NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECT

PACKAGE NO - I CHAPTER NO. Q8

VOLUME - V of V PAGE No. 1 of 10

CHAPTER - Q8 HYDRO ENGINEERING.

1.0 1.1 SCOPE OF WORK AND BATTERY LIMIT: NMDC will arrange to supply filtered potable water in a 727 cu.m RCC hill top reservoir at the mines area above the proposed crushing plant. Water required for the crushing plant shall be tapped through a M.S pipeline from the hill top reservoir. The required filtered Quality water for the Package shall be tapped from the Hill Top reservoir of 727 Cu.m capacity. The battery limit will be the delivery flange of the Hilltop reservoir. The water shall be drawn by gravity by making use of the elevation difference available between the hill top reservoir and the crushing plant. The total tentative requirement of water for different uses in the crushing plant as envisaged by the Owner for this package are furnished below. However, Tenderer to review the same and any additional / increase in requirement shall be furnished along with the bid. Sl.No a) b) c) d) e) Description Dust suppression for platform at crushing plant Dumper Qty.(m3/day) 750 10 482 200 48 1490

1.2

1.3

Drinking in the Crushing plant Primary & Secondary crusher Oil Cooling Dust Suppression in Crushing plant Secondary crusher dust sealing Total

The flow diagram enclosed with this tender document indicates the estimated requirement, the scheme and scope of work of the water supply facilities included in this Package. The Tenderer shall design the water circulation system for the primary and secondary oil cooling as well as the process and drinking water distribution system for crushing plant. MEC/01/Q6DH/NMDC-KIOP/PKG-I/TD/2009(2) Rev. 0 2009, MECON Limited. All rights reserved.

1.4

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECT

PACKAGE NO - I CHAPTER NO. Q8

VOLUME - V of V PAGE No. 2 of 10

The circulation system consists of hot return water Collection sump, Pumps, Valves and pressure gauges etc. The Tenderer shall provide a standby pump also to take care of maintenance or emergency situation. However, No standby pump is required for the dust suppression system. 1.5 Galvanized Iron pipes conforming to IS:1239 Part I(heavy) 2000, shall be used for supply of potable water to crushing plant and the Mines Office. The drinking water pipeline shall be designed for a minimum flow of 2 cu.m/hr in each branch line to the consumer. The major units / equipment for the water supply facilities envisaged are as follows: Sl.No a b c d e f Description RCC Tank of minimum 220 Cu.m capacity at crushing plant RCC sump of minimum 20 Cu.m capacity at downstream of crushing plant HDPE Tank of capacity 2000 litres for Office Complex Centrifugal pumps of minimum 22.5 cu.m/h @ 50 mWc Centrifugal pumps of minimum 15 cu.m/h @ 45 mWc Interconnecting Pipes and Valves, accessories& Gauges etc Qty 1 No 1 No 1 No 2 Nos 1 No 1 Lot

1.6

2.0

SPECIFICATION FOR SUPPLY, LAYING / ERECTION, TESTING AND COMMISSIONING: The pipelines and valves to be used for the Crushers cooling and Dust Suppression System shall be as per the mechanical data sheet enclosed. The Piping work shall be complete in all respects including all accessories essential for proper installation, operation and maintenance even though such items might not have been specifically mentioned in the specifications.

2.1

MEC/01/Q6DH/NMDC-KIOP/PKG-I/TD/2009(2) 2009, MECON Limited. All rights reserved.

Rev. 0

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECT

PACKAGE NO - I CHAPTER NO. Q8

2.2

VOLUME - V of V PAGE No. 3 of 10

2.3

Piping system shall be designed with high degree of reliability so that the systems perform the duty of fluid handling without any failure under all conditions of plant operation. Piping layout and laying must follow good engineering practice. Proper attention shall be paid to obtain full functional requirement of the piping system with a layout, which provides sufficient clearance for other equipment and operating personnel, convenient supporting points and neat appearance. Complete design of piping system shall be subject to approval by the Owner/ Consultant. The design shall take into account the effect of internal/ external pressures, surge pressure, self weight of piping, support reactions, wind effects at site, corrosion, erosion, etc., and any other effects dictated by good engineering practices. Piping systems shall not impose undue forces on equipment flanges to which they are connected. Special quality pipes such as GI for drinking and MS pipes for cooling, process and service waters shall be used. Frictional pressure drop in water lines shall be calculated using Hazen & Williams formula considering value of C = 100 for pipelines. The following flow velocities shall be maintained in the pipe network for various categories of water: Nominal pipe size (mm) Up to 150 200 to 450 500 to 1200 Above 1200 Recommended flow velocities (m/s) 1.2 to 1 .5 1.5 to 1.8 1.8 to 2.2 2.2 to 2.5

2.4

2.5

2.6

2.7

2.8

2.9

Note : The above table sets the maximum limits of the flow velocity. Lower velocities may be selected if found necessary due to hydraulic considerations in specific cases. MEC/01/Q6DH/NMDC-KIOP/PKG-I/TD/2009(2) Rev. 0 2009, MECON Limited. All rights reserved.

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECT

PACKAGE NO - I CHAPTER NO. Q8

2.10

VOLUME - V of V PAGE No. 4 of 10

All the pipe network shall be provided with manually operated valves for isolation /controlling purposes. Valves of size 250 mm and above shall be gear operated. The pipelines shall be provided with air release valves with isolation valves at high points and drain valves at the lower points. Each of the branch connection taken from the main network shall be provided with an isolation valve. Pipelines passing under or through equipment foundations or walls of buildings or any other inaccessible Structure, Roads, Pipes shall be taken through encasing pipes for protection and for easy insertion and removal. RCC encasing pipes as per class NP-3 with collar rings jointed by cement mortar (1:4) shall be used with ID not less than three sizes higher than the size of crossing pipe and in no case less than 300 mm dia. All the pressure pipes shall be laid with a nominal slope and the gravity network with slopes for self-cleaning velocities. Continuous welded MS pipes shall be used for water supply facilities. For drinking water, screwed and socketed Gl pipelines shall be used. Except where specified otherwise, all MS piping shall have butt-welded connections with minimum flanged joints for connections to equipment / accessories. Branches shall in general, be formed by welding. Welding of pipelines and fixing of supports shall be by electric arc welding unless otherwise permitted by Owner at site. Appropriate welding electrodes are to be chosen as per IS:815-1974. Provisions shall be made for branches for cleaning and flushing of pipelines wherever necessary. Provision shall be made for support of piping, which may be disconnected during maintenance work. All large pipes and Rev. 0

2.11

2.12

2.13

2.14

2.15

2.16

2.17

2.18

2.19

2.20

MEC/01/Q6DH/NMDC-KIOP/PKG-I/TD/2009(2) 2009, MECON Limited. All rights reserved.

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECT

PACKAGE NO - I CHAPTER NO. Q8

VOLUME - V of V PAGE No. 5 of 10

long pipes shall have at least two supports each arranged in such a way that any length of piping or valve may be removed without any additional supports being required. 2.21 Pipe supports shall be capable of supporting the pipelines under all conditions of operation Gl/MS water pipes up to 150 mm dia shall conform to lS: 1239 Part I (heavy)-2000. MS pipes of dia 200 mm and above shall conform to IS:1978 / IS:3589. Pipe fittings of dia up to 150 mm shall conform to IS:1239 Part II. For MS pipes, the fittings shall conform to IS:11428(Part-II)-1985.However MS pipe fittings of dia 200 mm and above, may be fabricated out of pipes conforming to lS: 3589/ IS: 1978 as permitted by the Owner. The supporting span for the pipeline shall be generally as follows:

2.22

2.23

2.24

Nominal pipe size (mm) 15 to 32 40 to 65 80 to100 150 to 250 & 300 350 to 600 700,800 900 to 1000 2.25

Maximum unsupported span (m) 2.0 3.0 4.0 6.0 9.0 10.0 12.0

MS pipes laid above ground and the structural steel supports shall be painted with 2 coats of red oxide primer followed by 2 coats of finish enamel paint of approved quality and colour. All MS / GI pipelines laid underground shall be protected from external corrosion by providing external coating and wrapping with 2 coats of coal tar primary paint followed by two alternative coatings & wrapping of coal tar finish enamel paint & fibre glass tissue soaked / impregnated with coal tar Rev. 0

2.26

MEC/01/Q6DH/NMDC-KIOP/PKG-I/TD/2009(2) 2009, MECON Limited. All rights reserved.

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECT

PACKAGE NO - I CHAPTER NO. Q8

VOLUME - V of V PAGE No. 6 of 10

enamel and a final wrapping with waterproof polyethylene sheet. The coating and wrapping shall be carried out as per IS: 10221-2000 and total thickness shall not be less than 3.6 mm. 2.27 In general BIS standard No.IS:5822-1994 ( Code of practice for the laying of ERW steel pipes for water supply) shall be followed for laying of the pipelines. DATA SHEETS VALVES. FOR PUMPS, PIPES & BUTTERFLY

3.0

3.1 Sl.No

PUMP DATA SHEET Description Parameters

1. LIQUID HANDLED WATER 2. PROPERTIES OF LIQUID PUMPING TEMP MAXIMUM (0 C) 50 0 MINIMUM ( C) 30 LIQUID DENSITY AT PUMPING TEMP. 1000 (kg/m3) 3. OPERATING CONDITIONS SUCTION PRESSURE (Kg/cm2) POSITIVE NPSH AVAILABLE (M) FLOODED SUCTION 4. MATERIAL OF CONSTRUCTION CASING CI IS 210 GR. FG. 200 IMPELLER BRONZE GR. 2 IS : 318 SHAFT CS IS 1570 GR. C40/EN 8 BRONZE GR. 2 IS : 318 / SHAFT SLEEVE SS 316 SEAL TIWA BRONZE GR. 2 IS : 318 / WEARING RING SS 316

MEC/01/Q6DH/NMDC-KIOP/PKG-I/TD/2009(2) 2009, MECON Limited. All rights reserved.

Rev. 0

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECT

PACKAGE NO - I CHAPTER NO. Q8

VOLUME - V of V PAGE No. 7 of 10

5. PUMP DESCRIPTION TYPE ARRANGEMENT NUMBER OF STAGES FLANGE DRILLING STANDARD SPEED OF PUMP,RPM TYPE OF SEALING IMPELLER TYPE 6. MOTOR DESRIPTION AMBIENT TEMPERATURE MOUNTING TYPE INSULATION HORIZONTAL, CENTRIFUGAL, END SUCTION BACK PULL OUT DESIGN. DIRECTLY COUPLED SINGLE ANSI B 16.5, 150 # RF 1450 GLAND ENCLOSED 45 Deg. C HORIZONTAL TEFC, SQUIRREL CAGE INDUCTION MOTOR CLASS 'F' BUT TEMPERATURE RISE LIMITED TO CLASS 'B'

7. COUPLING MAKE LOVEJOY BETWEEN MOTOR & PUMP SHAFT FLEXIBLE TYPE 8. Note: EACH PUMP SHALL BE SUPPLIED WITH THE FOLLOWING ACCESSORIES: i.) COUPLING SUITABLY BORED TO SUIT THE MOTOR DRIVE SHAFT. ii.) COUPLING GUARD.

MEC/01/Q6DH/NMDC-KIOP/PKG-I/TD/2009(2) 2009, MECON Limited. All rights reserved.

Rev. 0

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECT

PACKAGE NO - I CHAPTER NO. Q8

4.0 SPECIFICATION WITH WATER) FOR PIPES

VOLUME - V of V PAGE No. 8 of 10

(NORMALLY CHARGED

4.1 a) b)

DESIGN PARTICULARS Material Standard i.) For pipes DN 150mm below ii.) For pipes DN 200mm above.

Mild Steel & & IS: 1239 Part-I (or) IS:1978-1985 (Heavy) IS:1978-1985 (or) IS: 3589-2000

c)

Class i) & Heavy grade

For pipes DN 150mm below ii) For pipes a) DN 500 b) DN 400 c) DN 300 d) DN 250 e) DN 200 d) Fittings i) ii) e) For sizes DN 150 mm & below For pipes DN 200 mm & above For sizes DN 50 mm below

mm mm mm mm mm

OD OD OD OD OD

508 x 9.52 thk. 406.4 x 7.14 thk. 323.85x6.35 thk. 273.05x6.35 thk. 219.08x6.35 thk.

IS : 1239 Part II / IS:1789/IS:11428 IS: 11428 / fabricated from pipe

Flanges i) & IS : 6392,T-17

ii) For sizes DN 200 mm & above f)

MS Plate flanges of steel as per IS:2062 with dimensions as per IS: 6392, T-17 Connections between pipe and fittings i) For sizes DN 40 mm & Socket welding below Butt welding GI Pipes for drinking water IS 1387 ( Galvanised for drinking water) Rubber as per IS: 638 Rev. 0

g) h) i)

ii) For sizes DN 50 mm & above Special requirements Nuts & Bolts Gaskets

MEC/01/Q6DH/NMDC-KIOP/PKG-I/TD/2009(2) 2009, MECON Limited. All rights reserved.

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECT

PACKAGE NO - I CHAPTER NO. Q8

j) Painting

VOLUME - V of V PAGE No. 9 of 10

As per manufacturers standard

4.2 a) b)

ERECTION REQUIREMENT Segmental test pressure during erection 13.2 Kg/cm2 (g)

c) d) 5.0

System test pressure after completion of 8.8 Kg/cm2(g) erection and flushing with valves in position but prior to commissioning Hydro/ Leak test duration 4 hrs minimum. (No pressure drop and no sign of leakage shall be observed during the test) Line flanges to be provided for maintenance and end flanges with blank flanges to be provided for flushing. SPECIFICATION FOR CAST IRON BUTTERFLY VALVE (sizes: DN 50 to DN 300mm) DESIGN PARTICULARS

5.1 a) b) c) d) e) 5.2 a) b) c) d)

Fluid to be handled Working pressure Type Type of operation Rating CONSTRUCTION MODE Body Disc Seat Hand leaver/gear

Raw water / Drinking Water Max. 6 Kg/cm Wafer type conforming IS: 13095-1991 / BS: 5155 Size upto 200mm NB lever operated, size 250mm NB and above gear operated 10 Kg/cm (125 class)

Cast Cast Soft To be provided

MEC/01/Q6DH/NMDC-KIOP/PKG-I/TD/2009(2) 2009, MECON Limited. All rights reserved.

Rev. 0

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECT

PACKAGE NO - I CHAPTER NO. Q8

VOLUME - V of V PAGE No. 10 of 10

5.3 a) b) c) d) e) 5.4 a)

MATERIAL OF CONSTRUCTION Body Disc Shaft Seating ring / seal retaining ring Seat Cast iron IS:210-1978, FG 200( Min) SG Iron Stainless steel IS:6603-1972, 12 Cr 13 Stainless steel / IS:6603-1972, 04 Cr 18 Ni 10 Elastomers, Grade: Nitrile

TEST TO BE WITNESSED BY OWNER / CONSULTANT Hydro test Body Disc As per IS:13095/BS:5155 Disc Strength Test

5.5 a) b)

WORKMANSHIP FINISH & PAINT Workmanship Finish Good All burrs and sharp edges shall be removed and the inside surface should have smooth finish 2 coats of primer followed by 2 coats of finish enamel paint of approved colour and quality.

c)

Paint

MEC/01/Q6DH/NMDC-KIOP/PKG-I/TD/2009(2) 2009, MECON Limited. All rights reserved.

Rev. 0

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECT PACKAGE NO - I CHAPTER NO. Q9 VOLUME - V of PAGE No. 1 of V 1

CHAPTER-Q9 GENERAL LAYOUT, ROADS AND FIRE FIGHTING

1.0 General Layout Considering the material flow, the various facilities have been proposed at different elevations and as shown in General layout drg. no. MEC/01/Q6DH/KIOP/I/101/TS. It is necessary to carryout detailed survey work at different levels for locating the various facilities and conveyor systems for planning and designing of different structures including construction work. 2.0 Roads: It is proposed to construct 20m wide Mine road between Dumper platform and ROM stock pile and towards mines up to battery limit and also an approach road having formation width of 10m including drains with 4.0m wide black topping and 1250mm shoulder on either side connecting existing PWD road to Mines office, PCH & SCH. The service road shall have 4.0m black topping and 1250mm shoulder on either side. RR masonry bunds on valley side, Crash Barriers, Cat Eyes, informatory and warning road signs with suitable radium coating, Kilometers Stones, etc. shall be provided as per relevant standards. Roadside drains and culverts shall be planned along the proposed roads. 3.0 Fire fighting: In order to combat the fire at initial stage it self, it is necessary to plan and provide first-aid fire fighting extinguishers of suitable type and capacity. 4.0 IS Codes: IS : 1644-(latest version) Code of practice for fire safety of buildings (general) : Exit requirements and personal hazard.

MEC/01/Q6DH/NMDC-KIOP/PKG-I/TD/2009(2) 2009, MECON Limited. All rights reserved.

Rev. 0