TECH_SPEC_DE_R0

7/28/2019 TECH_SPEC_DE_R0

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TECHNICAL SPECIFICATION OFDUST EXTRACTION

SYSTEM FOR LIMESTONE HANDLING SYSTEMFOR BINANI CEMENT PLANT AT BINANIGRAM,

RAJASTHAN

BIL INFRATECH LTD.

Page 1 of 12

TECHNICAL SPECIFICATION OF DUST EXTRACTION SYSTEM

1.00.00 General

1.01.00 This specification is intended for carrying out design, engineering, manufacture, shoptesting, delivery of equipment on FOT site basis inclusive of packing & forwardingcharges, freight & insurance up to project site at Binani Cement Limited, Binanigram,Pindwara, Rajasthan, supervision during installation & commissioning, complete detailengineering & drawing, ducting & piping, performance testing and guaranty of variousequipment in Limestone handling system Package as specified and as required for safeand trouble-free operation of de-dusting systems. The equipment shall have sufficientdesign capacity to operate the plant up to 15% over and above the rated capacity.

1.02.00 Any additional plant, equipment, material, services which are not specifically mentionedhere, but are required to make the plant/system complete in the scope of the tenderercomplete in every respect in accordance with the technical specification and for safeoperation and guaranteed performance, shall be covered under the scope of thisspecification.

1.03.00 The Purchaser/Consultant reserves the right to make minor revisions to thedrawings/specifications which do not change the general scope of work. Such minorrevisions, unless directly affecting the frame work of the contract, shall be incorporatedwithout any cost to the Purchaser/Consultant.

1.04.00 The intent of this specification is also to cover supervision of erection, trial run & commissioning at site of the plant supplied under this specification to achieve efficientand guaranteed operation of the same to the entire satisfaction of thePurchaser/Consultant.

2.00.00 CODES AND STANDARDS

The design and construction of all the equipment should be generally as stated in thedesign criteria or as per Indian Standard Code or relevant recognized internationalstandards, codes and practices, approved by the Purchaser/Consultant.





RAJASTHAN

BIL INFRATECH LTD.

Page 2 of 12

3.00.00 SCOPE OF WORK AND EXCLUSIONS

3.01.00 Scope of Work

The bidder’s scope of work will include design, engineering, manufacture, assembly/pre-assembly, test at manufacturer's works, shop painting, supply, supervision duringerection and commissioning, detail engineering & drawing, supply of fabricated ducting,electrical, instrumentation of Limestone crusher package equipment, performancetesting & guarantying as specified hereinafter with all accessories as specified and asrequired for safe and trouble-free operation of LS crusher package equipment of Integrated cement plant for 6000 TPD clinker with (with 15% added design capacity)with adequate margin for Binani Cement Limited, Rajasthan.

Pulse Jet bag filters required for crusher and its associated equipment de-dusting

including slide gate, rotary Air lock, Bag filter fan, dampers as required in the ducting,compensators, isolators as required complete with drives, fabricated duct work withsupports and associated instruments.

The sub-control system as require being included such as dust collector timer panel.

3.02.00 The Bidder’s scope of work shall also include:

a. Civil assignment drawing with load for civil design shall be supplied.

b. C ompressed air requirement system-wise system shall be informed along with Vendor’s offer. Dry Compressed air for de-dusting system shall be supplied bypurchaser. Necessary tapping connection along with all field instruments shall bein the scope of vendor.

c. Painting of all equipment at manufacturer’s works is in bidder scope. Bidder shallalso supply his recommended amount of paint for field touch up.

d. First fill of lubricants.

e. The list of recommended spares for two years’ trouble free operation with unitprice

f. All special tools and tackles required for erection, commissioning andmaintenance.

g. Supervision of Erection & Commissioning

h. Performance Guarantee test

i. Required number of anchor bolts, foundation plates, sleeves, nuts and inserts to





RAJASTHAN

BIL INFRATECH LTD.

Page 3 of 12

be embedded in concrete for the equipment under this specification. During civilconstruction, Bidder shall supply all such items in advance

3.03.00 Scope of Services

Detail engineering including all duct layout and fabrication drawing, GA drawings for bagfilter, fan with supports.

Furnishing all required documents, data, drawings, manuals, test certificates, etc. as perapproved list.

Supervision during erection, testing and commissioning of the suppliedequipment and their accessories

The successful bidder must interact with the upstream & downstream packagesuppliers for finalization of terminal conditions & scope. No holidays for scope of supplies are allowed in between the relevant packages

3.04.00 Exclusions

Erection of Equipment

Construction of civil foundation, buildings & structures

4.00.00 SITE DETAILS

4.01.00 Location

The plant is located at Binani Cement Limited, Binanigram, Pindwara, district Sirohi,Rajasthan.

a) Nearest town : Pindwara by road 4.0 Km

b) Railway station : Sirohi Road by road 7 Km

c) Airport : Udaipur by road 120 Km

d) Nearest Highway :National Highway by road 10 km

4.02.00 Site conditions

a) Site elevation : 400 m above MSL.b) Maximum temperature : 48 Cc) Minimum temperature : 1 Cd) Basic Wind speed : As per IS:875 (part 3) - 1987

e) Seismic data : Zone III (as per IS: 1893 Part 1 2002)







RAJASTHAN

BIL INFRATECH LTD.

Page 5 of 12

5.04.00 Dust Extraction Ducting:

a. The ducts for conveying dusty air shall be of round shape and of streamlineappearance.

b. The velocity of air in the duct shall be high enough (in the range of 18 to 21 m/sec.)to transport the suspended dust in the air.

c. The ducting shall be made of M.S. Sheet of 3.15 mm thickness. The duct shall beproperly painted.

d. Duct support shall be provided as per stipulations hereunder :

Diameter of duct Spacing of support

Less than 200 mm Maximum 2.50 metreMore than 200 mm Maximum 3.00 metre

e. The duct work shall be properly reinforced to prevent sagging, buckling andvibration. Interior of ducts shall be smooth and free from obstruction.

f. Flexible connections shall be provided at the duct connections to inlet anddischarge of the fans. All flexible connections shall be non-collapsible type andtheir length shall be kept to a minimum.

g. Duct supports, wherever required, shall be provided. Hangers and support

positions shall be made as per good engineering practices.

h. Medium pressure ducts for dust extraction shall be welded and shall have flanged joints. Thickness of the flanges shall be minimum 5mm for duct sizes upto andincluding 500mm. diameter. For duct sizes above 500mm. diameter, the flangethickness shall be minimum 6mm.

i. All hangers and supports shall have to be approved by the Engineer. Verticalducts passing through floor slab shall be supported by means of collarsconstructed of structural steel angles securely fastened about the girth of the ductand resting on the floor slab. The supporting angle shall be fastened to the floorslab with a filler or bituminastic compound inserted in between the horizontal leg of

the supporting angle and the floor.

j. All ducts running on the floor/roof shall be adequately fixed in position by M.S.Angles. The supporting and fixing arrangement shall be approved by the Engineer.

k. All extraction points should have manual dampers for flow balancing. Motoriseddamper shall be used for isolation of non-operating extraction points. Interlockingof motorized damper with drive motor of main equipment of the stream asapproved during detail engineering stage shall be provided.





RAJASTHAN

BIL INFRATECH LTD.

Page 6 of 12

5.05.00 Bag Filter Unit:

5.05.01 General :

i. Air to cloth ratios shall be not more than 1.2 m3/m2/ min.

ii. For design of Filter bag 20 % spare capacity shall be provided

5.05.02 Bags :

i. Filter Cloth:

a. Suitable for Lime stone dust at an ambient temperature of 50 Deg.C.

b. Bag cages shall be of single piece design and shall be corrosion-resistant(galvanized, stainless steel or epoxy coated), depending on application.

5.05.03 Bag monitoring and Protection Equipment:

i. Bag cleaning shall be controlled by timer and differential pressure measurementacross the bag filter.

ii. Manual condensate drain, pressure gauge and regulator at the inlet of compressed air receiver/manifold shall be provided.

5.05.04 Housing Plenum and Hopper Construction :

i. Hopper valley (corner) angles shall not be less than 60 degrees (measured formhorizontal).

5.05.05 De-dusting Air Volume:

i. De-dusting air volume shall be sufficient to maintain pollution-free operation. Thesame to be calculated by the supplier and should submit the air volumecalculation.

5.05.06 Bag Filter Fans:

i. Fans shall be designed for 115% of bag filter design flow rate with 20% morethan the designed pressure.

ii. Fan speed shall not exceed 1500 rpm for 50 Hz motors unless otherwiseapproved in writing by the Project Owner / Consultant.

iii. Manually operated, accessible fan inlet damper shall be provided.





RAJASTHAN

BIL INFRATECH LTD.

Page 7 of 12

iv. Fan motor shall be adequately sized for the design flow at the lowest ambienttemperature.

v. Fans above 30 kW shall be mounted on anti-vibration pads, if located onelevated floors.

vi. An access door, bolted and gas tight sealed, shall be provided in the fan inletspiral for visual impeller inspection.

vii. Drive motor shall be suitable for outdoor application with an ambienttemperature 50 deg. C, energy efficient – 1, 415 V, 3 phases, 50 Hz, AC supply.

5.05.07 Expansion Joints:

Axial and lateral movements shall be based on upset temperatures.

All expansion joints shall have bolted flange-to-flange type connections on both sides of expansion joint for removal of complete unit. Minimum flange thickness shall be 8 mm.

All joints shall be provided with internal overlapping flow liners and full cavity insulationpillows to prevent dust particles from entering the cavity unless otherwise approved inwriting by the Project Owner / Consultant.

5.05.08 Exhaust Duct:

Exhaust duct shall in all instances be designed and constructed to meet requirements of all Permits; however, the following minimum requirements must be fulfilled:

Exhaust duct of bag filters shall be at least 3 m higher than the roof of the building inwhich they are installed unless otherwise approved in writing by the Project Owner /Consultant. Lateral exhausts shall not blow against the main wind direction.

Exhaust Duct shall be made of M.S. Sheet of 3.15 mm thickness. The duct shall beproperly painted

For fan discharge ducts the velocity preferably shall be in the range of 18 to 21 m/s at

maximum continuous rating.5.05.09 Airlocks:

General Application:

i. Airlocks shall be of rotary type for raw material, raw meal.

ii. Minimum size for airlocks shall be 250 mm x 250 mm.





RAJASTHAN

BIL INFRATECH LTD.

Page 8 of 12

iii The rotary valve rotor tip speed shall not exceed 0.5 m/s.

6.00.00 DELIVERY SCHEDULE

Delivery of the complete system of this package should not exceed 3-4 months fromeffective date of contract.

7.00.00 DRAWINGS, DATA AND MANUALS

7.01.00 Technical Information and Data to be submitted by the Tenderer with the Proposal

i. Basic engineering drawings and documents of the system.

ii. General arrangement drawing, including plans (Equipment and Floor) andsections, showing the overall dimensions and other details.

iii. Data / Details of Equipment

iv. Process Flow Sheet

v. Drive list.

vi. Instrument list with scope matrix.

vii. Instrument Specification & Data Sheets.

viii. P & ID indicating all measuring points.

ix. Preliminary load data of all equipment, chutes, ducts and dedusting vents.

x. List of drawings and documents to be submitted during detail engineering.

xi. Typical QAP and shop/site testing procedures.

xii. Data and drawings required in enclosed technical specification.

xiii. Manufacturer's catalogues and illustrative literature giving performance data,construction, special features, material details, etc.

xiv. Performance/characteristic curves for fans as applicable.

xv. Experience list for similar successful works with users’ performance certificates.





RAJASTHAN

BIL INFRATECH LTD.

Page 9 of 12

7.02.00 Technical Data and Information to be submitted after award of Contract:

i. Final version of all schematic, layout, general arrangement and cross-sectionaldrawings including ducting and data to be submitted.

ii. Civil assignment drawings including foundation details and load data

iii. Design and fabrication drawings of ducts.

iv. Detail drawings of important units, assemblies, parts, etc. as deemed necessary.

v. Size selection, capacity, design calculation, power calculation and complete loaddata for every individual equipment.

vi. Performance/characteristic curves for equipment as applicable.

vii. Noise data

viii. Manuals/Leaflets, brochures etc. describing all relevant constructional and othertechnical features for individual equipment.

ix. Detail part list showing nomenclature, part number and/or other informationnecessary for correct identification and ordering of spares.

x. Detail list of all special tools and tackle furnished under the Contract with drawingsand procedure of usage of the same.

xi. Final QAP and testing procedures.

xii. Reports on shop tests.

xiii. Test certificates for materials/bought out items.

xiv. Complete approval documentation from Statutory Authorities, if any.

xv. Erection, operation and maintenance manuals.

xvi. Drive list indicating all the load & type.

xvii. Instrument List with scope matrix / Make /Model.

xviii. SLD & Close Loop Control drawing with write-up.

xix. I/O List with address detail indicating alarm & trip list, if any.

xx. Sub-Control System Specification / Wiring Diagram / Installation Diagram.







RAJASTHAN

BIL INFRATECH LTD.

Page 11 of 12

The brand application procedure and compatibility between primer and finishing paintshall be certified by the paint manufacturer and subject to the Purchaser/Consultant'sapproval.

Two coats of epoxy resin based zinc rich primer compatible with subsequent finish coatsshall be applied.

The dry film thickness per coat of applied paints shall not be less than 35 microns forprimers:

Supplier shall get the color scheme for the equipment and its components approved bythe Purchaser/Consultant before application of paint.

Structures/equipment shall receive one coat of primer paint immediately after fabrication

at shop after appropriate surface preparation followed by spot priming.It is preferable to use peel able paints, adhesive tapes, punched metal sheets on theequipment for identification.

All electrical equipment, accessories and wiring shall have fungus protection involvingspecial treatment of insulation and metal against insect and corrosion.

10.00.00 PERFORMANCE GUARANTEE

Specific power consumption: Bidder to Specify equipment / system wise.

Bidder shall guarantee the successful performance of the system for two test run of 24hrs each within a span of 7 days.

11.00.00 LIQUIDATED DAMAGE DUE TO NON-FULFILLMENT OF PERFORMANCEGUARANTEES AND PENALTY

11.01.00 Liquidated Damages towards performance guarantees:

The supplier shall pay liquidated damages at the rate of 1% of contract price for every1% short fall in output from the guaranteed value, limited to max 5%. If short fall inoutput is more than 5%, supplier has to modify / replace the equipment to achieve therated output at their cost.

The supplier shall pay liquidated damages at the rate of 1% of contract price for full 1kwh/t increase in specific power consumption over the guaranteed value, limited to max5%. If specific power consumption is 5% more than the guaranteed value, supplier hasto modify/replace the equipment to achieve the guaranteed specific power consumptionat their cost.





RAJASTHAN

BIL INFRATECH LTD.

Page 12 of 12

Dust Emission: ≤50 mg/Nm 3

Penalty for every 2 mg/Nm 3 from 50 mg/Nm 3 will be 1.0% of the total contract price.Beyond that figures, filter will be rejected & the bidder has to replace/rectify theequipment/ components at no extra cost within 3 months time.

The total liquidated damage against performance guarantee shall not exceed 10% of thecontract price.

11.02.00 Liquidated Damage for Delay:

Without prejudice to the employer’s right to claim for other damages, the LiquidatedDamages at the rate of 1% of the Contract Price for each full one week of delay will bepayable by Bidder. However, the total Liquidated Damages payable against delay in

execution shall not exceed 5% of the Contract Value.11.03.00 Total Liability:

Without prejudice to the employer’s right to claim for other damages, the total liability forpenalties and liquidated damages on all accounts shall not exceed 15% of ContractPrice.

12.00.00 INPUT INFORMATION:

12.01.00 Details of Belt Conveyor:

i. BC – 01 : Capacity : 20 TPH, Width : 600 mm, Speed : 1.0 m/sec.ii. BC – 02 : Capacity : 40 TPH, Width : 600 mm, Speed : 1.0 m/sec.iii. BC – 03 : Capacity : 20 TPH, Width : 600 mm, Speed : 1.0 m/sec.iv. BC – 04 : Capacity : 20 TPH, Width : 600 mm, Speed : 1.0 m/sec.v. Crusher -1 Capacity : 20 TPH.vi. Crusher -2 Capacity : 40 TPHviii. Screen Capacity : 40 TPH

12.02.00 Drawings:

i. Plant Layout & Elevation drawing as specified above is enclosed .

Documents

TECH_SPEC_DE_R0