperature

48°C 11°C 28°C

4.2

Relative humidity

35.2%

4.3

Annual average rainfall

Annual average rainfall is about 1215 mm (most of which occurs during the monsoon season from June to October)

4.4

Basic Wind Speed (Vz) as per IS 875 (Part-III)

39m/sec.

4.5

Seismic Zone

Zone - IV

4.6

Present use of land

Non-Agriculture/Waste land

4.7

Topographical features of the site

Generally undulated

4.8

Source of Water

Amanat River (Around 40 km from site)

5.0

Auxiliary power supply:


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Auxiliary electrical equipment to be supplied against this specification shall be suitable for operation on the following system : a) For motors rated above 1500 kW b) For motors rated ≥ 200 KW & ≤ 1500 kW c) For motors rated below 200 kW d) DC motor starters, DC solenoids, DC alarm, control and protections of Breakers e) AC control & protective devices

11000V, 3 phase, 3 wire, 50Hz medium earthed AC 3300V, 3 phase, 3 wire, 50Hz medium earthed AC 415V AC, 3-phase, 4-wire, 50 Hz effectively earthed 220V DC, 2 wire, unearthed DC

f) Uninterrupted power supply

230V, 1 phase, 50Hz, 2 wire AC supply. The single-phase 110V AC supply shall be derived by CONTRACTOR BY PROVIDING 415V / 110V control transformers of adequate rating with MCCB / MCB on both the primary and secondary sides 230V, 1 phase, 50Hz, 2 wire AC supply

g) Lighting fixtures and space heaters

240V, 1 phase, 2 wire, 50Hz

h) The above voltages may vary as follows : All devices shall be suitable for continuous operation over the entire range of voltage and frequency indicated below without any change in their performance. AC supply

6.0

Voltage variation ± 10% Frequency variation ± 5% Combined voltage & frequency variation 10% DC Supply Voltage variation +10% -15% All the electrical equipment shall be designed for 50οC reference ambient temperature.


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Annexure II FORMAT FOR DEVIATIONS FROM TENDER DOCUMENT

Sl. No.

Clause No.

Tenderer’s Deviations

Reason for Deviations

The Tenderer hereby certifies that the above mentioned are the only deviations from the tender documents.

Signature

:

Name

:

Designation

:

Company seal

:


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Annexure III QUESTIONNAIRE TO BE FILLED IN AND SUBMITTED BY THE TENDERER

General Information :

Tenderer's name and address.

Quotation number and date.

Total estimated transporting weight of items offered by Tenderer (in tonne).

Special transport requirement.

Special storage requirement.

Technical Details :

1. 2. 3. 4. 5.

Type and Make (Attach G.A.drg & Catalogue) Model No. Overall size Principle of operation Whether two idler set or single idler set provided and their advantages?

: : : : :

6. Capacity and Designation

:

7. Operating voltage

:

8. Power consumption

:

9. Material of construction of different parts

:

10. Mounting details

:

11. Wiring diagram of the system

:

12. Total weight of the equipment

:

13. Rate indicator type

:

14. Recorder type

:

15. Accuracy

:

16. Belt Speed Measurement method

:


Page - 28 - of 33




Annexure – IV TECHNICAL DATA SHEET

DESCRIPTION

PARAMETERS Coal (-)50 0.8 2500 / 2750

Material Size of material in mm Density T/cum Rated/ Design Capacity in TPH Belt Speed in m/s Belt load in kg/m Temperature Moisture content in % Belt width in mm Take up Arrangement Idler Pitch mm Carrying Idlers Return

3.18 240.48 Ambient 10

Troughing Angle Roller Dia. Shell Thk. Troughing Angle Roller Dia. Shell Thk.

Belt Weight in kg Belt thickness

Top Cover Bottom Cover


1800 VGTU 1500 35° 159 mm 5.4mm 15° 127 mm 4.85 mm ST 1800 52.5 8 mm 6 mm

Page - 29 - of 33




Annexure – V OVERALL SUPPLY SCHEDULE

S.NO

DESCRIPTION OF EQUIPMENT

QTY.

INSPECTION CALL PERIOD (IN WEEKS)


DELIVERY PERIOD (IN WEEKS)

Page - 30 - of 33




Annexure VI QUALITY ASSURANCE PLAN (QAP) a) QAP shall be prepared and furnished by supplier for all components. b) Inspection and test requirements shall be decided with due consideration of factors like safety, duty cycle, operating conditions, equipment life, environment conditions, place of installation and statutory regulations, as applicable for a particular equipment. c) QAP shall clearly indicate the followings through use of codes in the appropriate columns: I.

Range of inspection & tests to be carried out by manufacturer and cross checked during manufacturing of equipment from raw materials to finishing stage.

II.

Suggestive check /hold points for CLIENT inspection and witnessing of tests during manufacturing and final product inspection.

III

Details of test certificates, internal inspection reports and calibration certificates to be furnished by supplier / manufacturer to CLIENT.

IV. Inspection documents to be furnished by supplier / manufacturers to CLIENT for reference during inspection along with acceptable norms as per codes / regulations. Test Certificates and Documents For each of the items being manufactured, following test certificates and documents in requisite copies including original shall be submitted to inspection agency. All test certificates must be endorsed by the manufactures and contractor with linkage to project, purchase order and acceptance criteria. I.

Details of stage wise inspection

II. Manufacturer’s bought out material test certificates III. Surface preparation and painting certificates


Page - 31 - of 33




Annexure VII C & I scope matrix: Belt Weigh Scale Sr. No.

Description

Complete Belt Weigh Scale assembly Junction box (For Load Cells & 2. Speed Sensor) Load Cells- 4 nos/system & 3. Speed Sensor – 1 nos/system Local control & Monitoring 4. (LCMP) Microprocessor based Control 5. & Weighing (CWP) Erection hardware & mounting 6. accessories for all supplied items Complete Cabling (Including Conduits/tray, fixtures, clamps 7. etc.) between Sensors and Junction Box Complete Cabling (Including Conduits/tray, fixtures, clamps 8. etc.) between Junction Box and LCMP Complete Cabling (Including 9. Conduits/tray, fixtures, clamps etc.) between LCMP and CWP Double compression Cable 10. glands & Lugs for Tenderer supplied cables Two years maintenance 11. spares Provision of Potential free hardwired signals (separate 12. Terminals) in CWP as per Table – 1. 1.

Design and engineering

Material supply

Material / Equipment Erection

Erection Supervision

Commissioning & Supervision

Tenderer

Tenderer

Essar

Tenderer

Tenderer

Tenderer

Tenderer

Essar

Tenderer

Tenderer

Tenderer

Tenderer

Essar

Tenderer

Tenderer

Tenderer

Tenderer

Essar

Tenderer

Tenderer

Tenderer

Tenderer

Essar

Tenderer

Tenderer

Tenderer

Tenderer

Essar

Tenderer

Tenderer

Tenderer

Tenderer

Essar

Tenderer

Tenderer

Tenderer

Tenderer

Essar

Tenderer

Tenderer

Tenderer

Tenderer

Essar

Tenderer

Tenderer

Tenderer

Tenderer

Essar

Tenderer

Tenderer

Tenderer

Tenderer

Essar

Tenderer

Tenderer

Tenderer

Tenderer

Essar

Tenderer

Tenderer


Page - 32 - of 33




(Note: Tenderer to note that the Incoming Power supply for CWP shall be given by Purchaser, further distribution to Field LCMP and sensors shall be carried out by Tenderer.) TABLE – 1 PLC Interface signals Sr. No.

1. 2. 3. 4.

DESCRIPTION Belt Weigh Scale – Healthy Belt Weigh Scale – Material Feed Flow Rate Belt Weigh Scale – Material Feed Flow Totalizer Pulse Belt Weigh Scale – Material Overload Indication


Type of Signal

DI AI DI DI

Page - 33 - of 33

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