01 cover page vol 2b fire hydrant type fire fighting...

TENDER DOCUMENT

NIT No.: DLI/C&E/WI-665/285

FOR

Tender for ‘Design, Engineering, Supply, installation, testing and commissioning of ‘FIRE HYDRANT TYPE FIRE FIGHTING PACKAGE AND ASSOCIATED WORKS’ for the project of “Augmentation of Raw Material Handling Receipt and Handling facilities with new OHP Part– B (Package- 061) of Bhilai Steel Plant, (SAIL)”.

VOLUME – 2B

TECHNICAL SPECIFICATION

ENGINEERING PROJECTS (INDIA) LIMITED (A GOVT. OF INDIA ENTERPRISE)

Core-3, Scope Complex, 7, Institutional Area, Lodhi Road, New Delhi-110003

TEL NO: 011-24361666 FAX NO. 011- 24363426

EPI – New Delhi Volume-2B, Rev.0 Page 1 of 25

VOLUME - 2B

CONTENTS Sl. No.

DESCRIPTION

1.

Documents/information to be furnished alongwith offer

2. Scope of Supply

3. Brief System Description

4.

Technical Specifications – Fire Hydrant type Fire Fighting Package

5. Spares

6. Technical data sheet (to be filled by the vendor)


GENERAL

The following Technical Specification shall be read in conjunction with General Technical Specification (GTS) of Bhilai Steel Plant, SAIL and General Specification. If there are any provisions in this Technical Specification, which are at variance with the provisions of General Technical Specification (GTS) of Bhilai Steel Plant, SAIL and General Specification, the provisions in this Technical Specification shall take precedence.

1.0 DOCUMENTS/ INFORMATION TO BE FURNISHED ALONGWITH OFFER.

(i) Clear Scope of supply. (ii) Type and quantity of oil, lubricants & consumables for initial fill till successful

commissioning of equipment. (iii) List of Commissioning spares and start-up spares with unit rates. (iv) List with unit rates of special tools and tackles, if any required. (v) Price Schedule for supply & erection work as per the format enclosed. (vi) List of recommended spare parts for 3 years trouble free operation and

maintenance alongwith unit rates as per the format enclosed in price schedule. (vii) Technical Data sheets duly filled by the vendor (blank data sheets enclosed). (viii) Weight of the equipment in Kgs. (ix) Catalogues/ Leaflets and O&M Manuals. (x) Reference list of your Customers for the similar supply of items. (xi) Unpriced Copy


2.0 SCOPE OF SUPPLY

The scope of the supply includes Design, engineering, manufacture, shop fabrication. assembly, testing and inspection at manufacturer’s works, packing , dispatch, transportation, delivery to site, receipt, required fabrication at site, installation, testing & commissioning completion of facilities, performance guarantee testing, final painting at site and handing over to Bhilai Steel Plant, SAIL / EPI of COMPLETE FIRE HYDRANT TYPE FIRE FIGHTING PACKAGE AND ASSOCIATED WORKS as per specifications and scope defined in tender documents complete with all accessories and drive, which are not mentioned specifically but are required for the efficient and trouble free operation of the equipment/system.

2.1 Following items are also included in bidder’s scope.

(i) Complete items as per the details given in the specifications.

(ii) Consumables like first fill of lubricating oils etc., if required, for the initial operation of the equipment till handing over.

(iii) Commissioning spares and start-up spare parts.

(iv) Special tools & tackles, if any required.

(v) Recommended spare parts for (3) three years trouble free operation and maintenance.

(vi) Painting of complete equipment (including final painting before handing over to the Employer).

(vii) Installation, testing & commissioning at site.

(viii) All drawings/documents along with operation and maintenance manuals as per requirement mentioned elsewhere in the tender document.

(ix) Getting approval of design/drawings and any other design calculation related to the equipment from BSP/MECON/EPI.

(x) Carrying out any modifications/deletions/additions/alteration in design/drawings/documents as required by client & Client’s consultant and EPI for proper execution of works at site till completion and handing over of the project to the client.

(xi) Drinking Water & Construction Power shall be provided free of cost to the bidder at one point. However, further distribution shall be in the bidder’s scope. Bidder has to ensure the optimum and effective utilization of Construction Water & Construction Power.

(xii) Construction Water shall be arranged by the bidder themselves.


2.2 Bidder to note the following:

1) BSP approved preferred make list shall be followed for Hydraulics & Pneumatics.

2) All HT and LT AC/DC motors, actuators, brakes etc. as per technological and process requirement.

3) Generally Squirrel Cage Induction Motor with DOL starter / Soft Starter will be

provided. Use of Slip ring motor in general will be avoided. Suitable Rotor contactor panels and SS-grid Resistance Boxes will be provided for slip ring motors if inevitable.

4) Soft starter will be provided for LT motors of rating more than 75kW.

5) All LT motors for conveyors will be S6 duty and will have class F insulation with temperature rise limited to class B.

6) Equipment selection and dating will generally be based on ambient temperature of+50 Deg.C. For specific areas and shops, the ambient temperature conditions indicated above will be taken into consideration and equipment suitably derated wherever necessary.

7) The equipment should be suitable for smooth, efficient and trouble free service in the tropical humid climate prevailing at plant site and under the ambient temperature conditions indicated above for the different shops and areas. In hot areas of higher temperature conditions, the equipment will be adequately protected against damage from radiant heat and hot air.

8) Roller bearings will be provided at DE end for motor of rating 30KW and above.

3.0 BRIEF SYSTEM DESCRIPTION


The turnkey package of this Contract Document comprises of the following sub-systems:

1) New Ore Handling Plant (OHP-II) including receiving, unloading, Stacking & Reclaiming and finally transporting of Raw Material required for Blast Furnace #8, Sinter Plant-III.

2) New conveyor line for New Lime Dolomite plant RMP3 and for proposed SMS-III.

3) Modifications/ up-gradations of existing equipment, including:

• An additional series of conveyor from OHP I to JH-20 and JH-42(Exst’g) parallel to existing route.

• Up gradation of capacity of existing shuttle conveyors J9BRSC1.

3.1 New Ore Handling Plant (OHP-II)

The raw material to be handled by the proposed system is mainly, Iron Ore Lump, Iron Ore Fines, Lime Stone (BF grade), Lime Stone (SMS grade), Dolomite (BF grade), Dolomite (SMS grade), Quartzite, Manganese ore. These raw materials are mainly required for Blast Furnace, Sinter Plant, Lime-Dolomite Plant, SMS. All the raw materials will be received at the plant boundary by rail. The type of Wagon will be BOXN, BOXNHA, BOY, BOBRN, BOST, BOBS, BOXNEL, BOYL,BOXN HS etc which will transport the raw materials depending upon the location of loading and type of raw materials.

(i) Design Considerations

The Ore Handling Plant (OHP-II) has been planned based on the following assumption:

A. Size of Raw Material

1. Lump Iron Ore : -40 mm

2. Iron ore fines : - 8 mm

3. Lime Stone (BF/SP grade) : -60 mm

4. Dolomite (BF/SP grade) : -60 mm

5. Quartzite : -50 mm

6. Lime Stone (SMS grade) : -25 mm

7. Dolomite (SMS grade) : -25 mm

8. Pellets : -18 mm

9. Manganese Ore : -25 mm

10. Coke Breeze : -25 mm

B. No of Days of Working per year: 330 days


C. Maximum material carrying capacity of each wagon shall be as per IS: 10095-1982 reaffirmed 2001. Iron-ore-lump will be received in Track-Hopper & all other material in Wagon Tipplers. Two Track Hoppers have been considered for materials received in BOBS/ BOBRN wagons (mainly iron-ore), whereas wagon tippler with side arm charger has been considered for unloading the materials received in BOXN/BOST/ BOXNHA/BOY/BOBS, BOXNEL, BOYL wagons.

(ii) UNLOADING, STORAGE, BLENDING AND RECLAIMING IN OHP-II

One number Wagon tippler WT no.B1 along with a Track Hopper TH-B1 with two parallel tracks on it have been envisaged for unloading Iron ore (lump and fines), Limestone & Dolomite (both BF grade and Sinter Plant grade), Mn-ore, Quartzite etc.

The Wagon Tippler shall be of Rota-side type capable of unloading BOXN and proposed BOXNHA ,BOXNHS, BOBS, BOY wagons as per IS:10095-1982, reaffirmed 2001. The rated unloading capacity shall be rated 20 Tips/hour. Adequate system of handling sticky rakes such as vibrator/ air blaster shall be provided.

25t wagon axle load and 110t gross weight of wagons (BOX, BOXN, BOXN HA, BOXN HS, BOXN EL, BOYEL) to be considered for design of Wagon Tippler and track hopper. 2 nos. Weighbridges included in contractor's scope. The location of Weigh Bridge shall presently be considered at entry of pre hopper yard. However as the total railway track is being engineered by RITES, the location of Weigh Bridge may undergo change in detailed engineering stage. The drawings of wagon tippler/track hopper shall be subjected to approval by RITES /SECR/RDSO as applicable.

The placement of rakes shall be done by Side arm chargers capable of handling a full rake BOXN, BOXNHA, BOBS, BOY, BOXN EL, BOYEL wagons.

Two nos. of track hopper each of length 210 m excluding maintenance bay and holding capacity of 6000 t each considering material of bulk density of 1.6 t/ cu.m. shall be included in contractor's scope. The side angle of hopper with vertical shall be minimum 60 deg. Each hopper shall have four compartments. Track hopper envisaged to accommodate minimum 18 BOBS wagons. Contractor to maintain sufficient height of the track hopper superstructure to take care of OHE.

Total 4 nos. Electric hoist of 5 t capacity shall be provided for maintenance of Paddle Feeder at both ends of Track Hopper building. Two nos. double door pressurized cabin shall be provided for paddle feeder inside the track hopper tunnel. Anti-derailment device/ check rail shall be provided in the track hopper subject to approval of RITES. Supply / Laying of 60 kg/ m rail with continuous MS insert plate within track hopper building only are in scope of contractor.

In addition to the above, one dedicated compressor station at track hopper TH-B1for unloading of BOBRN wagons is to be provided. Compressed air connection to BOBRN wagons to be provided at 15 mts interval. The details of requirement of compressed air, the pressure and type shall be obtained from RDSO. Other points as applicable for compressed air station shall be considered as per CS for compressed air facilities indicated elsewhere.

Provision of adequate illumination should be there on both pre & post tippler as well as on Merry Go Round circuit.


Two belt feeders below Wagon Tippler shall discharge the raw material on either of two conveyors i.e. Z1-C1 or Z1-C2 which, in turn will discharge the material at Jn House JH-Z1. From Jn House JH-Z1, conveyors Z3-C1 & Z3-C2 will carry the material and discharge at JH-Z3. There will be three incoming conveyors in Junction House JH-Z3. The tail end of two conveyors Z3-C1 & Z3-C2 will start from JH-Z1 and Belt conveyor Z3-C3 from JH-Z2. Junction house JH-Z2 shall be located in between the JH-Z1 & JH-Z3.

The track hopper with four nos. paddle feeders of 1500 tph each, two on conveyors Z2-C1 and two on conv Z2-C2 has been envisaged. From Jn. House JH- Z2, either of three conveyors Z3-C1, Z3-C2 (coming from JH-Z1) & Z3-C3 (begin from JH-Z2) shall carry the material upto Jn house JH -Z3. Reversible shuttle conveyors Z2RSC1/2 at JH-Z2 will facilitate to discharge the material on either of any three conveyors. Therefore, JH-Z2 shall be designed suitably so as to receive material from any of the conveyors coming from Track Hoppers. Non sticky liners/ polymer liners are to be fixed in the track hoppers to improve flowability.

Suitable interchangeability shall be provided below Wagon Tipplers and Track Hoppers for the conveyors by providing Diverter gates.

In Jn House Z3, three nos. Reversible Shuttle conveyors no. Z3-RSC1,2&3 can feed any one of conveyor no. Z6C1, Z6C2 and Z6C3. Contractor to provide jumbo gallery suitable for three nos. mobile trippers up to JH-Z5 from JH Z4 over conveyors Z6C1, Z6C2 and Z6C3. Out of three trippers, two nos. (Over conv. Z6C2 and Z6C3) shall extend upto JH-Z6 and one no. shall have provision of extension up to junction house coming in future. Maintenance hoist of minimum 5t cap shall be provided for the trippers. Each of the three conveyors Z6C1, Z6C2 and Z6C3 shall be capable of feeding the stacking conv. Z4BC1 as well as itself in JH Z4 and stacking conv. Z5BC1 as well as itself in JH Z5. Each of the two conveyors Z6C2 and Z6C3 shall be capable of feeding the stacking conv. Z6BC1 as well as future conveyor in Junction House –JH-Z6.

The raw material can be either transported via. Jn House Z4, Z5 or Z6 to the respective stacking conveyors Z4B-C1, Z5B-C1 & Z6B-C1 for stockpiling or can be fed directly to the reclaiming conveyors Z7-C1/ Z7-C2 which means convey material directly from the WT/ Track Hopper to:

(a) To the Blast Furnace#8 Stock House

(b) To the Fuel & Flux crushing circuit of Sinter Plant-III.

Suitable interchangeability shall be provided at Junction house JH-Z4, 5 & 6 for the conveyors by providing 2-way chutes in mobile tripper. 5T Electric hoist each shall be provided at JH-Z5 & JH-Z6. Whereas, JH-Z4 shall be designed only as a transfer point.

The Stacking conveyors Z4B-C1, Z5B-C1 & Z6B-C1 can form a stockpile 30m wide, 350m long and 10.5 m (maximum) high with the help of Twin boom stackers.

Suitable number of electrically operated Under-Slung Cranes, Hoists etc. shall be provided in all floors of Junction Houses and building for maintenance of equipment. Electro-Magnetic Separators, In-Line Magnetic Separators, Metal Detectors, Belt- Weigh-Scales, Air-Blasters/ Bin Vibrators shall be provided to make the system complete and the operation/ maintenance smooth.

(i) STORAGE AND RECLAMATION OF ORE


From the Wagon Tipplers WT-B1 and the Track Hopper TH-B1, the raw material may sometimes be fed directly to the consuming plant in case of emergency. However, this shall not happen under normal circumstances, when the three Twin-boom stackers over conveyors Z4B-C1, Z5B-C1 & Z6B-C1 store the raw material in the designated place of the yard in bed nos. 1 to 6. Flexibility shall be in built in the Jn Houses Z4, Z5, & Z6 to ensure stacking is trouble free.

Bed blending system shall be possible with the stacker running to and fro on the length of the pile -or- on a length between two defined position in case more than one material is stored in a bed marked by travel limit switches, which through a relay sequencing circuit, with time control-reverses the traveling gear after the travel in each direction covering the desired length of the pile. After a layer of some pre -determined amount is deposited in one traveling direction of the stacker, probes fitted on the stacker boom gives it a “raise” signal as soon as a net height of material is formed. The next layer is then formed.

Iron ore may require stockpile formation as described above for blending and uniformity. However, the emphasis on blending shall be for iron ore fines which shall be blended while stacking.

Four nos Bucket-wheel reclaimers have been envisaged for bed no. 1 to 6.

All stacking line conveyors feeders and stackers etc. shall have a rated capacity of 1500 tph & a designed capacity of 1800 tph.

All reclaim line equipment shall have a rated capacity of 1500 tph and a designed capacity of 1800 tph in the ore handling area.

Reclamation takes place by the conveyors Z7-C3 (Bed no. 1), Z4A-C1 (Bed 2or 3), Z5A-C1 (Bed no.4 or 5) and Z6A-C1 (Bed no. 6) and the reclaimed material via Jn House Z4A, B, Z5A, B, Z6A and Z6B shall reach Jn House Z7. Two reclaim conveyors Z7-C1 and Z7-C2 between Z6A to Z7 will receive all the materials from yard for further transportation.

Reclamation from OHP takes place for the following circumstances:-

• Feeding of iron ore lump, dolomite, limestone, manganese, quartzite, pellet etc. to BF#8 stock house.

• Transporting Limestone/ Dolomite (SP grade) and iron-ore fines to fuel & flux crushing area for Sinter Plant-III.

Two streams of belt conveyors shall reclaim the material from new OHP-B yard to above places. Belt conveyor Z7-C1 & C2 shall carry the material and transport thru Z8-C1, C2, Z9-C1, C2, Z10-C1, C2 to Z11-C1& C2 to Junction house JH-Z11. Junction House-Z11 can discharge the material either to existing conveyors R103/ R104 of Sinter Plant-III or proposed conveyor Z12-C1/ C2 of BF#8, with the help of reversible conveyors. To receive the material from Z11-C1 & C2, suitable modification in existing gallery of R103 & R104 is required. Also a junction house JH-Z11 with two reversible conveyors & tail end of belt conveyors Z12-C1 & C2 shall be erected above these conveyors. Further, conveyor Z12-C1 & C2 and then Z13-C1 & C2 shall move towards stock house of BF#8 and discharge at JH-Z15 onto reversible shuttle conveyors J15RSC1/2. The gallery from JH-Z14 to JH-Z15 shall have provision for installation of three identical conveyors i.e. Z15-C1, Z15-C2 and future conveyor Z15-C3. Suitable insert plate/ foundation bolts shall be


provided for future conveyor Z15-C3. However, future conveyor Z15-C3 is not in scope of contractor.

Specification of future conveyor:

Length - ~ 35 m: Lift 0.0 m: Capacity 1200 tph: Belt width – 1400mm

Centre to centre distance from Z15C2 – 3010 mm

A junction house JH-Z14 shall be provided in between the junction houses JH-Z13 & JH-Z15. Two series of belt conveyors shall discharge the Sinter at the Junction House Z14 over belt conveyor Z15-C1 & C2. Junction House JH-Z14 and conveyors Z14-C1/C2 shall be in the scope of Employer i.e. BSP.

Suitable Junction houses with RCC floors, diverter gates & galleries shall be provided to transfer the material from one conveyor to another. The scope of contractor shall finish at JH-Z15 with complete drive and discharge (including reversible shuttle conveyor) facilities. The receiving belt conveyor below Z15-C1 & C2 shall be in the scope of Employer i.e. BSP. However, JH-Z15 shall have a provision (inserts/ foundation bolts) to erect outgoing conveyors to Stock House.

3.2 OTHER ADDITIONS/ MODIFICATIONS AND UPGRADATION IN EXISTING OHP (REF. DRG. NO. MEC/S/9101/11/17/0/00/00/061.B01)

(i) An Additional series of conveyor from OHP to J-20 and JH-42(Exst’g)

Another proposed conveyor No J9-C1 parallel to J9-C3/J9-C4, besides conveyors R-102, shall start from Jn. House JH-9B and shall discharge the material in a proposed conveyor J9H-C1 in existing JH-9, which in turn feeds to conveyor J10-C2 in new Junction house JH-9H . Conv J10-C2 can feed proposed conveyor J11-C3, J11-RC2, J14-C2/J12-C2 (Exst’g) , J15-C2. Conv J15-C2 shall feed new reversible conv. J15-RC1 in junction house JH-15, which in turn can feed either existing SMS-II feeding conv. J15A-C1 or new conv. J15B-C1. Conv. J15B-C1 or another new conv. J15B-C2 which shall receive sinter from existing conv. SS-10 shall feed new conveyor J16-C3 in new junction house JH-15B which in turn shall discharge onto new conv. J16-C3A in new junction house JH-16A. Conv. J16-C3A shall discharge onto new conv. J17-C3 in JH-16A which shall convey material to conveyor J17A-C1 in JH-17(exst’g). Conveyor J17A C1 (Capacity 1500tph) shall discharge to either of the two conveyors J20C3 or J17B-C1 through a adjustable flap gate in junction house J17A. further J17B-C1 shall discharge the material over J42-C2 in JH-17B. The capacity of the outgoing conveyors J20C3 and J17B-C1/J42C2 shall be 500tph and 1000tph respectively. Conveyor J20-C3 shall be provided with one no. belt weigh scale and have provision of discharging onto existing sinter carrying conveyor J27-C5 (Exst’g) in junction house JH-20 (Exst’g). Conveyor J42-C2 shall have provision of discharging onto existing conveyor J44-C5 in junction house J42 (Exst’g). Necessary modification/strengthening shall be carried out in junction house J42 to take care of additional loads by new conveyor. Suitable electrical interlock shall be provided between the conveyors J27-C5 & J20-C3 in junction house JH-20 to trip all the incoming conveyors in case feed rate exceeds capacity (500tph) of the corresponding downstream conveyor J27-C5. Similar interlock shall also be provided between J44-C5 & J44-C2 in junction house JH-42 to avoid any spillage/chute blockage.


These additional conveyors with gate will facilitate a new additional route for BF # 7.

All above conveyor shall run adjacent to the existing conveyor/ galleries at same elevation. Junction houses JH-9H, JH-10A, JH-15B, JH-16A ,JH 17A and JH- 17B shall be new Junction houses. For conveyor no. J11-C3, J11-RC2,J14-C2, J15-C2, J15-RC1, J15B-C1, J15B-C2 , J17-C3, J17A-C1, J20-C3 & J42-C2, the existing junction houses (JH-10, JH-11, JH-14, JH-15, JH- 17, JH-20 and JH-42) shall be suitably modified to suit proposed conveyor transfer points/crossing over.

(ii) Up gradation of Reclaiming conveyors

The capacity up-gradation and utilization of reclaim conveyors are of utmost importance to ensure smooth operation in the OHP.

The list of conveyors in the reclaiming circuit that shall be upgraded to 1500 tph are given in table 03.01.

Table 03.01

EXISTING PROPOSED SLNo

CONVEYOR NO BELT WIDTH

mm CAP

BELT WIDTH mm

CAP tph

1 J9B-RSC1

1400

500 m3/hr

1400

1500

The capacity of all Belt conveyors shall be 1500tph for all raw materials viz. iron ore, limestone, dolomite with 1400mm belt width and belt speed shall be 2.0 m/s with a troughing angle of 35o. (Bulk density of raw material shall be considered as 2.2 t/m3 for power calculation/load data of structures and 1.6 t/m3 for volumetric capacity calculation of conveyor)

3.3 NEW LIME DOLO PLANT (RMP III) AND SMS III CIRCUIT

Existing conveyor R-101/R-102 shall be utilized to convey raw material required for Lime/Dolo Calcination plant RMP III and of SMS-III by tapping the conveyor from Jn house JH-N102 (With suitable modification in the Jn House) and taking a new route to the proposed Lime/Dolo calcination plant/SMSIII. Any civil work related to installation of new conveyors in existing junction house JN#102 shall be contractor’s scope.

The SMS grade limestone, dolomite and iron ore in existing OHP-I shall be reclaimed via. Jn House N101, N102. Existing Belt Conveyors R101/102 coming from OHP-I shall now mostly carry Lime stone and dolomite. In JH-N102, two existing reversible conveyor R103A & R104A are having a provision for taking material to Sinter plant III as well as proposed Lime Plant. A discharge chute below R103A & R104A to feed at the tail end of proposed belt conveyor L1C1 shall be provided at Junction house J-N102. Belt conveyor L1C1 shall discharge the material on L2C1 in junction house JH-L2. Conv L2C1 discharges onto conveyor L3C1 which discharges onto L4C1 in JH L3.Conv L3C1 in turn discharge material at Junction House JH-L4 to any of the two conveyors i.e. L5C1 & L7C1 with the help of diverter Gate.

Thereafter, conveyor L7C1 will carry the material and transfer onto conveyor L9C1. Conveyor L9C1 will carry the material up to Surge Bin building JHL9 through


reversible shuttle conv. JL9RSC1. Surge bin building JHL9 shall have 3 nos. bunkers of minimum geometric capacity 190 cub m each for storing iron ore lump/limestone /bauxite. Suitable rod gate and motorized rack and pinion gates shall be fitted at the bottom of bunkers. Three (3) nos. VVF controlled vibro feeders of 420 tph capacity each shall withdraw material from bunker and discharge it onto conveyor L10C1 which shall convey up to Junction house JH L10 for onward transportation to Surge Bin Building for SMS-III (Surge bins with Vibro-feeder as shown in flow diagram at JH-L9 are in contractor’s scope.) through SMS feeding conveyor. Conveyor L10C1 complete with discharge facilities and junction house JH L10 shall be in the scope of contractor and SMS feeding conveyor shall be in the scope of employer.

The other conveyor L5C1 shall receive material from conveyor L4C1 and discharge at JH-L5 on to conv. L6C1 which shall convey up to junction house JH-L6 and discharge onto lime plant feeding conveyor for onward transport to Lime & Dolomite calcination plant RMP III. Conveyor L6C1 complete with discharge facilities and junction house JH L6 shall be in the scope of contractor .However lime plant feeding conveyor shall be in the scope of employer i.e. BSP.

Calcined lime/dolomite is received from the day bins of lime/dolo product storage building of RMP III onto conveyor L8C1.Conv. L8C1 discharges onto conv. L9C2 in JH L8 which in turn discharges onto conveyor L10C1 in Surge Bin building JH L9. This finished product of RMP III is transported to the junction house JH L10 by conveyors L10C1 which shall also carry limestone, bauxite, iron ore received directly from OHP I yard to SMS III. The scope of contractor starts from tail end on conveyor L8C1 including skirt boards.

A fixed hopper of 8 cub m capacity on conveyor L10C1 near JH L9 with VVF controlled vibro feeder of 420 tph capacity shall also be used to transport coke fines as and when required in the storage bins of the bulk material charging system of SMS III. Any other material e.g limestone/ DRI can also be transported under emergency conditions through fixed hopper. Suitable ramp shall be provided to unload the material over hopper.


4.0 Technical Specifications of FIRE HYDRANT TYPE FIRE FIGHTING PACKAGE AND ASSOCIATED WORKS

The scope of work of Fire Protection, Fire Detection & Alarm package includes;

4.1 Fire Protection System

4.1.0 Fire Protection System

Contract specification for complete fire protection system to be provided for the OHP-Part B package is given below.

4.1.1 INTRODUCTION

In order to combat any occurrence of fire in various areas/units of the proposed OHP-B package, an elaborate system of fire protection will be provided. The system will be planned in conformity with Tariff Advisory Committee’ guidelines, BIS and other relevant standard/codes.

Major Facilities envisaged are as following:

i/ Fire Hydrant System ii/ Portable fire extinguishers 4.1.2 SCOPE OF WORK AND SERVICES

The scope of work covers on turnkey basis design & engineering, supply, erection, painting, testing, commissioning, and handing over of complete Fire Protection System envisaged for the OHP-B of Bhilai Steel Plant 7.0 MT expansion. Two years operation and maintenance spares, necessary tools, spanners etc. required for regular operation / maintenance of systems will be supplied along with the equipment.

Major work comprises of following:

a/ Fire fighting water at a three points separately for hydrant system within

the battery limit of the contractor will be provided .However Contractor has to tap water from this point and further design and supply of the entire fire fighting facilities under their scope of work.

b/ Fire Hydrant system consisting of internal as well as external hydrants for

the entire area. Number of hydrant and monitor points will be fixed at detailed engineering stage as per TAC Norms.

c/ Portable fire extinguishers. d/ Piping, valves, sluice gates etc. e/ All civil & structural works f/ Shop and site painting for all equipments, pipes etc. g/ Fire fighting facilities during construction period by installing fire

extinguishers and hydrant for protection of combustible material.


h/ Erection, testing, commissioning, PG test and Warranty for the complete fire

protection system. i/ All the requirements of TAC for complete FPS will be incorporated by the

contractor in their scope irrespective of whether the details are described in specification and/or shown in the drawings or not.

4.1.3 DRAWINGS AND DOCUMENTS Drawings/documents to be furnished

a/ Scope of work with general description of system and equipment offered specifying the important features supplemented with scheme drawings. The contractor has to give a confirmation with respect to the scope of work as detailed in this specification. The description to be accompanied by single line diagrams, and equipment layout to enable the Employer to have a proper appreciation of the equipment and its operation.

b/ Specification of equipment/material along with their makes/catalogues.

Approval certificate from authorizing bodies for various components of the systems.

c/ List of mandatory spares. d/ List of special tools and tackles e/ Certificate of approval from TAC and similar other authorizing body for

various component of the system.

4.1.4 TECHNICAL SPECIFICATION

Please refer General Technical Specification (GTS) for various fire protection systems/facilities for detailed specification. However a brief description is provided herewith.

Fire hydrant system:

Industrial quality water (quality as indicated in GTS) will be made available to the Contractor at three points approx. within 100-150 mtrs. from the proposed Package 061 at requisite pressure. Contractor shall furnish the pressure requirement at the battery limits for fire-fighting water duly corroborated with design calculation and subject to Purchaser’s approval. To cater to the needs of water based fire-fighting system, fire water piping network for hydrant system shall be provided with provision of yard hydrants and internal hydrants. The proposed networks shall be connected with the existing networks at the battery limits with an isolation gate valve.


The following specification of work shall be considered:- Category at hazard - ordinary (as par TAC) Yard hydrants - at 45 m intervals Internal hydrants - at 30 m intervals Min. pressure at remotest hydrant - 3.5 kg/cm2 2 nos. of 15 m long hose shall be provided along with fittings for each yard hydrant and 2 nos. of 15 m long hose shall be provided along with fittings for each internal hydrant. Tapping of fire-fighting water shall be based on two points feeding and shall conform to provisions of TS/GTS. Contractor shall extend the fire-fighting water lines with an isolation valve in a valve-pit to his proposed systems for fire-fighting water requirement for the entire plant area. The water based fire fighting system shall be designed, supplied & erected inline with the stipulations under various clauses of GTS and subject to Purchaser’s approval. Hydrant system as covered under Water System (GS-02) prevails over GS-10.

Portable fire extinguishers:

Different types of portable fire extinguishers will be deployed in various area of the complex as a measure of first-aid fire fighting.

Major units of OHP-B will be protected by portable fire extinguishers. The distribution of portable fire extinguishers will be as per IS : 2190 - 1992.

Portable extinguishers will be conforming to IS codes mentioned below and detailed specification provided in the GTS.

Mechanical Foam (9L.) - IS: 10204-2001 Mechanical Foam (50L) - IS:13386-1992 DCP extinguisher - IS 2171-1999 CO2 extinguishers - IS:2878-1986 Water type (gas cartridge) - IS:940-2003 Fire Bucket - IS: 2546-1974

In addition clean agent portable fire extinguisher (Heptafluro propane of 5.0 Kg capacity) will be also provided as per distribution norm of clean agent extinguishers in the computer/Control rooms.

4.1.5 ERECTION, TESTING, COMMISSIONING & PERFORMANCE GUARANTEE

The erection of all plant and equipment will be carried out according to the latest engineering practices and according to the working drawings, erection specification, instructions etc. duly approved by the Employer. The Contractor will carry out the work in the presence and/or as per the instructions of site


engineer/supervisory personnel deputed by the Employer. The erection will be carried out by highly skilled workmen.

The Contractor will be responsible for paying strict attention to statutory regulations for prevention of accidents and to other safety rules. The regulations for prevention of accidents will be deployed at appropriate places and should be distinctly visible to all personnel working in the area.

The Contractor will supply all required consumables, construction and erection materials, petrol, diesel oil, kerosene, solvents, sealing compound, tapes, brazing and soldering materials, welding and brazing gases, erection bolts, nuts and packing sheets/compounds, temporary supports, wooden blocks, spacers, templates, jute and cotton wastes, sand and emery paper etc. as required for the satisfactory completion of work.

The Contractor will make his own arrangement for storing, handling the equipment and pipelines at the stores and transporting it to the site for installation. In addition to the above, the contractor will follow all the relevant erection clauses/conditions stated under various chapters in the contract document. Contractor has taken note that training to fire engineers for maintenance/ checking of FDA and fire fighting system at OEM training centre. Training on fire risk analysis and its mitigation in the new OHP technology will be provided at site.

The contractor will provide all tools, labour including necessary subsistence, erection supervision, equipment, materials, accessories, to erect/install and make ready for operation & functionally complete the total fire protection system as described and specified in this document.

4.1.6 Testing, Commissioning & Performance Guarantee of the complete system. Testing

Contractor has taken note that all fire protection system will be tested and commissioned in presence of CFO / Fire Brigade representative or MECON before the commissioning of main units.

All tests and inspection of the installation will be done in conformity with the functional and statutory requirement of the system. The contractor will furnish a detailed testing and commissioning procedure for all the systems for approval by the employer. As soon as a given facility or a portion thereof is completed and ready to energize and start-up, the employer may test run and operate it without relieving the contractor of his responsibility or guarantee.

4.1.7 Start-up and commissioning

i/ Contractor will provide the services of all technicians, erection and start-up engineers necessary to bring the complete installation of fire protection system into operation.

The contractor will be responsible for the integrated commissioning of the

plant & equipment supplied by him including trials, commissioning and demonstration of performance guarantee test.


ii/ The Contractor will render the following services:

a) Prepare equipment for trial runs and start-up b) Start-up and commissioning of equipment. c) Preliminary operation, initial operation, trial operation and Final

acceptance test.

The Contractor will be required to clean up the equipment and surrounding area and prepare it for trial runs and operation.

Priming connections, cooling water supply to bearings, lubrication piping to bearings, stuffing box jackets and sealing glands of all rotating equipment will be checked by the contractor.

Sequence checking of all control systems, pneumatic and cable connections, checking operation of all interlocks and protective devices will be done by the contractor.

Blow down of all piping systems, installations and removing strainers in piping and equipment, as required will be done by the contractor.

Calibration and adjustment of relay settings, instruments etc., disconnecting and reconnecting the driven and driving parts of any equipment and drives, as required, during the trial runs and rectification, if any will be done by the contractor.

The Contractor will provide personnel as required for assisting starting up and commissioning of equipment as well as adjustments, repairs and rectifications of defects in erection of the equipment during commissioning of the equipment and upto final acceptance.

4.1.8 Commissioning

On completion of the trial operation, all the systems will be under observation in operative condition. The Contractor will provide skilled personnel including necessary tools and consumables wherever necessary to rectify the deficiencies observed.

4.1.9 Performance guarantee

The performance guarantee tests will be completed within a time schedule to be mutually agreed upon between the Employer and the Contractor. Details of the performance tests, test procedures and test schedules for the demonstration of the performance guarantee on NFPA Codes/TAC Regulations will be submitted to the Employer and will be mutually agreed upon.

The Contractor will conduct the operation during the performance tests and will take full responsibility of the operations.


If the Contractor is unable to achieve the performance values as a whole or in part during the performance tests, the Contractor will repeat the tests for demonstrating the performance values. Before repeating the tests the Contractor will take any and all measures as may be needed, at his own cost in order that the performance values can be achieved.

If even with two repetitive tests and if necessary, by using additional operating personnel from the Contractor's crew and at his own expenses, the performance values are not reached the Contractor will undertake at his own cost such modification or replacement as are considered necessary to obtain the performance guarantee values and the responsibility to demonstrate performance guarantee will continue to remain with the Contractor till so established.


4.1.10 Tentative Details of Areas where Portable Fire Extinguishers are to be

provided for Package- 061

Sr. No. Area Description Approx. Size (LxW) in Mtrs.

1 Despatcher D 2 near JH-10 10x8 2 Despatcher D 4 above LTSS-2 Bldg. 36x24 3 Despatcher D 5 above LTSS-3 Bldg. 25.25x19 4 Wagon Tippler Control Room 9x9 5 Pump House 1 (PH-1) 20x8 6 Pump House 2 (PH-2) 10x8 7 Pump House 3 (PH-3) 10x8 8 Pump House 4 (PH-4) 8x8 9 Pump House 5 (PH-5) 8x8 10 Compressor House 20x18 11 LTSS-1 including IMCC-1 30x20 12 LTSS-2 including IMCC-2 36x24 13 LTSS-3 including IMCC-3 25.25x19 14 LTSS-4 including IMCC-4 30x15 15 LTSS-5 including IMCC-5 20x17 16 Area Repair Shop 24x9 17 Store near Area Repair Shop 18x9 18 Yard Master Building 21x11 19 Welfare Office (2 Storey) (32.5x15) x 2 20 Canteen near Welfare Office 20x10 21 Electrical Facilities Building (2-1/2 Storey) (18x9) x 2.5 22 MCP Electrical Building near Z-10 8x7 23 In-Motion Weigh Bridge Operator

Cabin/Room 8x4

24 Office Building near Track Hopper (2 Storey)

(50.5x14) x 2

25 Canteen near Track Hopper 20x10 26 Paddle Feeder Operator Cabin/Room in

Track Hopper Building (2 Nos.) (6x2.6) x 2

Details of Areas where clean agent portable fire extinguisher (Heptafluro propane of 5.0 Kg capacity) will be also provided as per distribution norm of clean agent extinguishers in the computer/Control rooms.

27 In Despatcher D 2 near JH-10 10x8x3.5 28 In Despatcher D 4 above LTSS-2 Bldg. 13.5x8.5x3.5 29 In Despatcher D 5 above LTSS-3 Bldg. 10.5x6.2x3.5 30 In Wagon Tippler Control Room 9x9x3.5


4.1.11 LEVEL OF VARIOUS BUILDINGS AND JUNCTION HOUSES

(A) Z-LINE

Floor Levels (Mtr.) Sr. No.

Name of Building / Junction House

Ground Level (Mtr.)

No. of Floors I II III IV V

1 Wagon Tippler Building 307.250 5 307.250 304.982 298.500 295.000 291.100

2 Pump House-2 307.250 --- --- --- --- --- --- 3 LTSS-1 307.250 --- --- --- --- --- --- 4 JH-Z1 306.000 3 303.750 300.050 296.050 --- --- 5 JH-Z2 307.000 3 309.000 313.000 316.900 --- ---

6 Track Hopper Building 308.358 2 308.358 299.158 --- --- ---

7 JH-Z3 306.000 3 306.000 310.100 314.100 --- --- 8 JH-Z4A 303.000 4 303.000 307.100 310.600 315.800 9 JH-Z5A 303.000 3 303.000 307.100 310.600 --- --- 10 JH-Z6A 303.000 3 303.000 307.100 310.600 --- --- 11 JH-Z7A 303.000 3 303.000 307.100 310.600 --- --- 12 JH-Z4 303.000 2 309.000 312.600 --- --- --- 13 JH-Z4B 303.000 2 303.000 309.000 --- --- --- 14 JH-Z5B 303.000 2 303.000 309.000 --- --- --- 15 JH-Z6B 303.000 2 303.000 308.700 --- --- --- 16 JH-Z7 303.000 2 303.000 308.300 --- --- ---

17 Main Pump House-1 303.000 --- --- --- --- --- --- 18 Compressor House 303.000 --- --- --- --- --- --- 19 LTSS-2 303.000 --- --- --- --- --- --- 20 JH-Z8 303.000 2 316.600 321.600 --- --- --- 21 FTH-1 311.000 2 318.000 322.500 --- --- --- 22 JH-Z9 308.000 2 313.900 317.500 --- --- --- 23 JH-Z10 310.500 3 317.000 320.600 324.100 --- --- 24 JH-Z11 310.000 3 320.000 323.700 327.300 --- --- 25 Pump House-3 310.000 --- --- --- --- --- --- 26 LTSS-3 310.000 --- --- --- --- --- --- 27 JH-Z12 310.000 2 316.500 320.000 --- --- --- 28 JH-Z13 310.000 2 322.900 328.000 --- --- --- 29 JH-Z15 308.500 3 343.800 347.400 350.400 --- ---


(B) L-LINE


Name of Building /

Junction House

Ground Level (Mtr.)


1 JH-J102 310.000 1 317.100 --- --- --- --- 2 JH-L1 310.900 2 314.525 318.525 --- --- --- 3 JH-L2 310.100 2 325.625 328.225 --- --- --- 4 JH-L3 310.500 2 317.800 324.325 --- --- --- 5 JH-L4 310.000 3 316.800 320.400 324.000 --- --- 6 LTSS-4 310.000 --- --- --- --- --- --- 7 JH-L5 310.000 2 315.332 320.150 --- --- --- 8 JH-L6 308.500 2 322.670 327.670 --- --- --- 9 JH-L7 306.000 2 312.900 316.500 --- --- --- 10 Pump House-4 306.000 --- --- --- --- --- --- 11 JH-L8 304.000 2 304.000 309.300 --- --- --- 12 JH-L9 312.000 3 312.000 328.000 332.000 --- --- 13 JH-L10 307.000 1 352.600 --- --- --- ---

(C) J -LINE


Name of Building /

Junction House

Ground Level (Mtr.)


1 JH-J9B 308.500 1 308.500 --- --- --- --- 2 JH-J9H 309.200 3 312.120 316.000 320.000 --- --- 3 JH-J10A 310.000 2 324.000 327.800 --- --- --- 4 JH-11 310.000 3 312.400 319.600 323.800 --- --- 5 Pump House-5 310.000 --- --- --- --- --- --- 6 JH-J14A 310.000 2 317.578 321.100 --- --- --- 7 JH-J15B 309.500 4 314.650 318.650 322.150 325.650 --- 8 LTSS-5 309.500 --- --- --- --- --- --- 9 JH-J17A 307.300 2 313.700 317.700 --- --- --- 10 JH-J17B 307.300 3 323.300 327.100 330.800 --- --- 11 JH-J20 307.300 1 330.850 --- --- --- ---


5.0 SPARES (A) Commissioning Spares and Insurance Spares

Supply of commissioning spares and insurance spares as required shall be in scope of supply of the Bidder alongwith the equipment. The list of commissioning spares and the insurance spares as per the format as given in SBD shall be furnished alongwith the tender. It shall cover requirements of erection, cold tests, startup and initial operation of the plant till integrated testing & successful commissioning and commencement of commercial production up to a period of six months. Any leftover commissioning spares shall be the property of the Purchaser. Any commissioning spares required over and above the list given by the Bidder shall have to be provided by the Bidder free of cost up to the successful commissioning & commencement of commercial production of the plant and equipment. The Bidder shall supply adequate insurance spares to ensure smooth operation and maintenance of the plant.

(B) Consumables

The Bidder shall supply all consumables such as initial fill of lubricants, oils, grease, chemicals, refractories, resins etc. as required to complete the plant till commissioning and shall have a shelf life of minimum one year. The scope of consumables shall include electrodes, shims, packings, bolts, nuts, gaskets, rivets, washers etc. The Bidder shall fulfill the requirement given in SBD. The Bidder shall also furnish Indian equivalent of oils, lubricants, refractories and other consumables along with necessary specifications, drawings, catalogues etc. to enable the Purchaser to procure them from indigenous sources. The Bidder shall indicate the annual requirement of all such consumables.

(C) Operating, Maintenance and Two Years’ Spares:

(1) The Bidder shall ensure the interchangeability of the parts wherever possible.

The Bidder shall furnish an itemized list of interchangeable spares as given in SBD.

(2) The list of spares as necessary and recommended by the respective

manufacturer for two years’ of reliable and trouble free operation and maintenance of all equipment under this package shall be in the scope of the Bidder. The same shall be quoted separately. In the event of order the successful Bidder shall furnish complete specification of the same.

(3) Spares list giving complete list of the replaceable parts, fully illustrated, shall

be supplied. The list shall include the following information.

• Item designation

• Reference drawings


• Quantity installed

• Quantity recommended for two years’ normal operation including the

insurance spares

• Weight of each spare part

• Supplier or sub-supplier’s catalogue number

• Recommended minimum stock

• Expected replacement time

• Installation instruction in detail shall be supplied both for original

installation and future, for replacement of major electrical equipment,

circuit wiring diagram shall be provided.

(D) Special Erection / Maintenance Tools and Tackles:

(1) The Bidder shall supply a complete and unused wet of all the special tools and

tackles including required number of tool boxes as required for erection, maintenance, overhaul or complete replacement of the equipment and components required for the plant. The Bidder shall submit a list of such special erection and maintenance tools and tackles.

(2) All the tools shall be supplied in separate containers clearly marked with the

name of the equipment for which they are intended. (3) The Successful Bidder shall indicate list of construction machineries, handling

equipment and other facilities including tower crane or equivalent for erection at high elevation required for the execution of work based on their previous experience, considering site conditions and other considerations of work and furnish resource deployment plan. The successful Bidder shall mobilize these equipment at site for the execution of work and this is an important requirement of the project. The availability of required facilities shall be ensured for completeness of the project in time.

(4) For any fabrication / control assembly (necessary for erection) work to be

done in the plant premises the plan shall be indicated by the Bidder. The necessary equipment such as plate bending machines, special purpose welding machines, fixtures, tools & tackles and other equipment required for fabrication shall be arranged by the successful Bidder.

(5) The successful Bidder shall carry out the testing of welded joints by

radiographic and ultrasonic methods. They must have only qualified / certified welders with them for completing all the welding jobs.

(6) All the measuring instruments shall be calibrated having reference to NPL

(National Physics Laboratory). (7) All tools and tackles, apparatus, special instruments required for erection,

testing, commissioning and establishment of the Performance Guarantee Test,


measurements required for establishing the pollution control norms and such other instruments, as required, shall be arranged by the successful Bidder. After commissioning, the successful Bidder shall handover all the special tools & tackles to the Purchaser as per the requirement given in SBD.

(8) The successful Bidder shall supply all required consumables, initial fill, oil,

lubricants, construction and erection materials including but not limited to shims, packing plates, joining compounds, kerosene, solvents, sealing compounds, tapes, connectors, brazing and soldering materials, welding and brazing gases and rods, electrodes and wires, erection bolts, nuts, rivets, piano wire, packing sheet and packing compounds, temporary supports, spacer templates, jute and cotton waste cloth, sand and emery paper etc. for the commissioning of the plant.

(9) For load testing of handling equipment, loads shall have to be arranged by

the successful Bidder. Electrical/ operation tests, as per standard practice, shall also be arranged and completed by them.

(10) All materials, equipment, tools, tackles etc. brought at site by the successful

Bidder within the plant area shall not be removed without the written permission of the Purchaser. Similarly, all enabling works built/erected and/or acquired by them within the plant premises shall not be dismantled and removed without the written permission of the Purchaser.

(E) Information/ Data on Spares and Consumables

The list of Spares & consumables shall be furnished by the successful Bidder as required in SBD. However, the successful Bidder shall furnish various information regarding spares, consumables, tools & tackles etc. as per the schedules indicated in this Technical Specification.


DATA SHEETS


6.0 TECHNICAL DATA SHEET (To be filled by the vendor) 6.1 FIRE HYDRANT SYSTEM

1. Material of Pipe :

2. Pipe Standard :

3. Class of Pipe :

4. Thickness of pipe material :

5. Make of Pipe :

6. Maximum recommended 0C : operating temperature : 7. Maximum recommended : operating pressure : 8. Type of protective coating on Pipe : 9. Make of Landing Valve : 6.2 PORTABLE FIRE EXTINGUISHERS (To be furnished separately for all types

of Fire Extinguishers envisaged by the bidder for complete package)

1. Manufacturer’s name :

2. Capacity :

3. Quantity :

4. Location of the Fire Extinguishers :