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TECHNICAL SPECIFICATION OF DUST EXTRACTION SYSTEM FOR LIMESTONE HANDLING SYSTEM FOR BINANI CEMENT PLANT AT BINANIGRAM, RAJASTHAN

BIL INFRATECH LTD.

TECHNICAL SPECIFICATION OF DUST EXTRACTION SYSTEM

1.00.00 1.01.00

General This specification is intended for carrying out design, engineering, manufacture, shop testing, delivery of equipment on FOT site basis inclusive of packing & forwarding charges, freight & insurance up to project site at Binani Cement Limited, Binanigram, Pindwara, Rajasthan, supervision during installation & commissioning, complete detail engineering & drawing, ducting & piping, performance testing and guaranty of various equipment in Limestone handling system Package as specified and as required for safe and trouble-free operation of de-dusting systems. The equipment shall have sufficient design 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 here, but are required to make the plant/system complete in complete in every respect in accordance with the technical operation and guaranteed performance, shall be covered specification.

not specifically mentioned the scope of the tenderer specification and for safe under the scope of this

1.03.00

The Purchaser/Consultant reserves the right to make minor revisions to the drawings/specifications which do not change the general scope of work. Such minor revisions, unless directly affecting the frame work of the contract, shall be incorporated without 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 efficient and guaranteed operation of the same to the entire satisfaction of the Purchaser/Consultant. CODES AND STANDARDS The design and construction of all the equipment should be generally as stated in the design criteria or as per Indian Standard Code or relevant recognized international standards, codes and practices, approved by the Purchaser/Consultant.

2.00.00

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TECHNICAL SPECIFICATION OF DUST EXTRACTION SYSTEM FOR LIMESTONE HANDLING SYSTEM FOR BINANI CEMENT PLANT AT BINANIGRAM, RAJASTHAN

BIL INFRATECH LTD.

3.00.00 3.01.00

SCOPE OF WORK AND EXCLUSIONS Scope of Work The bidders scope of work will include design, engineering, manufacture, assembly/preassembly, test at manufacturer's works, shop painting, supply, supervision during erection and commissioning, detail engineering & drawing, supply of fabricated ducting, electrical, instrumentation of Limestone crusher package equipment, performance testing & guarantying as specified hereinafter with all accessories as specified and as required 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 with supports and associated instruments. The sub-control system as require being included such as dust collector timer panel.

3.02.00

The Bidders scope of work shall also include: a. Civil assignment drawing with load for civil design shall be supplied.

b.

Compressed air requirement system-wise system shall be informed along with


Vendors offer. Dry Compressed air for de-dusting system shall be supplied by purchaser. Necessary tapping connection along with all field instruments shall be in the scope of vendor.

c.

Painting of all equipment at manufacturers works is in bidder scope. Bidder shall also supply his recommended amount of paint for field touch up. First fill of lubricants. The list of recommended spares for two years trouble free operation with unit price All special tools and tackles required for erection, commissioning and maintenance. Supervision of Erection & Commissioning Performance Guarantee test Required number of anchor bolts, foundation plates, sleeves, nuts and inserts to
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d. e.

f.

g. h. i.

TECHNICAL SPECIFICATION OF DUST EXTRACTION SYSTEM FOR LIMESTONE HANDLING SYSTEM FOR BINANI CEMENT PLANT AT BINANIGRAM, RAJASTHAN

BIL INFRATECH LTD.

be embedded in concrete for the equipment under this specification. During civil construction, 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 bag filter, fan with supports. Furnishing all required documents, data, drawings, manuals, test certificates, etc. as per approved list.

Supervision during erection, testing and commissioning of the supplied equipment and their accessories The successful bidder must interact with the upstream & downstream package suppliers 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 4.01.00 SITE DETAILS 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 : 48C c) Minimum temperature : 1C d) Basic Wind speed : As per IS:875 (part 3) - 1987 e) Seismic data : Zone III (as per IS: 1893 Part 1 2002)
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TECHNICAL SPECIFICATION OF DUST EXTRACTION SYSTEM FOR LIMESTONE HANDLING SYSTEM FOR BINANI CEMENT PLANT AT BINANIGRAM, RAJASTHAN

BIL INFRATECH LTD.

5.00.00 5.01.00 5.02.00

DESIGN GUIDELINES AND PARAMETERS Bag Filters - dust concentration at outlet should be restricted to 50 mg/ Nm . Selection of Bag Filter Capacity: a. b. c. Bag Filters capacity shall be designed based on ACGIH with 15% added design capacity. Bag Filter shall be provided in Primary Crusher House & Secondary Crusher house only i.e. DE System 1 & DE System - 2. Primary Crusher House Bag Filter Unit [DE System 1] shall have the following suction points: i. At discharge of conveyor BC-01. ii. At receipt of primary crusher. Primary crusher capacity 20 TPH. iii. At receipt of conveyor BC-02 from primary crusher. iv. At discharge of conveyor BC-03. v. At receipt of conveyor BC-02 from BC-03. The residual shall be return back to the system. Hence the bag filter shall be installed over the conveyor BC-02 as shown in the drawing No. MHCDID12001M-4-0002 & 0003. Secondary Crusher House Bag Filter Unit [DE System 2] shall have the following suction points: i. At discharge of conveyor BC-02. ii. At receipt of secondary crusher. Secondary crusher capacity 40 TPH. iii. At receipt of vibrating screen from secondary crusher. Screen Size : 5100x1810 mm. iv. At receipt of conveyor BC-04 from vibrating screen. v. At receipt of conveyor BC-04 from vibrating screen. The residual shall be return back to the system. Hence the bag filter shall be installed over the conveyor BC-04 as shown in the drawing No. MHCDID12001M-4-0002 & 0003.
3

d.

5.03.00

Dust Collecting Hood : a. b. Centre line of the hoods shall be located at the point of generation of maximum pressure during formation of dust. The hoods shall be adequately sized to collect all dusty air generated at the point. Velocity in the hood must not be so high as to draw larger size particles unnecessarily and shall be limited to 2.0 2.5 m/sec. The hoods shall be made of M.S. sheet of adequate thickness not less than 3.15 mm.
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c.

TECHNICAL SPECIFICATION OF DUST EXTRACTION SYSTEM FOR LIMESTONE HANDLING SYSTEM FOR BINANI CEMENT PLANT AT BINANIGRAM, RAJASTHAN

BIL INFRATECH LTD.

5.04.00

Dust Extraction Ducting: a. b. c. d. The ducts for conveying dusty air shall be of round shape and of streamline appearance. 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. The ducting shall be made of M.S. Sheet of 3.15 mm thickness. The duct shall be properly painted. Duct support shall be provided as per stipulations hereunder : Diameter of duct Less than 200 mm More than 200 mm e. f. Spacing of support Maximum 2.50 metre Maximum 3.00 metre

The duct work shall be properly reinforced to prevent sagging, buckling and vibration. Interior of ducts shall be smooth and free from obstruction. Flexible connections shall be provided at the duct connections to inlet and discharge of the fans. All flexible connections shall be non-collapsible type and their length shall be kept to a minimum. Duct supports, wherever required, shall be provided. Hangers and support positions shall be made as per good engineering practices. 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 and including 500mm. diameter. For duct sizes above 500mm. diameter, the flange thickness shall be minimum 6mm. All hangers and supports shall have to be approved by the Engineer. Vertical ducts passing through floor slab shall be supported by means of collars constructed of structural steel angles securely fastened about the girth of the duct and resting on the floor slab. The supporting angle shall be fastened to the floor slab with a filler or bituminastic compound inserted in between the horizontal leg of the supporting angle and the floor. 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. All extraction points should have manual dampers for flow balancing. Motorised damper shall be used for isolation of non-operating extraction points. Interlocking of motorized damper with drive motor of main equipment of the stream as approved during detail engineering stage shall be provided.
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g. h.

i.

j. k.

TECHNICAL SPECIFICATION OF DUST EXTRACTION SYSTEM FOR LIMESTONE HANDLING SYSTEM FOR BINANI CEMENT PLANT AT BINANIGRAM, RAJASTHAN

BIL INFRATECH LTD.

5.05.00 5.05.01

Bag Filter Unit: General :

i.
ii. 5.05.02 Bags : i.

Air to cloth ratios shall be not more than 1.2 m3/m2/ min. For design of Filter bag 20 % spare capacity shall be provided

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

ii.

5.05.04

Housing Plenum and Hopper Construction : i. Hopper valley (corner) angles shall not be less than 60 degrees (measured form horizontal).

5.05.05

De-dusting Air Volume: i. De-dusting air volume shall be sufficient to maintain pollution-free operation. The same to be calculated by the supplier and should submit the air volume calculation.

5.05.06

Bag Filter Fans: i. Fans shall be designed for 115% of bag filter design flow rate with 20% more than the designed pressure. Fan speed shall not exceed 1500 rpm for 50 Hz motors unless otherwise approved in writing by the Project Owner / Consultant. Manually operated, accessible fan inlet damper shall be provided.
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ii.

iii.

TECHNICAL SPECIFICATION OF DUST EXTRACTION SYSTEM FOR LIMESTONE HANDLING SYSTEM FOR BINANI CEMENT PLANT AT BINANIGRAM, RAJASTHAN

BIL INFRATECH LTD.

iv.

Fan motor shall be adequately sized for the design flow at the lowest ambient temperature. Fans above 30 kW shall be mounted on anti-vibration pads, if located on elevated floors. An access door, bolted and gas tight sealed, shall be provided in the fan inlet spiral for visual impeller inspection. Drive motor shall be suitable for outdoor application with an ambient temperature 50 deg. C, energy efficient 1, 415 V, 3 phases, 50 Hz, AC supply.

v.

vi.

vii.

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 insulation pillows to prevent dust particles from entering the cavity unless otherwise approved in writing 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 in which 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 be properly 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. ii. Airlocks shall be of rotary type for raw material, raw meal. Minimum size for airlocks shall be 250 mm x 250 mm.
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TECHNICAL SPECIFICATION OF DUST EXTRACTION SYSTEM FOR LIMESTONE HANDLING SYSTEM FOR BINANI CEMENT PLANT AT BINANIGRAM, RAJASTHAN

BIL INFRATECH LTD.

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 from effective date of contract.

7.00.00 7.01.00

DRAWINGS, DATA AND MANUALS Technical Information and Data to be submitted by the Tenderer with the Proposal i. ii. Basic engineering drawings and documents of the system. General arrangement drawing, including plans (Equipment and Floor) and sections, showing the overall dimensions and other details. Data / Details of Equipment Process Flow Sheet Drive list. Instrument list with scope matrix. Instrument Specification & Data Sheets. P & ID indicating all measuring points. Preliminary load data of all equipment, chutes, ducts and dedusting vents. List of drawings and documents to be submitted during detail engineering. Typical QAP and shop/site testing procedures. Data and drawings required in enclosed technical specification. Manufacturer's catalogues and illustrative literature giving performance data, construction, special features, material details, etc. Performance/characteristic curves for fans as applicable. Experience list for similar successful works with users performance certificates.

iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii.

xiv. xv.

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TECHNICAL SPECIFICATION OF DUST EXTRACTION SYSTEM FOR LIMESTONE HANDLING SYSTEM FOR BINANI CEMENT PLANT AT BINANIGRAM, RAJASTHAN

BIL INFRATECH LTD.

7.02.00

Technical Data and Information to be submitted after award of Contract: i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii. Final version of all schematic, layout, general arrangement and cross-sectional drawings including ducting and data to be submitted. Civil assignment drawings including foundation details and load data Design and fabrication drawings of ducts. Detail drawings of important units, assemblies, parts, etc. as deemed necessary. Size selection, capacity, design calculation, power calculation and complete load data for every individual equipment. Performance/characteristic curves for equipment as applicable. Noise data Manuals/Leaflets, brochures etc. describing all relevant constructional and other technical features for individual equipment. Detail part list showing nomenclature, part number and/or other information necessary for correct identification and ordering of spares. Detail list of all special tools and tackle furnished under the Contract with drawings and procedure of usage of the same. Final QAP and testing procedures. Reports on shop tests. 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.

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TECHNICAL SPECIFICATION OF DUST EXTRACTION SYSTEM FOR LIMESTONE HANDLING SYSTEM FOR BINANI CEMENT PLANT AT BINANIGRAM, RAJASTHAN

BIL INFRATECH LTD.

xxi. Instrument Hook-Up / Location / Tapping Drawing, if any. xxii. Other relevant data, document or drawings as deemed necessary and sought by Purchaser/Consultants. 8.00.00 8.01.00 TESTING & INSPECTION: General The manufacturer shall conduct all tests and inspections required to ensure that the equipment furnished shall conform to the requirements of this specification and in compliance with requirements of applicable Codes and Standards. The bidder shall furnish in details the quality assurance programme (QAP) during manufacturing as envisaged by him for Purchaser's/ Consultant's review and approval. The particulars of the proposed tests and the procedures for the tests shall be submitted to the Purchaser/Consultant for approval before conducting the tests. The Purchaser/Consultant's representative shall be given full access to all tests. The Supplier shall intimate the Purchaser/Consultant well in advance so that if desired his representative can witness the test. Where stage inspection is to be witnessed by Purchaser/Consultant, in addition to above, the tenderer shall submit to the Purchaser/Consultant at the initiation of the contract, the detailed Bar Diagram chart showing the manufacturing programme and indicating the period where Purchaser/Consultant or his authorized inspecting agency is required at the shop.

9.00.00

SURFACE PREPARATION AND PAINTING

All machinery, equipment, piping etc. shall receive surface preparation and painting according to the following general guideline. This specification does not relieve the Supplier from supplying any other special paints or coatings where special local conditions require so. All steel surfaces shall be free from all mill scales, rust, oil, grease or any foreign matters. The paint manufacturer's recommendation, if any, shall be strictly followed during surface preparation. All welded areas shall be given special attention for removal of welding flux in crevices. The paint manufacturer's instructions regarding thinning, mixing, method of application, handling and drying time shall be strictly followed and considered a part of this specification.

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TECHNICAL SPECIFICATION OF DUST EXTRACTION SYSTEM FOR LIMESTONE HANDLING SYSTEM FOR BINANI CEMENT PLANT AT BINANIGRAM, RAJASTHAN

BIL INFRATECH LTD.

The brand application procedure and compatibility between primer and finishing paint shall be certified by the paint manufacturer and subject to the Purchaser/Consultant's approval. Two coats of epoxy resin based zinc rich primer compatible with subsequent finish coats shall be applied. The dry film thickness per coat of applied paints shall not be less than 35 microns for primers: Supplier shall get the color scheme for the equipment and its components approved by the 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 the equipment for identification. All electrical equipment, accessories and wiring shall have fungus protection involving special 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 24 hrs each within a span of 7 days.

11.00.00 11.01.00

LIQUIDATED DAMAGE DUE TO NON-FULFILLMENT OF PERFORMANCE GUARANTEES AND PENALTY Liquidated Damages towards performance guarantees: The supplier shall pay liquidated damages at the rate of 1% of contract price for every 1% short fall in output from the guaranteed value, limited to max 5%. If short fall in output is more than 5%, supplier has to modify / replace the equipment to achieve the rated output at their cost. The supplier shall pay liquidated damages at the rate of 1% of contract price for full 1 kwh/t increase in specific power consumption over the guaranteed value, limited to max 5%. If specific power consumption is 5% more than the guaranteed value, supplier has to modify/replace the equipment to achieve the guaranteed specific power consumption at their cost.
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TECHNICAL SPECIFICATION OF DUST EXTRACTION SYSTEM FOR LIMESTONE HANDLING SYSTEM FOR BINANI CEMENT PLANT AT BINANIGRAM, RAJASTHAN

BIL INFRATECH LTD.

Dust Emission: 50 mg/Nm 3 3 Penalty for every 2 mg/Nm from 50 mg/Nm will be 1.0% of the total contract price. Beyond that figures, filter will be rejected & the bidder has to replace/rectify the equipment/ components at no extra cost within 3 months time. The total liquidated damage against performance guarantee shall not exceed 10% of the contract price. 11.02.00 Liquidated Damage for Delay: Without prejudice to the employers right to claim for other damages, the Liquidated Damages at the rate of 1% of the Contract Price for each full one week of delay will be payable 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 employers right to claim for other damages, the total liability for penalties and liquidated damages on all accounts shall not exceed 15% of Contract Price. 12.00.00 12.01.00 INPUT INFORMATION: Details of Belt Conveyor: i. ii. iii. iv. v. vi. viii. 12.02.00 BC 01 : Capacity : 20 TPH, Width : 600 mm, Speed : 1.0 m/sec. BC 02 : Capacity : 40 TPH, Width : 600 mm, Speed : 1.0 m/sec. BC 03 : Capacity : 20 TPH, Width : 600 mm, Speed : 1.0 m/sec. BC 04 : Capacity : 20 TPH, Width : 600 mm, Speed : 1.0 m/sec. Crusher -1 Capacity : 20 TPH. Crusher -2 Capacity : 40 TPH Screen Capacity : 40 TPH

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

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