1030-H000-A06010-0016-1615-0001_R0 (1)

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

ESSAR STEEL LTD. - HAZIRA COKE OVEN PLANT – 1.35 MTPA

TECHNICAL SPECIFICATION FOR

STACKER CUM RECLAIMER MACHINE

ESSAR ENGINEERING SERVICES LTD.

HAZIRA

TSP NO: 1030-H000-A06010-0016-1615-0001_R0 DATE: 14th October - 2010

ESSAR STEEL LTD.-HAZIRA

ESSAR STEEL LTD.-HAZIRA COKE OVEN PLANT - 1.35 MTPA

TECHNICAL SPECIFICATION FOR STACKER CUM RECLAIMER MACHINE TSP NO - 1030-H000-A06010-0016-1615-0001_R0A

ESSAR ENGINERING

SERVICES LTD - HAZIRA

TSP No.: 1030-H000-A06010-0016-1615-0001_R0 Page 2 of 69 TS FOR STACKER CUM RECLAIMER MACHINE

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PREPARED BY

(EESL)

CHECKED & APPROVED BY

(EESL)

APPROVED BY

(PROJECT GROUP)

M K BAGARIA N C MODI - S NARAYANAN D.V RAO




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CONTENTS

CHAPTER NO. DESCRIPTION PAGE NO.

1 GENERAL INFORMATION 4 2 SCOPE OF WORK 5 3 TECHNICAL SPECIFICATION 9 4 INSPECTION & TESTING 35 5 DELIVERY 37 6 PAINTING 38 7 WORKMANSHIP & PERFORMANCE GUARANTEE 41 8 SPECIAL INSTRUCTIONS TO SELLER 44 9 DOCUMENTS TO BE SUPPLIED 45 10 DEVIATIONS 49

ANNEXURES

I SITE CONDITIONS 50

II FORMAT FOR DEVIATION FROM TENDER DOCUMENT 51

III QUESTIONNAIRE TO BE FILLED IN AND SUBMITTED WITH OFFER 52

IV OVERALL SUPPLY & IMPLEMENTATION SCHEDULE 63 V QUALITY ASSURANCE PLAN 64 VI LIST OF PREFERED MAKES 65 VII TECHNICAL DATA SHEETS 66




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Chapter 01 1.0 GENERAL INFORMATION 1.01 ESSAR STEEL LTD. – HAZIRA (ESTL) having integrated steel plant at Hazira, In

addition to that ESTL has planned to install coke oven plant to produce coke around

1.35 MTPA.

1.02 Intent of Specifications:

Intent of this specification is to procure a Stacker cum Reclaimer Machine which shall

be suitable to stack Coking coal and non coking coal at a rate of 1500TPH (rated) and

reclaim the same at the rate of 800TPH (Rated). This specification shall provide broad

guideline to all Bidders for their scope & technical parameters of the Stacker cum

Reclaimer Machine.

1.03 This specification is a part of the tender document. The bidder shall submit a

comprehensive offer in accordance to the requirements indicated in this specification.




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Chapter 02 2.0 SCOPE OF WORK & SUPPLY 2.01 The scope of work of the bidder shall consists of design, engineering, manufacture,

fabrication, inspection, assembly shop testing, painting at shop (as well as at site after erection and before commissioning), packing, Transportation and supply up to site store of ESTL at Hazira, Seller to supply documents/drawings for proper erection guidance, erection supervision, testing and commissioning of following machine complete with electrical equipment and standard accessories as covered under this specification.

The scope of work shall also include the following but shall not be limited to:

1. Supply of spare parts for two-year normal operation. Seller to furnish the list of

recommended spares for two-year normal operation.

2. Commissioning spares.

3. First fill of lubricant.

4. Furnishing all drawings & documents along with calculations as required by

BUYER for approval.

Equipment Qty Material handled Bulk Density of material

Stacker cum Reclaimer Machine Capacity:

Rated: 1500/800 TPH Design: 1800/960 TPH

1 Hard and soft Coking Coal

0.8 T/m3

2.02 Stacker cum Reclaimer machine shall be designed for outdoor duty and shall be

complete with mechanical, structural, power supply, conveyors, chutes, drives, controls etc., drawing and documents as detailed in subsequent chapter.

2.03 Stacker cum Reclaimer machine shall be complete with all structural & mechanical components comprising of:

A. Drive Mechanism i) Long travel mechanisms,




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ii) Boom conveyor drive mechanisms, iii) Boom luffing arrangement, iv) Slew mechanism for boom, v) Bucket wheel , vi) Lubrication arrangement, vii) Rail Clamp mechanism, viii) Power and control cable reeling drum

B. Long Travel Arrangement C. Under Carriage D. Upper Revolving Part E. Bucket Wheel F. Tripper Car G. Machine Boom structure with counter weight. H. Machinery house I. Tower Structure / pylon – with suspension J. Operator’s cabin K. Discharge Chute L. Communication and controls M. Auxiliary and accessories

i) Belt weigher on Boom conveyor ii) Dust suppression & control system, iii) Counter weight iv) Spring / Hydraulic loaded field buffers at either end of track v) Machine anchorage system for machine parking & maintenance. vi) Stand for boom maintenance. vii) Hydraulic jack viii) Coal by pass arrangement (Coal can either go to boom conveyor from

yard conveyor or coal can go to the same yard conveyor for further conveying)

2.04 The supply shall include all electrical equipment, safety switches, instrumentation,

controls and monitoring facilities; media & power supply from take over points / battery limits, etc., as applicable, complete in all respects.

2.05 Stacker cum Reclaimer machine shall be complete with all electrical accessories required for its safe, smooth and efficient operation. A fully functional, electrical and control system shall be in accordance to the design and features of the Stacker cum Reclaimer machine, as well as classification of the crane, but not necessarily limited to the following equipment:




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Flexible Cable Trailing Cable, Power & Control Power & Control Cable Reeling Drum of magnetic coupling type MV – switchgear Power transformers Motor control centers (L V - switchgear) Motors Techo generators Brake Thrustors Frequency Converters Programmable logic controller (PLC) Control device, like • Motion limit Switches • Switches for hydraulic system • Speed sensing switches • Local control switches • Position sensing switches like encoders, etc. • Alarm horns • Tilt switch • Emergency push button • Over traveling switch. • Limit switches for luffing • Probe switch • Position transducer • Wind warning system / Anemometer • Anti-collision devices

Installation Material • Cabling system • Terminal boxes • Cable terminations • Cable supports • Conduits • Identification labels etc. • Earthing system, Earthing shoes

Lighting System and lightening protection Aviation Lamps




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Any other system required for completeness and satisfactory performance

2.06 All items essential for the desired operation of this machine whether specifically mentioned in this specification or not, shall be included in the scope of work.

2.07 Supply of spares for two years trouble free operation for machines. Lists of such spares along with item wise prices shall be furnished along with quotation.

2.08 Required quantity of initial fill of transformer oil, grease, lubricants, hydraulic fluid etc. and other consumables which are necessary for cleaning / flushing including erection, testing and commissioning the machines.

2.09 Necessary tools and tackles for each machine required for maintenance, testing or inspection of the machines or any of the installations on it. List of such spares shall be furnished along with the quotation.

2.10 All miscellaneous items and spares required for commissioning of the machine. The list of such spares shall be furnished along with the quotation.

2.11 All auxiliary equipment, accessories, mounting and installation materials etc. required making the supply complete in all respects for efficient, trouble free operation & guaranteed performance of the equipment & system are in the scope of Seller.

2.12 Statutory approval wherever required shall be taken by the successful bidder for the machine being supplied by them from relevant authorities.

2.13 The scope of work shall stand supplemented by such details as are given in this specification, tender drawing, Instructions to the Seller, general conditions of contract or any other part of the tender document.

2.14 Exclusions The following are excluded from the bidder's scope of supply:

- Design, details, supply and installation of complete rail tracks with foundations. - Dust suppression of the yard conveyor system. - Yard conveyor. - Development of storage yard.




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Chapter 03 3.0 TECHNICAL SPECIFICATION 3.01 General 3.01.01 Stacker cum Reclaimer machine shall be designed for outdoor duty and shall be

complete with mechanical, structural, power supply, conveyors, chutes, drives, controls etc

3.01.02 Stacker cum Reclaimer machine shall be designed & supplied as per the latest edition of IS: 14416, 14417 & 15367 or equivalent International standards and stipulations made therein.

3.01.03 Main, additional and special loads shall be followed in accordance with various stipulations of IS: 13148.

3.01.04 In addition to IS / BIS mentioned in this technical specification, the Seller may offer the machine & material of the Stacker cum Reclaimer in accordance with the relevant ISO, DIN. BIS and FEM codes and standards applicable for this equipment.

3.01.05 Stacker cum Reclaimer machine shall be designed and manufactured to take care of the height, width, and centre distance of stockpile(s) stored in storage yard.

3.01.06 The material of the construction of the various parts of the Stacker cum Reclaimer machine shall be suitable to handle the raw material specified.

3.01.07 The machine shall be complete with bogie mounted tripper. The tripper shall have minimum possible height to reduce belt tension and power requirement of the yard conveyor on which the machine is mounted. The bucket wheel shall be mounted at the end of the boom conveyor. The material received from the bucket wheel shall be discharged on the yard conveyor (through the boom conveyor & chute) for on ward supply to consumer shops.

3.01.08 The design of the bogie and carriages of the Stacker cum Reclaimer machine shall be such that differential movement of the wheel sets of the machine on two rail tracks resulting in skewing effects does not occur. The traverse bogies shall be provided with material removing guard plate as well as rail cleaners at both ends so that the machine can travel even if there is spillage or overflow of material on rail track and the L.T. drives shall be selected accordingly.

3.01.09 The slewing mass of the machine shall be balanced to contain the centre of gravity well within the slew-bearing diameter.

3.01.10 Adequate numbers of locating pins etc. shall be provided to ensure easy assembly after dismantling of machine or mechanism etc.




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3.01.11 All matching parts shall be given identifiable marking for easy erection.

3.01.12 Materials used for equipment's structures shall be of good quality shall be free from fracture, cracks, blow holes, lamination, pitting etc.

3.01.13 Stability of this mobile equipment shall conform to the norms laid down in relevant IS / International standards. However, stability of machine must confirm to the following: • Minimum of stability factor of m/c during operating condition without operating

wind shall be kept as 1.5. • Minimum of stability factor of m/c during non-operating condition with high

wind velocity shall be kept as 1.2. • Minimum of stability factor of m/c during operating condition with operating

wind shall be kept as 1.3.

3.01.14 Safe and adequate access with approach for repairs, handling, maintenance and removal of all mechanical and electrical parts shall be ensured without recourse to additional scaffolding. Adequate clearances between the floors shall be provided to facilitate easy maintenance. Also, the clearance between ground and undercarriage shall be kept min. 3 m for maintenance purpose.

3.01.15 All parts requiring replacement or inspection or lubrication shall be easily accessible without the need for dismantling of other equipment or structures. All electrical cables shall be laid so that they are not liable to damage and can be easily inspected and easily accessible for repair and maintenance.

3.01.16 Suitable handling facilities or provisions such as eye bolts, lifting lugs, ladders etc. of adequate capacities shall be provided on the machine at all necessary locations for maintenance of various mechanisms.

3.01.17 Adequate working space on the platform around all machinery parts shall be provided for personnel working for maintenance or inspection.

3.01.18 Safety hand railing preferably of tubular constructions shall be provided around all walk ways. Railing shall not be less than 1000 mm in height with an intermediate member at a height of 500 mm. The minimum size of handrail shall be 32NB.

3.01.19 All edges or openings shall be provided with toe guards. Toe angles or bent plates shall be minimum 100 mm in height.

3.01.20 Essential openings, on the platforms or walkways shall be covered with removable covers.




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3.01.21 All moving parts, wherever required from the safety point of view, except long travel gear wheels, shall be provided with covers opening on strong hinges. These covers shall preferably be made of minimum 3 mm thick plate. All heavy covers shall be provided with inspection windows.

3.01.22 Sufficient number of power points / outlets shall be provided at suitable places on the machine to plug in welding transformers and hand tools for maintenance purposes.

3.01.23 Standardization of assemblies shall be carried out to the maximum extent possible.

3.01.24 Sizes for all equipment viz. wheels, brakes etc. shall be selected from preferred number series and shall be of reputed make.

3.01.25 At suitable points, built in arrangement shall be provided for easy replacement of heavy electrical equipment. Built in jacking up arrangement for bogie, frame etc. for changing of wheels and lifting provision for cable reeling drums and other heavy parts shall also be provided.

3.01.26 The design of the equipment shall ensure that there is no spillage of material on any part of the equipment. Dust covers shall be provided for all motors, gear boxes, drums etc.

3.01.27 End limit switches and over run limit switches shall be provided at both the ends of the travels for all machines. The corresponding strikers shall also be supplied by the Seller.

3.01.28 The machines shall be provided with adequate numbers of buffers.

3.01.29 Independent drives shall be provided for all motions.

3.01.30 Relevant stipulations of IS: 13148 shall be followed for Safety regarding Over-turning and Drifting.

3.01.31 Safety against movement by the Wind: Independent of the stability against overturning due to wind velocity, suitable check shall be made that the Stacker cum Reclaimer machine cannot be set in motion if maximum wind speed is increased by 10 percent. Following assumption would be considered: • Coefficient of friction for wheels provided with brake - 0.14. • Resistance to rolling of un-braked wheels mounted on anti-friction bearings -

35N /10 KN. • Coefficient of friction between the clamps & the rail – 0.25.




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3.02 Operating Requirements 3.02.01 Stacker cum Reclaimer machine shall be operated through programmable logic control

(PLC) in a “semi – automatic mode” of operation. However manual mode of operation will override PLC control system. All operations of the Stacker cum Reclaimer including its long travel shall be controlled from the operator’s cabin only.

3.02.02 Suitable mechanism to be provided to adjust the stacking / reclaiming rate from 10% to 100% rated capacity as per demand.

3.02.03 Local push button stations shall be provided near all drives for repair and maintenance.

3.02.04 The operator’s cabin shall have double door provision so as to prevent ingress of dust.

3.02.05 Dry fog type dust suppression system shall be provided at all material transfer points. Dust exit to atmosphere shall not exceed 150 mg/m3.

3.02.06 In case, the wind velocity exceeds 72Km/h, an audio-visual signal shall be given by the anemometer. At 90 Km/h of wind velocity, the total power shall be cut off and the electro-hydraulic rail clamps shall get operated automatically along with brakes applied to all motion.

3.02.07 All drive limit switches shall be provided with additional backup switches and all brakes shall be fail safe type.

3.02.08 Suitable communication system shall be provided among Stacker cum Reclaimer operator, central control room & local personal.

3.02.09 Microprocessor based Fire Detection & Alarm panel shall be provided along with smoke detectors, adequate number of fire extinguishers at suitable locations.

3.02.10 Adequate illumination shall be provided near all drives, working/maintenance area of the machine, material discharge points, MCC rooms, platforms and walkways, staircases, ladders, etc. to enable operation/maintenance of the machine. Sufficient number of emergency lights shall be provided at control room, exit points, ladders, etc., so that during power failure essential activities like switching off the controls and exit of personnel are possible.

3.03 DRIVE MECHANISM 3.03.01 Long Travel

1) Stacker cum Reclaimer machine shall be carried on double flanged track wheels arranged in equalizer for uniform distribution of loads. The under carriage shall have statically determinate support system to ensure its stability and to afford an




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evenly distributed load over the entire travel assemblies and to cater to any unevenness in the level of the rails.

2) The travel motion shall be provided with requisite number of motors suitably synchronized at each corner. Minimum 50% of wheels at each corner shall be driven. In the event of failure, any drive motor, the corresponding motor on the other side shall be automatically disconnected. However, the machine shall be operable with the remaining drives.

3) The drive shall be infinitely variable (VVVF) from 2.0% to 100% nominal speed. For smooth acceleration / deceleration the drive motors are frequency controlled.

4) Protection against overloads shall be provided through suitable control system. The control system shall ensure smooth acceleration for all motions and variable speeds.

5) The equipment shall be supported on wheels mounted in bogies and shall be driven by electric motors through reduction gears. 'L' type supports shall be provided for drive mounting. Chain drives and open gears shall not be used. For easy maintenance the drive shall be located on the inside of the rail tracks.

6) The four corners of the Stacker cum Reclaimer shall be provided with resilient buffers to absorb the impact.

7) Rail sweeps to clear rail shall be provided in front of outer wheels.

8) Safety stops shall be fitted on the rail to limit the travel in addition to limit switches provided. These safety stops shall not interfere with the removal of wheels.

9) Jacking pads shall be provided for removal and changing of the wheels.

10) In case of failure of one drive, it shall be possible to shift machine to repair/parking area, if required, by remaining pair of drives.

3.03.02 Boom Conveyor

1) The conveyor system for boom conveyor shall be designed in accordance with latest edition of IS: 11592 or equivalent taking operator’s conditions into account.

2) The belt speed of the boom conveyor shall be matching to the belt the speed of the yard conveyor.




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3) Boom conveyor shall have minimum belt width of 1400mm.

4) Impact table with impact pads/ impact idlers shall be provided at the discharge of boom conveyor.

5) Deck plate shall be provided for Boom conveyor to prevent the spillage of material over belt.

6) Belt weigher with weighing range of 20 – 100 % shall be provided on boom conveyor.

3.03.03 Boom Luffing and Slewing arrangement

1) The Iuffing of the cantilever boom shall be with the help of hydraulic arrangement.

2) A positive interlocking system shall be provided such that the luffing movement of the boom shall be possible only when the trolley and the operator’s cabin are brought to the predetermined positions beyond the hinge point inside the tower.

3) The slewing mechanism shall be driven by electric motors. Drive motion shall be transmitted via safety coupling, planetary gearing with pinion to the external gear of slew bearing.

4) Hydraulic luffing and slewing of the boom shall be provided for Stacker cum Reclaimer with following respective ranges Luffing : (+) 12° to (-) 8° Slewing : 2100 (1050 on either side of the track)

5) Two pumps, two electric motors with dual line system shall be provided to ensure that in the event of one of the drive unit failing, full operation can be maintained without interruption. Failure of any drive unit shall produce audio visual alarm in the operator's cabin.

6) The acceleration and deceleration or raising and lowering the boom shall be smooth and operation shall be without giving any jerk to the boom.

7) The design and construction of hydraulic system shall be suitable to operate in the atmospheric conditions and dusty operating environment of the plant. The system shall be complete and consist of hydraulic fluid, various kinds of valves, accumulators, hydraulic motors/ hydraulic pumps, various accessories such as filters, strainers, magnet and restructures, hydraulic pipe work, fittings and fluid passages, flexible pipe work, sealing devices, instruments for indicating various parameters such as pressure, temperature etc., control devices for local and automatic operation of the system, safety devices and alarm for abnormal




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operating conditions, interlocks for sequencing and safe operations.

8) The hydraulic system/ components shall be designed / selected so that the working pressure shall not exceed 180 bars.

9) The hydraulic circuit shall be designed to minimize surge pressure. Suitable accumulators of adequate size shall be used to withstand maximum rate of surge pressure rise as well as the back surge pressure. All components shall be capable of withstanding the peak pressure.

10) Necessary connections, valves, outlines and apparatus shall be provided to facilitate testing, flushing, drainage, fluid sampling and repair & maintenance.

11) A suitable capacity reservoir with provisions for oil filling, air breathing, drawing, and inspection shall be provided.

12) The reservoir shall be designed to prevent the ingress of any foreign materials including water and dust.

13) Inner face of the reservoir shall be sand blasted and shall be suitably painted, so that it does not have any adverse effect on hydraulic fluid used.

14) Suitable level indicators shall be provided in the reservoir. Low level of the fluid in the reservoir shall produce warning alarm in the operator's cabin and switch off the hydraulic pumping unit.

15) Pump and pump motor shall be designed to operate under load conditions at a minimum of 125% of system operating pressure and give a flow rate of 125% of system operating flow rate.

16) Lockable type valves shall be provided to prevent tampering.

17) All hydraulic valves, accessories and devices shall be provided with identification metal tags.

18) Necessary relief valve shall be provided to protect the hydraulic system from excessive pressure. The fluid leaked through the relief valve shall be suitably carried to the reservoir. The overload of the system in raising or lowering of the boom shall give necessary warning signal in the operator's cabin.

19) Limit switch for luffing shall be provided to restrict the luffing range from maximum inclination to maximum declination and a set of limit switches for slewing of the boom in both directions of rotation of machine.

20) The slewable upper part shall be supported by a combined roller/ball bearing with external gearing. The slew bearing shall be sized in such a way that all




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normal forces and moments shall be safely absorbed.

21) The slew bearing shall be connected to the stiffened and machined portal structure and slewing platform by means of high-tensile bolts.

22) The slew bearing shall be equipped with a special sealing system preventing the penetration of dust or dirt into the raceways. The external gear is protected against the penetration of foreign matters by means of a sheet metal covering.

3.03.04 Operator’s Cabin 1) Operator’s cabin with all necessary controls for performing the various

operations shall be located in such manner as to ensure complete view of the operations.

2) The equipment shall be controlled and operated from an operator’s cabin suitably located on the boom to give operator an full view of the operating zone in either direction of travel and optimum vision all round. The cabin mounted on boom shall have automatic leveling device i.e. the cabin shall always be horizontal irrespective of boom inclination.

3) The cabin shall be of adequate size to house all the required control equipment and shall contain ample room for its adjustment and repair.

4) The cabin shall face towards the centre line of the boom runway. It shall provide maximum visibility in all directions through large unobstructed, tinted double pane, safety glass windows. Windows shall be provided with windscreen washes, electrically operated wipers and a water tank. Provisions shall be made to allow frequent cleaning of exterior surface of glass.

5) Control facilities for the following shall be provided in the cabin: a. Machine Travel b. Cabin lighting c. Dust Control System, and d. An emergency stop button to switch ‘off’ all motions. This shall not

interrupt power to the auxiliary circuits, lighting, signals, etc.

6) Indicators and alarm for main supply, control supply, motions, and wind pressure phase failure, etc. shall be provided in the operator’s cabin.

7) A signal horn, audible up to 600 m, controlled from operator’s cabin shall be provided on the Stacker cum Reclaimer machine.

8) PTT type communication system shall be provided for communication between




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operator’s cabin and electrical house. And for communication of operator’s cabin with central control room, suitable hardware type system shall be provided.

9) The cabin shall be furnished with sufficient facilities for comfortable seating of the operator with provision of height adjustment.

10) The operator’s cabin shall have shall have double door provision, so as to prevent ingress of dust and shall be provided with split type Air Conditioner.

11) The cabin shall be of welded steel construction adequately stiffened and braced. It shall be of insulated design, weatherproof, dust-tight, thermal and acoustically insulated. It shall be of equipped with a sliding or swinging door, fire extinguisher, training seat, air conditioning equipment and all other items required or a complete operator’s cabin.

12) Safe means of access shall be provided to the operator’s cab and to every place where any person engaged on the inspection & repair.

3.04 Machinery House 3.04.01 A machinery house shall be of adequate size to accommodate:

• Drive mechanisms for bucket operation, • Machine travel mechanism, • Boom luffing mechanism • Electrical equipment like switch gears, motors controls centre, transformer, etc

3.04.02 Adequate space for maintenance shall be provided inside machinery house.

3.04.03 The electrical house shall be complete with sun protected roof, pressurized ventilation system, V lockable doors etc.

3.05 Bearings and Plummer Block 3.05.01 All bearings shall be protected against dust and grit. Allowance shall be kept for

impact and side thrust.

3.05.02 Wherever necessary spherical seating and separate thrust bearings of suitable dimensions shall be used. Otherwise, anti friction ball or roller bearings of specified make only shall be used throughout.

3.05.03 Life of all antifriction bearings shall not be less than 50000 working hours.

3.05.04 All bearing housings shall be made cast or wrought steel. Housings shall be of split type constructions to permit easy removal of shaft. The underside of the base of each




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pedestal shall be machined and shall bear upon machined surface.

3.05.05 Plummer block housings shall be oriented on the supporting structure in such a manner that no shaft loads are transmitted to the housing cap. Plummer block shall have provision for lubrication. Suitable oil seals shall be provided wherever necessary.

3.05.06 Heavy caps shall be provided with means for lifting.

3.06 Coupling 3.06.01 All coupling shall be of steel or cast iron of Grade FG 300 of IS 210:1978 and shall

be designed to transmit maximum torque developed. Flexible coupling shall be fitted between motor shaft and gear box extension shaft.

3.06.02 Couplings shall be designed to suit the maximum torque required to be transmitted or to suit the total braking torque of the mechanism whichever is greater.

3.06.03 High-speed couplings shall be selected of a natural frequency such that no resonance can occur at any operational speed.

3.06.04 For boom conveyor, fluid coupling shall be provided in case of motor is 30 kW & above.

3.07 Shafts 3.07.01 Shafts and axles shall have sufficient strength, rigidity and adequate bearing

surfaces. Shafts shall be subjected to cyclic loading and shall be designed for fatigue life also.

3.07.02 All shafts shall be made of carbon or alloy steel. Keyways and splines shall conform to relevant Indian / International standards.

3.08 Gears and Gear Boxes 3.08.01 Gears in power operated motion shall machine cut and shall conform to relevant

Indian / International standards. Gear boxes shall have built-in Lubrication system either splash or force fed type.

3.08.02 Straight and helical spur gearing or bevel gear shall be used. Worm gears shall not be used unless specified otherwise. All spur gears shall have 20 degree pressure angle with involutes teeth profile.

3.08.03 All gears shall be of hardened and tempered alloy or carbon steel with machine cut teeth. Surface hardness for pinion shall be 60±2 HRC and for gear it shall be 220 to




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225 BHN. Difference in hardness of pinion and gear shall not be less than 60±2 HRC. The gear teeth shall be ground and finished to suit the service conditions.

3.08.04 Gear teeth shall be cut in metric module system only.

3.08.05 All gears shall be completely enclosed in oil tight designs or guarded by covers firmly attached to rigid supports where complete enclosure is not possible.

3.08.06 The housing for Gear boxes shall be of cast steel or fabricated. Fabricated gearboxes shall be made of minimum 8-mm thick steel plate and shall be stress relieved.

3.08.07 Casing shall be split horizontally at each shaft centerline and fastened and arranged so that the top half can be removed for inspection and repair without disturbing the bottom half.

3.08.08 Directly above the mesh line of teeth, hand-holes with bolted covers be provided in the gear box body for inspection of the teeth.

3.08.09 The gearboxes shall be provided with breather vents, oil level indications, dipsticks and easily accessible drain plugs.

3.08.10 Radial clearance between the gear box inner surface and the outside diameter of the gear shall be at least 1.25 times the depth of the largest gear tooth inside the gear box or 20 mm whichever is higher. The facial or side clearance between the inner surface of the gearbox and the face of the gear or pinion shall be at least 20 mm.

3.08.11 All gearboxes shall be mounted on machined surfaces and shall have machined feet. Shims shall not be used.

3.08.12 Gearboxes shall be provided with lugs or other means for lifting purposes.

3.08.13 Interior of all gearbox housing shall be sand blasted. Suitable resistance paint matching to the lubricant used shall be applied inside the gearbox.

3.08.14 External cooling arrangement shall be provided wherever required to dissipate the heat generated inside the gearbox. However, external-cooling coils shall be avoided.

3.09 Track Wheel 3.09.01 Each track wheel shall be shrunken onto a shaft and mounted in two-wheel bogie.

The wheels shall be mounted in such a manner as to facilitate removal and replacement.

3.09.02 The track wheel shall be double flanged with a straight tread, and shall be either of forged, rolled or cast steel. Clearances between rail head and wheel flanges shall be




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suitable to the tolerances as specified in IS 3177. The steel of track wheels shall not contain more than 0.06% either of sulfur or phosphorous.

3.09.03 Wheels shall be heats treated to have a hardness of 60±2 HRC on the rolling surface and flanges to a depth of not less than 10 mm with a smooth pass to the non-hardness zone.

3.09.04 It is capable of withstanding the maximum load to which it shall be subjected. It shall allow the appliance to perform its normal duty without abnormal wear.

3.09.05 The tread diameters of wheels shall preferably be standardized to sizes specified in the latest edition of IS: 1136. Minimum tread diameter of the wheels shall be 630 mm. Complete wheel bogies shall be interchangeable with each other.

3.09.06 The dimensions of flanges of track wheels shall be not less than the values given in Table 1.

Diameter of Wheels Depth of Flanges

Thickness of Guiding Wheel at Flange Base

Over 500 and including 1000 25 25 Over 1000 30 30

3.10 Bolts, Nuts Screws and Washers 3.10.01 All bolts and set screws in rotating parts shall be locked. Bolts in tension shall be

avoided wherever possible. Tapered washers and tapered pads shall be provided on underside of steel sections with tapered flanges and shall be tack welded in place.

3.10.02 All bolts and nuts shall preferably be in accordance with the latest edition of IS: 1364 & IS: 1367. Black bolts and nuts shall not be used. Friction grip fitted bolts shall be used where necessary for proper assembly.

3.10.03 Washers shall conform to the latest edition of IS: 2016, IS: 5372 and IS: 5374 as appropriate.

3.11 Brakes 3.11.01 D.C. Electro magnetic type / Electro-hydraulic thruster brakes shall be used unless

specified otherwise.

3.11.02 Brakes shall be provided for the traveling motion and they shall be capable of holding the machine in position during storm conditions. These brakes shall come in operation automatically from anemometer.




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3.11.03 All the brakes shall be capable of taking 150% of respective full load motor torque.

3.11.04 Brakes shall be provided on the bucket wheel drive so that the wheel does not rotate when the power is off.

3.11.05 Rating of brakes for all mechanisms shall be selected as per required braking moment necessary for each mechanism with factor of safety and the required heat dissipation capacity.

3.12 Rail Clamps and Anemometer System 3.12.01 For design of clamps, coefficient of friction between the clamp and rail shall be taken

as 0.25 and to withstand a wind velocity up to 250 KMPH.

3.12.02 Automatic interlocked hydraulically operated spring loaded rail clamps shall be provided to act on the track rails to prevent creep after power is off. The hydraulic rail clamp shall be complete with power unit incorporating motor, pump, accumulator, piping, valves, and fittings, limit switches for sensing clamp / unclamp position, return line filter etc.

3.12.03 Rail clamps are mounted on carriages, attached to the pylon frame. The arrangement shall guide the clamp jaws and prevent scrubbing of the jaws on the rail during traverse. Rail clamp jaws shall be adjustable for wear and are replaceable.

3.12.04 Rail clamps are interlocked with the long travel drives to disengage prior to energizing the travel drives and to stop the drives in the event that clamps are applied while traversing.

3.12.05 The machines shall be protected against drift due to wind by means of two electric / hydraulic operated (one on each rail) rail clamps and two hand operated rail clamps.

3.12.06 Wind anemometer with suitable controls shall be provided to warn the operator of high wind velocities and stormy conditions. The control of anemometer system shall be as given below:

i) When the wind velocity reaches 20 m/sec there shall be an audiovisual warning alarm in the operator’s cabin. The operator can then plan to stop the operation. If the operator fails to stop the operation of the machine and wind velocity reaches to 31 m/sec all the drives of the machines shall stop automatically and the rail clamps will apply automatically.

ii) The equipment shall be built to withstand wind velocity up to 180 km/hr., when not operating.




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3.12.07 The electrical / hydraulic operated rail clamps shall be designed to operate automatically when the machine is switched off. These rail clamps shall also be designed to be operable remotely from the operator's cabin.

3.12.08 The automatic rail clamps shall be such that when wind pressure is higher than what the braked track wheel can hold, the automatic rail tong jaws are clamped tighter by means of some suitable mechanism.

3.12.09 The automatic and manual rail clamps shall be equipped with limit switches to monitor their operations. The long travel shall not be possible to start until and unless these clamps are in released position.

3.12.10 In addition anchoring device shall be provided to positively arrest the traveling motion of the Stacker cum Reclaimer machine under storm conditions.

3.12.11 Two anchoring device arrangement s are to be provided.

The system to be mounted in the rail clamp carriage and contain two vertically arranged anchoring pins (one at each side of the tracks rail), which engage to land-based anchor-holes at a fix tie down position of the Stacker cum Reclaimer machine. At the same position tie—downs shall be applied to avoid lifting off of the wheels in case storm wind gusts. The status of the tie down pins shall be monitored in the operator’s cabin. When engaged, any type of travel movement is prevented.

3.13 Buffers 3.13.01 Stacker cum Reclaimer machine shall be fitted with energy absorbing buffers to stop

the travel motion on either direction at the rail track ends.

3.13.02 End buffers on long travel bogies or equalizer and travel-end to be provided for arresting the motion in case of failure of the safety system.

3.14 Bogie Assembly 3.14.01 The design of the bogie assembly shall include provision for replacement of a

complete two-wheel bogie.

3.14.02 The bogie assembly shall be designed for equal load distribution and to compensate the rail tolerances.

3.14.03 The design of the bogie and carriages of the equipment shall be such that differential movement of the wheel sets of the machine on two rail tracks resulting in skewing effects does not occur. The traverse bogies shall be provided with material removing guard plate as well as rail cleaners at both ends so that the machine can travel even




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if there is spillage or overflow of material on rail track and the L.T. drives shall be selected accordingly

3.14.04 The rail bogie assembly shall have wheel failure supports, rail ploughs, buffer mounting, rail clamp mountings and guard for the travel drives.

3.15 Tripper Car 3.15.01 The machine shall be complete with bogie mounted tripper. The tripper shall have

minimum possible height to reduce belt tension and power requirement of the conveyor on which the machine is mounted.

3.15.02 Tripper car with discharge and feed pulley, idlers, travel wheels, etc. shall be connected to the main structure of stacker by means of hinged connection.

3.15.03 The tripper shall be designed as per latest edition of IS: 14386.

3.15.04 Discharge chute shall be provided with required liners. Care shall be taken to avoid fouling of chute with the skirt board provided on the boom conveyor during luffing motion of the boom.

3.15.05 Tripper shall be designed considering yard conveyor of 1400mm belt width.

3.15.06 Inclination of the tripper shall be restricted to the angle of 12⁰ maximum.

3.15.07 Diameter & face width of Tripper pulleys shall be equal to that of drive pulley of yard conveyor. (Details of drive pulley of yard conveyor shall be provided by Buyer after award of order to successful bidder.)

3.15.08 The feeding arrangement from the tripper shall be suit the following requirements: • To feed material from yard conveyor to the boom conveyor. • To completely by pass the boom conveyor so that the material can be fed to the

same yard conveyor, or • To feed material from boom conveyor to yard conveyor.

3.16 Bucket Wheel 3.16.01 The bucket wheel shall be mounted at the end of a boom conveyor. The material

received from the bucket wheel shall be discharged on the ground conveyor (through the boom conveyor and chutes) for onward supply to consumer shops.

3.16.02 The bucket shape shall be designed as per the characteristics of the material to be handled and the discharge capacity, proper cutting clearance, taking wheel chamber into account bucket area for better emptying. The wheel shall be inclined towards the conveyors to increase wheel chute inclination and to achieve better emptying. The




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movement of the bucket shall be uniform and so timed that the reclaiming process, filling and discharge of the bucket operate with maximum efficiency. The flow of material shall be almost uniform and the end of discharge phase of the bucket shall coincide with the beginning of discharge phase of following bucket.

3.16.03 The bucket shall be made of wear resistance steel or steel with wear resistant liners and fitted with replaceable, high abrasive resistant silicon manganese bucket teeth or tips on wear resistant bucket blade. Bucket wheel shall be driven by hydraulic motor or electric motor with hydraulic coupling through a reduction unit. The bucket wheel drive shall be independent of boom conveyor drive and equipped with a speed monitor as a safety facility on bucket wheel main gearing.

3.16.04 Buckets shall have minimum life of 2.0 years and bucket teeth shall have minimum life of 6 months.

3.16.05 Bucket wheel shall be driven through a hydraulic drive system so that reclaiming rate can be adjusted with demand of occasion to prevent overloading of the drive by switching off the drive in case of jamming of the bucket in the stockpile. Brakes shall be provided on the bucket wheel drive so that the wheel does not rotate when the power is off.

3.16.06 Torque limiting device shall be provided for overloading and jamming of bucket in stockpile.

3.17 Chute and Skirt Board 3.17.01 Discharge chute & skirt board shall be provided with Hardox-400 liner plate.

3.17.02 Adequate care shall be taken to avoid fouling of the discharge chute with skirt board provided on the boom conveyor during luffing motion.

3.18 Technological Steel Structure 3.18.01 The under carriage, upper revolving part, bucket wheel boom, pylon, counterweight

boom and structure shall be designed to take care of the operational requirements including ease of access and maintenance. The member of the structure shall be designed in accordance with the latest edition of IS: 13148 or equivalent international standards to take care of prevalent environment condition.

3.18.02 Safe means of access shall be provided to the operator’s cab and to every place where any person engaged on the inspection, repair and lubrication of the equipment shall be called upon to work. Adequate hand holds and footholds beings provided where necessary. Hand holes and access openings shall be as per




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relevant Indian / International Standard(s) where available.

3.18.03 All steel structures and the portal frames shall preferably be of box construction with double web plate girder. The span to depth ratio shall not exceed 18.

3.18.04 Structural steel conforming to the latest edition of IS: 2062 or equivalent only shall be used.

3.18.05 Electrodes of low hydrogen type only shall be used for welding of steel structures, which are subject to dynamic loading. Parts of steel frame carrying machinery shall be provided with doubling plates of adequate thickness welded and machined to true surface.

3.18.06 For side alignments of motors, strong adjustable screws with lock nuts and sliding blocks shall be provided. Welded snug shall be fitted at pedestals, gearboxes etc. for alignment.

3.18.07 Stud or body bolts shall not be used as fasteners for mechanical items except for fixing inspection covers.

3.18.08 Design of the structures for these equipment shall take into account the following factors and shall have ample precautions taken to withstand the following: 1) Reinforcement of the natural sway of the structure due to unbalanced dynamic

oscillations of the machines. 2) Fatigue produced in the members due to frequent stress reversals. 3) All impact loads, super-imposed loads and loads due to wind.

3.18.09 Platform, walkways and ladders shall be provided for access to all equipment,

machinery and fittings requiring periodic attention and maintenance.

3.18.10 Every platform shall be securely fenced with double tiered guard rails having a minimum height of 1 m and toe boards, unless parts of the equipment structure provide safety. The platform shall be of sufficient width to enable, normal maintenance work to be carried out safely. On bridge platform, which shall not be less than 0.75 m in width the fencing shall extend along the full length of the outer edge. A toe plate shall be provided on all platforms to prevent rolling down of materials from platforms.

3.18.11 Ladder shall provide wherever possible. Sides of the ladders shall extend to a reasonable distance above the platforms, or other reliable hand holds shall be provided. Ladders shall if possible, slope forward. Vertical ladders exceeding 3 m in length shall be provided with back safety guards.




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3.19 Dust Suppression & Control System 3.19.01 The dust suppression system shall be capable of suppressing effectively the dust

which is raised from the receiving hopper and also from all other material transfer points of the reclaiming system.

3.19.02 Dust suppression system shall be of Dry fog dust suppression type. Water tank with minimum capacity of 2 m3 or reserve of 8 hours of continuous operation, whichever is higher, shall be considered to be provided on the equipment for dust suppression water requirement.

3.20 Safety Requirements 3.20.01 Stacker cum Reclaimer machine shall comply with the relevant safety regulation

under the Factories Act, 1948, Indian Electricity Rules and other Statutory Regulations, Rules, Acts.

3.20.02 Stacker cum Reclaimer machine shall be equipped with adequate safety devices and provided with adequate working clearances all around the equipment fitted on the machines to comply with the Buyer's specific requirements, safety codes and statutory regulations prevalent at the place of installation.

3.20.03 An alarm shall be fitted to the Stacker cum Reclaimer to give the driver audible and visual warning when the load exceeds the safe working load, and a device preferably electrical shall be fitted which shall automatically stop when the load exceeds the safe working load, which shall not preclude the load from being lowered.

3.20.04 Adequate numbers of fire extinguishers and fire extinguishing systems suitable for prevention of electrical fire as per safety rules shall be provided in the operator's cabins, electrical rooms and in other areas considered necessary. Adequate numbers of sand buckets shall also be provided at suitable locations for preventing fire hazards.

3.20.05 Suitable fire alarm with fire detectors shall be provided for the electrical premises. The fire protection systems shall comply with provisions made by tariff advisory committee, a statutory body under Insurance Act 1938, and Explosives Act prevailing at place where the Stacker cum Reclaimer is to be erected.

3.20.06 Smoke detection system shall be supplied for fire indication in the electrical switch room and transformer area. In addition to these, portable dry chemical extinguishers shall be located adjacent to all major electrical drives and oil filled machinery.




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3.20.07 The machines shall be provided with adequate numbers of buffers.

3.20.08 End limit switches and over run limit switches shall be provided at both the ends of the travels

3.20.09 Suitable interlocking features shall be provided for the boom hoisting.

3.21 Guarding 3.21.01 All gear wheels, pinions etc. shall be totally encased. Effective guards shall be

provided for revolving shafts.

3.21.02 Long travel cross-shafts shah be guarded throughout their length.

3.21.03 Suitable guard shall be provided on the down shop-lead side to prevent accidental contact between ropes and live conductors.

3.21.04 Suitable ballast with its case shall be provided as per the requirements to meet the stability conditions.

3.22 Lubrication 3.22.01 Provision shall be made for lubricating all bearings which shall be easily accessible

from the working platforms of the Stacker cum Reclaimer machine.

3.22.02 The bearing of the portal traveling mechanism shall be piped to several central points (one unit to each corner group of travel mechanism), lubricated by one motor operated central lubrication unit (one unit to each corner).

3.22.03 All bearing which are grease lubricated, shall be fitted with heavy-duty grease nipples. All points to be lubricated shall be arranged to permit ready access and easy by operating and maintenance personal.

3.22.04 Any grease nipples, which are not readily and safely accessible, shall be piped, with rigid tubing securely attached to framework, to plates where they are accessible. Multiple piped grease nipples, which are in close proximity to one another, shall be grouped in batteries of nipples.

3.22.05 Lubricating nipples, pipes and adapters shall comply with relevant Indian Standards.

3.22.06 The lubrication systems shall be complete with grease pumps, double supply lines, direction control valves, the distributors etc.

3.22.07 The level of grease in the grease tanks shall be monitored electrically and low level of the grease shall give the audio warning signal in the operator’s cabins.

3.22.08 A lubricating chart shall be provided indicating all the lubricating points, the type of




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lubricant and recommended frequency of lubrication.

3.23 Weather Protection and Painting 3.23.01 All electrical, structural and mechanical equipments shall be adequately protected

from weather.

3.23.02 All weather proof covers shall be easily removable.

3.23.03 Stacker cum Reclaimer machine shall be working in corrosive atmosphere prevailing near sea-shores a well as in the atmosphere containing dust particles of the material. The equipment shall be provided with two coat of anti-corrosive primer after sand blasting and final two coats of anti-corrosive epoxy paint.

3.24 ELECTRICAL SYSTEMS 3.24.01 General

All equipment and material offered shall be in accordance with the relevant ISO, DIN. BIS and FEM codes and standards applicable for this equipment.

3.24.02 Design of Electrical Equipment

• All equipment and material shall be new, of the highest quality, and selected and applied in accordance with good engineering, design and construction practice.

• The electrical design and installation shall be based on maximum protection of personnel and equipment, ease of maintenance and convenience of operation. The protection for the electrical components shall be as follows:

Motors IP 65 (to be provided with lifting hook, Greasing hole)

Devices – Indoor IP 42 Devices – Outdoor IP 65

3.24.03 Power Supply

• The primary electric supply to the facility is 3.3 kV / 6.6 kV, 3-phase, 4-wire 50Hz which is brought to the centralized junction Box via XLPE Cable. The main power supply to the stacker cum reclaimer is to be taken from the centralized junction box by a core flexible trailing cable with cable drum of magnetic coupling type with torque motor / stall torque motor, including connection box and earthing installation on the supply side. Power supply shall be controlled by a circuit breaker in control room, from which power shall be taken to the Stacker cum Reclaimer. It shall be possible to trip the circuit breaker from the machinery house of the Stacker cum Reclaimer. Circuit breaker to isolate the main supply




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to the Stacker cum Reclaimer shall be provided in the machinery house. It shall be possible to switch off this breaker from the operator’s cabin also.

• A 3.3 kV - 6.6 kV / 415 V power transformer is to be provided to step down the primary voltage level of 3.3 kV or 6.6 kV to 415 V for LT Drives & other electrical auxiliaries. A Dry type transformer of suitable rating to be provided with 3.3 kV - 6.6 kV / 415 V AC voltage ratio with off load tap changers. The insulation class of transformer should be ‘H’ with temperature rise limited to class ‘F’.

• Separate Cable reeling drum (CRD) for power and control cables shall be provided. The feeding of the cables to CRD shall be properly guided through the cable guides to prevent the trailing cables from falling on the track rails or getting entangled with fixed structures.

• Safety limit switches/devices to prevent over stretching of cable at the feeding point on the ground shall be provided.

3.24.04 Control System

• Control of the entire machine including the “semi-automatic operation” programs is to be effected by the programmable logic controller (PLC). Data exchange between the machine and the central control room shall be by means of a potential free control through a flexible control trailing cable. The PLC shall also have serial communication interface provision and hard wire interfacing with central control system. (Seller has to confirm whether 110V & 230V is required or not for control system.)

• The PLC shall be mounted in a separate cubical in the Electric house container and shall mainly consists of:

CPU (central processing unit) Digital input modules 24 V, DC Digital output modules 24 V, DC Analog input modules Analog output modules Power supply modules

• The PLC shall fulfill the following functions: Interlocks Automatic operation Alarm annunciation and recording Operational data logging Defect diagnostics




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Maintenance data logging etc.

• PLC shall have Modbus communication to interface with other PLC.

• The control of installation is to be freely programmable. Stacker cum Reclaimer machine control can be made manually by master switches from the driver’s cabin, which is traveling along the main girder. Most control functions shall be performed by the programmable controller. The contactors are mounted in closed cubicles located in the electrical room. The doors of the closed cubicles are lockable.

3.24.05 Emergency Push Buttons

Mushroom emergency push buttons are provided in operator’s cabin, Electric rooms, Machinery house, Legs of the crane and checker’s cabin. In addition mushroom emergency long travel trip buttons are provided at ground level.

3.24.06 Traveling Alarm • Audible signal bell alarm and four red rotary warning lights are provided.

• Forward and Reverse contactors shall be interlocked electrically and preferably mechanically as well.

• Set of over traveling limit switches and end buffers at both ends of travel zone shall be provided to prevent possibility of overturning of the machine.

3.24.07 Operator’s Cabin

• The operator’s cabin shall be suitable for outdoor installation and dust-proof and watertight.

• PTT type communication system shall be provided for communication between operator’s cabin and electrical house. And for communication of operator’s cabin with central control room, suitable hardware type system shall be provided.

• Following equipment shall be provided Isolated walls and roofs Rubber mats Insolating safety glass for the windows with electrically operated wipers Lockable door with gasket Lifting lungs on the roof Corrosion protecting painting (ground painting) and final painting Air conditioner




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Lighting / Emergency lighting arrangements Sockets for tool and hand lamps Swiveling operators chair with armrests Fire extinguisher

• Control facilities for the following are recommended to be provided in the

operator’s cabin Stacker cum Reclaimer travel (additional facility shall be provided to carry

out operation from control room also) Yard conveyor Boom conveyor Bucket wheel operation Boom luffing and slewing Cab positioning Dust suppression equipments Indication and alarm for main supply, control supply, motions, wind

pressure, phase failure, etc.

3.24.08 Probe Switch Probe sensor shall be provided at the boom part of the boom head end to prevent the boom touching and consequential burial of head end into the stockpile material, by providing signal to luff-up the boom as pile height increases with more discharge of material in to the pile.

3.24.09 Anti-Collision Switch

• Switches shall be provided on both sides of the boom to prevent accidental hitting of the boom with the pile-top / yard machine operating on parallel track, while slewing.

• Belt sway switch, pull cord switch and zero speed switch on boom belt conveyor shall be provided.

• Safety chain for boom luffing shall be provided.

3.24.10 Lighting System • Flood lights shall be provided on the apron for the operator to see the Stacker

cum Reclaimer operation during the night and in front and rear position of the equipment to properly light the tracks during Stacker cum Reclaimer travel in the night.




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• Flood lights with Metal Halide lamps, 70w / 150w /250w / 400w with 230V shall be provided. 2 x 28W tube light shall be provided in electrical room and operator’s cabin. Connection is made by plugs. Approximately 15 vibration proofs fittings with fluorescent lamps for lighting of the crane.

• All lighting circuits shall be protected with MCB.

• Battery operated emergency lights shall be provided at strategic locations. These shall be the automatic type. The light shall automatically come ‘ON’ when normal power fails and shall go ‘OFF’ automatically when normal supply comes back. The unit shall incorporate a trickle charger for keeping the battery on charge. The battery shall be rated for at least 60 minutes.

• Cable selection shall be determined in accordance to VDE, taking into account duty rating and ambient temperature.

3.24.11 Motors

• The motors shall capable to transmit maximum torque required to produce motion in the most unfavorable case and allow the Stacker cum Reclaimer to perform its normal duty without abnormal wear.

• A/C motors shall have be of totally enclosed, fan-cooled, weather protected, hose-proof design (IP 65) with class ‘F’ insulation with temperature rise limited to ‘B’ and shall be suitable for crane duty. A/C motors shall have thermistors, overload and short circuit protection.

• The motors shall have at least the following cyclic duty factors Long Travel 60% Boom conveyor 40% Bucket Wheel 60% Slewing 40% Other motion 40%

3.24.12 Cables

• All power cables shall be PVC insulated, armored and PVC sheathed preferably with copper conductor. All control cables shall be 2.5 mm2 copper.

• Power and control cables shall be protected with HRC fuses/circuit breakers.

• The sizes of the cables shall be so chosen that they are rated to carry the full load current continuously after allowing for necessary dc- rating factors for the




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conditions of installation, and also so that the percentage voltage drop in the cables should not exceed 3% in running condition.

• All cables shall be neatly clamped at suitable intervals. All fixing materials shall be given suitable anti-corrosive paint.

• All cables shall be terminated by suitable cable glands.

• Metallic conduits shall be provided wherever necessary for the protection of the cables.

• Power and control circuits to the cab shall be provided with a to take care of movement of cab during luff operation.

• Electrical circuits may be printed/painted/pasted at the inside of control cable covers.

• Material of Insulation of Power Cables should be EPR Material Type IE-3 to IS : 6380/84.

• Material of Insulation of Control Cables should be EPR Material Type IE-2 to IS: 6380/84.

• Material of Insulation of inner & outer sheath of Power & Control Cables should be EPR Material, Type IE-3 to IS: 6380/84.

• Eartthing sall be provided as per following details. o Electrical Panel earthing from - 50 x 6 GI strip. o Instrumentation panel earthing – copper cable. o Lighting DB – GI wire. o Motor earthing – 50 x 6 GI strip.

3.24.13 Protection • In case of excessive wind pressure, an alarm shall sound and all motions shall be

cut off and the Stacker cum Reclaimer shall get clamped to rails hydraulically.

• Mechanical type end-limit switches and magnetic type pre-limit switches shall be provided. The pre-limit switch shall act first to trip the motor and apply mechanical brakes. On reaching the end-limit switch, the breaker on the secondary side of the transformer shall get tripped. For the trolley an additional pre-limit switch shall be provided ahead of the two limit switches mentioned above.

• Phase failure relay shall be provided to trip the main circuit breaker.

• Smoke detector, operation counter, etc, shall be provided.

• A warning bell shall sound automatically during long-travel operation.




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3.24.14 NOTE Electrical items shall be in general as per following standards indicated for main items. Other items shall be as per relevant Indian / International standards. 1) Stacker cum Reclaimer - IS : 14416, IS: 14417 & IS : 12663 2) Transformers - IS : 2026 3) Motors - IS : 325 4) MCC - IS : 13947 5) Cables - IS : 1554, IS : 7098




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Chapter 04 4.0 INSPECTION AND TESTING 4.01 This chapter shall be read in conjunction with Tender Notice and General Terms &

Conditions attached separately.

4.02 Inspection & testing of equipment shall be carried out by Buyer or an authorized

agent of Buyer at the works of Seller 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 reference national /

international standards.

4.03 The Buyer or any one or more authorized by him, shall have the right to visit

contractor’s / sub-contractor’s premises to check the physical progress of work,

inspection, testing etc., of the contract items or any part thereof at any time during all

stages of manufacture. The contractor shall extend all necessary facilities for

carrying out such inspection and check of progress of work.

4.04 Inspection of equipment by the Buyer / engineer shall be only with a view to ensure

that the equipment is fabricated / manufactured, assembled, tested as per approved

drawings and prescribed specifications. Inspection by the Buyer / his representative

shall in no way relieve the Seller of his responsibility as per the contract and shall be

in no way binding on the Buyer / engineer.

4.05 Immediately after approval of drawings / documents, the Seller shall give six (6) sets

of all such drawings / documents along with the soft copy to the Buyer to enable the

Buyer / engineer to carry out inspection of the equipment.

4.06 Buyer / Engineer may reject the whole or any part of the equipment at any time if

after inspection / testing. Buyer / engineer at their discretion determine the

equipment or any part thereof to be unsatisfactory or does not fulfill the terms of the

contract, Buyer's / engineer's decision regarding rejection shall be final and binding

on the Seller.

4.07 Seller to perform a mechanically run performance test to verify capacity at his

workshop. Seller shall notify Essar prior to the test and submit test procedure for




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review. Essar shall reserve the right to witness such test and request copies of the

test results.

4.08 Manufacturer's test certificates shall be furnished by the Seller for all bought out

materials, components etc.

4.09 Wherever such test certificates are not available, the item shall be got tested by the

Seller at his own expense at government recognized authority on mutually agreed

upon.




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Chapter 05 5.0 DELIVERY 5.01 All components of the equipment covered under this specification shall be delivered

to site stores of ESSAR STEEL LTD. - HAZIRA, India in 10 (Ten) months as per the

address and delivery schedule to suit commissioning of equipment in 12 (Twelve)

months from the date of placement of order.

5.02 Identification, tagging, marking, packing and storing

5.02.01 Inscription on equipment (labels) shall be in English.

5.02.02 Unless requested by Buyer, Seller shall dispatch equipment with all its attachments,

parts, components, spares, documents etc as a single lot with logical identification of

packing.

5.02.03 All items supplied shall be packed for a long storage under the climatic conditions

prevailing at the site. Each item shall be clearly marked with its description, purpose and

plant designation code as applicable. When more than one item packed in a single case

a general description of the contents is to be shown on the outside of each case and

detailed list to be enclosed. All cases and other packages must be suitably marked and

numbered for identification purpose.

5.03 Preparation for shipment:

5.03.01 The Seller shall be responsible for ensuring that all accessories of equipment are

carefully and / or suitably packed for shipment, so that they arrive at site in good

conditions and remain so during storage at site.

5.03.02 Seller will be responsible for all damage due to improper preparation of the goods for

shipment.

5.03.03 All openings shall be covered or plugged to prevent entering of dirt and moisture to

interior.

5.03.04 Threaded connections shall have thread protectors that will exclude dirt and moisture.




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Chapter 06 6.0 PAINTING SPECIFICATIONS

6.01 The following specification shall be applicable for all equipment covered under this

document unless separate painting specification is elaborated in the respective

attachments.

6.02 This specification covers the facilities and quality requirement for surface preparation

and painting of structures, equipment, piping, etc.

6.03 The term "painting" referred herein covers rust preventive, preventive and decorative

coating along with surface protection.

6.04 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 bands. All machined mating surfaces (e.g.

flanges) shall be properly cleaned, greased and protected before dispatch.

6.05 General compatibility between primer and finishing paints shall be certified by the

paint manufacturer supplying the paints.

6.06 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.

6.07 The machine finished surfaces shall be coated with white lead and covered before

shipment or before being put out into the open air.

6.08 The color code to be followed for the final coat shall be intimated to the successful

Seller.

6.09 The complete paint system for any item includes the following activities :

i) Proper surface preparation

ii) Application of primer coats

iii) Application of intermediate coats

iv) Application of finished coats

6.10 As the equipment is to be installed in Port zone, anti rust paint coating shall be

provided to prevent rust & corrosion due to local climatic conditions.




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6.11 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:

GENERAL SPECIFICATION FOR SURFACE TREATMENT AND PAINTING

Sl.No

Description Surface Preparation

Painting scheme Total DFT

At shop At site

1

Steel structure AND Mechanical equipment (temp. not over 800C) Both static and rotary equipment for indoor or outdoor duty

SP-S

a 2

1/2

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 1200C 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 1800C dry heat, DFT / coat - 100 microns)

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 1300C dry heat)

240

2

Equipment with hot indoor or outdoor duty surface (temp. Up to 2000C) S

P-S

a 2

1/2

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 1200C dry heat}

2 COATS OF A single pack synthetic rubber based aluminium paint. {Air drying time - 2 hours (touch dry) DFT / coat - 25 microns, 24 hours (hard dry), Temperature resistance – up to 2000C dry heat, colour - smooth aluminium}

180

3

Equipment with hot surfaces (temp. up to 4000C) S

P-S

a 2

1/2

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 4500C 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 4000C dry heat, Colour - smooth aluminium

180




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FINISHED COLOR COAT

Sl. No

Structural Members Paint Codes

1 Horizontal Members Will be furnished later.

2 Vertical Members Will be furnished later.




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Chapter 07 7.0 WORKMANSHIP AND PERFORMANCE GUARANTEE 7.01 The material used shall be new and best of its kind available and shall conform to

relevant latest Indian and international standards.

7.02 After the equipment are completely erected at site, each item / equipment will be

thoroughly inspected for correctness and completeness of the installation and they

shall be subjected to final tests as to performance and guarantee to be carried out in

the presence of Contractor or his representatives and the Buyer or his representative

to demonstrate that the performance of the equipment conforms to relevant

standards and specifications and meet the requirements as given in this

specification. The tests/ checks to be conducted shall be generally as under:

7.03 The load test shall be conducted in stages. The equipment shall be run for 8 to 10

hours continuously at no load, 25%, 50%, 75% of rated capacities and for 16 to 20

hours at 100% of the rated capacities or at rate mutually agreed upon between

Contractor and Buyer or their representative. The intervening period shall be

available for making adjustments and arrangements by the contractor as may be

required.

7.04 Proper operation of all limit switches and signals like LT limit switches, limit switches

for rail clamps, limit and safety switches for cable reeling drums, limit and safety

switches/ alarm for centralized lubrication systems, anti-collision device etc, shall

be demonstrated by the Contractor in the presence of Buyer or his representative.

7.05 During operations of the equipment at no load and at full load, performance of all the

drives shall be checked in respect of current drawn by the motors, temperature rise,

vibrations, gear box noise and its heating, bearing heating etc. consumption of power

and various consumptions like lubricants etc. shall also be measured and

compared with the respective rated values.

7.06 All signals and alarms for the operator in the cabin shall be demonstrated and

performance of all by-pass devices in the operator's cabin shall also be

demonstrated.

7.07 Testing of the software and hardware of PLC and instrumentation shall be

demonstrated.




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7.08 Any other observations/ tests felt necessary for judging the performance of the

machines and mutually agreed between Contractor and Buyer shall be carried out.

7.09 If during the test runs, there is an interruption exceeding 2 hours due to any

cause other than power failure or shortage of input materials for which the Buyer is

responsible, the test run shall be discontinued and fresh date shall be decided

mutually by both the parties.

7.10 The warrantee shall cover faulty design / material / workmanship. All rectifications or

replacement under the warrantee shall be done by the Seller free of cost.

7.11 The Seller should study the specification and satisfy himself regarding the workability

of the proposed system and shall take full responsibility for the design, manufacture,

quality of the material, workmanship, etc. of the entire system including utilities,

electrics, instrumentation etc.

7.12 The approval of drawings and / or inspection by Buyer or their authorized

representative does not absolve or relieve the Seller from any of his obligations under

this contract. The Seller is solely responsible and accountable for any defects and

subsequent delays in supply due to design/inspection.

7.13 The Seller shall warrantee for satisfactory performance of the facilities for a period of

24 months from the date of receipt at site by the Buyer or 18 months from the date of

commissioning whichever is earlier.

7.14 The equipment shall be considered to have performed satisfactorily when it qualifies

the following tests.

• The dynamic test will be carried out with a load 120% of safe working load for

all motions.

• The static test shall be carried out with a load equal to 140% of the safe

working load. This test will be carries out under still condition.

• Design capacity of material is delivered with all its drives and accessories

functioning properly over a minimum period of sixteen (16) hours.

• It runs successfully for a continuous period of 15 days at the rated capacity.

7.15 Demonstration of performance guarantee is the most important clause binding the

Seller.

7.16 Performance Guarantee Parameters, Penalty and Rejection:




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Sl.

No.

Performance

Guarantee Parameters

Acceptable limit

without penalty

Acceptable limit

with penalty

Rejection

Point

1.

Rated Capacity of

Stacker cum

Reclaimer

Short fall up to

5% from rated

capacity

Short fall of 6 –

10% from rated

capacity

Shortfall

beyond 10% of

rated capacity

Penalty shall be charged @0.5% of total cost on pro-data basis on % shortfall between 5% to 10 % of rated capacity.




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Chapter 08 8.0 SPECIAL INSTRUCTIONS TO SELLER 8.01 The Sellershall design the equipment considering the "site conditions".

8.02 Metric system shall be followed and English shall be the language of all

communication.

8.03 This specification is issued for design, manufacture, fabricate, supply, &

commissioning services of the equipment to be supplied with this specification.

8.04 Seller/contractor to provide complete set of all missing drawings and list of bill of

material to ESSAR STEEL LTD. - HAZIRA.

8.05 The break-up of plant and equipment shall be indicated in the following two broad

categories:

i) Those to be manufactured in India.

ii) Those to be procured from the foreign sources.

8.06 In both cases where the equipment is to be procured from India or abroad, the

successful Seller shall be responsible for design, generation of all data and design

drawings required by him for manufacture/fabrication. The Seller shall furnish a

division list of supply and services along with the offer.

8.07 The Seller shall separately quote for all the bought out items other than his

manufacture.

8.08 In case of usage of special motors are involved in the system/package, same shall be

in the scope of the Seller.

8.09 The Seller shall furnish add on price for the following items, as applicable:

1. Gear boxes

2. Motors

3. Fabricated steel items (per ton basis)

4. Process instruments

5. Pipes, hoses & fittings etc.

8.10 All bought out items shall be as per the preferred makes of ESTL / Essar Engineering

Services Limited, Hazira.




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Chapter 09 9.0 DOCCUMENTATION 9.01 Documents to be supplied by the Seller with offer: 9.01.01 The following information / documents are to be submitted by the Seller along with the

offer:

1) Reference list of units supplied by the Seller.

2) General description of design considerations and all the assumptions made by

the Seller.

3) Specification of individual equipment indicating capacity (rated and designed),

dimensions, drive ratings, safety factors, drive details, duty rating, weight of

individual equipment, weight of heaviest part, etc.

4) Arrangement drawings showing following particulars (minimum)

• Construction features.

• Wheel load and wheel base.

• Dimensions and technical parameters as per technical specification.

• Operator’s cabin and power feeding arrangement.

• Location of all drives and their arrangement.

• Motor rating.

• Operating speeds.

• Maintenance & repair provisions.

• Rail track details.

• Dust suppression system details.

• Operating weight.

• Any other information for making the arrangement drawing complete.

5) Details of operating station with PLC.

6) Brief note on operation philosophy.

7) Scope matrix.

8) Make and model of equipment / parts / components.

9) Specifications of materials of construction of parts / component along with

standards and chemical composition.




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10) Arrangement drawing for the equipment / system including sections and details

giving relevant information, binding dimensions etc.

11) Standard / special accessories being considered for supply along with the

equipment.

12) Preliminary load data.

13) Preliminary electrical single line diagram, drive list and emergency power

requirement.

14) Requirement of power, utilities and services, etc at battery limits.

15) Deviations from tender documents.

16) The questionnaire filled in and submitted by the Seller as per Annexure.

17) Overall schedule as per Annexure.

18) Exclusions list indicating all the items with broad specification required to

complete the plant and equipment supplied by the Seller for the operation and

maintenance.

19) Performance guarantees parameters.

20) Detailed time schedule for execution.

21) List of spares.

9.02 List of drawings to be submitted for approval: 9.02.01 Drawings listed hereinafter shall be submitted to the Buyer/his Consultant in stages

for approval, starting within one month of issue of letter of intent and prior to the

commencement of fabrication.

9.02.02 The load data / drawing must be submitted within one month to enable the Buyer to

start the civil / structural / electrical works.

9.02.03 The Buyer/ Consultant shall send his comments within two weeks of receipt of the

drawings. However, approval of drawings by the Buyer / his Consultant will not relieve

the Seller of his responsibilities for correctness, adequacy of design & completeness

of his work as per the contract. All the drawings & documents will be in English

language. Drawings shall be complete in all respects with dimensions, item lists,

weights, sub Seller’s name etc.




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9.02.04 If the drawings & other particulars are returned by the Buyer / his Consultant, because

they are in- complete or incorrect, the Seller shall not be given any extension of time

on this account.

9.02.05 After approval, prints of all approved drawings shall be furnished by manufacturer to

the Buyer / Consultant for necessary distribution.

9.02.06 Copies of drawings for approval of statutory authority (if required) shall be submitted

at least 3 months prior to first dispatch or sufficiently in advance so as to take care of

statutory clearances required at appropriate time. Obtaining clearances from statutory

authorities shall be the responsibility of the equipment Seller.

9.02.07 Following design data, calculations and drawings shall be submitted by the successful

Seller to the Buyer / his consultant in stages for approval starting within one month of

issue of letter of intent and prior to commencement of manufacture/ fabrication.

1) General arrangement drawings drawn to the scale and containing all the

information required along with civil load data for individual equipment.

2) Assembly drawings of individual drives.

3) Layout of cabin showing the location and fixing of all the equipment inside it

such as controllers, operator's seat, protective panel, isolating and control

switches fire extinguisher etc.

4) Technical characteristics of equipment.

5) In addition to the above, the Buyer/ Consultant reserve the right to insist on the

submission of calculation and/or drawings for any mechanical, structural and

electrical components as required.

9.03 Drawings / data/ calculations for reference

1) Operation Philosophy

2) Civil load data drawings for the equipment.

3) Sample calculation for selection of drive mechanism, Motor horse power &

brake calculations.

4) Sample calculation of structural design for verification of machine structure

stability.

5) Hydraulic circuit drawings for each system, lubrication arrangement etc.

6) General Arrangement of rail clamp




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7) Parts list, bill of materials and material specification.

8) Major sub assembly drawings of drives.

9) Drawings of all wearing out parts

10) List of special tools & tackles.

11) Catalogues / leaflets for all equipment including bought out items. Details of

bought out items with makes shall be given separately.

9.04 Contract drawings and documents to be furnished along with the supply:

1) Erection drawings, erection specification & erection instructions

2) Instruction for storage and re-conservation including those for electrical,

instrumentation and communication items.

3) Performance data

4) Test charts and inspection certificates in bound volume

5) Operation & maintenance manuals

6) Safety manuals

7) List of spares for 2 year's normal Operation / maintenance

8) Manufacturing drawings and bill of materials for all spares and wearing parts

(excluding those for proprietary items)

9) Ordering specifications including catalogues and details for all spares

(including proprietary items) along with spare lists.

10) Ordering specifications for operating consumables / supplies.

11) All as built drawings, in bound volumes incorporating approved changes if any

made during erection and commissioning, shall be supplied progressively within

two months of commissioning of the (all drawings are to be furnished even if

there is no change) equipment.

12) Classified list of drawings in A4 size.

13) Micro film & soft copy (editable version) of all drawings.




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Chapter 10 10.0 DEVIATIONS

10.01 The Seller shall indicate any deviation and / or exclusion from technical specification

in respect of scope of work, specification and any other detail mentioned in the

document. Deviations mentioned elsewhere in the tender document shall not be

entertained either at offer evaluation or after award of the contract. Seller shall bear

the cost of such, if the same is brought to notice of Buyer after award of contract.

10.02 After placement of order, the successful Seller shall strictly follow the technical

specification, material specification and any other parameter indicated in the tender

specification of its amendment, if any.

10.03 Format of deviation from tender document is given in annexure II




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Annexure I Site Conditions

The meteorological details of the site are indicated below.

Temperature

Mean yearly Temperature : 26.6 ºC

Maximum Absolute Temperature : 45.6 ºC

Mean Yearly maximum daily Temperature : 42.3 ºC

Mean Yearly minimum temperature : 10.9 ºC

Rainfall

Maximum rainfall in 24 hours : 459mm

Avg. annual rainfall : 1,203.5mm

Wind

Predominant wind Direction : South to West

Avg. speed : 12.2 Km/h

Max. Speed : 158.4 Km/h

Seismic – Zone : 3




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Annexure II

Format for deviations from Tender Document

The Seller hereby certifies that the above mentioned are the only deviations from the tender

documents.

Signature : Name : Designation : Company seal

Sl. No. Clause No. Seller’s Deviations Reason for Deviation




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Annexure III Questionnaire to be filled by Seller

(A) GENERAL

1 Seller's name and address.

2 Quotation number and date.

3 Total estimated transporting weight of items offered

by Seller (in tonnes).

4 Weight and dimension of the heaviest single

package.

5 Special transport requirement.

6 Special storage requirement.

7 Previous experience.

List of similar plant / equipment supplied.

8 Available manufacturing facility.

9 Available spare capacity

10 Seller's representative in India

(B) TECHNICAL INFORMATION

1. Bucket Wheel

a)

Capacity of machine m3/h

- Average(based on 4 h continuous operation

while reclaiming) in m3/h

- Peak in m3/h

- Design in m3/h

b) Type of Bucket Wheel

c) Diameter of bucket wheel across the lips (mm)

d) Bucket volume (capacity) (m3)

e) Number of buckets

f) Number of bucket discharge per minute

g) Ring Volume (m3)




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h) Effective ring volume per bucket (for volumetric

calculation)

i) Bucket material

j) Bucket tooth/lip material

k) Type of bucket tooth/lip

l) Type of liner for discharge chute

m) Angle of inclination of bucket wheel with reference

to vertical plane (degrees), if applicable

n) Water fill volume of the bucket

o) Lubrication method for bucket wheel mechanism

p) Bucket wheel mounting arrangements

2. Bucket Wheel Drive

a) Type of Drive b) Motor Speed (rev/min)

c)

Motor 1. Rating(kW) 2. Type of Enclosure 3. Degree of protection 4. Class of insulation 5. Synchronous speed 6. Starting method 7. Reversibility

d) Supply voltage and frequency

e)

Gear box: 1. Make 2. Type 3. Ratio 4. Casing material 5. Service factor

f) Lubrication method

g)

Coupling (input/output) 1. Type 2. Size of coupling 3. Service factor

h) Bucket wheel speed 9rev/min) i) Inspection speed

k)

Brakes 1. Type 2. Location 3. Drum diameter (mm)




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4. Braking torque 5. Brake rating 6. Supply voltage

3. Bucket Wheel Sizing

a) Number of bucketsb) Maximum bucket discharge per minute c) Percentage of bucket volume to be considered d) Percentage of annular ring volume to be considered 4. Travel Mechanism

a) Type of wheels

b) Minimum centre distance between two adjacent wheels(mm)

e) Diameter of wheel (mm) f) No. of driven and non-driven wheels e) Total number of wheels f) Number of drive wheels

g)

Type of rail joints 1. Type 2. Size 3. Rail centres

h) Rail clamps 1. Number 2. Type

i)

Maximum whell load without impact 1. Vertical – Operating/non-operating 2. Horizontal (in both directions) Operating/non-

operating

j) Type of foundation for rails (Tolerance limits in X, Y and Z directions along with diagram to be furnished)

k) Travel speed (m/min) 1. Operational 2. Idling

l) Machine travel length (m) m) Lubrication method

n) Safety arrangement details shall be given like rail clamping and interlocking of the drive motor with safety arrangements.

o) Whether provision for jacking under carriage made

p) Special tools for maintenance to be included or not (if yes, list shall be furnished)

q) Anemometer is to be provided with automatic clamping of rails.

4.1 Travel Drive

a) Motor 1. Type




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2. Make 3. Type of enclosure 4. Starting method

b) Maximum Speed (rev/min) 1. Operational speed 2. Idler speed

c) Motor rating (kW) d) Supply voltage and frequency e) Number of drives f) Type of speed control

g)

Gear box: 1. Type 2. Make 3. Service factor 4. Gear box ratio 5. Mounting method of gear box

h) Lubrication method

i)

Coupling: 1. Type 2. Size of coupling 3. Service factor

j)

Brake: 1. Type 2. Location 3. Braking torque 4. Operating voltage

k) Brake drum size (mm) l) Whether rail sweeps provided 5. Bucket Wheel Boom

a) Boom length from slewing centre to centre line of bucket wheel (m)

b) Belt speed (m/sec)

c) Walkway: 1. Provided – one side/both side 2. Minimum width(m)

d) Boom conveyor width (m) e) Capacity of the conveyor f) Boom conveyor belt type g) Maximum boom inclination angle (degree)

h) Maximum boom declination angle (degree) 1. Operational 2. Non-operational

i) Whether wind guard provided j) Type and no. of scrappers

5.1 Boom Conveyor Drive




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a) Location of boom conveyor drive b) Take up type and its location c) Belt rating, cover thickness and type of cover

d)

Motor: 1. Type 2. Type of enclosure 3. Degree of protection 4. Class of insulation 5. Starting method

e) Speed (rev/min) f) Rating of motor (kW) g) Supply of voltage and frequency

h)

Gear box 1. Make 2. Type 3. Ratio 4. Casing material 5. Mounting method 6. Transmitting capacity/Service factor

i) Lubrication method

J)

Coupling: 1. Type 2. Size 3. Transmitting/Service factor

k)

Brake: 1. Type 2. Drum diameter (mm) 3. Braking torque (kg/m) 4. Operating voltage 5. Make

6. Upper Carriage

a) Height of boom pivot from top of rail ( m)

b) Locking arrangement between upper carriage and under carriage against accidental slewing

7. Under Carriage

a) Type of support

b) Whether impact table provided

c) Type of equalizing arrangements provided

8. Slewing Mechanism

a) Details of slewing ring: 1. Type of bearing 2. Type of gearing




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3. Arrangement of slew ring b) Lubrication method for slewing ring c) Slewing speed at bucket wheel centre (m/min) d) Slewing speed – constant/variable e) Maximum range of booms slewing (degree) f) Range of slewing speed

8.1 Slewing Drive

a)

Motor 1. Type 2. Rating (kW) 3. Rated speed (rev/min) 4. Type of enclosure 5. Degree of protection 6. Class of insulation 7. Method of starting 8. Type of speed control

b) Number of drive

c)

Reduction gear box: 1. Make 2. Type 3. Ratio 4. Casing material 5. Output transmitting capacity/Service factor

d)

Coupling – high speed 1. Type 2. Size 3. Make

e)

Coupling – low speed 1. Type 2. Size 3. Make

f)

Brake: 1. Make 2. Type 3. Drum diameter (mm) 4. Location 5. Braking torque 6. Operating voltage

g) Lubrication method

h)

Slewing gear 1. Diameter of slewing gear 2. Make of slew gear 3. Size of bearing for slew gear 4. Make of bearing

9. Luffing




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a) System for boom luffing b) Location of lifting/hoisting mechanism c) Range of luffing (m) d) Luffing speed at bucket wheel centres (m/min) 9.1 Hydraulic System Hydraulic circuit diagram to

be furnished by the Seller.a) Number of cylinder b) Size: Bore (mm) x Stroke (mm) c) Motor rating (kW) d) Motor speed 9rev/min)

e) Type of arrangement in case of safeguard against differential pressure

f) Maximum system pressure 9.2 Mechanical System

a) Diameter of rope b) Number of falls c) Rope speed (m/min) d) Motor speed (rev/min) e) Braking strength of rope and construction of rope

f) Number of independent rope winch system provided

g) Winch type h) Whether each system capable of taking 100% load i) Service brake details j) Details of additional brakes other than service brake

10 Tripper Car Details

a) Belt width

b) Belt Speed

c) Troughing Angle

11 Walkways on Tripper

12. Yard Conveyor

a) Belt width (mm) b) Belt speed (m/sec) c) Troughing angle

13. Type of Boom Suspension

14. Cable Reeling Drum

a) Type of power and control CRD b) Power feeding point

c) Motor: 1. Type 2. Rating




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3. Supply voltage and frequency 4. Make

d) Type of cable drum

e) Maximum length of cable excluding the safety turns that the drum can accommodate

f) Driving mechanism of drum g) Type of cable h) Size of cable i) Current carrying capacity of the cable j) Type of operating mechanism of CRD k) Whether separate CRD for control cables provided l) Location of trailing cable

15. Operator’s Cabin

a) Over all dimension: Length (m) x breadth (m) x height (m)

b) Location of operator’s cabin c) Method of ventilation / air-conditioning d) Whether cabin leveling provided 16. Belt Weigher for Reclaiming Rate Indication

a) Type b) Capacity range (m3/h) c) Accuracy (± percent) d) Location of belt weigher e) Whether totalizer and chart recorder required 17. Operational Data

a) Mode of operation b) Method of reclaiming 18. Electrical Switchgear Room / Electric House

a) Overall dimension Length x breadth x height

b) Location c) Method of ventilation /air-conditioning

d)

Power supply arrangements: 1. Incoming supply voltage level 2. LT transformer provided 3. LT switchgear (mention make, type, rating &

breaker/contactor/switch fuse units)

19. Programmable Controls

a) Make of PLC b) Model number c) Word length of microprocessor d) Memory size e) - No. of analog and digital inputs




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- Input card voltage

f) - No. of analog and digital inputs - output card voltage

g) Number of input/output per module h) Maximum number of modules, the system can take i) Number of countersj) Details of VDU k) Details of keyboard l) Location of PLC

m) Satisfactory operating temperature range n) Location of monitoring unit o) Frequency of scanning cyclep) Type of communication system provided

20.1 Memory

a) Is memory volatile b) If memory is non-volatile , type of memory usedc) Life of battery back-up provided

20.2 Timers

a) Number of timers b) Time in travels c) Minimum time delayd) Maximum time delay

20.3 Input / Output

a) Are all input/output opto-isolated b) Have indications been provided for all input/output c) Have separate fuses been provided for each output

d) If yes, has any fuse failure indication been provided for each fuse

20.4 Printer

a) Type of printer b) Duty c) Printing speed (character per second) d) Number of characters/line e) Make and model f) Number of columns of the printer

20.5 Programming Unit

a) Make and model b) Has CRT/Seven segment display been included

c) Whether the programming unit can accept control sequences in the form of ladder diagrams or statement/using numeric codes

20.6 Type of Enclosure




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20.7 Air Conditioning

a) Whether it is possible to operate the programmable controller in the event of failure of air-conditioning?

b) Whether air-conditioning is provided in :

1. Control cabin 2. MCC room

20.8 Instrumentation Board

a) Details of instrumentation board b) Details of control desk 21. List of fire protection equipments

22. Location of self-lubrication

23. Additional features

24. Details of Switchgear

a) Type b) Capacity c) Protection provided 25. Limit switches

a) Make b) Type c) Numbers d) Method of actuation 26. Flood Lights

a) Make b) Type c) Location d) Numbers e) Lux level of extreme reach of bucket wheel 27. Details of earthing system

28. Tower structure

a) Type of construction b) Method of construction c) Codes being followed 29. Anemometer details

30. Hoppers and chutes

a) Material and thickness of mother plates b) Material and thickness of liners c) Method of fixing of liners with mother plates 31. Details of Dust Suppression arrangements

a) Type




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b) Location of spray headers c) Number and types of nozzles and their spacing d) Nozzle flow rate and pressure e) Material of construction of nozzle f) Capacity and location of tank g) Details of pumps provided on machines




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Annexure IV Overall Supply & Implementation Schedule

Sl. No.

WORK DESCRIPTION WEEKS FROM

Start Finish

1.0 Design & Engineering

a Civil

b Structural

c Mechanical

d Electrical

2.0 Equipment Manufacture

a Structural (for items fabricated at works)

b Mechanical

c Electrical

d Refractory

e Bought out items

i) Ordering on sub vendors

ii)Manufacturing schedule & progress status

iii) Delivery

3.0 Equipment delivery at site

a Structural (for items fabricated at works)

b Mechanical

c Electrical

4.0 Civil Works

5.0 Structural fabrication at site

6.0 Structural erection

7.0 Equipment erection

8.0 Test and trials

Note: Delete items which are not applicable.




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Annexure V Quality Assurance Plan (QAP)

a) Seller / Contractor shall furnish Quality Assurance Plan (QAP) for respective equipment

after completion of detailed engineering and finalization of billing schedule and prior to

start of manufacturing.

b) QAP shall be prepared and furnished by Seller for all components.

c) 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.

d) 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 ESTL 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 Seller / manufacturer to ESTL.

IV. Inspection documents to be furnished by Seller / manufacturers to ESTL 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.

a) Details of stage wise inspection

b) Manufacturer’s material and performance/relevant test certificates

c) Performance test certificate for all characteristics

d) Calibration / acceptance / special certificates for electrical items

e) Surface preparation and painting certificates




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Annexure VI

List of Preferred Makes

The Seller shall submit the makes of all fabricated items, bought-out items (Mechanical,

electrical, hydraulic, instrumentation and controls, pipes, hoses, fittings, etc.) for Buyer’s approval

/ clearance.




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Annexure VII Technical Datasheet

Rail mounted self propelled, Boom type luffable, slewable, Stacker cum Reclaimer machine complete with electric etc. shall be as per specification. The main characteristics of the machine shall be as follows.

Sr. No. Description Stacker cum Reclaimer Machine

1) Type Rail mounted self-propelled boom type luffable, slewable, Stacker cum Reclaimer machine.

2) Quantity 1 (one) 3) Capacity, (TPH)

Stacking: Rated Design

1500 TPH 1800 TPH

Reclaiming: Rated Design

800 TPH 960 TPH

4) Boom Length, Boom Length shall be indicated by Seller by which indicated stockpile can be stacked and reclaimed properly.

5) Track center 8 m 6) Track rail size R 105 (52 Kg/m) 7) Duty Continuous.

8) Power supply

6.6 kV, 3 - phase, 4 - wire, 50 HZ through flexible cables and cable reeling drums.

9) Travel speed ~15 m/min. (forward and reverse speed shall be indicated

by the bidder) 10) Length of travel 270 m

11) Slew speed Slew range

~ 0.01 to 0.2 rpm ±105° on either side of track center

12) Luffing mechanism a) Speed b) Range c) Operation d) Power Pack e) Tank capacity

2 m/min at boom tip -8° to +12°

Through two numbers hydraulic cylinders and power pack. 18⁰ Max Bar set pressure 8 Operating Hour reserve (Minimum)

13) Cross section of the stock Trapezoidal




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pile

14) Top and Bottom width of stock pile

Top-14.4 m Bottom - 43 m

15) a) Height of stock pile w.r.t. rail level

b) Dist. between top of rail to bottom of pile

c) Stockpile edge distance from the rail

9.6 m with respect to rail level 400 mm 5m

16) Yard Conveyer a) Speed of Belt b) Width of Belt c) Toughing Angle d) Idler diameter

~3.7 m/s (Maximum) 1400 mm 35° Ǿ159 mm

17) Yard length 300 m

18) Details of material to be handled as specified below :

Material Coking Coal Bulk Density 0.80 t/m3

Moisture Content By Weight Up to 20%

Angle of Repose 35⁰

Surcharge angle 20⁰

Flow ability Poor

Abrasiveness & Corrosiveness

Mildly abrasive

19) Boom conveyor a) Belt width b) Belt Speed

Min.1400 mm ~ 3.7 m/sec (Maximum)

20) Bucket Wheel a) Type b) Diameter c) Number of buckets d) Rotational speed. e) Type of drive / motion.

Cell less (removable type)

Hydraulic drive to set feed rate from 10%-100% of rated capacity.

f) The cutting edge/ lip shall be made of highly wear resistant Manganese steel having hard faced surface. The minimum hardness of replaceable liner shall be 350 BHN.

To be indicated by Seller




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The teeth shall be of replaceable type. g) Bucket body shall be of minimum 12mm thick SAILHARD / equivalent h) Suitable chutes, slope sheets and skirt plates shall be adequately provided to achieve

correct feeding of the material on the boom conveyor / yard conveyor. The plate thickness shall not be less than 10 mm. The angle of sliding surface shall not be less than 60°. Chutes shall be fabricated with minimum 10 mm thick MS plate and shall be lined with 10 mm thick Mn-steel / equivalent liner plates.

21) Travel mechanism a) Travel wheel dia. b) Rail clamps c) Buffer type

Minimum 630 mm. 2nos. electrical or 2nos. mechanical hydraulic release type Spring operated

22) Walkway of minimum 1000-mm width grating floor and hand railing shall be provided on both the sides of the boom conveyor maintenance purpose.

23) The machine shall be suitable for stacking / reclaiming material from the stock pile of the given cross section with full capacity by operating from one side of the stock pile leaving a maximum 2% as dead stock.

24)

The electrical room shall be provided with minimum 1.5 t split type AC. The operator’s cabin shall be provided with minimum 1t split type AC. It shall be located on boom tip structure and mounted on hydraulic cylinder for level adjustment. Size shall be about 2 m X 2m X 2.3 m. Insulation for cabin shall be envisaged. Double door provision to be considered for Operator’s Cabin.

25) Press to talk system shall be provided. 26) Over travel device (non-contact type) shall be provided. 27) Auto tension trip device shall be provided for cables.

28)

The boom’s hoisting movement upwards shall be restricted to maximum limit to prevent it from damaging the equipment structure. However, the provision shall be made to enable the boom end brought to ground for repair and maintenance by passing the operational limit switch that restrict its down ward movement.

29) Foundation Type Continuous Footing




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Acceptable Tolerances

1. Trolley rail centre distance > + 3 mm 2. The difference in the height of two opposite points

of the trolley perpendicular to the travel direction of the trolley

0.15 % of trolley rail centre distance with maximum of 10 mm.

3. Unevenness of the bearing surface of trolley rails + 3 mm for rail centre up to 3 m. 4. Diverge of centre of trolley rail & girder web Half the thickness of girder web. 5 Lateral straightness of trolley rail to theoretical

centre axis. + 1 mm for 2 m rail length.

6 Angular deviation in horizontal plane of the axes of wheel axle bore

+ 0.04 % from theoretical position.

7 Alignment divergence in the vertical plane of the axle bores of the wheels mounted on bogies

0.15% or maximum 2 mm of trolley wheel centre distance.

8 Diverge in the centres of wheels rolling on the common rail

+ 1 mm from the rail centre.

9 Misalignment in the centre of guide roller + 1 mm from the centre axis of the rail.

10 Tolerance of the wheel diameter As per latest edition of IS: 919.