B.F1,RSP-TS(TK-01)R1


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CENTRE FOR ENGIN

UPGRADATION OF BF NO. 1
Chapter no. Description Page No.
1. Introduction 1.1 1.5
2. Scope of Work 2.1 2.78
3. Technical Specifications 3.1 3.360
4. Performance Guarantee Test 4.1 4.5
5. Special Instruction to Bidders 5.1 5.3
Annexures
Schedules
Drawings


UPGRADATION OF BF NO. 1
Annexure no. Description No. of Pages
List of Preferred Makes 21
3.2.1-1 Technical Specification for Civil Works 37
3.8.5-1 Technical Specificati
on for GIS sub-station 15
3.5.7.3-1 Technical Specification
for Hydraulic System 12
3.5.7.4-1 Technical Specification
3.5.7.5-1 Technical Specification
for Lubrication System 12

UPGRADATION OF BF NO. 1
CONTENTS SCHEDULES
Schedule- no. Description No. of Pages
2.5.9.1 - 1 Technical Particulars of Pump 2
2.5.9.1.- 2 Technical Particulars of Diesel Engine 1
2.5.9.1 - 3 Technical Particulars of Cooling Tower 3
2.5.9.1 - 4 Technical Particulars of Heat Exchanger 2
2.5.9.1 - 5 Technical Particulars of Soft Water Plant and
Accessories
2.5.9.1 - 6 Technical Particulars of Valves 1
2.5.9.1 - 7 Technical Particulars
of Duplex Water Filter 1
2.5.9.1 - 8 Technical Particulars
of Fire Extinguishers 1
2.5.9.1 - 9 Technical Particulars of CA Fan 3
2.5.9.1 - 10 Technical Particulars of Bag Filter 1
2.5.9.1 - 11 Technical Particulars of Hot Gas Generator 1
2.11 - 1 Declaration of Site Visit 1
2.11 - 2 Requirement of Construction Water & Power 1
2.11 - 3 List of Exclusions 1
2.11 - 4 List of Deviations 1
2.11 - 5 List of Similar Jobs Executed 1
2.11 - 6 List of Recommended Spares for two years Operation 1
2.11 - 7 List of Special Tools and Tackles 1
2.11 - 8 List of Erection and Commissioning Spares 1
2.11 - 9 Implementation Schedule 1


UPGRADATION OF BF NO. 1
Schedule- no. Description No. of Pages

UPGRADATION OF BF NO. 1
Drawing no. Description

UPGRADATION OF B.F NO. 1 PAGE 1.1
1. INTRODUCTION
GENERAL
1.1.1 Rourkela Steel Plant (RSP) is the first
Furnace supporting system for top porta
l support comprises 9 nos. of hearth
columns and 8 nos. stack column
s supported over mantle ring.
2 Bell top charging system.
volume.
d stockhouse having sint
er & coke screening
facilities.
Cooling System & Refractories
Cooling system in open loop with industrial water.
Plate cooling from hearth


UPGRADATION OF B.F NO. 1 PAGE 1.2
Graphite & Carbon layers in hearth
bottom with carbon bl
ocks in hearth
wall.
No under hearth cooling system.
Cast House
Electro-pneumatic drilling machin
e and electro-mechanical mudgun.
Hot Blast System
Hot blast system designed for 1000
C hot blast temperat
ure. Stoves nos. 1.2,
Dust catcher for primary gas cleaning.
Arrangement of Scrubber & ESP for final gas cleaning.
Electrics, Instrumenta
tion & Automation System
Electrics and Instrumentation & Automa
tion facilities in many areas are old

UPGRADATION OF B.F NO. 1 PAGE 1.3
breast cooler suitable for 1200
C HBT shall be provided. New tuyere stock
assembly shall be suitable for CDI
system @150 kg/thm. Handling facility
Top BLT equipment presently installed in B.F No. 2 will be shifted to B.F


UPGRADATION OF B.F NO. 1 PAGE 1.4
r bosh, belly, lower stack & part of
middle stack. All the othe
r cooling elements in throat, upper stack, hearth
In front of copper staves, gunniting of
silicon carbide of thickness 50 mm is
Twin Flat cast houses 90
apart with new configuration of hot metal & slag
runners suitable for higher hot metal production is envisaged. The cast house
shall be equipped with new 20/5 t
EOT cranes and other maintenance
facilities shall be there for handling
of runners, rocking runners and its
New hydraulic mud guns and drilling machine (2 nos. each) is envisaged for
the upgraded furnace. New cast house equipment like trough cover

UPGRADATION OF B.F NO. 1 PAGE 1.5


UPGRADATION OF B.F NO. 1 PAGE 1.6
1.5.2


UPGRADATION OF B.F NO. 1 PAGE 2.1
SCOPE OF WORK
2.1.1 The scope of work of the Bidder shall
broadly cover Upgradation of B.F No. 1 &
its peripheral facilities on Turnkey basis
with the incorpora
tion of modern and
proven design features to
enable the furnace achieve an average hot metal
production of 2900 tpd (avg) and a campa
ign life of 16 - 17 Mt hot metal
B.F No.1 & its peripheral facilities sha
ll be designed to achieve a productivity
level of 2.0 t/m
/day (on working volume basis) in
order to achieve average hot
metal production rate of 2900 tpd (avg) by us
ing the existing raw material quality.
In general, the following activities shall be
Dismantling of the existing equipment / facilities



UPGRADATION OF B.F NO. 1 PAGE 2.2
assembly shall be suitable for CDI
system @150 kg/thm. Handling facility
Top BLT equipment presently installed in B.F No. 2 will be shifted to B.F

UPGRADATION OF B.F NO. 1 PAGE 2.3
r plates are envisaged
for bosh, belly, lower &
part of middle stack. All
the other cooling elements
in throat, upper stack,
In front of copper staves, gunniting of
silicon carbide of thickness 50 mm is
Flat cast houses (90
apart) with new configuration of hot metal & slag
runners suitable for higher hot metal production is envisaged. The cast house
shall be equipped with new 20/5 t
EOT crane and other maintenance
facilities shall be there for handling
of runners, rocking runners and its
New hydraulic mud guns and drilling machine (2 nos. each) is envisaged for
the upgraded furnace. New cast house equipment like trough cover



UPGRADATION OF B.F NO. 1 PAGE 2.4
2.1.2 The scope of work shall cover dismantling & removal of debris, design,
engineering, construction, procurement,
manufacture, fabrication, supply,
transportation, insurance, storage, ha
ndling, erection, testing, commissioning and
stabilisation of B.F No. 1 & its peripheral
facilities covering the areas of civil,
structural, mechanical, utility, piping, elec
trical, instrumentation & automation to
the satisfaction of
2.1.3 Upgradation of B.F No. 1 proper & its
peripherals will be executed on Turnkey
basis. Total implementation
schedule of B.F No. 1 upgrad
ation shall be 21 months
from effective date of contract. The fu
rnace is planned to be put down after
stabilisation of B.F No. 5 and hence ex
ecution of upgradation activities will be
ation regarding location, work terrain,
climate condition, railways, roads, airpor

UPGRADATION OF B.F NO. 1 PAGE 2.5
Supply of all erection consumables lik
e oil, kerosene, cotton waste, oxygen



UPGRADATION OF B.F NO. 1 PAGE 2.6
erever required, shall be
Bidder for the equipment being supplied by them from relevant state /
central authorities.
Instructions in English for assemb
g and commissioning
of the equipment.
The furnace & all associated facilities sh
all be handed over to the bidder by the
Employer after blowing out and cooling of the furnace for starting the
2.1.7 Any equipment/ work/ services, which ma
y not have been specifically mentioned
in this document but are necessary
for the design, engi
neering, erection,
successful commissioning, performance gua
All necessary civil works such as excavation, dismantling works
of RCC elements, removal of sand fillings, heat resistant treatments,
insert/bolts fixing, PCC, RCC, modificat

UPGRADATION OF B.F NO. 1 PAGE 2.7
Foundations and other rela
supporting structures for walkways, plat
forms, pipe supports, cable gallery
i) Dismantling and reconstruction of
Skip Hoist Winch foundation as per
system, process and technological requirement.
ii) Modification/strengthening of RCC
elements of the building as per
requirement.
Skip Pit
i) Dismantling and reconstr
cation of skip bridge
supporting foundation walls of the skip pit as per system, process and
technological requirement.
ii) All necessary modification works in th
e skip pit as per system, process and
technological requirement.
Stock House
Necessary dismantling / cutting /
chipping including the required
tion, fixing of inserts/bolts & other
/ new facilities such as bunkers,
conveyors, screens, dust
extraction system etc as per technological &
process requirements.
Chipping / dismantling of damaged
portion of floor and making good
including laying of screed



UPGRADATION OF B.F NO. 1 PAGE 2.8
Closed Loop Cooling Water System
New Buildings in RCC framed constr
uction with brick cladding for pump
houses and heat exchanger includi
ng equipment foundations, trenches,
sumps, trestle/saddle foundations, drains
& all finishes & fa
cilities as per
system requirements.
RCC foundations for stru
ctural steel columns for shed including RCC
flooring over compacted boulder soling.
Construction of RCC framed cooling tower with all necessary facilities such
as sumps, drains, baffles, inserts/bolts
RCC foundations for ESPs, dust hoppers,
Electrical buildings / rooms in RCC fra
med construction with brick cladding
walls including equipment foundations,
cable vault / cable trenches with
r drainage arrangement, inserts, all
finishes, doors, windows, rolling shu

UPGRADATION OF B.F NO. 1 PAGE 2.9
Epoxy based Insulated flooring shall be cons
idered in front of all new electrical
panels, except for the rooms wh
Cast House Slag Granulation
The scope of civil works includes augmen
tation of granulated slag disposal &
storage as indicated in
e Bidder shall include the following:
Site cleaning, levelling of ground and rem
oval of slag and scrap by cutting and
sizing, loading, transpor
ith debris to a place
earmarked by the employer, transfer
structural steel framed structure with st
building is having adequate space to house the proposed CDI unit for B.F
No.1. The civil work for the proposed CDI unit for B.F No.1 in the main
existing CDI building shall include construction RCC foundations for
equipments & chimney on the ground floor
as per technolog
system requirement.
Electrical Room, MCC Room and Ven
tilation Room: Construction of RCC
framed two storied building with
system, ventilation system and associated equipment of CDI including
foundations for various equipments, cable
cladding for Pump house
including construction of sump, foundations for
pumps, cable trenches, civil supports fo



UPGRADATION OF B.F NO. 1 PAGE 2.10
system and process requirement .The ot
her facilities for buildings/facilities
shall include suitable handling facilitie
s, apron, water pr
oofing roofs, water
pipes, surface drain and its interconn
RCC foundations for trestles supporting ga
s pipe lines and flue duct. The GA
cal, system and process requirement.
Construction of approach road as per requirement.
Any other civil work not specifically
mentioned but n
ecessary for the
Civil works for conversion of Turbo
Alternator (TA-4) Foundation into
Turbo Blower Foundation in Turbo Blow
er Station, which broadly involve
the followings
 Non-Destructive Testing (NDT) for
TA-4 foundation shall be carried
out by the Bidder and the report shall be submitted to Purchaser for
reference. NDT shall include visu
al inspection, rebound hammer test,
taking out RCC core samples & finding
characteristic strength of the
RCC and conducting endoscopy at core locations / ultrasonic pulse
velocity tests/carbonation tests.

UPGRADATION OF B.F NO. 1 PAGE 2.11
floor/slabs, repair to existing RCC elements, dismantling of
RCC/PCC/Brickwork and making good,
The broad area of civil works for Hot Blas
t System are given below, however the
civil works shall not be limited to theses but shall be guided by
ment for entire scope of work for
Site cleaning and removal of
debris before the comme
ncement of work as per
requirement.
Modification/ strengthening/refurbishing/
All civil works, as per technological, sy
stem and process requirement, for all
including but not limited to:
Foundations for Back draft chimney, ai
r and gas pipeline supports, various
supports for platforms/



UPGRADATION OF B.F NO. 1 PAGE 2.12
Modification/ strengthening/refurbishing
The broad area of civil works for Centralis
ed CA Fan and Heat Recovery System
are given below, however the civil works
shall not be limited to theses but shall
be guided by technical/technological aspect
s and requirement for entire scope of
Construction of a centralized CA fa
n building in RCC framed construction
with brick cladding walls including hand
ling facilities, equipment foundations,
foundations for structural s
upports, cable trenches, all finishes, inserts, doors,

UPGRADATION OF B.F NO. 1 PAGE 2.13
Construction of a MCC room in RCC fr
amed construction with brick cladding
walls including handling facilities, cable
trenches, all finishes, inserts, doors,
Site cleaning, preparation, transfer of



UPGRADATION OF B.F NO. 1 PAGE 2.14
During execution of civil works, if
fouling of any existing underground
service line/facilities (whose prior information was not available) with
proposed facility is encountered, su
itable rearrangement of the proposed
facilities is to be done by the Bidder.
No extra claim on account of this shall
be entertained after award of work. Howe
ver, if this is unavoidable due to
system design and existing site cons
traints, the relo
cation of underground
facilities shall be under the scope of Bidder and the cost towards

UPGRADATION OF B.F NO. 1 PAGE 2.15
own arrangement to tap and lay necessary
Furnace Proper
Entire furnace shell including Base plate and associated structures (e.g.
shaft column, mantle ring, working



UPGRADATION OF B.F NO. 1 PAGE 2.16
Dismantling of existing GCP (Gas Cleaning Plant) including all
associate structures.
Structures in the stock house area
for replacement/modification of
screens, vibro-feeders, weigh hopp
ers, conveyors, walkways as per
mechanical requirement.
Existing passenger-cum-cargo Lift structure.
Dismantling of structures if requir
ed along the new route of cooling
ts for CH defuming system.
Dismantling of other misc. existing
structures and CGI sheeting work
as may be required for implementation of project as a whole.
All temporary structures required fo
r ensuring the stability of existing
structures during dismantling & reconstruction.
Stove Area
Dismantling of existing Stove She
lls along with base plate and
anchorage, platforms at different le
vels, staircase, handrails, ladders,
The structural reconstruction works are as follows:
Furnace Proper, Cast House, Dust Catcher and Skip Area:
Blast Furnace shell as per new pr
ofile including base plate and
Four poster column support along with platforms at different

UPGRADATION OF B.F NO. 1 PAGE 2.17
of technological requirements.
Cast house side and gable
Modification if any in the stock house structure to accommodate
new weigh hoppers, screens, vi
bro-feeders, conveyors,
GCP supporting structures includi
ng working and maintenance
platform with approach stairs,
stair tower, handrails, duct/pipe
Support structures for all new wa
ter pipe lines including pipe
bridges as per requirement.
Over Head emergency water ta
Other platforms, stairs, ladde
rs, structures for handling
equipment as per requirement.
Cast House De-fuming system
Supports for all Duct/hood supports
Construction of Hydraulic Room.
Structures for extension of
furnace control room as per
requirement.



UPGRADATION OF B.F NO. 1 PAGE 2.18
Miscellaneous Area
Structures for passenger-cum-cargo Lift.
Supporting structures for pipelines
within battery limit other
Cable Bridges and trestles for Electrical Cable Routing.
Gratings/chequer plates in walkways as per
technological/functional requirements.
Platforms at different levels
In the existing CDI building for B.F
No. 4, there is space provision at
different floors for CDI system of B.F No. 1. CDI system for B.F No.
1 shall be planned accordingly as under:
Structural Supporting arrange
ments for installation of
equipments pertaining to CDI-System
Structural platforms / floors with access as per technological
requirement.
Structural shed for Bag filter for B.F No. 1 over the
superstructure of existing CD
ogical requirement.
Structural supports for different
utility pipeline
s, fine coal
Coal-Dust-Distribution Station / Platform with enclosure and

UPGRADATION OF B.F NO. 1 PAGE 2.19
Dismantling/strengthening of structures if any.
The entire CDI-bldg. (existing)
shall be painted along with
The existing CDI building structure for B.F No. 4 shall be
common for CDI systems of B.F No. 4 and B.F No. 1.
Platforms for valve maintenance and other purposes with
Supports / trestles for BF Gas pi
proval on them (after incorporating
Purchasers comments/ observa
tions if any). The Purchaser reserves the right of



UPGRADATION OF B.F NO. 1 PAGE 2.20
The Successful Bidder shall submit fabr
ication drawings (based on approved
GA/design drawing) along with BOQ to
the Purchaser in hard copies for
bmit softcopy of fabrication drawings.
Before starting the work Successful Bidder
shall prepare structural design criteria

UPGRADATION OF B.F NO. 1 PAGE 2.21
Site cleaning, preparation,
transfer of benchmarks &
I DISMANTLING
A) Furnace
1. Top equipment including its handling
facilities, hydraulic system of MTA and its
ipe lines, lubrication pipelines & equalizing
system, throat armour assembly
2. Top Cone Assembly including dome lining
lates, Off-takes, Uptakes & down comers,
furnace bleeder valves with their winches &
3. Furnace coolers lot
4. Tuyere Stock assembly including Tuyere,
5. Bustle Pipe including hangers and BP nozzleslot
6. Iron Notch and Slag Notch Assembly lot
7. Skip charging system lot



UPGRADATION OF B.F NO. 1 PAGE 2.22
(B) Cast House

2 Mud Guns & Drilling Machine including
(C) Dust Catcher

valve along with winch & pulley, dust valve,
ug mill, bleeder valves
Lot
(D) BLT Equipment of BF-2

including Lower material gate & Lowe seal
valve, Bellow Arrangement, Goggle valve,
Transmission Gearbox, Rotating Chute, BLT
Handling system, Equalizing valve, Relie
Note: BLT equipment shall be dismantled by the Contractor of Main Package from B.F
No. 2 and handed over to RSP for re
visioning. Dismantling shall be done
carefully without any damage
to the equipment. Gas cu
tting of bolts shall be
avoided during dismantling to avoid any damage to the equipment
2.4.1.2 Erection, testing and commi
ssioning of existing equipment supplied by RSP after
Scope of work shall include erection,
testing and commissioning of equipment
II ERECTION, TESTING &
COMMISSIONING OF FREE ISSUE
ITEMS (Top Equipment includin
BLT)





UPGRADATION OF B.F NO. 1 PAGE 2.23
Sl No Description Qty. Unit
Remarks
II ERECTION, TESTING &
COMMISSIONING OF FREE ISSUE
ITEMS (Top Equipment includin
BLT)


Lower Seal Valve Assembly with Material





1 lot

5 nos.

3 nos.
B Back Drafting System

1. Back Draft valve 1 no.
2. Expansion Joint 1 no.
2.4.1.3 Design, Engineering, Supply, Erection, Te
sting and Commissioning of Equipment
Jobs under this category in
different areas are listed
hereunder. The erection of all
equipment shall be carried out based
on erection drawings of the Successful
the manufacturer of equipment (if



UPGRADATION OF B.F NO. 1 PAGE 2.24
Sl no Description Qty. Unit
III DESIGN, ENGINEERING, SUPPLY,
ERECTION, TESTING &
COMMISSIONING OF FOLLOWING
ITEMS


A1 Equipment

1 Over Burden Probes with temperature
sensors & gas sampling system
2 Handling system for OB probes 2 nos.
3 Hydraulic operated Furnace Bleeder Valves
4 Power Pack & accumulator station for
Furnace Bleeder Valves
6 SG Iron Stave Cooling Plates in Upper an
lot
7 Cu-Staves/ Inserted copper plates in Bosh,
Belly and Lower Stack
lot
8 SG Iron Stave in Tuyere and Hearth Zone lot
11 Tuyere Stock Assembly (Double Cardan
12 Handling facilities for Tuyere Stocks (3t
13 Skip Charging System comprising of skip
15 10t Electric hoist for sk
17 3t Jib Crane over Skip Bridge for handling

UPGRADATION OF B.F NO. 1 PAGE 2.25
Sl noDescription Qty. Unit
18 3t Jib Crane over furnace top for handling
of Furnace Bleeder Valve and top Skip
Pulleys
19 Hydraulic & lubrication system for BLT,
Lot
20 Passenger-cum-Cargo Lift
21 35t Erection Trolley including pulleys,
22 SLI alongwith drives, ropes/chains an
23 Hoists for BLT system along with
24 Seamless pipes for under hearth cooling Lot
(B) Cast House

B1 Equipment

3 Power pack for Hydraulic mud gun, drilling
machine and manipulator
5 Hyd. Manipulator for handling of covers
over Main Troughs
6 Mobile equipment for maintenance o
runners (Bobcat along with suitable
attachments)
7 10t Electric Hoist for handling of Mud
8 Cast House Crane (20/5t capacity), span
17m (approx.) with remote control facilities
9 3t Electric Hoist for maintenance of Cast



UPGRADATION OF B.F NO. 1 PAGE 2.26
Sl no Description Qty. Unit
11 Pusher Car 2
C Dust Catcher

C1 Equipment

1 Winch operated dust catcher cut off valve
(bell type) assembly including winch, ropes
2 Manual Knife gate valve below Dust
Catcher (Stainless Steel)
4 Hydraulic Power Pack & accumulato
station for Dust Valves.
5 Dust Catcher Bleeder Valves dia. 400 &
D Back Draughting System

1 5t Electric Hoist for Back Draught Valve 2 Nos.
Note: The Bidders shall indicate their sour
ces of supply for the copper coolers and SG
2.4.1.4 Design, Engineering, Supply, Fabrication
/ Modifications, Erection, Testing and
Commissioning
Area wise jobs to be carried out unde
Description Qty. Unit Wt.
A) Furnace

1 Receiving Hopper with ceramic liners
3 Uptakes and Down-comers including
manholes
lot
4 Equalising pipelines lot

UPGRADATION OF B.F NO. 1 PAGE 2.27
Description Qty. Unit Wt.
5 Bustle Pipe with Nozzle and Hange
lot
6 Top cone assembly including Off-take an
lot
B) Cast House

2 Iron and Slag statione
main trough covers)
lot
C) Dust Catcher

D) Back Draught System

1 Back Draught Chimney and Branch Line
1 lot
2.4.2 Pressure testing of coolers at site be
fore and after erection as per procedure
specified/ approved by the Employer, shall al
so be in the scope of work of the
2.4.3 All fasteners including high tensile



UPGRADATION OF B.F NO. 1 PAGE 2.28
2) Arrangement of coolers in bosh, be
lly & lower stack, upper stack up to
d tightening accessories
3) Cast house layout drawing with major dimensions
4) GA of uptakes and downcomer with major dimensions
5) GA of tuyere stock assembly
6) GA of bustle pipe with hangers an
d fixing arrangement of centre line of
7) Manufacturer's catalogues, leafle
ts for various bought-out items
8) The Bidder shall note that the ab
ove are minimum requirement only. The
Bidder shall ensure that all other
necessary write-up and information
required to fully describe the equi
pment offered are submitted with the

UPGRADATION OF B.F NO. 1 PAGE 2.29



UPGRADATION OF B.F NO. 1 PAGE 2.30
Hydraulic System for weigh hopper gate
Construction of foundation for supports
of hydraulic pipe lines feeding to
weigh hoppers and supply and installa
tion of hydraulic pipelines as per
requirement.
Augmentation of conveyors (SFC-1, SFC
-1.1 and SFC-1-1 for sinter fine
disposal system to 200tph ha
ving belt width of 800mm.
New handling facilities for
ession hoods over equipment inside the stock
lled after erection of new equipment.
Upgraded version of load cells (4 nos
. each) for ore, additives, sinter and
A new double storied hydraulic room (civ
il) shall be erected at a suitable
location in the stock house premises
to install hydraulic power pack for
weigh hopper gates and check weighing sy
stem, electric panel for hydraulic
system and PDB for power supply to
Hoist arrangement shall be there for maintenance purpose.
Design, manufacture, supply, installa
tion, testing & commissioning of
exhaust ventilation system in hydraulic room.
Structural modification in stoc
k house for all new installation.
Bunker modification to accommodate the new feeders & screens.
The material Flow Diagram for the exis
ting installation is shown in Drawing.

UPGRADATION OF B.F NO. 1 PAGE 2.31
with hold back), pulleys with bearings
and plummer blocks, idlers, take-up
unit, inter connecting chutes with liner
s, internal and external scrapers
(sprung bladed tungsten tipped), brakes,
Any statutory approval, wher
ever required, shall be
taken by the Successful
Bidder for the equipment being supplied by
them from relevant state / central
Supply and application of all paints,
primers and finish paints to the
equipment and other services as per IS 5:2007.
Conducting performance guarantee tests to
establish the operating parameters
for the individual equipment and in combination.
Any rectification / modification requir
ed for interface work during erection
of equipment / technological structures
shall be within the scope of work of
Supply of all holding down bolts and nuts for all equipment, fabricated
chutes, skirt boards, blank plates, ha



UPGRADATION OF B.F NO. 1 PAGE 2.32
to be included in the scope of work of the Successful Bidder.
2.4.8.3 Requirement of Drawings and Technical Document
The following drawings / documents shall be submitted by the Bidder along with
the offer:
General arrangement drawings showing
sections of equipment and systems
with overall dimension
The Bidder shall furnish a plan of Quality Assurance and Quality Control
both in respect of site work as well as
manufacture of equipment, which he
proposes to follow for the purpose of en
suring the quality of equipment and
workmanship at various stages.
The Quality Assurance Plan (QAP) and Quality Control Plan shall be
All bought out items shall be procured
from the manufacturers as per the
List of Preferred Make furnished in the
Annexure-2.12-1
of this
document.

UPGRADATION OF B.F NO. 1 PAGE 2.33
Hot Blast System
Upgradation of Stoves of B.F No. 1, R
SP will be done by incorporating state of
the art technologies available with th
e Bidder on turnkey mode for achieving
higher hot blast temperature of 1200
The Stove System to be provided by the Technology Supplier shall be
Internal Combustion Chamber Type wi
th Ceramic Burner at the bottom of
2.4.9.2 Dismantling



UPGRADATION OF B.F NO. 1 PAGE 2.34
2.4.9.3 Basic & Detail Engineering, Fabrica
Testing and Commissioning
Preparation and submission of basic
supplied by the Successful Bidder:
Equipments / items, which shall be supp
lied, erected, tested & commissioned in
All stove valves shall
be hydraulically operate

UPGRADATION OF B.F NO. 1 PAGE 2.35
Power pack for the hydraulics of stove
valves along with pi
Any other Valves required as per the system design.
Expansion joint of all types wherever
required. The material for expansion
Cold testing, hot testing and integrated
testing including proper functioning of
all equipment mentioned above, as per
procedure approved by the Employer.
Integrated Pressure testing of stoves and hot blast main up to the battery
limits, pressure testing of gas lin
es, air lines as per procedure
specified/approved by the Employer.
Destructive / Non-destructive testing of



UPGRADATION OF B.F NO. 1 PAGE 2.36
Coal Dust Injection System
2.4.10.1 Dismantling and modification/ re-rout
ing work of existing equipment and
nging it to normal condition.

UPGRADATION OF B.F NO. 1 PAGE 2.37
2.4.10.15 Supply shall be based on the latest technol
ogy. First grade materials, free from the
defects shall be used for ma
nufacture of the equipment.
Only recent models of the
equipment will be acceptable to the Employer.
Granulated Slag Disposal System
The existing slag granulation system is ab
le to granulate the entire liquid slag
arising from the upgraded B.F No. 1. Howe
ver, facilities for granulated slag
disposal system shall be augmented by
providing a new disposal conveyor and a
new disposal area near B.F No. 2 stock
house area at a distance of about 120 m
from the existing disposal area as shown in
has once through type high pressure
and low pressure Industrial
water cooling system similar to other Blast Furnaces
of RSP. The under hearth is being cool
ed with air. These systems shall be
The Bidder is required to design and provi
de most suitable and advance type of
Soft water (SW) based closed loop c
ooling system for furnace including under
hearth & stoves valves. Bidder shall desi
gn the cooling system based on heat flux
of the furnace of their technology. Accordi
ngly they have to achieve Performance
Guarantee parameters. The scope of work
is for separate and dedicated closed
loop cooling system. All the facilities shall be provided new.
The scope of supply shall consist of, but
not be limited to the following main
equipment, systems & sub-systems
3 Nos. of electrically driven recirc
ulation pumps (2W+1S) &1 No. diesel
engine driven pump for re-circulation of soft water
2 Nos. of electrically driven Booster
pumps (1W+1S) & 1 No. diesel engine
driven pump for re-circulation of boosted soft water
2 Nos. of electrically driven circul
ation pumps (1W+1S) & 1 No. diesel
engine driven pump for circulation/ ma
keup of soft water from intermediate
4 Nos. of Plate type Heat Excha
nger (2W+1HS+1CS) common for both SW



UPGRADATION OF B.F NO. 1 PAGE 2.38
2 Nos. of electrically driven Industr
ial water Booster pumps (1W+1S) for
furnace shell Spray & top cone injection

UPGRADATION OF B.F NO. 1 PAGE 2.39



UPGRADATION OF B.F NO. 1 PAGE 2.40
GCP of two stage annular gap design w
ith variable venturi in secondary
stage, capable of top pressure contro
l and also work along with future Top
Pressure Recovery Turbine (TRT).
An external demister fo

UPGRADATION OF B.F NO. 1 PAGE 2.41
1) Hoods and ductwork for fume
2) Runner covers (one in ea
ch cast house) for main trough
3) Hoods and ductwork for fume extraction at skimmers
4) Hoods and ductwork for fume



UPGRADATION OF B.F NO. 1 PAGE 2.42
2.5.3.3 The following drawings/ documents shall be submitted by the Successful Bidder
to the Employer for approval:
GL drawing of the Cast House Defumi

UPGRADATION OF B.F NO. 1 PAGE 2.43
6)

DN1400 BF Gas piping tapping from GCP
outlet to Heat Recovery System
Mixed Gas pipeline DN500 from main
DN 1400 CA Fan line from CA Fan Stati
on to Heat Recovery System and
Vent, Purge (Nitrogen purging) & Conde
em with valves
2.5.4.5 Battery Limits
DN 1400 BF gas will be tapped before



UPGRADATION OF B.F NO. 1 PAGE 2.44
Coal Dust Injection System
CDI unit will consist of following utility
systems such as flue gas supply system,
nitrogen supply system, BF/ Mixed gas
supply system, dust extraction system,
fire fighting system, cooli
ng water system for CDI units including but not limited
to pumps, valves, blowers/fans, pipe & fittings etc. required for all utilities and as
The scope of design, engineering, suppl
y erection, testing & commissioning shall
include but not limited to following items:
Flue gas supply system
tor, Combustion Air Fan,
BF Gas & Mixed Gas piping with N
instrumentation, electrics & utility pipi
ng work. Flue gases
will be generated
from hot gas generator and re-circula
ted through Condenser similar to the
existing system being installed for B.F No. 4.
Bag filters, Mill I.D. Fan, Stack and re
lated valves, instrumentation, electrics
DN 200 Nitrogen header at a pressure of 16-18 kg/cm
(g) is available at
Blast Furnace area near column A/29 fo
r catering need of B.F No. 4 & B.F
No. 1. DN 150 tapping with valve has b
een provided and kept in blanked
condition. Nitrogen from the tapping will be taken to B.F No. 1 along the
route followed by Nitrogen line going
for CDI of B.F No. 4 &. The same
will be connected with header for th
e existing Nitrogen vessels for CDI of
Further distribution of Nitrogen for
CDI will be done by Bidder as per
system requirement. All the PRVs
shall be duplex type & should be

UPGRADATION OF B.F NO. 1 PAGE 2.45
Air Conditioning & Ventilation System
for control room & MCC room as
Battery limit for all the utilities has been
detailed in the technical description
(Chaper-3) of respective utilities and all
jobs are included in the turnkey job for
providing utilities as per re
quirement of the system offered. The Bidders are
The following existing equipment are to
be dismantled from their existing



UPGRADATION OF B.F NO. 1 PAGE 2.46
Condensate extraction pumps with
drives and auxiliaries 2 nos.
Steam, condensate, water, instrument air piping, all fittings, all
Technological Structures includi
ng equipment and pipe supports,
All Electrical & Instrumentation sy
stem associated with TA#1 1 lot
2.5.6.2 Scope of Supply for Turbo-Blower Proper
Blower discharge gate valve (motor operated) 1 no.
Blow-off valve and silencer each having 100% capacity. The
Condenser 1 no.
Condensate extraction pumps with
drives and auxiliaries 2 nos.
Piping for steam, condensate, coolin
g water, cold blast air, blow-
Air compressors (1w+1s) along with dryers, receivers for pulse
Technological Structures including
equipment and pipe supports,
Heavy Duty Tube Axial fan base
d dry pressurized ventilation
system for new electrical building

UPGRADATION OF B.F NO. 1 PAGE 2.47
2.5.6.2 Battery Limits for New Turbo Blower
Main Steam line:
Temperature 475
Auxiliary steam line:
Pr. 10 to 18 kgf/cm
Temperature 300 to 360
Limit At one point 20 m
from New Turbo-Blower
Temperature 165
Header size = DN 100
Limit At about 20 m away
Suction air line Limit Totally new.
Cold blast line Cold Blast pr. 3.7 kgf/cm
Cold Blast temperature Bidder to indicate
Limit One header of OD 1200 x
10thk to be taken to connect
the cold blast line going to Blast Furnace#1 at
approximate distance of 60
m from new Turbo-Blower
Cooling water line Pr. 1.5 kgf/cm
Temperature 35
Limit At supply and discharg
For smooth and trouble free operation of el
ectrical and electronic equipment the
premises mentioned below shall be provi
ded with air conditioning and ventilation
system.
2.5.7.1 Air-conditioning System
All Control/ PLC Rooms shall be pr
ovided with Air-conditioning system.
However, some of the envisaged premises have been mentioned below:-
Sl.
No.
Premises System description
1 Extended Furnace
Package AC with accessories, with 50% standby



UPGRADATION OF B.F NO. 1 PAGE 2.48
2 CLCS Control Room Package AC
with accessories, with 50% standby
3 GCP Control Room Package AC
with accessories, with 50% standby
4 33 kV Control room Package AC with accessories, with 50% standby
5 Mudgun & Drilling
m/c room
Package AC with accessories, with 50% standby
6 PLC, skip drive room Package AC with accessories, with 50% standby
7. New CDI Elect. Bldg Package AC with accessories, with 50% standby
8. New Hydraulic room
equipments
Split AC with accessories
2.5.7.2 Ventilation System
The different Ventilation system shall be provided as per the requirement for the
enclosed working areas. However, some of the envisaged premises have been
mentioned below:-
Sl.
No.
Premises System description
1 Switch Gear room Dry Pressurized Ventilation System
2 Cable Basement Dry Pressurized Ventilation System
3 Cable vault Dry Pressurized Ventilation System
4 MCC room Dry Pressurized Ventilation System
5 Stove MCC room Dry Pressu
rized Ventilation System
6 Electrical room below Stove
MCC room
Dry Pressurized Ventilation System
7 CLCS Bldg Dry Pressuri
zed Ventilation System
8 GCP control Bldg Dry Pressurized Ventilation System
9 Mud-gun Control room (MCC
room)
Dry Pressurized Ventilation System
10 Primary Pump house Exhaust Ventilation System
11 Soft water plant building Exhaust Ventilation System
12 33 kV Transformer room Exhaust Ventilation System
13 6.6 kV Transformer room Exhaust Ventilation System
14 Battery Room Exhaust Ventilation System
MCC Room for CA Fan Dry Pressurised Ventilation

UPGRADATION OF B.F NO. 1 PAGE 2.49
Sl.
No.
Premises System description
Combustion Air Fan building Exhaust Ventilation
New CDI Elect. Bldg Dry Pressurised Ventilation
Cooling Water Pump House
for CDI
Exhaust Ventilation
Electrical building for New
2.5.7.3 The Air conditioning and Ventilation system



UPGRADATION OF B.F NO. 1 PAGE 2.50
extraction pumps, Blower discharg
e valves, NRV, Blow-off valves,
2.5.9.1-1 Technical Particulars of Pump
2.5.9.1-2 Technical Particulars of Diesel Engine
2.5.9.1-3 Technical Particulars of Cooling Tower
2.5.9.1-4 Technical Particulars of Heat Exchanger
2.5.9.1-5 Technical Particulars of So
2.5.9.1-6 Technical Particulars of Valves
2.5.9.1-7 Technical Particulars of Filters
2.5.9.1-8 Technical Particulars of
2.5.9.1-9 Technical Particulars of CA Fan
2.5.9.1-10 Technical Particulars of Bag Filters
2.5.9.1-11 Technical Particulars of Hot Gas Generator
2.5.9.2 Drawings/ Documents To Be Submitted
By The Successful Bidder For Approval
The bidder shall submit the following drawing/documents for Employers
Process flow diagram indicating the proposed Furnace cooling system.

UPGRADATION OF B.F NO. 1 PAGE 2.51
P&I diagram indicating the proposed
monitoring and control plan along
with list of instruments for cooling system.
Equipment disposition in various bu
ildings along with material handling
equipment.
GA drawings of all equipment and plants.
Pipe line routing within the new water



UPGRADATION OF B.F NO. 1 PAGE 2.52
List of electrical loads.
Blower characteristic curves
Turbine performance curves.
blower superimposing turbine.
Condenser performance curves.
Condensate extraction pumps
Schematic diagram showing terminal points.
GA drawing of the equipments show
Equipment layout in TG hall in different floors.
All pipe routine drawing (plan,
elevation and sections) for
steam/condensate lines, cold blas

UPGRADATION OF B.F NO. 1 PAGE 2.53
from the work site and inside the plan
t boundary. The entire debris shall be
removed without causing ex
Design



UPGRADATION OF B.F NO. 1 PAGE 2.54
2.6.5.2 Bidder shall be responsible for the proj
ect management of
erection work with
proper and adequate supervision for ensu
ring progress of refr
actory erection work,
Sl. No. Description
Quantity
To cater to the load of
proposed BF-1 a new 33/6.6kV
substation will be installed near existing LCSS-1 substation
after dismantling existing Dedusting System, all nearby
temporary sheds. Please refer Single line diagram no.
33kV relay & control panels Lot
33kV Isolator 2 nos.
12.5 MVA 33kV/6.9kV ONAN transformer with Nitrogen
system (NIFPS) and NGR
6.6kV Isolator 3 nos.
2 MVA 6.6kV/433V dry type transformer 3 nos.
ACDB 1 no.
RTU for provision of connect
ivity with existing SCADA
system of RSP. RTU will ha
ve interface with new 33kV

UPGRADATION OF B.F NO. 1 PAGE 2.55
Sl. No. Description
Quantity
Illumination system Lot
otection system Lot
33kV cables from proposed GIS switchboard to 33kV
33kV bus tubes from 33kV Isolators to 12.5 MVA
transformers
6.6kV cables, LT cables and
controls cables alongwith
33kV Power Source tapping Lot
One no. incoming 33kV Power source will be taken from
spare feeder available at s
of the 33kV switchboard of
CPP-I. 33kV cable alongwith
pilot wire cables & control cables from CPP-I up to the new
Second incoming feeder will be
taken from the spare feeder
available at 33kV indoor switc
hgear at new MSDS-V. 33kV
cable alongwith pilot wire ca
bles & control cables from
MSDS-V shall be laid in burie
d cable trench in soil up to
CRM and then it wi
ll be laid in the
6.6kV Power source arrangement for Closed loop system
In order to feed new HT pu
mps for Closed loop system,
6.6Kv switchboard at BF 1,2 &3 Pump house will be
extended through bus trunking arrangement and the new
panels will be located at the space available in front of
6.6kV Power source arrangement for CDI
i)
6.6kV power supply shall be
taken from existing 6.6kV
switchboard installed under CDI for BF-4. Outgoing feeders
are available to cater to 6.6kV loads under CDI for BF-1.
Bidders scope shall include
6.6kV cables and control cables
from Purchasers 6.6kV switchboard.
Tapping of 415V power source for LT loads of CDI unit
i)
415V power supply shall be taken from existing LT
switchboard installed under CDI for BF-4. Outgoing feeders
are available to cater to LT loads under CDI for BF-1.
Bidders scope shall include LT
cables from Purchasers LT
switchboard upto proposed MCC under the subject project.
MCC room will be installed in MCC room at new electrical
building for BF-1, CDI
Electrical system for skip
The drive motors of the proposed BF-1 Skip shall be AC
motors and shall be operated



UPGRADATION OF B.F NO. 1 PAGE 2.56
Sl. No. Description
Quantity
Converter Transformer and IGBT based AC drive (VFD)
system. New Converter transformers ( 2 nos.) shall be fed
from the proposed 6.6kV switchboard of BF-1 substation.
IGBT based Active front e
- Closed Loop Cooling system (CLCS) MCC
- Cast House Defuming MCC
- BF Proper and Dust Catcher MCC
- BLT MCC
- Stove MCCs ( 4 MCCs: 3 nos. for 3 stoves & one no.
common MCC)
- Stock House MCCs ( 3 nos)
- GCP MCC
-
- Heat Recovery system MCC
- Any other MCC as per technological requirement
Power distribution Boards ( PDBs)
Furnace auxiliary PDB
Programmable Logic controller
(PLC) with hot standby CPU
Stock House/ Charging PLC

UPGRADATION OF B.F NO. 1 PAGE 2.57
Sl. No. Description
Quantity
Closed Loop Cooling System PLC
GCP PLC
Cast house defuming PLC
Mudgun Drilling Machine system PLC
100% redundant I/Os shall be
provided for BLT PLC, Stock
For PLCs where 100% redundant I/Os have been
considered, 10% spare points wi
ll be provided in
each card
and 20% spare cards of each type will be considered
For other PLCs, 20% spare points will be provided in each
card and 20% spare cards of each type will be considered
PLC shall have bus based co
mmunication facilities with all
VFDs and intelligent MCCs.
VFDs for the mechanisms which require speed control and
for the conveyor motors wh
ich are rated 110kW & above
Electronic soft starting system
shall be provided for the
motors rated 110kW and above (except conveyor motors)
Electrical panels related to Hydraulic system,
Lubrication/greasing system, auxiliary relay panels, air
conditioning and ventilation systems
(These Panels will be fed from Cast House PDBs)

Stock level indicator panels
alongwith DC power supply
arrangement
Electrical Panel for hydraulic
operated Mudgun and Drilling
Machine system (with integral panel AC) comprising of the
Dedicated PLC control w



UPGRADATION OF B.F NO. 1 PAGE 2.58
Sl. No. Description
Quantity
Back up hard-wired relay
control (in case of PLC
failure).
HMI for real time and historical trending of
Electrics of Defuming Stations
(Transformer-Rectifier for
For CDI, Solenoid valves near
distributor shall be rated for
24 V DC. Necessary DC rectif
iers (working & standby
alongwith changeover facility) &
Distribution Board shall be
provided. The panel shall be located in available space in BF
1 furnace Control Room. 2 Nos. 240 V Power supply sources

Furnace Control Desk
GCP
Hydraulic mud gun and dri
ll machines (in mudgun
operating rooms in both cast houses).
m/c operation shall be consider
well as radio remote control
Local control station for all i
ndividual equipment for BF-1.
LCS for BLT system shall also be under the scope of this
Welding Distribution Boards ( WDBs)

Lighting transformers

UPGRADATION OF B.F NO. 1 PAGE 2.59
Sl. No. Description
Quantity

Electrical Panels/Starters
for Sump Pumps etc.

of the all the areas under
Cam limit switches, proximity switches, local isolating
MCCBs for cranes & hoists, Pu
ll Cord Switches, Belt Sway
Parallel redundant uninterrupt
ed single or three phase (as
necessary) power supply syst
em with VRLA maintenance



UPGRADATION OF B.F NO. 1 PAGE 2.60
Sl. No. Description
Quantity
room
2x10 kVA parallel redundant system at CLCS control
room
2x10 kVA parallel redundant system at GCP control
Audio- visual annunciation windows for all necessary
LED type Mimic at Furnace control room
Mimic at Skip Winch house for getting the position of skip
during manual operation
Supply & installation of all electrics pertaining to various
handling equipment like Cast House, Stove House & other
Cranes, Hoists, Pumps etc. for BF-1
The Cast house crane shall ha
ve Squirrel cage induction
motor with VFD drive
along with standby VFD drive
arrangement. Cast house crane shall have hardwired cabin
control and also radio remote control. The VFD panel shall
Supply, laying and termination of all 33kV cables, 6.6kV
cables, LT power & control, pilot wire cables, signal cables,
interfacing cables with existing system and special cables for
all items under the scope of work. All incoming cables for the
panels, outgoing cables from pane
The scope also includes Supply,
laying and termination of all
Power and control cables for the BLT system.
Cabling arrangement:
Preparation of route, cable in
stallation materials like MS
painted ladder type cable trays, Galvanised perforated cable
trays, Galvanised steel c
onduits, supporting materials for
tion materials, hardware &
accessories for cable terminating and jointing, cable fixing,
dressing, tag numbers, route ma
rkers, Over head walkable
Construction of Electrical buildin

UPGRADATION OF B.F NO. 1 PAGE 2.61
Sl. No. Description
Quantity

Shifting of existing 16 M
VA 33kV/6.9kV transformer
alongwith associated equipment
from present location (i.e
adjacent to Generator transforme
r room for Turbo Alternator
(TA) no.1) to a new transformer
project. This new transformer room shall be installed by
dismantling existing Electrical store near the existing
transformer rooms. Shifting of 16 MVA transformer includes
installation, testing and comm
issioning of the same. Required
modification in the existing transformer room shall also be
under the scope of bidder to su
itably install new MCC. The
facilities in the new transformer room shall be similar as
existing transformer room for 16 MVA transformer
Shifting of existing 33kV cab
les for incomer of 16 MVA
transformer to the new location of 16 MVA transformer.
Bidder shall assess the quantum of job for the same and
suitability of the shifting of ex
isting cables. In case the cable
length is short, additional shor
t length of cables shall be
jointed. New 6.6kV cables shall be under the scope from
outgoing side of 16 MVA transformer upto existing 6.6kV
switchgear.
All required cabling arrangeme
DC control panel for turbo bl
ower: One no. DC control panel
shall be provided for the emergency DC oil pump. 220V DC
power supply shall be taken from the existing DC source of
control panel shall be provi
backup control panel shall be
provided for manual remote
operation of the major drives. This backup control panel shall
be installed near the Turbo-Blower. The back-up control
panel shall consist of n
ecessary control switches,
pushbuttons, indication lamps of
LED cluster type, speed
Miscellaneous items
All PLC and field termination shall be through Marshalling
Sump pumps for the basement
of substations which are
Insulated PVC rubber mats for
laying in front of all new



UPGRADATION OF B.F NO. 1 PAGE 2.62
Sl. No. Description
Quantity
electrical panels.
Danger Boards and Shock Treatme
nt Charts at appropriate
Tools & tackles:
Numerical relay test kit. numer
ical relay test kit shall be
model no. MPRT-8430 of Megger make or its equivalent
in M/s Omicron make, with professional software &
accessories
Painting of all relevant installed equipment/ frame/structure
Dismantling & Related Work
Dismantling of existing electrical
equipment, cables, lighting
and other items which are becoming redundant after
Upgradation of BF No. 1 with
installation of new electrics;
are to be carried out in accordance with a Dismantling Plan.
The Plan is to be prepared by th
e Successful Bidder and to be
cleared by the Employer. The dism
antling plan must take care
of the equipment which are requ
ired to conti
nue in operation
The major equipment/ auxiliaries to be dismantled, listed and
handed over by the Successful
Bidder to the Employers
Existing Motor Control Centre
s, PDBs, Control desk,

UPGRADATION OF B.F NO. 1 PAGE 2.63
Sl. No. Description
Quantity
Existing Electrical system of Skip
Preparation of drawings a
nd documents and submission for

Arrangement of Construction Po
wer supply as mentioned in
For the Electrical & automation systems the design
engineering, erection, testi
ng & commissioning shall be
carried out by the Principal manufacturer (OEM) of the major
systems /equipment based on the technological requirements
provided by the Successful
bidder. Support of automation
spares for next ten years shall be confirmed from the OEM.
Battery Limits-Electrical
33kV Power Source tapping
1) One no. incoming 33kV Power source
will be taken from spare feeder
available at section-II (Cubicle no.
28 / 29 /30) of the 33kV switchboard of
2) Second incoming feeder will be taken fr
om the spare feeder available at 33kV
6.6kV Power source arrangement for Closed loop system
1) In order to feed new HT pumps for
Closed loop system, 6.6kV switchboard at
BF 1,2 &3 Pump house will be extended through bus trunking arrangement
and the new panels will be located at
the space available in front of existing
6.6kV and 415 V Power source arrangement for CDI
6.6kV and 415 V Power source for CDI shall be taken from existing



UPGRADATION OF B.F NO. 1 PAGE 2.64
415 V Power source arrangement for Turbo Blower
415 V Power source for Turbo blower
shall be taken from existing power
source for TA-1.

UPGRADATION OF B.F NO. 1 PAGE 2.65
Bill of materials
QAP
Bidder shall ensure that all other nece
ssary write-up, charact
eristics curves and
information required to fully describe the equipment are submitted.
INSTRUMENTATION & PROCESS AUTOMATION
The scope of work shall cover de
sign and engineering, manufacturing/
procurement, assembly, testing, software
development & simulation of system /
system components at works, packaging,
supply, transportation to site, handling
and storage at site, erec
tion, testing and commissioni
ng of Instrumentation and
Process control system, Telecommunication



UPGRADATION OF B.F NO. 1 PAGE 2.66
2.8.3


UPGRADATION OF B.F NO. 1 PAGE 2.67
CDI control room. The I/Os related to the new CDI system for B.F No.
1 shall be housed in the new electrical control room. The remote I/Os
related to the injection system w
ill be housed in the Furnace control
room.
Turbo blower PLC: A common PLC fo
r Electrical and Instrumentation
control of the Turbo blower process.
This PLC shall be housed in the
new control room of Turbo blower. A
dedicated digital controller shall
be considered for governor spee
UPS panels Existing Thermal control room
HMIs & servers Existing co
ntrol room at 7.5 m level
Engineering station Existing Instrumentation room above
control room
Level-0 instrumentation comprising of
primary sensors like, resistance



UPGRADATION OF B.F NO. 1 PAGE 2.68
Oracle- standard edition license. This
shall be installed in the two HMI
servers and shall be used to collect a
nd maintain historical data from the
Blast furnace level-1 system for communication with higher level system
One (1) no. 24 Channel
(Minimum)

UPGRADATION OF B.F NO. 1 PAGE 2.69
o)




UPGRADATION OF B.F NO. 1 PAGE 2.70
Furniture for control rooms and other
areas including operators chairs and

UPGRADATION OF B.F NO. 1 PAGE 2.71
The Bidder is required to furnish the following minimum drawings / documents in
Process & Instrumentation diagram
em architecture diagram with
interconnection of major components.



UPGRADATION OF B.F NO. 1 PAGE 2.72
Heat loss data.
Single line loop schematic diagrams

UPGRADATION OF B.F NO. 1 PAGE 2.73
Drawings submitted by the Successful Bidder shall be authenticated / signed by
2.10.4 The following drawings/ documents / data / catalogues shall be submitted in 10
r after approval by Employer:-
1) Erection/ Operation & Maintenance



UPGRADATION OF B.F NO. 1 PAGE 2.74
assuring the quality of equipment and work
manship at various stages. The Quality
Assurance Plan (QAP) and Quality Cont
rol Plan (QCP) shall be mutually
e Employer/ Consultant. Th
e same shall there after
form a part of the contract.
TRAINING
The Bidder shall make arrangement for tr
aining of Employers
personnel abroad
for 150 mandays, consisting of consultant
s, operating & maintenance personnel
from the following areas:
Hot Blast System
Gas Cleaning Plant
The training will be done to the modern
Blast Furnace Plant & its auxiliaries, Hot
blast system, CDI, GCP, Turbo Blower

UPGRADATION OF B.F NO. 1 PAGE 2.75
Pneumatic/ hydrostatic testi
individual equipment
Integrated pressure testing of furna
ce, stoves, hot blast main including
bustle pipe along with all associated systems
Destructive / Non-destructive testing of



UPGRADATION OF B.F NO. 1 PAGE 2.76
cluding supervisory manpow
er and other material
shall be provided by Successful Bidde

UPGRADATION OF B.F NO. 1 PAGE 2.77



UPGRADATION OF B.F NO. 1 PAGE 2.78
Working Volume, m
(indicative) 1450 (min)
/day 2.0
Sinter in burden, % 80
Fuel Rate (Coke Rate + CDI Rate), kg/tHM
CDI Rate, kg/tHM 100 (Operating), 150 (Design)
Hot blast volume at snort normal / (incl.
Oxygen enrichment), Nm
/min
Oxygen Enrichment of Blast, % 4
C 1100-1150 (Operating), 1200
(g) 1.8 (Operating); 2.0 (Design)

UPGRADATION OF B.F NO. 1 PAGE 3.1
TECHNICAL SPECIFICATION
BASIC DESIGN AND SITE CONDITIONS
Rourkela Steel Plant is located in the nor
th-western tip of Orissa and at the heart
of a rich mineral belt. It is well connect
ed by both railways and road transport.
The nearest railway station in Rourkela on the Howrah-Mumbai rail mainline.
Rourkela is very well connected with most
of the important cities of India.
The plant site is about 2
km(s) from Rourkela Railway Station. Blast Furnace
No.1 is the end furnace of BF Shop.
Bidder shall plan all the work under his sc
ope without affecting
2. Ambient Temperature 55
C (min.)
3. Relative Humidity 100% (max.)
4. Wind Load As per IS 875:1987(Part-3)
5. Earthquake Load As per IS 1893:2002(Part-1)
6. Atmospheric Condition Dust Laden
However, maximum temperature and maxi
mum relative humidity shall not occur
at the same time.
The nearby airports are Ranchi (173 km
), Bhubaneswar (378 km) and
Kolkata (413 km).
The site can be served by both Kolkata and Haldia ports which are approximately
413 km away from the site by rail.
Communication Facilities
Postal, Telegraph, Telephone,



UPGRADATION OF B.F NO. 1 PAGE 3.2
Useful Volume 1139
Working Volume 995
Throat Height 2200 mm
Stack Height 14900 mm
Belly Height 2400 mm
Bosh Height 3400 mm
Hearth Height 3600 mm
Bog Depth 1100 mm
Stack Angle 85
Bosh Angle 80
The following operating parameters have been achieved during 2011-12 in B.F
Item 2011 - 12
H.M Production, tpd 1360
/d 1.329
Oxygen enrichment, % 0.60
% Sinter in burden 66.81
Coke Rate, kg/tHM 529
/min. 1404
Hot Blast Pressure, kg/cm
(g) 1.05
(g) nil
After the proposed upgradation the design
& operating paramete
rs of B.F No. 1
Working Volume, m
(indicative) 1450 (min)
/day 2.0

UPGRADATION OF B.F NO. 1 PAGE 3.3
Sinter in burden, % 80
Fuel Rate (Coke Rate + CDI Rate), kg/tHM
CDI Rate, kg/tHM 100 (Operating), 150 (Design)
Hot blast volume at snort normal / (incl.
Oxygen enrichment), Nm
/min
Oxygen Enrichment of Blast, % 4
C 1100 - 1150 (Operating), 1200
(max) 3.3
(g) 1.8 (Operating), 2.0 (Design)
The furnace profile will be provided by
the Successful Furnace Builder based on
their design and technology and acco
rdingly B.F No. 1 will be upgraded
Furnace Designer / Builder may indicate th
eir best B.F profile and parameters
Typical projected raw material analysis
for use in Blast Furnaces at RSP are as
follows :
Raw Materials % Fe % SiO
% CaO
Iron ore 63.50 1.80 2.10 ---
Sinter 53.11 5.80 3.10 10.60
Quartzite --- 97.50 2.70 1.13
Coke : Ash 18%
8.23 CSR 63.30
78.01 CRI 19.60
Pulverized Coal
Item Quality Item Quality
Moisture % (avg.) 2.0
VM, % 22.0-32.0 FSI 4.0 max.
Sulphur % --- HGI 50 min.



UPGRADATION OF B.F NO. 1 PAGE 3.4
DISMANTLING
The dismantling work shall be carried out with utmost care so that the adjacent
structures which are not to be dismantle

UPGRADATION OF B.F NO. 1 PAGE 3.5
The design criteria for civil
engineering work shall be in accordance with this




UPGRADATION OF B.F NO. 1 PAGE 3.6
Apart from the operating loads indicat
ed by the equipment manufacturers,
the design of buildings and structures shall be based on dead and imposed
: 875 Part 1 to Part 5 1987.
Concentrated and uniformly distribute
d live load on floors and platforms
shall be considered depending upon th
e usage and in accordance with a
maximum expected process requirements, to be indicated by the equipment
manufacturers. When the loads are mova
ble, they shall be so placed as to

UPGRADATION OF B.F NO. 1 PAGE 3.7
respective IS codes as well as the s
tipulations recommended by equipment
manufacturer.
The design of buildings and structures
shall take into account the loadings
due to future extension of units and installation of additional equipment,
where necessary, in future in the units.
Permissible Stresses
Allowable stresses for all re
Soil investigation & survey
is being carried out through
separate package. Bidder
may obtained Final / interim report / bore hole
log data, as may be status of report,
from the Purchaser for reference before submitting their Bid.
A copy of Final soil investigation &
survey report will
be handed over to
Successful Bidder for reference with resp
ect to planning & de
sign at the time of
The foundations for structures and equipm
ent shall be proportioned to resist
the worst conditions of loadings and sh
all be generally de
signed as per the
Equipment requiring special foundations as a result of dynamic, unbalanced
forces, shall be designed as per IS:
2974 (Part-1) 1982,
(Part-3) 1992 &
(Part-4) 1979. The Bidder is require
d to design and construct such
foundation free of objectionable resonan
ce, vibration or rocking. In the
event that such equipment is installed above ground level, the supporting
structure and foundation shall be investig
ated also for natural frequency and
designed properly to avoid resonan
ce and amplitude shall be within
allowable limits.
The depth of foundation shall be
Based on the data on subsoil and underground water level adequate
precautions shall be taken for design of foundation and underground
structure. All underground structures
such as basements, cellars, tunnels,



UPGRADATION OF B.F NO. 1 PAGE 3.8
floatation shall be taken. All water reta
ining structures sh
all be designed as
per provisions of IS: 3370 Part 1 &
2 1965 & Part 4 1967. However, in
The exposure condition shall be Modera
te for normal type of structures
(open foundations and production buildings
) and shall be severe for under

UPGRADATION OF B.F NO. 1 PAGE 3.9
All brick and rubble masonry walls shall be
plastered on both sides. Thickness of
plaster shall be minimum 20mm for exte
rnal surfaces and 15mm for internal
surfaces of walls. Thickness of plaste
r for ceiling shall be minimum 10 mm.
Cement sand mortar mix for
All outside plastered surfaces of masonr
y walls shall be applied with cement
based paint of approved make and quality
and to be applied as per manufactures
specification.
Inside surfaces of masonry walls shall be
treated with white wash/colour wash or
paint of approved quality, make and colour
, or to be tiled as the case may be, on
the basis of technological and/or aesth



UPGRADATION OF B.F NO. 1 PAGE 3.10
are to be connected to the existing ones, the Bidders shall carry out the required
Generally minimum earth coverage of
one meter shall be provided over
underground drainage pipelines unless the

UPGRADATION OF B.F NO. 1 PAGE 3.11
All paved areas shall be with flexible t
ype of construction. Thickness of different
layers of materials shall
be adequate for traffic intensity and imposed loading.
Sub-base 150mm thick consolidated moorum filling on
compacted soil
Base 250mm thick boulder soling blinded with
moorum
Macadam (WBM)
150mm thick water bound moorum above
all be drained by provision of drain.
Sufficient areas shall be paved around plant buildings so as to facilitate parking of
vehicles. Paved areas shall have same t
ype of construction as roads and the top
connecting roadways with a cross slope of
approximately one per cent.
ary buildings minimum 1500



UPGRADATION OF B.F NO. 1 PAGE 3.12
frequency corresponding to operating
speed and critical speed. Vibration
amplitude shall be calculated at all
bearing locations a
permissible limits as per IS/ ISO
10816-Part2, 2001or as specified by the
equipment manufacturer. Transient anal
ysis shall be carried out at each
fundamental frequencies of the top deck
and the amplitude of vibration shall
be within the permissible limit. The columns/foundation shall also be
checked for accidental loads/ failure load as provided by equipment
manufacturer.

UPGRADATION OF B.F NO. 1 PAGE 3.13
DIN 2089 Helical compression springs
out of round wire and rod;
DIN 2096 Helical compression springs
out of round wire and rod;
quality requirements for hot formed compression springs
VDI 2060 Criteria for assessing the st
ate of balance of rotating rigid
The design calculations
for all the buildings a
nd foundations including
The Bidder shall prepare general layout
drawings giving salient levels and
dimensions of the whole area s
howing all over ground and underground
services and facilities, buildings, road



UPGRADATION OF B.F NO. 1 PAGE 3.14
The Bidder, before submitting
his tender, shall visit the site and ascertain the local
conditions, labour rules, availability of c
onstruction materials, traffic restrictions,
all obstructions in the area a
nd also ascertain all site
soil conditions and shall allow for any extras
likely to be incurred due to all such
conditions in his quoted prices. After the
award of work no additional claims will
be entertained on these accounts under an
y circumstances, whatsoever, from the
successful Bidder.
The successful Bidder shall set out and level the work and will be responsible for
the accuracy of the same. He is to provi
de all instruments and proper qualified

UPGRADATION OF B.F NO. 1 PAGE 3.15
Engineer. Such checking, if
any, shall not, however, re
The Bidder shall provide and maintained at his own cost, pumps and other
equipments to keep the works free from
water and continued to do so until the
The Bidder shall keep the site
clear on a continuous basi
The Bidder shall protect all bench mark,
and reference pillars /lines including
ground water gauges from damage or movement during working. In case of any
damage the Bidder shall have to restore th
e same to its original condition at his
Unless otherwise mentioned in the specifi
le codes /standards
as published by the Bureau of Indian Sta
ndards on the date of
award of contract
shall governed the work in respect of
design, workmanship, quality and properties
of materials, method of tes
ting and other pertinent features. In case of variance
The Successful Bidder shall strip the surface of the site prior to the
commencement of excavation to remove ve



UPGRADATION OF B.F NO. 1 PAGE 3.16
Excavation for foundations and Trenches
The Bidder shall excavate at various leve
ls including hard
rock to remove
materials of any nature or description, which may be encountered. Side
slopes,
The Bidder shall excavate at various leve
ls including hard
rock to remove
materials of any nature or description, which may be encountered. Side
slopes benching and/or shoring/strutti
ng for excavation work shall be sole
responsibility of the Bidder. The bed
of the excavation shall be properly
dressed and made level. All mud and sl
ush shall be removed before taking

UPGRADATION OF B.F NO. 1 PAGE 3.17
caused to the work in progress in the ar
ea or to other agencies working in
the area or cause damage to property and structures nearby.
Back Filling
Suitable materials obtained from excava
tion of foundations sh
all be used as
far as possible for back filling. Earth
used for filling shall be free from
organic and other objectionable matter.
All clods of earth
shall be broken or
removed. If sufficient amount of suitable
materials are not available at site
ed by Standard Proctor Test. Tests
shall be conducted by the Bidder as di
rected by the Purchaser at his own
cost.
Removal of heaps & Mounds
Immediately upon completion of each phase
of work, the Bidder shall at his
own cost clear the mounds or heaps of
earth which may have been raised or
made and remove all earth and rubbis
h which may have become surplus in
the execution of works, as directed.
Filling with sand
uniform horizontal
not exceeding 200 mm in thickness with approved river sand and each layer
to be watered and compacted mechan
ically to a well compacted mass.
Cement



UPGRADATION OF B.F NO. 1 PAGE 3.18
Cement: Ordinary Portland cement shal
l conform to IS 269-1989 / IS 8112-
1989 and Portland blast furnace slag cement shall conform to IS 455-1989.
Soundness test is to be carried out on cement samples from time to time.
increased during monsoon period.
Aggregates
All aggregates shall conform to IS
383-1970. Fine aggregates shall be
approved river or pit sand. Coarse a
ggregates shall be approved crushed
stone. Aggregates shall be clean and fr
ee from any foreign material. Test on
aggregate shall be carried out from time
to time to ascertain the suitability of
Reinforcement in general shall be of tested quality. Cold twisted steel bars
or TMT bars conforming to IS 1786-
1985 as shown in dr
awings shall be
free from oil paint and rust coatings
. However, MS r
ound bars conforming
to IS 432-1982 or IRC mesh fabric re
inforcement conforming to IS 1566-
1982 can also be used if specifically
required and shown in the drawings.
The material for shuttering shall be
steel plates as
wooden planks as per the requirement.
Jointing materials
All rubber and PVC water stops joint fille


UPGRADATION OF B.F NO. 1 PAGE 3.19
456-2000 and recommended guidelines in SP: 23-1982. The minimum
Over the full period of construction, the
Bidder shall carry out works tests of



UPGRADATION OF B.F NO. 1 PAGE 3.20
number of specimen to be tested and
their criteria for acceptance shall be
according to IS: 456-2000. Frequency of wo
rk tests shall be as per IS:456-2000.
Workmanship shall conform to IS:
ement shall be
free from loose mill scale, rust, oil,
All embedment shall be accurately set and rigidly fastened. Anchor bolts

UPGRADATION OF B.F NO. 1 PAGE 3.21



UPGRADATION OF B.F NO. 1 PAGE 3.22
Compaction
Level pads

UPGRADATION OF B.F NO. 1 PAGE 3.23
out where required shall be
used in accordance with the me
thod specified by the manufacturer.
The grout must not dry out after it is placed in position. The surface shall be
Tolerance is a specified permissibl
e variation from lines, grades or
dimensions given in drawings. No to
lerances specified
for horizontal or
vertical building lines or footings shall be construed to permit encroachment
beyond the legal boundaries. Unless othe
The term `shuttering' shall include all centering and form work required to



UPGRADATION OF B.F NO. 1 PAGE 3.24
and all items such as planking, lagg
ing, walling, moulds, covers, cross
The minimum period for removing form
Formwork shall be so designed that
the side of beams and slabs can be
removed without disturbing soffit forms
and their supports. Props and supports
shall allow accurate adjustment of th
e formwork to line and level and be
capable of being removed in an approve
d sequence without causing any injury

UPGRADATION OF B.F NO. 1 PAGE 3.25
Standard form ties, clamps, bolts, insert
All rubbish shall be removed from the in
terior of the formwork, and inside of

The formwork and/or mould for Pre-cast co
ncrete units shall be made of metal
and true to shape and dimension of th
e finished product as indicated on the
drawings. The moulds shall be close jo
inted and perfectly smooth with joints
caulked to prevent leakage of cement
slurry. The moulds shall be of rigid
construction to prevent distortion and bulgi
ng of sides and base. The moulds shall
be designed with suitable fastening to allo
w them to be struck off without injury
to the casting. The moulds shall generall
y be vibrated on a mechanically operated
All pre-cast members shall be marked in
a manner approved by the Engineer in a
conspicuous place, with date of manuf
acture and marking number. The upper part
of the member shall be marked
Erection





UPGRADATION OF B.F NO. 1 PAGE 3.26
Cement
Cement used shall conform to IS
269-1989 / IS 8112-1989 or IS 455-1989.
The sand used shall be of approved qua
lity river or pit sand and it shall
conform to IS 1542-1992 for plaster a
nd to IS 2116-1980 for masonry mortar.
Sand for the mortar shall be evenly graded from coarse to fine and shall be free
from loam, clay, dust and any ot
her organic or foreign matter.
Admixtures/Plasticisers
Admixtures/plasticiser of approved make
and quality may be allowed in the
mortar, if permitted by the Engineer.
Water
Water shall be clean and of potable quality.
The proportion of cement and sand for mo
rtar shall be as specified in the
technical specification/drawing.
Workmanship
The workmanship shall conform to IS
2250-1981 for preparation of masonry
The cement and sand shall be proportioned by volume in gauge boxes and
thoroughly mixed dry. The water shall be
added by sprinkler just sufficient to
make a stiff and workable paste. In case
of mechanical mixing, the mortar shall
be mixed back and forth for at least
10 minutes with addition of water.
Mortars shall be used within one hour of
the first contact of cement with water.
All materials remaining after this peri
od shall be discarde
d. Mortars, which

Cement Mortar
Cement mortar shall be as specified
The brick used shall be of class
5 designation conforming to IS 1077-1992.
Brick shall be whole, sound, well burnt,
and free from cracks, square and well
shaped, uniform in size and shall emit a clear ringing sound when struck. The
compressive strength of brick shall be minimum 5 N/mm

UPGRADATION OF B.F NO. 1 PAGE 3.27
Scaffolding
Scaffolding shall conform to IS 2212-1991
and shall be designed to withstand
The Bidder shall carry out work in as
clean a manner as possible and shall
remove excess materials and mortar dr
oppings and rubbish, daily. Where brick
walls and stone masonry are to receive pl
aster, the joints shall be cleaned of
excess mortar and raked to a depth of
12 mm and the surface shall be brushed
clean.
Workmanship
The Bidder shall carry out the whole of
the brickwork in a uniform manner
according to IS 2212-1991. All the brick shal
l be kept under water till they are



UPGRADATION OF B.F NO. 1 PAGE 3.28
Plaster Work

Mortar for plasterwork shall be as
specified in Clause 3.4.12.6 of this
specification.
Workmanship
All plasterwork shall be carried out
according to IS 1661-1972. The thickness
and proportion of cement plaster shall be
as specified in
the thickness of plaster is 20 mm or
more, it shall be done
in two operations
(coats).
The surface to be plastered shall be
cleaned of all extraneous matter and
rubbish. Brickwork joints shall be

Lime
White wash shall be prepared from sh
ell (fat) lime conforming to IS 712-1984.
Gum and blue pigment
Gum and blue pigment for white wash sha
ll be of best quality and of approved

UPGRADATION OF B.F NO. 1 PAGE 3.29
Water
Water shall be clean and of potable quality.
Paints shall conform to relevant Indi
an Standards and shall be of approved
brands. Only ready mixed paints shall
be used for the work, unless otherwise
approved by the Engineer. The materi
als for succeeding coats on any one
surface shall be product of the same manu
facturer supplying the first coat for
Aluminum paint shall conform to IS 2339-1963.
Brushes shall be of type and size suit
able for the work, conforming to IS 487-
White Washing And Colour Washing
Slaking of lime shall conform to IS 1635-1992. The lime shall be placed about
300 mm deep in a drum with about 1200
mm deep water standing in the drum.
Lime shall be added to the water and not water to the lime. The lime in water



UPGRADATION OF B.F NO. 1 PAGE 3.30
first stroke and horizontal
stroke from left to ri
ght followed by stroke from
right to left. Each coat must be allo
wed to dry, before
the next coat is
Cement paint shall be of approved brand a
nd quality. It shall be applied strictly
in accordance with the manufacturer's instructions.
Before painting is commenced on a surface, all dirt, oil, grease, effloresce
kept stirred during
use and no paint,
which has been mixed for a period longer than one hour shall be used.

UPGRADATION OF B.F NO. 1 PAGE 3.31
Application
The cement paint shall be applied in two coats. After the first coat of paint
has hardened sufficiently it shall be
cured by keeping the surface damp for
Ready mixed paint
Only ready mixed paints of approved br
ands shall be used. The product shall
be such, when applied, it shall spread evenly in a thin coat and flow on
smoothly and shall dry quickly forming
a tough durable film without showing
The surface of steelwork to
be painted shall be cleaned
free of dirt, oil, rust,
mill scale and be thoroughly dry before
painting. Cleaning, degreasing, de-
rusting and de-scaling wherever necessary
shall be carried
out as specified
The surface of woodwork to be painte
d shall be cleaned and rendered dry,
free of dirt, grit and grea
se and shall be rubbed sm
ooth with the appropriate
quality of sand paper. All knots patche
s and sappy spot shall be touched up
with shellac varnish.
Painting steel work
Painting of steel work shall be carrie
d out as per general specification for
After the primer coat has dried, nails, holes, cracks and the like shall be filled
up with approved wood putty and the su
rface finished smooth. The type of
intermediate and finish coat shall be as specified in the technical specification
or on drawing. The surface shall be rubbed
smooth before application of each
coat. Each coat shall be allowed to dr
y before the succeeding coat is applied.
Finished surface shall have no brush marks and shall be uniform in colour.
Lime punning
Work included



UPGRADATION OF B.F NO. 1 PAGE 3.32
The Successful Bidder shall furnish ma
terials, labour, plant, equipment and
Lime: Lime shall conform to IS 712-1984.
The proportion of lime punning shall be thr
ee parts of lime and one part of very
fine sand unless otherwise specified. One part of lime shall be made of one part
of slaked stone lime and one
part of slaked shell lime.
Slaking of lime and preparation of
putty shall conform to IS 1635-1992. The
lime shall be placed about 300 mm deep
in a drum with about 1200 mm deep
water standing in the drum. Lime shall be
added to the wate
r and not water to
lime. The lime in water shall then be vigorously stirred. Lime shall be
One part of freshly slaked stone lime and
one part of freshly slaked shell lime
shall be thoroughly mixed with water to bri
ng it to the consistency of cream. It
shall then be left to settle for at leas
t one week. Water shall
then be drained off
from the top leaving a paste of lime. The paste shall be well stirred to form a
homogenous mass and strained through a cl
ean cloth. Lime thus prepared and
very fine sand shall be thoroughly mixe
d in the proportion specified and water
shall be added to make a paste of desired consistency.
Workmanship
The plaster shall be allowed to dry
The lime punned surface shall be cured
by adequate watering for a period of
Waterproofing of roof surface
Work Included
The Bidder shall furnish materials, labour,
On roof top 4mm thick
Atactic Polypropylene modified plastomeric bitumen
with glass fiber reinforcement (minimum 50gsm), finished on
both sides with a thermo fusible hi

UPGRADATION OF B.F NO. 1 PAGE 3.33
(HDPE) film and mineral finished
on top surface (MOPLY FP MINERAL 4mm
of TEXSA INDIA Ltd. or e
quivalent) Laying of the membranes shall be done by
manufacturers authorized a
pplicators only. The cost incl
udes cleaning of the roof
surfaces and filling of the joints, micro-le
veling, cutting & filling of chases in
brick wall / RCC for termination of memb
rane on vertical faces and necessary
overlaps of the membranes at the joint as
per manufacturer sp
in drain mouth and in gutter.
Damp proof course
Work included
The Successful Bidder shall furnish materi
als, labour, plant, equipment and tools
Cement: Cement shall conform to IS 269-1989 or IS 455-1989.
Aggregates: All aggregates shall co
nform to IS 383-1970. Fine aggregates
shall be approved river
sand or pit sand. Coarse
aggregates shall be
approved stone chips of size not exceed
ing 6 mm. Aggregate shall be clean
and free from any foreign material.
Waterproofing compound: It shall
be of approved quality and make.
Water: Water shall be clean and of potable quality.
Bitumen: Bitumen shall conform to IS 3384-1986.
Unless otherwise specified in the technica
l specification, the damp proof course
shall be 40 mm thick with 1:1.5:3 conc
The masonry surface shall be levelled and
joints shall be raked to receive the
damp proof course. Damp pr
oof course shall be provide
d at positions shown on
the drawings. It shall be laid for the full width of the wall. The top surface shall be
kept rough or ribbed for proper adhesion
with the mortar for masonry coming
over it. All other surfaces of the damp pr
oof course shall be
finished fair and
Work included
The Bidder shall furnish materials, labour,
Cement: Ordinary Portland cement
shall conform to IS 269-1989 &
Portland blast furnace cement shall conform to IS 455-1989.



UPGRADATION OF B.F NO. 1 PAGE 3.34
Aggregates: All aggregates shall co
nform to IS 383-1970. Fine aggregates
Cement waterproofing compound: A
ll cement water proofing compound
shall be of approved quality.
Solvent less resin: High build polymeric surfacing which forms a thick
resilient and flexible membrane on conc
Waterproofing shall be carried out as pe
r the manufacturer's specification and as
stated below:
The sub-base of the underground struct
ure shall be cleaned of all dirts
and kept dry by continuous pumping
of water. 20 mm thick plaster with
cement sand mortar 1:3 mixed with
cement waterproofing compound as
per manufacturer's specification sha
The plastered surface shall then be
painted with two (2) coats of
approved solventless resin to form a
thick resilient and
flexible resinous
membrane over the plastered surface.

UPGRADATION OF B.F NO. 1 PAGE 3.35
Work included
The Bidder shall furnish materials, la
bour, plant, equipment and tools to
all be granite, tr
ap, basalt, or similar hard stone
as approved by the Engineer
. Stone shall be free from
cavities, patches of soft



UPGRADATION OF B.F NO. 1 PAGE 3.36
Workmanship
The sub-grade shall be dressed to correct
level and shall be
proper consolidation befo
The stones shall be placed absolutely
close to each other. The specified
thickness shall be made up in one laye
r only. The crevices between the stones
shall be hand packed with stone balla
sts which shall be hammered into

Cement
Cement shall conform to IS 269-1989 or IS 455-1989.
Aggregates
The aggregates shall conf
orm to IS 383-1970. Fine aggregates shall be
approved river or pit sand. Coarse a
ggregates shall be
approved broken
stone of size 12 mm and down.
Water
Water shall be clean and of potable quality.
Glass strips used shall be 2 mm thic
k and the depth will be equal to the
Colouring pigment
Generally workmanship shall conform to IS 2571-1970 -Code of Practice for

UPGRADATION OF B.F NO. 1 PAGE 3.37
divided panels as specified below. The
thickness shall be as indicated in the
Technical Specification/drawing and the
As soon as the surface has hardened, it sh
all be kept continuously moist for at
by impounding water on it.
Work Included
The Bidder shall furnish materials, labour,
plant, equipment and
Cement: Cement shall conform to IS 269-1989 or IS 455-1989.
Coarse aggregates: It shall be of appr
oved broken graded
stone of size 10 mm
and down, conforming to IS 383-1970.
Sand: The sand shall be approved river or pit sand shall conform to IS 383-



UPGRADATION OF B.F NO. 1 PAGE 3.38
Floor hardener: It shall be
of best quality heavy duty metallic hardener -Ironite
Water: Water shall be clean and of potable quality.
The proportion of mix for gra
nolithic bedding shall be 1 pa
rt of cement, 1 part of
sand and 2 parts of granite chipping. The
mix for the floor hard
ener shall be in
accordance with the manufacturer's specification.
Workmanship
The thickness of granolithic finish shall be 25 mm and shall be laid in
accordance with IS 5491-1969 -Code of Prac
tice for laying in-situ granolithic
divided panels and evenly well tamped
into place, screeded and lightly floated to
required levels. No dimensions of a
panel shall exceed 2 m.
When the granolithic finish has partia
lly dried, approved floor hardener mix
shall be applied on the granolithic finish
in two or more coats and finished
evenly with a trowel. Each coat shall be
applied before the pr
evious coat dries.
Workmanship for floor hardener fini
sh shall conform to manufacturer's
specification. The thickness of the fl
oor hardener toppi
ng shall be 15 mm
minimum.
The finished surface after hardening shall be cured for a minimum period of
seven (7) days by impounding water on the finished surface.
Work included
The Bidder shall furnish materials, labour,
Plain or coloured terrazo cement tiles:
The terrazo tiles shall conform to IS
1237-1980. They shall be of approved col
our and size. The type, quality,
distribution and size of marble chips sh
Cement: Cement shall conform to
IS 269-1989 or IS
455-1989. White or
coloured cement shall conform to the requirements specified for cement in the

UPGRADATION OF B.F NO. 1 PAGE 3.39
pit sand and shall conform to IS 383-
Lime: Hydraulic lime shall conform to IS 712-1984.
Pigment: Pigments used for colourin
g cement shall conform to IS 2114-1984.
Water: Water shall be clean and of potable quality.
to damp, sun, rain, accidental inju
Workmanship for laying Terrazo tiles
Generally workmanship for laying tiles shall conform to IS 1443-1972 -Code of



UPGRADATION OF B.F NO. 1 PAGE 3.40
with the point of a trowel and any
loose cement, dirt or dust in the
joints shall be removed.
After fixing of tiles the flooring shall be allowed to mature
undisturbed for a period of seven (7) days. Polishing shall be
commenced only after the floor as we
ll as the joints have dried out.
The floor shall be polished by machine in three operations by expert
For second grinding : 120 to 150
For final grinding : 220 to 350
Sufficient quantity of water shall be
continuously used when polishing
to prevent scratching. After polis
hing the floor shall be thoroughly
washed clean and dried. When dry, th
e floor shall be covered with oil
free and dry saw dust. Prior to ha
ndling over of building to the
Employer, the saw dust shall be removed and floor shall be washed
clean with dilute oxalic acid soluti
on and dried. Floor shall then be
finally polished with machine fitted
with hessian bobs or felts until the
Skirting and dado shall be fixed only af
ter laying the tiles on the floor.
Where tiles are to be fixed on walls,
the portion of the wall to be so

UPGRADATION OF B.F NO. 1 PAGE 3.41
the building, the skirting and dado shall be cleaned with dilute oxalic
White Glazed Vitreous Tile in Dado
Work Included
The Bidder shall furnish materials, labour,
White vitreous tiles: The white vitreous
tiles shall be flat and glazed on the top
surface. They shall be generally 150 mm
x 150 mm in size with a thickness of
about 5 mm unless otherwise approved by
the Engineer. They shall conform to
IS 777-1988 in all other respects. The Bi
dder shall submit to the Engineer for
his approval samples of tiles which he pr
oposes to use in the work and all tiles
used shall be similar to the approved samples.
Ordinary or white portland cement: The
cement shall conform to IS 269-1989
Sand: The sand used shall be of approved
river or pit sand, conforming to IS
Water: Water used shall be clean and of
potable quality as per Clause 4.3 of IS
Workmanship
The tiles shall be laid on 19 mm thick
bedding of (1:3) cement sand mortar.
Before laying each tile shall be covered on the back side with neat cement slurry
and glue (araldite) and fixed to the bedding mortar. The tiles shall be gently
tapped to the bedding mortar with a woode




UPGRADATION OF B.F NO. 1 PAGE 3.42
Plate glass
Where plate glass is specified for the work, it shall be of thickness as specified
with a permissible tolerance of 0.5 to
0.8 mm for polished plate glass. The
transparent type glass shal
l have polished surface gi
ving clear a
Putty
Putty for use on wooden frames shall c
onform to IS 419-1967 and putty for
use on metal frames shall conform to IS 420-1953.
Workmanship
Glazing of metal doors, windows and ventilators shall conform to IS 1081-
1960 and glazing of timber doors, windows and ventilators shall conform to IS
All glass shall be cut according to th
e sizes required as per drawings. Glass
shall be delivered to site in cut si
zes bearing the manufacturer's name/trade
mark and the quality, thickness and unit we
ight shall be clearly marked on the
packages.
The method of glazing in each case shall

Steel doors, windows and vent
ilators: Steel doors,
windows, ventilators and
their fittings for residential and office buildings shall conform to IS 1038-
Steel doors / Air tight steel doors for i
ndustrial buildings shall be made as
per the drawings specified by the purchaser.
Steel windows for industrial buildings
shall conform to IS 1361-2000 and
External doors shall be
provided with threshold as shown in IS 1081-1960

UPGRADATION OF B.F NO. 1 PAGE 3.43
Unless otherwise specified, coupling secti
on shall be of mild steel. Handles,
peg stays and pivots shall be of lead
ed tin bronze (gun metal). Hinges for
side-hung shutters shall be of projec
specified. Weather bars shall not be
provided unless specifically indicated
on the drawings. The type, size, number and position of fixing lugs shall
conform to IS 1038-1983. The steel doors,
windows and ventilators shall be
painted with one coat of red oxide zinc chromate primer, conforming IS
2074-1992 before they are fixed. Final pa
inting shall be done with two coats
of ready mixed approved flat oil paint of approved colour
Structural steel materials
Workmanship
Steel doors, windows and ventilators shal
l be fixed plumb in line and level.
Fixing and glazing of metal doors, wi
s shall be in
accordance with IS 1081-1960
ng and glazing of metal
Rolling Shutter (Hand Operated a
nd Mechanical Gear Operated)
Rolling shutters shall be fabricated



UPGRADATION OF B.F NO. 1 PAGE 3.44
The locking arrangement shall consist of sliding bolts at both ends of the
bottom plate fitted to engage with suitable receiving pockets at the bottom of
Unless otherwise specified, for overall
area of rolling shutters upto 8 sq.m.

Anodized aluminum sections of `IN
DAL' extrusions or of any other
approved equivalent. Minimum wall
thickness of the aluminum box
section frames shall be 3.18 mm.
Glass shall be 5.5 mm thick, clear sh
All works shall be fixed straight an
d leveled, so as to guarantee perfect
working of all components. Assemb
ling of components and fixing of
frames shall be as per the manufact
urer's specification/instructions.
False Ceiling
False Ceiling with coloured aluminium strip modular panels

UPGRADATION OF B.F NO. 1 PAGE 3.45
Suspension systems:
The suspension systems shall be concealed and fully adequate for
ngs, suspenders shall be either
galvanised or painted as per ma
nufacturer's specification. The
whole of the ceilings shall be firmly and securely fixed against the
walls.
The suspension system shall incl
ude all necessary supports for
light fittings, ventilation grills, etc.
The acoustical/thermal insulation
where required shall be of non
combustible, resilient, flexible a
nd resin bonded mat of fibre glass
of suitable thickness and qualit
y to cater to
requirement.
Workmanship:
All ceiling panels shall be fixed in
accordance with the instructions
of the relevant manufacturer.
All abutments, perimeter of cut edge
s shall be neatly finished with
edge trimmer as per details
of the relevant manufacturer.
Standard aluminum false ceiling with
anodised aluminum T-
ceiling system.
Particle board ceiling tiles shall be
un-veneered teak wood particle
board bonded with BWP grade phe



UPGRADATION OF B.F NO. 1 PAGE 3.46
The acoustical/thermal insulation where required shall be as
Workmanship
Entire ceiling system including suspen
sion arrangement, frame work of
grid system, levelling of false ceilin
g, panels, alignment of light fitting
and ventilation grills sha
ll be carried out as pe
r the instruction of the
relevant manufacturers.

Floor Jacks: The jack shall be ma

UPGRADATION OF B.F NO. 1 PAGE 3.47
anti-static property similar to "Anstat" of Premier Vinyl Flooring
Limited or any other approved equivalent.
Workmanship
Entire workmanship shall be carried
out in strict accordance with the
specification. Rigidity, steadiness and
levelling of the false floor system
shall be ensured. Painting work for w
ood surfaces, floor and walls, fixing
The material, design and workmanship shall be as per MORTH standards and
specifications.
The material, design and workmanship shal
l be as per Indian
Railways standards
STRUCTURAL WORK
The Successful Bidder shall carry out the



UPGRADATION OF B.F NO. 1 PAGE 3.48
In the design of BF Shell thermal load sh
other loads as per ASME Boiler Code se
ct VIII, Div 1, 2001&
sect VIII, Div 2,
onform to IS: 875, Part I, 1987
Live load shall generally
conform to IS: 875, Part II,
1987 in the absence of any
load indicated by the manufacturer of the equipment.
Dust load of 50 kg/sqm on roofs shall be c
onsidered in Blast Furnace, Cast House
and in other areas where there is possibil
ity of accumulation of dust on roof. Dust
the uniform live load specified.
Wind load on structures shall genera
lly conform to IS: 875, Part III, 1987.
Seismic forces shall generally conf
orm to IS: 1893, Part-1-2002 and IS: 1893,
Structural steel work shall be of welded
construction as far as
possible. Necessary
provision in the design shall be kept
for temporary loads, which are expected
during erection and maintenance of equipment
Type of Structures
lded beam column type construction. Steel
structures shall generally be fabricated at shop according to the assembly
requirements.
Splices in structures required for transportation, assembly and erection facilities
The support structures shall be designed fo
r adequate rigidity and stability in both
the directions.
Normally rigidity shall be provided by fi
xing the column base

UPGRADATION OF B.F NO. 1 PAGE 3.49
All openings on platforms shall be either
covered with steel removable covers or
Connection System of Structural Steel Members
Minimum weld size is 6mm
All structural steel (except for Four Post
er Column support) shall conform to IS:
2062-2011, grade as applicable
. The Bidder shall submit
the test certificates
conforming to appropriate sta
ndards for all steel material
s used in fabrication. All
structural steel shall be free from rust,
scales, lamination, cracks, fissures and
other surface defects.
For major elements of Four Poster Co
lumn Support SAILMA-350/450 grade steel
may be used.
Chequered plates shall conform to IS: 3502-1994.
Bolts and Nuts
All bolts and nuts shall c
onform to IS: 1363-2002 or IS
: 1364-2002 as applicable
and unless specified otherwise shall be
hexagonal. All nuts shall conform to
property class compatible to the property
class of the bolt used. High strength
friction grip bolts (HSFG bolts) shall
conform to IS: 3757-1985.The nuts for the
same shall conform to IS: 6623-2004. Hexa
gonal fit bolts sha
ll conform to IS:
3640-1982 with matching nuts and washers. The successful Bidder shall submit
test certificates when called for.
Plain washers shall be made of mild
steel conforming to IS: 5369-1975 unless
otherwise specified. One washer shall be supplied with each bolt and in case of



UPGRADATION OF B.F NO. 1 PAGE 3.50
special types of bolts more
than one washer as needed for the purpose shall be
supplied. An additional doubl
e coil helical spring wash
er conforming to IS: 6755-
1980 shall be provided for bolts carrying
dynamic or fluctuating loads and those
in direct tension. Tapered washers
conforming to IS: 5372-1975 and IS: 5374-
1975 shall be used for channels and
beams respectively. Washers for high
shall conform to IS: 6649-1985.
Crane Rails
Electrodes
Mild steel electrodes shall conform to IS
814-2004. For welding in any particular
position, electrodes used shall be those
recommended by manufacturer for use in
that position. Properties of
weld material shall match
with properties of parent
material.
and erection facilities shall be deve

UPGRADATION OF B.F NO. 1 PAGE 3.51
Fabrication
Fabrication of steel struct
ures shall conform to IS: 800 - 1984 and tolerances of
Control Assembly
All segments in each course of furnace shell shall be control assembled at
shop to ensure the accuracy of each segment and the course as a whole.
Control assembly shall be carried out
for at least two courses at a time
starting with the bottom most course. After the control assembly is accepted,
the bottom most course shall be tran
assembly shall be continued for next c
ourse. This assembly check has to be
carried out in the presence of the Purchaser. Suitable fixtures, clamps and
clips shall be used during assembly
The component parts shall be so assemb
led that they are neither twisted nor
otherwise damaged. Specified cambe
All parts of bolted and welded members
shall be held firmly in position by
means of jigs or clamps while bolting
or welding. No drifting of holes shall
be permitted except to draw the parts together and no drift used shall be



UPGRADATION OF B.F NO. 1 PAGE 3.52
The erection clearance for cleated ends
of members connecting steel to steel
should not be greater than 2mm at each e
nd. The erection clearance at ends of
beams without web cleats should not be more than 3mm at each end, but where
for practical reasons the great
er clearance is necessary,
suitably designed seatings
Shearing or flame cutting may be used pr
ovided that a mechanically controlled
cutting torch shall be used for the flame cutting and the resulting edges shall be
reasonably clean and straight. Sheared me
mbers shall be free from distortion at
sheared edges. Special care shall be take
n to remove the burnt edges of high
tensile steel when flame cutting met
hod is employed. When gas cutting is
adopted, the flame cut edges shall be machined.
Edge preparation for welding may be done by machine controlled flame cutting
with edges free of burrs, clean and strai
ght. The butting surfaces at all joints of
girders or columns shall be planed so as
to butt in close c
ontact throughout the
finished joint.
orm to clause 10 of IS: 7215-1974. All holes
shall be drilled to required size or sub

UPGRADATION OF B.F NO. 1 PAGE 3.53
Before the erection of struct
ures, centrelines an
d level pads are to be fixed on the
foundation as per drawing. The Successful
Bidder shall also ch
eck centrelines of
all foundation blocks including checking li
ne, level, position and plumb of all
1 Out of roundness (largest
2 Displacement of the centre of
the shaft cylinder with respect to
mantle ring or lower level of
0.002(H-h), not exceeding 30 mm,
where h= ht. Of mantle ring or
lower level of bosh (for BF
without mantle ring) & H=Height
from bottom up to the regulated
3 Displacement of top throat
flange with respect to the centre
of mantle ring or lower level of
4 Level difference at any point of
5 Edge level of notch in shaft shell
Welding
The welding and the welded work shall
generally conform to
IS: 816 - 1969 and
much work as possible shall be
welded in shops and the layout and sequence of operations shall be so arranged as
to eliminate distortion
The welding surfaces shall be smooth, unifo
rm and free from fins, tears, notches
or any other defect which ma
y adversely affect welding an
d shall be free of loose
scale, slag, rust, grease, paint, mois
ture or any other foreign material.
Any weld found defective shall be cu
t by using either chipping hammer or
gouging torch in such a manner that adjacent material is not injured in any way.
Fusion faces and the surrounding surfaces
within 50mm of welds shall be free
from all mill scale and free from oil, paint or any substance, which might affect
the quality of the welds or impede the
quality/progress of welding. They shall be
free from irregularities, which would interf
ere with the deposition of the specified



UPGRADATION OF B.F NO. 1 PAGE 3.54
size of weld or be the cause of defects. All mill scale within 50mm of welds shall
be removed prior to welding by thor
ough power wire brushing or by other
all be examined by X-ray although this may be beyond
the number of such tests specified without any extra cost.
Visual Examination
The Successful Bidder shall conduct visual
examination and measurement of the
external dimensions of the weld for all joints. Before examining the welded joints,
areas close to it on both sides of the weld
for a width not less than 20 mm shall be
cleaned of slag and other impurities. Ex
amination shall be done by a magnifying
glass which has a magnification power of
ten (10) and measuring instrument,
which has an accuracy of 0.1 mm or by we
ld gauges. Welded joints shall be
examined from both sides.
The Successful Bidder shall examine the following during the visual checks:


UPGRADATION OF B.F NO. 1 PAGE 3.55
from the testing agency certifying
defect free welds and submit to the purchaser.
All steel structures shall be subjected
to inspection by
the Purchaser and
Successful Bidder shall provide all facilities for inspection. All welds shall be
checked visually or by other testing methods.
Ultrasonic testing (100%)
are to be carried out by
the Successful Bidder in
presence of the Purchaser /Purchasers representative for all butt-welded joints.
Unless directed otherwise, inspection shal
l be made at the place of fabrication
prior to dispatch. Should
any structure found not to
comply with any of the
provisions of this specification, it shall be
liable for rejecti
on. No structure or a
part of it, once rejected shall be resubmitted for inspection /test, except in cases
where the Purchaser considers
the defect as rectifiable.
Defects, which may appear
during fabrication, shall be made good with the
consent of and according to the procedure laid down by the Purchaser.



UPGRADATION OF B.F NO. 1 PAGE 3.56
Roof , side and gable covering with

All fixing accessories shall be as
per manufacturers recommendations.
Rainwater gutters and down pipes shall be ma
de of mild steel plates or steel metal
shall conform to relevant Indian Standa
rd. Unless otherwise specified, MS gutters
and down pipes shall be manufactured
from 5mm & 6mm thick copper bearing
mild steel plates respectively conf
orming to IS: 2062-2011. The following Indian
IS: 2527-1984 Code of Practice for fixi
ng rainwater gutters & down pipes for
Scope of work comprises of surface pr
eparation, material supply and required
quantity of thinner as recommended by pa
int manufacturer a
recommended painting materials on the surf
aces of structural steel work, supports,
platforms, stair case, pipe supports

UPGRADATION OF B.F NO. 1 PAGE 3.57
Two coats of single pack air drying phenolic modified alkyd
composition with zinc phosphate as
a primer with total dry film
thickness of 80 microns shall be app
lied. One coat of primer shall be
applied at shop before despatch. The
other coat shall be applied after
erection at site.
Two coats of single pack air
drying high gloss phenolic alkyd



UPGRADATION OF B.F NO. 1 PAGE 3.58
One coat (DFT 20 micron) of heat re
sistant finished paint(F-9 as per
IPSS:1-07-064-03) on outside surface of
shell segment af
ter fabrication
and two coats of heat resistant finish
ed paint(F-9 as per IPSS:1-07-064-03)
after erection shall be applied.
One coat of epoxy primer (P-5 as per IPSS:1-07-064-03) of DFT 40
micron (min) thickness on the inside f
ace of shell segment after fabrication
Surface preparation for the above shall
be St-2 standard
as per IPSS:1-07-
Painting of chimney:
For chimney inside surface, two coats of
heat resistant paint
(up to 200
conforming to IS: 13183-1991 of appr
oved quality and shade including
surface preparation, primer, DFT/co
Paint shall not be applied under the following conditions.
The Successful Bidder shall prepare the
sequence of dismantling to be employed
and submit it to the Purchaser for his reference.
Testing Erection & Commissioning
Fabrication, erection, testing and commissi
oning of steel structures shall be in
accordance with IS: 800-1984, IS: 7215-1974. Erect
ion tolerances shall be within
specified limits & as per IS: 12843-1989.

UPGRADATION OF B.F NO. 1 PAGE 3.59
MECHANICAL
Dismantling of the existing equipment
Dismantling of equipment under clause
no. 2.4.1.1 shall be done as per the
dismantling scheme which shall be pr
epared by the Successful Bidder and
1) Existing furnace is provided with
cooling system in open loop with
2) It has been envisaged to dismantle
the existing furnace shell along with the



UPGRADATION OF B.F NO. 1 PAGE 3.60
With a view to increase the life of the furnace linings the newly
reconstructed furnace shall be provided w
ith state of the art cooling system
along with cooling elements. The type
of coolers at various zones of the
Zone Type of Cooler
Hearth Heat resistant SGI staves having smooth front face with
in-situ cast seamless cooling pipes.
Iron Notch Heat resistant SGI stav
es having smooth front face with
2 rows of in-situ cast seamless cooling pipes
Tuyere Zone Heat resistant SGI stave having smooth front face with
in-situ cast seamless cooling pipes
Bosh Cu-Staves/ Inserted copper plates with hot face grooves
Lower Stack Cu-Staves/ Inserted copper plates with hot face grooves
SG Iron staves having hot face grooves and with in-situ
cast seamless cooling pipes. Topmost row may have
projections for supporting
the refractory lining.
Cooling of projections shall
be carried out by separate
3) The copper staves shall have special
ribs in the front in order to support
frozen slag skull, which acts as an in
sulation. Bidder to note that the top of
less than 25 m level.
4) Copper Staves/cu-plates shall be
made from continuously cast copper slabs
which shall be hot rolled to desired th
ickness prior to machining and drilling
of water channels. The copper staves sh
all be made from electrolytic copper
of 99.9% (minimum) purity.
5) The SG Iron staves in middle & upper
stack upto throat shall be provided
with hot face grooves in the front, wh
ich shall be filled with gunnite
refractory/ SiC bricks.
6) All the staves from bosh zone to uppe
r stack (up to throat) shall be equipped
with external compensators on the appr
i) In order to reduce the stack gas pr
essure drop and help in blowing more

UPGRADATION OF B.F NO. 1 PAGE 3.61
Dome lining shall be of refractory castable type with minimum 150 mm
1) 25 nos. of double cardan type tuyere st
ock assembly of flexible, rugged and
proven design shall be provided. The t
uyere stock shall be capable of
handling a blast volume of 2500 Nm
/min, at temperature of 1200
C at a
2) Properly designed expansion joints of
stainless steel sha
will help in compensating dimensional deviations present during installation
and thermal expansions during operation.
3) Conical blowpipe shall be of welded
steel construction wi
th stainless steel
20 nos.of tuyere holders shall be provide
d for holding the Tuyere coolers. The
material for tuyere holders shall be forged
steel. The outer flange of the tuyere
holder shall be welded to the furnace sh
ange supports the
Chemical composition of the tuyere holder shall be as follows:
Mo= 0.30%, Ni= 2.50%, V= 0.20%, Fe remainder
Mechanical properties:
(min.)
Elongation: 18% (min)
Impact: 127 (min)
3.5.3.6 Tuyeres and Tuyere Coolers
Blast furnace shall be provided with 20 Tuyeres and Tuyere coolers. The Tuyeres
shall be able to handle the blast volume of 2500 Nm
/min, at temperature of
C and pressure of 3.2 kg/cm
(g). The tuyeres shall
be of latest design,
double chamber type (tuyere nose and tuye
re body) suitable for dedicated high
velocity and high pressure
water cooling of nose and
tuyere body respectively. It



UPGRADATION OF B.F NO. 1 PAGE 3.62
shall be made up of cast copper. The tuyere shall have channels for water-cooling
and shall be free from any casting defects. T
uyere shall be tight fit with the tuyere
cooler. Spherical groove shall be provided
on the tuyere where the blowpipe sits
and shall have grind finish for proper matching with the blowpipe.
Tuyere cooler is fitted between tuyere
and tuyere holder assembly and it shall be
water-cooled. It shall be made from c
opper casting with water-cooling space for
Iron notch frame shall be of cast steel confirming to IS 1030:2004.
3.5.3.8 Furnace Bleeder Valve along with Power Pack
Two nos. hydraulic operated swing type ou
tward opening furnace bleeder valves
shall be fixed at the top of the Uptakes.
The bleeder valve shall be cup type valve
equipped with combined hard faced and soft
seal, the soft seal
being fitted to the
valve seat. It shall be of compact design
quick maintenance. The valves shall be ab
le to handle crude bl
ast furnace gas and
to withstand top pressure operation of the furnace.
Suitable power pack along with pipelines
Two nos. Jib crane of 3t capacity shall be provided. One no. shall be placed over
furnace top for handling of furnace bleeder valves and top skip pulleys. The
second one shall be placed over Skip Bri
dge for handling of lower skip pulleys.
The offered crane shall be of rugged design suitable for long life under special
duty and site conditions, trouble free ope
ration and easy maintenance. Design and
manufacture of the Jib crane shall
comply with IS
807:2006 & IS 15419:2004,
taking due note of dust laden atmospheri
c conditions and various requirements as
ctions of the specification.
3.5.3.10 Over Burden Probes with Temperat
ure Sensors & gas sampling system
1) The supply of stationary type
i) Two stationary thermal probes co

UPGRADATION OF B.F NO. 1 PAGE 3.63
i) Two numbers ruggedly designed th
ermal probes shall be installed
radially inside the furnace, above th
e burden level at an
inclination of
(approximately) from the horizontal axis.
ii) Platforms shall be provided to facilitate installation and maintenance
iii) Each of the above platforms sha
ll be provided with monorails and a
post at the end of the platform for
installing manual hoist of 3t lifting
capacity for handling of the prob
es. Special device/ accessories
required for removal/ handling of probes shall also be included in the
iv) One of the probes shall reach the
furnace centre and shall have 6 (six)
sampling points. The second probe sh
and shall have 5 (five) sampling
points. The sampling points on the
1) In order to cater to
the increased production level of Blast Furnace, it is
envisaged to provide a new skip sy
stem having skip car volume 11.0 m
Suitable capacity skip hoist for hauling
the required burden shall be provided.
The new skip hoist shall be housed in the new skip hoist building to be



UPGRADATION OF B.F NO. 1 PAGE 3.64
Iron ore lumps 2.2 8 - 50
Sinter 1.6 6 - 40
Limestone 1.5 10 50
Mn ore 2.3 10 - 50
Coke 0.55 25 80
4) Some of the Technical Parameters n
eeded for designing of the skip system
are as follows:
Fuel rate (Coke rate + CDI rate) per
ton of pig iron (kg/thm)
CDI rate, kg./thm 100
Hot metal production / day for skip
Useful volume of skip 11 m
5) Skip Car
Two nos. new skip car of 11 m
(total volume) shall be provided. The skip
body shall be fabricated from mild stee
l plates and prefer
ably lined inside

UPGRADATION OF B.F NO. 1 PAGE 3.65
with cast austenitic manganese steel
Suitable hoist assembly for the skip ha
ulage shall be provided for trouble free



UPGRADATION OF B.F NO. 1 PAGE 3.66
to the skip. One pair of
clamps shall be used to
fasten the running-on ropes
(winding) while the other pair fo
Suitable nos. of pulleys shall be provided for proper functioning of the skip
system. Pulleys shall be double groove
bearings enclosed in cast steel housings.
Bearings of the pulley assembly shall
11) Paint
All the equipment shall be pa
inted with 1 coat of primer
paint as per the color code to be decided by the Employer. Painting shall be
3.5.3.13 Under Hearth Cooling
Cooling of hearth bot
tom shall be achieved by means of soft water. The bottom
cooling pipes shall be stainless steel
of suitable grade and dimension. Gaps
1) The new reconstructed furnace shall
have twin cast house installed at 90
apart. The cast house shall be flat ca
st house and equipped with facilities
such as covered main trough with for
ced air cooling, covered runners, new
hydraulic mud guns, hydraulic drilling machines, trough cover
manipulators, rocking runner assemblie
s with drive, mobile equipment,

UPGRADATION OF B.F NO. 1 PAGE 3.67



UPGRADATION OF B.F NO. 1 PAGE 3.68

UPGRADATION OF B.F NO. 1 PAGE 3.69



UPGRADATION OF B.F NO. 1 PAGE 3.70
All electrical equipment shall be pr
operly derated to give satisfactory
performance at the ambient conditions specified.
All the materials /equipment shall be
suitable class and reputed make only.
10) 35t Erection Trolley
1 Electrically
Operated hoist
6.3t 5 m
lifting heigh
adjustment duri
dismantling
Operated monora
15t, 15m lift Erection of
4 Spur gear hoist with
trolley
3 Manual operated
1.5t, 14m lif
Dismantling of
4 Manual operated
3t, 13m lift Dismantling
plates of materi
1 Spur gear hoist with
trolley
5 Manual operated
6.3t, 6m liftDismantling
Lower seal valv
1 Trolley with ultralow
6 Manual operated
6.3t, 13m lif
Dismantling
1 Spur gear hoist with
trolley

UPGRADATION OF B.F NO. 1 PAGE 3.71
7 Manual operated
5t, 6.5m liftDismantling
lower material
1 Trolley with ultralow
8 Manual operated
3t, 13m Dismantling
Upper material
1 Spur gear hoist with
trolley
9 Manual operated
10t, 6m lift Dismantling of
transmission
4 nosSpur gear hoist with
trolley
10 Manual operated
3t, 3m lift Tilting gearbox
2 Spur gear hoist with
trolley
11 Manual operated
12 Manual operated
3t, 6m lift Mechanical
2 Spur gear hoist with
trolley
13 Manual operated
1.5t, 4m liftRelief Valve 1 Spur gear hoist with
trolley
14 Manual operated
1.5t, 4m liftEqualizing
1 Spur gear hoist with
trolley
13) Workmanship
All the parts of the offered equipment
shall be manufactured with quality
material and workmanship. These offered equipment shall be assembled
within acceptable allowable accur
acy and shall be shop tested
A new Dust Catcher System suitabl
e for high top pressure of 2.0 kg/cm
along
Cut off valve serves for the quick se
paration of uptake & down comer from
the dust catcher during temporary shut
down of the blast furnace. It is



UPGRADATION OF B.F NO. 1 PAGE 3.72
maintenance requirements. The valve should be efficient in operation and
justifiable in terms of down time savi
ngs during blast furnace shut down
The dust valve is connected to
the dust discharge pipe
of the dust catcher. It
keeps the dust catcher gas tight. It

UPGRADATION OF B.F NO. 1 PAGE 3.73
The dia 250 mm Bleeder Valve is mounted on the gas offtake connected
1 Electrically
Operated
20t Handling of skip car 1
2 Electrically
Operated
3t Handling facilities of
Tuyere Stock Assembly
3 Electrically
Operated
10t Handling mudguns and dri
machines
4 Electrically
Operated
10t Skip winch room 1
5 Electrically
Operated
5t Skip winch room 1
6 Electrically
Operated
10t jib craneHandling of Rocking runn
7 Electrically
Operated
3t Maintenance of cast house
crane equipment
8 Electrically
Operated
10t Handling back draft valve1
The offered electric hoist and winch sh
all be of rugged design suitable for
duty and site conditions
easy maintenance. Design and manufacture of the electric hoists shall
comply with IS 3938:2008, Indian Elect



UPGRADATION OF B.F NO. 1 PAGE 3.74
the Govt. of Jharkhand. It shall also comply with the requirements as
specified under the various Inter Pl
ant Steel Standards (IPSS) that are
applicable.
3.5.3.15 Back Drafting System
1) Presently the back drafting in Blast furnace No.1 is inadequate. A new back
drafting line shall be
provided along with back drafting chimney. The
tapping for the back draft line shall be
preferably taken from bustle pipe and
the line shall be connected to the new back draft chimney horizontally.
A new back draft valve and expansion joint shall be installed in the new
Purchaser. Necessary platform with
access stair along with handling facility
shall be provided for the maintenance of the valve.
The valve shall be soft water cooled
gate (floating) t
ype and hydraulically
The drive shall be integrated with BLT power pack.
3.5.3.16 BLT Hydraulic system
Receiving hopper shall be of welded steel plate construction and shall be
provided with ceramic liners
conforming to material S235JRG2 or similar. The
useful volume shall be atleast 2
times useful volume of skip car.

UPGRADATION OF B.F NO. 1 PAGE 3.75
3.5.4.3 Material Hopper with Liners
Material Hopper shall be designed
for maximum design pressure of 2.0
bar
and maximum design temperature of 200
C. Material hopper shall be of
welded steel construction conformi
ng to material Sa516 Gr.60/70, IS 2002
d with ceramic liners.
3.5.4.4 Uptakes and Down comers including manholes
Existing uptakes and down comers shall
be dismantled and replaced with new
one. The size of the pipe shall be such
that the Blast Furnace gas generated can
from GCP to furnace shall be dismantled and new
Top cone assembly shall be such that it shall properly match with the furnace
profile. The top flange shall be welded to the top cone so that the BLT system
sits properly without any misalignment.
The Top cone shall
have openings for
1) The battery limit of scope of this
package shall be 1 metre away from
Cold Blast mixing point in the Hot Bl
ast Main and towards Blast Furnace
2) The existing bustle pipe having



UPGRADATION OF B.F NO. 1 PAGE 3.76
Arrangement of hot metal and slag r
unners shall be suitable for 3000 tpd hot
metal production. The arrangement should be
such that change
in directions of
metal flow is optimized and sudden drop in
elevations are avoided to eliminate
the potential wear zones in
the runner layout. The runne
rs shall be fabricated
and lined with refractory
/ castables. The main tr
oughs shall be naturally
cooled. All the runners shal
l be provided with cove
runner shall also be provided. Mobile
equipment for maintenance of runners
shall be provided.
The runner layout shall be so designed th
at the slag runner shall feed slag to
existing slag granulation plant. The runne
r layout shall have
provision of fixed
spouts to tap slag in the slag pots, sim
ilar to slag tapping provision in existing
3.5.4.7 Dust Catcher
1) Existing Dust catcher shall be dism
2) Two numbers new bleeder lines sha
ll be provided for connection from
dust catcher to respective dust catcher
bleeder valves. The pipeline shall
confirm to IS 3589:2001 and shall be
suitably lined with refractory
castables. The dust catcher valves shall be installed over the bleeder
lines. Drawings of equipment supplie
r shall be used for erection and
commissioning of these bleeder valves.
This specification covering broad tec
hnical parameters and requirements for
Design criteria for belt conveyor system and accessories:
Application
This covers general requirements for belt conveyors for handling of
proposed materials. Specific require
ment and layout shall be as per
Technical Specification and drawings
mentioned in this document.
The belt conveyors shall include all
types of pulleys, idlers, belting,
drive unit, drive frame, head frame,
tail frame, take-up unit, short post,
stringer channel, deck plate, discharge chute, skirt board, external
scraper (sprung bladed tungsten tipped
), internal scraper, protection
switches, protection cage, fastener

UPGRADATION OF B.F NO. 1 PAGE 3.77
Steel structure
Steel structure specified herein shall
be applied to steel structures such
as conveyor stringers, short posts, h
ead frame, drive frame, take up
i) All transfer points sh
all be provided with non-
choking chutes and shall
be designed such that impact of
the material on the conveyor is
minimum. It shall be designed to ensu
re continuous flow of material to
the centre of the belt. Chutes shall
be made of 10 mm thick MS plates
with angle stiffeners and shall be r
ectangular cross-section with welded
connection. Chutes shall be construc
ted in pieces of suitable size and
length so as to facilitate their main
tenance. Chute pieces shall be joined



UPGRADATION OF B.F NO. 1 PAGE 3.78
manganese steel liners conforming to
IS 276: 2000 (Grade I) fitted with
countersunk bolts. Skirt shall flare sli
ghtly outwards in the direction of
belt travel to prevent material fr
om wedging. The height of the skirt
boards shall be 450 mm and shall be su
fficient to contain the material
volume as it is loaded on the belt. The
skirt plates shall be fitted with
rubber strips (100 mm wide x
12mm thick) of hardness 65-70
Shore A
by means of vertically slotted holes
to permit adjustment. Cut pieces of
conveyor belting shall not be used. Rubber strips shall be so fixed as to
facilitate easy replacement. Edges of
rubber strips shall have an angle

UPGRADATION OF B.F NO. 1 PAGE 3.79
v)

y
(indicative)
Lift (m)
(indicative)
(m/s)
1 Ore & additive
700 1000 As existing As existing 1.5
2 Sinter Conveyor
240 1000 As existing As existing 1.5
3 Sinter fines
200 800 As existing As existing
4 Belt Feeder BF-66
200 1000 As per
requirement
requirement



UPGRADATION OF B.F NO. 1 PAGE 3.80
3.5.5.3 Drive System:
Drive systems consisting of motors, g
earboxes and couplings as per rating
Electric Motors:
(kW) (min.)
2 45 1500
2 30 1500
3 As per
calculation
2 As per
calculation
Calculation for kW rating of motors is to be submitted by the Successful
Type Qty.
ratio
Triple stage
helical with
2 1500 40 67.5
Triple stage
helical with
Triple stage
helical with
1.5 times the
calculated
Triple stage
helical
31.5
1.5 times the
calculated
The gearbox casing shall be of fabricated construction and free from
plugs and dowel holes shall be
provided at conveniently accessible location. There shall be a

UPGRADATION OF B.F NO. 1 PAGE 3.81
provision for indicating the level of
oil. Dowel pins shall be supplied
The joints of the casing shall be
The bearings shall be of antifrict
shall be minimum 20000 working hours.
eepage of oil at the seal
Oil splash lubrication shall be provided.
Every gear box shall have a name
plate bearing the following
Manufacturers name, trade-mark and year of manufacture
Designation of gear box indicating
Every gear box shall be accompanie
d with the following information
Bearings and oil seals used
The Gear box input couplings, output
couplings and drive pulleys
shall be assembled at suppliers works by the Successful Bidder and
shall be despatched after dismantling the coupling bolts only with half
coupling fitted on the respective shafts. Care must be taken while
despatching to avoid any damage to
the mounted coupling or shaft.
Proper markings shall be given
for easy assembling at site
Sl. no. Conveyor
Description
Type Qty.
kW/ 100 rpm
Ore & additive
Geared
Sinter Conveyor SC
Geared
Sinter fines
Geared
kW/100rpm
Belt Feeder BF-66 &
Geared
kW/100rpm



UPGRADATION OF B.F NO. 1 PAGE 3.82
Conveyor Description Type Qty.
Geared 2
Sinter Conveyor SC 1-1 & SC
Geared 2
Geared 3
kW/100rpm
Geared 2
kW/100rpm
The Bidder shall select the couplings
of standard makes (as per List of
Preferred Makes) considering th
e kW/100 rpm, torque rating,
Sl. No. Conveyor
Description
Ore & additive
OC 1-1 & OC
800 1150 2 160
Conveyor SC
630 1150 2 140

UPGRADATION OF B.F NO. 1 PAGE 3.83
Sl. No. Conveyor
Description
Sinter fines
500 950 3 125
630 1150 2 140
Tail Pulley
Sl. no. Conveyor
Description
630 1150 2 140
Sinter Conveyor
500 1150 2 125
Sinter fines
SFC-1, SFC 1.1 &
Belt Feeder BF-66
Ore & additive
1150 4 125
Sinter Conveyor SC 1-
1150 4 100
950
Belt Feeder BF-66 &



UPGRADATION OF B.F NO. 1 PAGE 3.84
Pulleys shall be of welded cons
truction as per IS 8531: 1986. End
plates and bosses shall be of m
ono-block construction as far as
All drive pulley surfaces shall be
hot lagged with vulcanised natural
rubber lagging, grooved in diamond
pattern. The lagging thickness
All non-drive pulleys (ta
il, take-up and snub)
surfaces shall be hot
lagged with vulcanised na
tural rubber with pl
ain lagging. The lagging
thickness shall be 10 mm.
The plummer blocks for pulleys shall be horizontally split type
construction made of cast iron. The pl
ummer blocks shall be dust tight
with double labyrinth seals. Conical
head shape nipples conforming to
IS 4009 (Part 2): 1981, shall be provided for greasing. Side covers of
plummer blocks shall be heavy-du
Belt width
1000 139.7 380 3-roll inline
800 139.7 315 3-roll inline
Impact idler (35
width
1000 139.7 88.9 380 3-roll in line
800 139.7 88.9 315 3-roll in line

UPGRADATION OF B.F NO. 1 PAGE 3.85
width
1000 139.7 88.9 380 3-roll in line
Belt width (mm) Idler diameter
1000 139.7 1150 Single roll

139.7

950

Self aligning carrying idler (35
Belt width (mm) Idler
1000 139.7 380 3-roll inline
800 139.7 315 3-roll in line

Belt width (mm) Idler diameter
1000 139.7 1150 Single roll
800 139.7 950 Single roll
width
1000 139.7 380 3 roll in line
800 139.7 315 3 roll in line
Roller used in idlers shall be made from ERW steel tube. Wall
thickness shall be 5.4 mm. The roller
spindles shall be provided with
seize resistant type ball bearings (S
KF / FAG) The bearings shall be



UPGRADATION OF B.F NO. 1 PAGE 3.86
adequately sealed and lubricated fo
r life. The rolls shall be supported
1 800 and 1000 Nylon/nylon 630/4
bottom cover 2 mm, grade M
24 as per IS 1891 (Part
3.5.5.4 Vibrating Feeders
The vibrating feeders shall be
Description Vibrating feeder
Electro-Mechanical vibrating feeder, linear
motion fitted with unbalance motor exciter. The
feeders shall be provided with dc injection
Quantity (no.) 17 (seventeen)
Rated capacity
11 nos. 200 each for sinter bunkers
4 nos. 220 each for ore bunkers
2 nos. 120 each for coke bunkers
Moisture content in
input material

UPGRADATION OF B.F NO. 1 PAGE 3.87
Description Vibrating feeder
Power supply 415
Hours of operation 24
Type of mounting Suspended, however foot mounted is preferable
wherever possible.
Inclination To be decided by the Bidder
Indicative trough
size of feeder
(width x length)
(mm x mm)
To suit the existing layout. The Bidder must
ensure the length of the feeder bed for
discharging of material
covering the entire deck
of the screens for coke, feeding to sinter weigh
hoppers for the rated capacity and feeding to
Sl No. Description Specification
Tray C
ARBON STEEL PLATE AS PER
Liner 5.0 mm stainless st
eel (SS 409 M) without
intermediate joints
Spring Spring Steel
Frame Structural Steel as
Each Vibrating Feeder shall be provided with :
Frames
Description Sinter and Coke screen
Type Linear motion, vibrating screen, single deck,
fitted with unbalanced motor/cardan shaft
drive arrangement. Screens shall be provided



UPGRADATION OF B.F NO. 1 PAGE 3.88
Description Sinter and Coke screen
with soft starter
Quantity (no.) 2 (two) Sinter screen
ATED FEED RATE CAPACITY
EFFICIENCY
Size of input material (mm) 0-80
Hours of operation per day 24
Deck material Stainless steel for Sinter screen
Separation (-)5mm sinter
(-)25mm coke
Inclination As per requirement
Side skirt plate Wear resistant
stainless steel (SS 409 M) liner
plate of min. 5mm thickness.
Shaft Forged steel
Moisture content of input
material
INES CONTENT IN THE
INPUT MATERIAL
Screen dimension Sinter Screen
to be housed inside the stock
house. Maximum controlling dimensions shall
be restricted within 2m x 5.3m (approx.)
Coke screen dimensions shall match with the
Provision of capacity
variation
Type of mounting Trolley/foot mounted
Power supply 415
Feeders and screens and its associated
system, accessories covered under this
specification shall comply with all curre
ntly applicable statutory regulations

UPGRADATION OF B.F NO. 1 PAGE 3.89
2 (two) nos electric hoist shall be s
upplied and erected for maintenance and
handling of sinter & coke screens a
nd 1 (one) no for handling of hydraulic
equipment.
designed as per IS:3938-1983.
Location Sinter & coke screens and hydraulic room
Purpose For maintenance and handling of sinter &
coke screens and hydraulic equipment.
Type Electrically operated.
Capacity (t) 7.5t for maintenance and handling of the
room



UPGRADATION OF B.F NO. 1 PAGE 3.90
Nomenclature Description
(approx. in m)
Lift (approx. in m) To be decided by the Bidder
Hoisting speed (m/min) 3.0
Traveling speed (m/min) 10
Quantity (no.) 2 (two) nos. for maintenance and handling
of the sinter & coke
screens and 1 (no) in
Monorail Suitable for sele
Standard to be followed Duty
12 Gear box rating 1.25 times the selected motor kW
3.5.5.7 Hydraulic Power Pack
i) 1 No. Oil Hydraulic Power Pack sha
ll be provided for operation of weigh
system mentioned above.
ii) The flow and pressure for the syst
ems shall be selected by the Bidder,
based on the system requirement.
iii) The Power Pack shall comprise of
2 Nos. main pumps (1 W + 1 S). The
main pumps shall be axial pist
on variable displacement type.
iv) The Power Pack shall comprise of
1 No. Filtering-cum-Cooling system (1
W + 1 S). The Filtering-cum-Cooling system pumps shall be fixed
displacement gear type. The capacity
of pumps for Filtering-cum-Cooling
systems (with oil to water, Plate type heat exchangers) shall be at least
v) Filters used shall be duplex type w
ng indicators. Micron

UPGRADATION OF B.F NO. 1 PAGE 3.91
xi) For the pipelines, size up to DN 30,

1. Stock House
Hydraulic Room
Exhaust Ventilation System.
Fan type: Heavy duty tube
axial fan, wall mounted,
Capacity & Head: Bidder to
decide.
Ventilation system shall be as per technical specification given in TS.
Design Consideration of Ventilation System
Exhaust ventilation system envisaged in
the specification shall comprise of
tube axial fan (RPM
not exceeding 1000), bird
The tube axial fan shall be industrial, heavy duty type, suitable for
continuous operation, statically and
dynamically balanced, single stage,
directly coupled with drive motor
and shall be manufactured, tested
according to IS:3588-1986
Filter
Air filter shall be HDPE- Steel wire reinforced- dry panel type. It
should be easily removable and wash
able type. This filter should be



UPGRADATION OF B.F NO. 1 PAGE 3.92
Drive motors
Specification of drive mo
tors for the ventilation system shall be as per
Clause given in Electrical chapter.
The starter shall have dust and verm
All power and control cables require
d for installation
and commissioning
of the proposed package units & ven
tilation systems are included in the
scope of successful Bidder. Power
cables shall be generally XLPE
insulated, PVC sheathed, aluminium co
nductor, 3.5 core, 1.1 KV grade,
armoured type cables shall be laid
through G.I. pipes
when embedded on
the floor for easy remova
l/replacement. Control cab
le shall be 1.1 KV
grade, PVC sheathed, mu
lti core, multi strand co
pper conductor with no
armouring. The specification of LT powe
r & control cables shall be as per
IS:1554-1988.
ventilation system
shall be suitably earthed as
per IS:3043-1987.
Civil and Structural Work
All civil and structural work
including Rooms , Foundation and
Handling facilities required for
installation of air conditioning and
ventilation system shall be included in the scope of the Bidders.
Making wall and slab opening for running supply & discharge air duct,
Hot blast main connects bustle pipe to st
oves. Hot blast from the stove flows to
bustle pipe through HBO and HBM. Hot blast main in the stove area up to
Bustle Pipe will be required to
be changed under this package
Joints shall be provided in Hot Blast ma
in and in Hot Blast Branch. Hot Blast
Main shall be fabricated from ultrasonically tested, Boiler quality plates
conforming to IS 2002, Gr2 :

UPGRADATION OF B.F NO. 1 PAGE 3.93
Tie rods & Thrust collars
Two thrust collars, one n
ear dished end and other near stove no.1.1 shall be
provided in HBM. Three Tie Rods sh
One pressed dished end of specified
shape shall be provided. Also one
manhole with end cover shall be provide
d in this dished
end. Dished end
and End cover shall be fabricated from
ultrasonically tested, Boiler quality
Bustle Pipe shall be fabricated from u
ltrasonically tested, boiler quality plates
A separate back drafting system shall
be provided. Horizont
al pipe of Back
draughting system shall be fabricated fr
om ultrasonically te
plates conforming to IS 2002, Gr2 : 2009
All tapping / nozzles shall be provide
d in Hot Blast Main for measuring
Hanger supports with top and bottom
bearings. (Plain spherical thrust
Flat Arch Construction: Stainless steel
hangers will be provided at 3 junctions
of HBM and its three branches.
Permissible tolerances for misalignmen
t of the Centre line of HBM in the
3.5.6.2 Pipe lines
Gas shall be distributed
to stoves through new clean
gas main header of
1800 mm ID (steel). The clean gas ma
in shall be located at around +41
meter height shown in the enclosed
Drawing. One no. bleeder valve shall be



UPGRADATION OF B.F NO. 1 PAGE 3.94
provided at the end. Clean gas main sha
ll be fabricated from ultrasonically
tested quality steel plates conforming to IS 2062, Gr.B:2011.
Clean gas branches
Three clean gas branches, one for each stove for feeding gas to stove
(connecting gas main) shall be provide
d. All three branches shall be
provided with Goggle valves, Gas shut
off valves, Flow measuring element,
Combustion Air shall be distributed to
stoves through the air main header of
Three Air branches, one for each stove
for feeding Air to stove (connecting
Air main) shall be provided. Each branch
valve, Flow measuring elements, Cont
rol valves and manual goggle valve.
These lines shall be tested as per specified test procedure in the presence of
the Employer. Combustion air branches shall be fabricated from
ates conforming to IS 2062, Gr.B:2011
Cold blast main (CBM)
Existing cold blast main shall be cut near stove house and new header shall
be installed. Cold blast main shall be fabricated from ultrasonically tested
quality steel plates conforming to
Three Cold blast branches, one for each
stove for feeding co
ld blast to stove
(connecting CBM) shall be provided. Thes
e branches shall be provided with
Cold Blast Shut off valves and pressu
rizing valves. Pressurizing line shall
ll be tested as per specified test procedure in the
presence of the Employer. Cold blast
branch and pressurizing lines shall be
fabricated from ultrasonically tested
steel plates conforming to IS 2002,

UPGRADATION OF B.F NO. 1 PAGE 3.95
fabricated from ultrasonically tested
steel plates conforming to IS
Pressure relief line shall be fabricate
d, erected and tested. These lines shall
These lines shall be provided in each gas branch line before and after
Goggle valve for main
Waste gas branch lines
Each stove will have two (2) Waste gas branch lines with new chimney
valves. End of the each branch line shall be connected to the waste gas pipe
line which will be over ground and finally it will be connected to chimney,
Waste gas branch lines shall be fabric
ated from ultrasonically tested steel
plates conforming to IS 2002,
Medium Hot Blast Air for Hot Blast Valve
Hot Blast Air & BF Gas for Back
Composition Comp. of Hot Blast Air :



UPGRADATION OF B.F NO. 1 PAGE 3.96
Comp. of B.F. Gas :
H.B Temperature 1200

ii)
Technical Specification
Quantity 3 Nos.- For Hot Blast Valve (1 no.
for each stove)
Type Water cooled floating gate type,
Design temperature 1400
Mounting position Vertical in horizontal pipeline
iii)
Material Specification
Valve body Boiler quality plate / IS 2002 (Gr-2):
Gate -do-
Flanges & companion flange
Seat Ring 15 Mo3 forged ring (seamless) or
iv) Construction / Special Features
The seating faces of valve shall be
located within cooling water range.
Industrial water will be used for the c
ooling purpose. It shall be suitable for
working under pressure 10 kg/cm
and shall be tested at 1.5 times of the
working pressure. Each of these Valves (i.e. Hot Blast Valves & BD Valve)
nos. of companion flanges.

UPGRADATION OF B.F NO. 1 PAGE 3.97
stuffing box shall be such that it can
be easily repacked without dismantling
major part of the valves.
Before machining, all welded parts of va
lve shall be stress
relieved and sand
v) Actuation
These valves shall be operated by m
eans of Hydraulic actuation system
connected to the common Hyd. Power Pack.
vi) Instrumentation
These valves shall be installed in the Co
ld Blast Branch Lines and are meant for
the Stove when stove is on gas
i)
Medium Specification
Medium
Operating temperature 180
ii)
Technical Specification
Quantity 3 Nos. (1 no. for each stove)
Type Double eccentric butterfly valve
with laminar seal of SS and
Operating pressure 350 kpa
Design pressure 450 kpa
Design temperature 400
Pressure difference at opening /
closing
Mounting position horizontal in vertical pipeline
iii)
Material Specification
Valve body Boiler quality
Valve disc -do-
Flanges & companion flanges



UPGRADATION OF B.F NO. 1 PAGE 3.98
thickness suitable to pressure class
Shaft Stainless steel AISI 410
Body seat IS 2002 (Gr-2)
iv) Construction / Special Features
The offered valve shall be of double e
ccentric butterfly type with flanges.
The body of valve shall be of welded st
eel construction. Proper laminar seal
to be provided in the discs of the valv
es. Seat pressure testing of the valve
shall be done from pressure side of the disc.
v) Actuation
These valves shall be operated by m
eans of Hydraulic actuation system
connected to the common Power Pack.
vi) Instrumentation
accessories
This valve is required to shut off the cold
blast mixing flow and shall be installed
in the cold blast mixer line connecting to
hot blast main through mixing chamber.
i)
Medium Specification
Medium Cold Blast Air
Composition:-
Operating Temperature 300
ii)
Technical Specification
Quantity 1 No.
Type Double eccentric butterfly valve
with laminar seal of SS and
Graphite
Operating pressure 350 kpa

UPGRADATION OF B.F NO. 1 PAGE 3.99
Design pressure 450 kpa
Pressure difference at opening /
closing
Design temperature 400
Mounting position In horizontal pipeline
iii)
Material Specification
Valve body Boiler quality plate IS 2002 (Gr-
Valve discs -do-
Flanges & companion flanges
Shaft Stainless steel AISI 410
Body seat IS 2002 (Gr-2): 2009 with hard
iv) Construction / Special Features
The offered valve shall be of double
eccentric butterfly ty
pe with flanges.
The body of valve shall be of welded steel construction. Laminar seal to be
provided in the disc of valves. Seat pr
essure testing of
the valve shall be
done from pressure side of the disc.
v) Actuator
This valve shall be operated by m
eans of Hydraulic actuation system
connected to the common Power Pack.
vi) Instrumentation
other accessories
These valves are required to cut off airf
low to stove when stove is on blast and
shall be installed in horizont
al pipeline near Stove.
i)
Medium Specification
Medium Combustion air with dust
content of 16 mg/Nm



UPGRADATION OF B.F NO. 1 PAGE 3.100
Operating temperature 50
ii)
Technical Specification
Quantity 3 Nos. (1 no. for each stove)
Type Double eccentric butterfly valve
with laminar seal of SS and
Graphite
Operating pressure 350 kpa
Design pressure 450 kpa
Design temperature 400
Pressure difference at opening /
closing
Mounting position In horizontal pipeline
iii)
Material Specification
Valve body Boiler quality plate IS 2002 (Gr-
Valve disc -do-
Shaft Stainless steel AISI 410
Body seat Stainless steel
iv) Construction / Special Features
The offered valve shall be of 2 leve
r double eccentric butte
rfly type with
flanges. The body of valve shall be of
welded steel construction. Proper
laminar seal to be provided in the disc
s of the valves. Seat pressure testing
of the valve shall be done from
v) Actuation
These valves shall be operated by m
eans of Hydraulic actuation system
connected to the common Power Pack.
vi) Instrumentation

UPGRADATION OF B.F NO. 1 PAGE 3.101
Leak rate-2 as per DIN 3230 part-3. Seat
pressure test shall be done from
both sides of disc
These valves are required to cut off gas
flow to the Stove when Stove is on blast
and shall be installed in Ga
s Branch Line near Stove.
i) Medium Specification
Medium
B. F. gas of CV 778 kCal/Nm
Composition:-
Dust content 40 mg / Nm
Operating temperature 40
ii) Technical Specification
Quantity 3 Nos. (1 no. for each stove)
Type Double eccentric butterfly valve
with laminar Seal of SS and
Graphite
Operating pressure 350 kpa
Design pressure 450 kpa
Design temperature 400
Pressure difference at opening /
closing
Mounting position In horizontal pipeline
iii) Material Specification
Valve body Boiler quality plate IS 2002 (Gr-
Valve disc -do-
Flanges & companion flanges
Shaft Stainless steel AISI 410
Body seat Stainless steel



UPGRADATION OF B.F NO. 1 PAGE 3.102
iv) Construction / Special Features
The offered valve shall be of double eccentr
ic butterfly type with flanges. The
body of valve shall be of welded steel
construction. Proper laminar seal to
v) Actuation
These valves shall be operated by m
eans of Hydraulic actuation system
connected to the common Power Pack.
vi) Instrumentation
weight & other accessories
Medium
B. F. gas of CV 778 kCal/Nm
Composition:-
Dust content 40 mg / Nm
Operating temperature 40
ii) Technical Specification
Quantity 3 Nos. (1 no. for each stove)
Type Double eccentric butterfly valve
with rubber / viton seal and
counter weight for emergency
Operating pressure 5 kpa
Design pressure 20 kpa
Design temperature 100
Pressure difference at opening /
closing
Mounting position In horizontal pipeline

UPGRADATION OF B.F NO. 1 PAGE 3.103
iii)
Material Specification
Valve body Boiler quality plate IS 2002 (Gr-
Valve disc -do-
Flanges & companion flanges
Shaft Stainless steel AISI 410
Body seat Stainless steel
iv) Construction / Special Features
The offered valve shall be of double e
ccentric butterfly type with flanges.
The body of valve shall be of welded
steel construction. Proper rubber/
viton seal to be provided in the discs of
the valves. Seat pr
essure testing of
the valve shall be done from pr
The valve shall have counter weight
for automatic closing during power
failure/emergency situation.
v) Actuation
These valves shall be operated be by
means of Hydraulic actuation system
connected to the common Power Pack.
vi) Instrumentation
Gas bleeder valves are installed in gas bl
eeder lines to bleed off the residual gases
Medium
B. F. gas of CV 778 kCal/Nm
Composition:-
Dust content 40 mg/Nm
Operating temperature 100



UPGRADATION OF B.F NO. 1 PAGE 3.104
ii)
Technical Specification
Quantity 3 Nos.(1 no. for each stove)
Type Double eccentric butterfly valve
Max. operating pressure 6 kpa
Design pressure 25 kpa
Differential pressure 10 kpa
Design temperature 150
Mounting position In vertical / horizontal pipe
iii)
Material Specification
Valve discs -do-
Flanges& companion flanges
Shaft AISI 410
Body seat Stainless steel
iv) Construction / Special Features
The offered valve shall be of double
eccentric type with flanges. The body
of valve shall be of welded steel co
er/viton seal to
be provided in the disc of the valves
. Seat pressure testing of the valve
shall be done from both sides of the
disc. The valve should open when the
v) Actuator
Valve operation shall be by means of el
ectrical actuator of suitable reputed
make like AUMA/ BEACON ROTORK / BONFIGLIOLI. Gearbox shall
be mounted separately and connected
by a shaft. Hand wheel shall be
provided for manual operation. Electrics
shall be pre-wired and terminated
over a terminal box.
vi) Instrumentation

UPGRADATION OF B.F NO. 1 PAGE 3.105
Chimney valves or waste gas valves shall be
installed in waste gas lines leading to
the Chimney to allow waste or flue gase
s to flow from Stove to Chimney. The
Valve shall be used to disconnect Stove from Chimney. The Valves shall be
double eccentric butterfly Valves, hydr
aulically operated through the common
i)
Medium Specification
Medium Waste/flue Gases
Dust content 5-6 mg/Nm
Operating temperature 300
ii)
Technical Specification
Quantity 6 Nos.( 2 for each stove)
Max. operating pressure 250 kpa
Differential pressure 10 kpa
Design temperature 500
Mounting position Vertical in horizontal pipeline
iii)
Material Specification
Valve discs -do-
Flanges& companion flanges
Shaft AISI 410
Body seat IS 2002 (G
iv) Construction / Special Features
The body of valve shall be of welded
steel constructi
on. Proper laminar
seal is to be provided in the disc of
the valves. Seat pressure testing of the
valve shall be done from pressure side of the disc.
v) Instrumentation
Pressurizing Valves shall be installed in
the Bypass Line of Cold Blast Valve to



UPGRADATION OF B.F NO. 1 PAGE 3.106
i)
Medium Specification
Medium Cold Blast Air
Operating temperature 200
ii)
Technical Specification
Quantity 3 Nos.(1 no. for each stove)
Type Double eccentric butterfly valve
with laminar seal of SS and
Max. operating pressure 350 kpa
Design Pressure 450 kpa
Differential pressure 350 kpa
Design temperature 400
Mounting position In vertical / horizontal pipe
iii)
Material Specification
Valve discs -do-
Flanges& companion flanges
Shaft AISI 410
Body seat IS 2002 (G
iv) Construction / Special Features
The offered valve shall be of double
eccentric type with flanges. The body
of valve shall be of welded steel co
nstruction. Laminar seal to be provided
in the disc of the valves. Seat pressu
re testing of the valve shall be done
from pressure side of the disc.
v) Actuator
Valve operation shall be by means of el
ectrical actuator of suitable reputed
make like AUMA/ BEACON ROTORK
/ BONFIGLIOLI. Gearbox shall
be mounted separately and connected
by a shaft. Hand wheel shall be
provided for manual operation. Electrics
shall be pre-wired and terminated
over a terminal box.
vi) Instrumentation

UPGRADATION OF B.F NO. 1 PAGE 3.107
accessories
Depressurizing Valves shall be installe
d in the depressurizing line connecting
i)
Medium Specification
Medium Hot flue Gases
Operating temperature 300
ii)
Technical Specification
Quantity 3 Nos.(1 no. for each stove)
Type Double eccentric butterfly valve
with laminar seal of SS and
Graphite
Max. operating pressure 350 kpa
Design Pressure 450 kpa
Differential pressure 350 kpa
Design temperature 600
Mounting position In vertical / horizontal pipe
iii)
Material Specification
Valve discs -do-
Flanges& companion flanges
Shaft AISI 410
Body seat IS 2002 (G
iv) Construction / Special Features
The offered valve shall be of double
eccentric type with flanges. The body
of valve shall be of welded steel co
nstruction. Laminar seal to be provided
in the disc of the valves. Seat pressu
re testing of the valve shall be done
from pressure side of the disc.



UPGRADATION OF B.F NO. 1 PAGE 3.108
v) Actuator
Valve operation shall be by means of el
ectrical actuator of suitable reputed
make like AUMA/ BEACON ROTORK / BONFIGLIOLI. Gearbox shall
be mounted separately and connected
by a shaft. Hand wheel shall be
provided for manual operation. Electrics
shall be pre-wired and terminated
over a terminal box.
vi) Instrumentation
Manual Gas bleeder valves shall be insta
lled in gas down comers 1 no. before and
1 no. after each Goggle Valve and also 1
no. in the gas header to bleed off the
Medium B. F. gas and air mixture
Dust content 40 mg/Nm
Operating temperature 50
ii)
Technical Specification
Quantity 7 Nos.(2 nos. for each stove, 1
before and 1 after Goggle Valve
Type Standard CI Gate Type Valve
Max. operating pressure 6 kpa
Design Pressure 25 kpa
Differential pressure 12 kpa
Design temperature 100
iii) Mounting position In vertical / horizontal pipe
iv) Construction / Special Features
The offered valve shall be of standard
CI Gate type with flanges. Seat
done from both sides of the disc.
v) Actuator
Valve operation shall be by means of
manual actuator. Hand wheel shall
be provided for manual operation.

UPGRADATION OF B.F NO. 1 PAGE 3.109
12)

These valves are required to cut off ga
s flow in the line during maintenance and
shall be installed in horizont
i)
Medium Specification
Medium
B. F. gas of CV 778 kCal/Nm
Composition:-
Operating temperature 60
ii)
Technical Specification
Quantity 3 Nos. ( 1 for each Stove)
Operating pressure 6 kpa
Design Pressure 25 kpa
Design temperature 100
Mounting Position Vertical in horizontal pipeline
iii)
Material Specification
Valve plate -do-
Flanges & compani
on flanges -do-
iv) Construction / Special Features
The offered valve shall be of plate type with flanges. The body of valve
shall be of welded steel construction. Seat pressure testing of the valve shall
v) Actuator
Valve operation shall be by means of
onnected to the
common Power Pack. Clamping and declamping shall be done by hydraulic
actuator and linear movement by electro
-mechanical actuator. There will be
from the Stove Platform also.
vi) Leak Rate: Nil in closed position
These valves are required to cut off air flow in the line during maintenance and
shall be installed in horizontal air branch lines.



UPGRADATION OF B.F NO. 1 PAGE 3.110
i)
Medium Specification
Medium Combustion Air with dust
content of 16 mg/Nm
Operating temperature 50
ii)
Technical Specification
Quantity 3 Nos
Operating pressure 6 kpa
Design Pressure 25 kpa
Design temperature 100
iii) Material Specification
Valve plate -do-
Flanges & compani
on flanges -do-
iv) Construction / Special Features
The offered valve shall be of plate ty
pe manually operated with flanges. The
body of valve shall be of welded steel
construction. Seat pr
essure testing of
the valve shall be done from
v) Leak Rate: Nil in closed position
Hydraulic Power Pack
Hydraulic power pack along with in
Hot Blast Valves 3 Nos.
Gas Shut-off Valves 3 Nos.

Back Draught Valve 1 No.
Air shut-off Valves 3 Nos.
Mixer Shut-off Valve 1 No.
Cold Blast Valve 3 Nos.
Goggle Valve for gas lines 3 Nos.

UPGRADATION OF B.F NO. 1 PAGE 3.111
Hot Blast Valve 1 No.
Gas Shut-off Valve 1 No.

Back Draught Valve 1 No.
Goggle Valve 1 No.
Air shut-off Valve 1 No.
Mixer Shut-off Valve 1 No.
Cold Blast Valve 1 No.
All above valves shall be considered



UPGRADATION OF B.F NO. 1 PAGE 3.112
(ii) Pumping Unit
The pumping unit shall consist of pu
mp, motor, venting valves, control

UPGRADATION OF B.F NO. 1 PAGE 3.113
The initial fill of oil required for
hydraulic power pack shall also be
All butt-weld joints shall be made
by Tungsten Inert Gas Welding only.



UPGRADATION OF B.F NO. 1 PAGE 3.114
continuously for some time (De-aera
tion must be done before normal
operation and checking of leakage).
Centralized Grease Lubrication System:

UPGRADATION OF B.F NO. 1 PAGE 3.115
The feeders shall be supplied with
mounting pads of 15mm thickness
and screw. Plastic caps to be provided for all openings.
e working pressure of 250 kg / cm
the bores should be honed and piston
and slide valve should be heat
treated and ground. Leakage test will
be conducted with a lubricant
with viscosity of 120 to 150 CST at 50
C. The feeder should be tested
at 250 kg / cm
over a period of 2 minutes in each extreme position of
the piston. The rate of
any branch should not
exceed three drops per minute. Pressu
re for free movement of piston
i.e. against no load shall not exceed 20 Kg/cm
Isolation Valves : Isolation Valves
shall be provided in sufficient
quantity as per requirement of all Valves.
All the main line and branch lines upto the dose feeders shall be shown
as NB pipes of sch 80 ASTM A106 Gr
. B. Seamless black pipe or DIN
2448 St 35 ND 16 bar upto 30 NW
and DIN 2448 St 35 ND 160 bar
from 40 NW & above.
Lines from dose feeder to the points
of lubrication shall be shown as 10
mm OD x 1.5 mm thick carbon steel
of annealed tubes as per DIN
2391/C material St 35.4 NBK to
DIN 1629 or to IPSS 1-02-033-085.
Fittings (Tee, Elbow, reducer, coupling)
for NB pipes will be shown as
made of 3000 lb forged steel ASTM
All Expansion Joints shall be manufact
ured with standard materials and
workmanship. Convolutions will have
1 (one) layer, heavy wall type
convolutions, weld ends and connection stri
ps. The material of convolutions shall
be Incoloy 825. The chemical composition of Incoloy 825 is given below:
C : 0.05 max.
Si : 0.50 max
Mn : 1.00 max
Cr : 19.5 to 23.5
Ni : 38 to 46
P : 0.03 max
S : 0.03 max
Mo : 2.5 to 3.5
Ti : 0.6 to 1.2
Al : 0.2 max
Cu : 1.5 to 3.0



UPGRADATION OF B.F NO. 1 PAGE 3.116
Fe : Remaining
: Structural steel
as per IS 2002:2009,
These Expansion Joints shall be assembled properly within allowable accuracy
rious stages of manufacturing
Expansion Joints shall be designed,
manufactured, assembled and tested in
accordance with the latest
Chequer (Refractory) Supporting Structures (Columns, Grids &
Girder)
All the items of Chequer Supporting St
ructures (i.e. Columns, Grids &
Girders ) shall be supplied as per upgr
aded technology. The material for the
Columns, Grids and Girders shall be a
Capacity of the offered EOT Crane fo
r Stove House shall not be less than
15t. Capacity of Electric Hoists wherever required shall be decided by the
Bidder based on requirement. Crane and
Electric Hoists shall be of rugged
design suitable for long life under specifi
ed duty and site conditions, trouble
free operation and easy maintenance.
Design, manufacture, installation and te
sting of the EOT Cranes & Electric
Hoists shall be in accordance with
latest revision of IS 3177:1999, IPSS,
IEC & IS 3938:1983 as applicable to
the respective equipment / items of
For the purpose of equipment design,
the ambient conditions are to be
considered as 55
C maximum ambient temperature & 100% maximum
relative humidity. All equipment shall be de-rated for 55
C. Atmospheric
conditions of Stove House area will be sa
me as Blast Furnace area i.e. dust
All equipment / items shall generally comply with the latest revision of the
All equipment / items shall also comply with the statutory requirements of
the Government of India and
the Government of Jharkhand.
Lowering speed with regenerative br
aking shall not exceed 3 meter /
minute.
Technical parameters for EOT Crane and Electric Hoist :
a. Type Double Girder
Motorised Trolley
Mounted Wire Rope type

UPGRADATION OF B.F NO. 1 PAGE 3.117
b. Capacity 15t As per requirement
c Span (m) As per requirement----
d Lift (m) 30 (approx.) As per requirement
e. Length of
Travel (m)
32 (approx.) As per requirement
f. Location Indoor Indoor
g. Quantity 1 (One) As per requirement
h. Speeds
(a) Hoisting &
6m/min (max
3m/min (min
As per requirement
(b) Cross Travel10 m/min As per requirement
(c ) Long Travel 20m/min ------
i LT Rail CR100 ------
j No. of falls 4 4
k Duty Class Class II Class II
Pendant Push
movement of the
Pendant Push
Button Station
independent of the
movement of the
Trolley of the
Pendant Push Button



UPGRADATION OF B.F NO. 1 PAGE 3.118
Platform
Pendant Push
operated from the
platform at
suitable level,
Pendant Push Button shall
be operated from the
platform located for
maintenance of Back
Draught Valve and
suitable locations for other
norms for the
tolerances in
Structural
assembly and in
parameters
Sub-assemblies / units shall be designed such that they can be dismantled
quickly without disturbing the nei
ghbouring units with which they are
ll be arranged for conve
nience of operation,
inspection, lubrication and ease of
replacement with minimum down time.
Safe access for maintenance and remova
l of all parts shall be ensured
Quality and Workmanship
Workmanship and materials shall be of
good tested quality suitable for the
defined purpose and in accordance with
latest relevant Standards covered
Painting of Hot Blast Main
One coat (DFT 20 micron) of heat re
sistant finished paint (F-9 as per
on outside surface of pipe segment after fabrication and
two coats of heat resistant finished paint (F-9 as per
after erection shall be applied.

UPGRADATION OF B.F NO. 1 PAGE 3.119
One coat of epoxy primer (P-5 as per
of DFT 40 micron
(min) thickness on the inside face of
pipe segment after fabrication and one
coat (P-5 as per
after erection shall be applied
Surface preparation for the above sh
all be St-2 standard as per
One coat (DFT 20 micron) of heat re
sistant finished paint (F-9 as per
on outside surface of pipe segment after fabrication and
two coats of heat resistant finished paint (F-9 as per
after erection shall be applied.
Two coats of epoxy primer (P-5 as per
of DFT 40
micron (min)/coat thickness on the inside face of pipe segment after
Surface preparation for the above sh
all be St-2 standard as per
Inspection/ Testing
Leakage and Pressure Testing of stoves
Leakage Test
After erection of the stove



UPGRADATION OF B.F NO. 1 PAGE 3.120
Pressure Test
Raw coal of size upto 50 mm will be brought
to existing coal storage of B.F No. 4
yard by railway wagons. The existing raw co
al storage yard made for CDI system
of B.F No. 4 will be common for CDI syst
em of B.F No. 1 also. Coal for CDI
system of B.F No. 1 will be transported to existing CDI building through series of

UPGRADATION OF B.F NO. 1 PAGE 3.121
existing conveyors. Coal will be supplied through these conveyors up to the raw
coal silo envisaged for B.F No. 1. Battery
limit for CDI plant (
under this package)
shall start from receiving raw coal above raw coal silo.
Raw Coal Silo of 300 m
capacity shall be made of
steel and lined with 12 mm
thick liners of Mn Steel conforming to
IS 276:2000 Gr.1 in the cylindrical inner
surface of silo for receiving and storing
the coal from reversible conveyor. In
conical portion and 1 m above
the conical portion, wear pl
ates hard facing overlay
of 6 mm shall be provided over base plat
es. Overlay shall have hardness of 62-64
HRC. The silo shall be provided with suit
able gate at the bottom to control the
flow of coal from the raw coal silo. Level and weight measuring system will be
provided for ascertaining the quantity of coal stored in the silo. Necessary
Design of the grinding mill will be such that it should grind 80% of total coal
below 90 microns and maximum size will not
be more than 1 mm size. Moisture
content will not be more than 1% in the output from the grinding mill. As grinding
mill is the heart of CDI complex, therefore,
reliability of grinding mill shall be
almost 100%. Design of the mill shall be robust with smooth operation under most
rigorous conditions. Capacity of the mill shall be selected in such a way that it



UPGRADATION OF B.F NO. 1 PAGE 3.122
Ash content : 12-15%
in ash : 50% (approx.)
Volatile matters : 20-30%
Thermal value of the coal
: 6000 kcal/kg (approx.)
Raw coal size : 50mm
Fineness of dust : (80% 90 microns)
The design of the grinding & drying circuit will also be suitable for the following
parameter of flue gas:
CO: 4000 PPM (max.) and O
12% (max.).
Technical description:-
In this mill grinding, drying, classifying a
nd conveyance are effected in one single
compact unit. The mill will operate continuously.
The mill supplied shall be of pressure and shock resistant design for coal grinding.
The material to be ground is fed centrally to the coal mill.
The material to be ground falls on the rotating mill yoke and is moved under the
grinding balls by means of centrifugal for
ce. It is ground and l
eaves the grinding
area via the exterior circumference of the mill yoke. Here a hot gas flow, which is
moving upwards, takes over the material
and conveys the ground materials to the
classifier. During flow conveyance the ground
material is dried. In the classifier
the oversized grain is separated and is
led back to the grinding area. The ground
material of end fineness leaves
the mill with the gas stream.
The grinding fineness shall be re-adjuste
d during operation. Foreign matter, which
reaches the mill (such as stones, steel partic

UPGRADATION OF B.F NO. 1 PAGE 3.123
3.5.7.3 Pulverised Coal Storage and Injection Unit
The Bag Filters will be provided to separate the Pulverised Coal from the outlet
gas stream of Grinding Mill. The negative pr
essure created in the line by means of
dedicated I.D. fans continuously sucks these gases. The Bag Filters will be of



UPGRADATION OF B.F NO. 1 PAGE 3.124
Each pressure vessel shall have the nece

UPGRADATION OF B.F NO. 1 PAGE 3.125
20 nos. of injection lances of special steel
quality for fine coal injection to blast
furnace shall be provided. These lances are high temperature resistant and
withstand blast furnace heat for a r
easonably long period (t=1200oC) with non-
For handling of various equipment of CD
I system during maintenance activities,
6 nos. of electric hoists including 2 nos. of
10t capacity electric hoists, 1 no. 5t
2t capacity electric hoist.
In general it should be as per General Te
enclosed with this
In addition to above electric hoists sha
ll be provided for handling of equipment
having weight 1(one) tonne
or more and suitable hand
ling facilities shall be
provided for remaining equipment ha
Staircases and maintenance platforms will also be provided for adequate approach
to the equipment, wherever necessary.
Electrically operated hoist sh
all be supplied as per General technical specification
enclosed at
3.5.7.5 Lubrication System
Lubrication system for all equipment shall
be, in general, as
specification enclosed at



UPGRADATION OF B.F NO. 1 PAGE 3.126
3.5.7.6 Regulations and Standards
The components of equipment shall be designed, assembled and tested in
accordance with the standard
s of National Standards Institutions of the country
where these are manufactured, Standards
laid down by Statutory Authorities of
necessary approval from Indian Statut
ory Authority/ Authorities and other
concerned agencies and submit the same
to Employer. All costs on this account
will be borne by Principal contractor/ Associate.
As far as possible the contractor shall us
e Indian standard gr
ades of steel for
fabricated /machined items. If any item is
made using some other standards, then
copy of the standard in Eng
lish version alongwith Indian equivalent standard shall
be submitted.
Granulated Slag Disposal System
Slag granulatin and diposal system
shall be as per enclosed drawing no.
Blast Furnace (B.F.) No. 1 has once thr
ough type high pressure and low pressure
cooling system similar to other Blast Furnaces of RSP.
High pressure water is supplied through co
ld pumps installed in existing high
pressure Pump House. A common water supp
ly header from pump house to Blast
Furnaces is laid on trestles. This common
header runs parallel to B.F. 1 to 3.
Tapping for B.F. 1 has been taken near the furnace from the common header. The

UPGRADATION OF B.F NO. 1 PAGE 3.127
pumps installed in Pump House. A common
cold water supply header from pump
house to Blast Furnaces is laid. This comm
on header runs parallel to B.F 1 to 3.
For B.F. 1, tapping has been taken n
ear the B.F 2 from the existing common
The B.F. No. 1 is planned to be upgr
staves and SG iron
staves are envisaged in diffe
rent zones. For effective a
nd efficient working of BF
cooling system and also to increase the campaign life, it is proposed to provide
closed circuit cooling system
using soft water (SW) with a view to avoid chokage
and deposition of salts inside the cooling elements.
The upgraded B.F No. 1 shall have a closed
loop cooling system, which shall be
suitable for design BF top pressure of 2.0 kg/cm
(g) (operating) and design
operating hot blast temperature of 1200
The closed circuit cooling system shall comprise mainly of the following
facilities/systems:-
1. Primary SW Cooling water System
2. Secondary IW Cooling water System
3. Emergency Cooling water System
1. Primary SW Cooling System
a.) Primary cooling water system consis
(Low pressure
circuit)
: This shall be used to cool the Copper and
Iron staves of Bosh,
Belly and Stack, Stove
valves (hot blast valve, chimney valve &
back draft valve)
circuit)
: This shall be used for Tuyere, Tuyere Coolers
b.) In Circuit No. 1, there shall be 3
Nos. (2W+1S) of electrically driven
recirculation pumps. There shall also
be a Diesel engine driven pump of
adequate capacity & head. In case of
failure of electrically driven pumps,
this shall supply water in this circuit. The Diesel engine driven pump
shall be equipped with Diesel tank,
battery start-up system and battery
charging system.



UPGRADATION OF B.F NO. 1 PAGE 3.128
For circuit No. 2, there shall be 2 No
s. (1W+1S) of electrically driven
Booster pumps. There shall be a Dies
el engine driven pump of adequate
capacity & head. In case of
failure of electrically driven pumps, this shall
supply water in this circuit. The Diesel engine driven pump shall be
equipped with Diesel tank, battery st
art-up system and battery charging
system.
c.) Necessary dosing systems shall be there for on-line dosing on the suction
2. Secondary Industrial Water (IW) Cooling System
The objective of this system is to cool
The emergency cooling water system shall be there to take care of the
protection of various cooling elements
of Blast Furnace as well as stoves in
case of power failure, which
would lead to stopping of
electrical motor driven
pumps. This system mainly consists
of an emergency ove
rhead tank and a
diesel engine operated pump.
A minimum 1550 m
(useful volume) SW overhead emergency tank made of
steel (50m staging) shall be there. From this tank, Soft water shall be provided
to take care of the emergency cooling of furnace and Hot Blast Valves,

UPGRADATION OF B.F NO. 1 PAGE 3.129
The diesel operated pump shall be starte
d in case of power
failure. This pump
shall circulate the SW (from Intermedia
te Tank) through emergency tank to BF
and various valves in stoves. The ca
pacity of the pump shall be around 1000
/h (minimum). This pump shall be e
quipped with Diesel tank, battery start-
up system and battery charging system.
The diesel operated pumps is required
to be operated/ run
every day or every
alternate day for at least 4 hou
r to keep it fit and to make sure that it shall be
available in case of emergency.
The Cooling systems shall be designed to ta
ke care of the entire heat load of Blast
Furnace including Stoves. The equipment of cooling systems shall have the
design capacity which shall be more than
the entire heat load at least by 10%.



UPGRADATION OF B.F NO. 1 PAGE 3.130
pH 7.0
Phenolic alkalinity mg/l 2.5
Total alkalinity mg/l 52.5
) mg/l 64.0
) mg/l 64.0
Chloride (as Cl) mg/l 52.5
Sulphate (as SO4) 2.25
Calcium (as Ca) mg/l 7.40
Magnesium (as Mg) mg/l 5.80
Iron (as Fe) mg/l 23.5
Turbidity NTU 25
Conductivity s/cm 155
Suspended Solids 25.0
Total dissolved Solid 168.0
The quality of available Industrial Water
may vary with seasons
. The analysis of
Diesel engine operated pump shall be pr
ovided in the both primary circuits of
each BF which shall operate automatically in
case of power failure. All electrical
and instrumentation facilities for this sh
all be provided. The capacity of the pump
shall be such that it can supply required am
ount of water to the coolers of BF and
facilities in stoves area during emergency.
An intermediate tank of 1550 m
(useful volume) capacity above ground level
(outside bottom level of
the tank 1.0 m above ground leve
l) shall be provided to
store the Soft water generated from Soft
water plant. Soft water storage tank
capacity shall be able to cater at least
30- 45 minutes during power failure. This

UPGRADATION OF B.F NO. 1 PAGE 3.131
The Soft water close loop cooling system
shall have requisite nos. of expansion
tanks, de-aerators and dosing systems. Th
e dosing system shall be provided for
Soft water at intermediate tanks as well as on delivery lines of the Soft water
Emergency shell spray system/ facilities sh
all be provided. The water to be used
for this shall be industrial water. For th
is 2 nos. of pumps (1W+1S) of adequate
All necessary piping system shall be provided along with valves, pipe fittings
supports and other equipment/ items to make
the cooling systems complete in all
respects.
Fire extinguishers and fire
fighting hydrants shall be
provided in primary pump
house, Soft water plant building and
other places where it is necessary.
Exhaust fans or ventilation system as
specified in the subs
equent clauses for
primary pump house, Soft water plant
building and other places as mentioned
Facilities for steam / Nitrogen purging,
inside the furnace, shall be provided.
As a general rule on the up stream and dow
n stream of any equipment an isolation
valve shall be provided. It shall be
electrical/ pneumatic actuator operated
wherever it is necessary. But valves of
The entire existing cooling system of
Blast Furnace No. 1 after the existing
isolation valve near the common header
shall be dismantled. The tentative
Description
Dismantling of existing Valves (
DN 150)
Dismantling of existing Valves (DN 200 and above)
Dismantling of existing Pipes & fittings (
Dismantling of existing Pipes
Dismantling of existing Pipe



UPGRADATION OF B.F NO. 1 PAGE 3.132
Dismantling of utility piping work shall be done after taking shut down and
blanking of the service pipelines a
nd obtaining written clearance of the
Care shall be taken to avoid damage to adjoining facilities and structures while
dismantling and disposal of dismantled ma
terials. Dismantled material shall be
disposed off as directed by Employe
r within a lead
distance of 10 km.
The battery limits and area of work indi
cated above are indicative only. Actual
dismantling and replacement work shall be
of the existing systems and instructi
ons of Employers site engineer. The
above-said drawings shall be handed
over to the Successful Bidder only. In
absence of drawings the Successful
Bidder shall carry out the dismantling
work as per site condition and instructi
on of site engineer of Employer. The
Successful Bidder shall assess the area of
work for lines for services for which
this contract (within battery limit).
All the items supplied shall be of reputed
make (As per list of Preferred Make):
i) Tentative Summary of Majo
r Equipment for each Furnace:
Item Description Qty
Overhead Emergency Tank
Capacity = minimum 1550m (useful volume)
Staging height = 50m (minimum)
Capacity = minimum 1550m (useful volume)
RCC construction above ground level
Primary Circuits Recirculation Pump with Motor
(2W+1S)
Type- Horizontal, split ca
sing, Centrifugal Pump
Flow (m/hr) = As per system requirement
Differential Head(dH) = As per system requirement
Motor rating (kW HT) = As per system requirement
considering margin and de-
Pump & Motor assemble in common frame

UPGRADATION OF B.F NO. 1 PAGE 3.133
Item Description Qty
Recirculation Pump
Type- Horizontal, split casing Pump
Differential Head(dH) = As per system requirement
Pump coupled with diesel engine fuel handling system
Primary Circuits Booster Water Pump
(1W+1S)
Differential Head(dH) = As per system requirement
Motor rating (kW HT) = As per system requirement
considering margin and de-
Differential Head(dH) = As per system requirement
Primary Circuits Circulati
(1W+1S)
Type- Horizontal, split casing.
Flow =150m/hr (minimum)
Differential Head(dH) = 70m
Motor rating (kW LT) =
Diesel Engine Operated Circulation/ Makeup Pump
Type- Horizontal, split casing.



UPGRADATION OF B.F NO. 1 PAGE 3.134
Item Description Qty
Flow (m/hr) = 1000 m
/h (minimum) 1500
Differential Head(dH) = 70m
(1W+1S)
Flow = As per system requirement
Differential Head(dH) = As per system requirement
Motor rating (kW HT) = As per system requirement
(2W+1S)
Flow (m/hr) = As per system requirement
Pressure = As per system requirement
Heat Exchanger (Plate Type) for each Primary circuit
(2W+1HS+1
Primary Side (Soft water)
Flow (m/hr) = As per system requirement
Design Pressure = As per system requirement
Test Pressure = As per standard
Primary T
= As per system requirement
Medium = Soft water
Secondary Side (Industrial water)
Flow (m/hr) = As per system requirement
Design Pressure = As per system requirement
Test Pressure = As per standard
= As per system requirement
each primary
circuit
Capacity = As per system requirement
Material IS:2002-2009 Grade-2

UPGRADATION OF B.F NO. 1 PAGE 3.135
Item Description Qty
1 No. for
each primary
circuit
Capacity = As per system requirement
Material IS:2002-2009 Grade-2
Soft water plant
Fully automated
PH 7.5
Phenolic alkalinity 2.5
Total alkalinity 52.5
Total hardness (CaCO
Ca hardness (CaCO
Chloride (as Cl) 2.25
Sulphate (as SO4) 23.5
Calcium (as Ca) 1
Magnesium (as Mg) 1
Iron (as Fe) 1.6
Chloride (as Cl)
Turbidity 4
Conductivity 155
Suspended Solids 10.0
Total dissolved Solid 168.0
Dosing station for Chemical treatment
(A separate dosing unit and
chemicals supply shall be by
a third party agency under Successful Bidders
responsibility. Successful Bidder shall be responsible for
this service for three months)
system
requirement.
24 Sump Pump (wherever requi
red in pump house) 2 nos.



UPGRADATION OF B.F NO. 1 PAGE 3.136
Item Description Qty
25 Corrosion Inhibitor Dosing st
Tank, Injection pump, Stirre
r, Flow measurement /
The selection of Pumps shall be ca
rried out by the Successful Bidder to
suit the requirement of the syst
em supplied by him. Technical
Specification shall be as
TECHNICAL SPECIFICATION FOR PUMPS
Type Horizontal
Split volute casing
Submersible
Quantity As per system
requirement + one
stand-by in each
As per system
requirement + one
stand-by in each
As per system
requirement +
one stand-by in
Casing CI (IS:210-2009, FG
CI (IS:210-2009, F
CI (IS:210-2009,
Impeller SS (ASTM A351, CF
SS(ASTM A351, CF
Shaft SS (AISI-410) SS (AISI-410) SS (AISI-410)
Bearing Heavy duty,
antifriction deep
grooved, self
aligning type ball
antifriction deep
grooved, self aligning
antifriction deep
grooved, self
aligning type ball
Duty Continuous Continuous Intermittent
Temp. of
fluid (max.)
As per design of
Code for IS-1520: 1980/ API IS-1520:1980/ API -

UPGRADATION OF B.F NO. 1 PAGE 3.137
Pump
Pump
Hydraulic Institute Hydraulic Institute Hydraulic
Institute
As per code As per Code As per Code
Noise Level 85 dB at 1m
distance
85 dB at 1m distance 85 dB at 1m
distance
(max.) 75
(max.) 75
(max.)
Seal Mechanical Self flushed gland
Double, leak
proof, mechanical
seal in oil
chamber
Ambient
temperature
Bearing life 50,000 h (min.) 50,000 h (min.) 20,000 h (min.)
speed
1450 rpm 1450 rpm 1450 rpm
Static &
Dynamic
Rotating parts of all the pumps sh
all be statically & dynamically
During emergency the diesel engine
operated pump shall be operated.
An overhead day tank shall be pr
ovided to store the diesel. The
capacity of the day-tank shall be suffi
cient for 8 hour continuous run of
the pump. This tank shall be filled
with diesel by means of a hand
pump from the diesel drum. Howe
ver, the Successful Bidder shall
supply 2 nos. of hand pumps. The dies
el engine operated pump shall
start automatically in case of power failure. This engine shall be



UPGRADATION OF B.F NO. 1 PAGE 3.138
equipped with necessary battery star
t-up and battery charging systems
of adequate capacity for smooth op
ry connections
electrics and instrumentations are also
in the scope of work. The diesel
engine shall be suitable for the pump. It shall work on LDO or HSD
subject to approval of the Employer
(RSP). This pump shall be located
in primary P.H.
Soft Water Plant
The capacity of the plant shall be 2 x10 m
/h (mimimum). Soft water plant as per
system requirement. The Soft water plant shall be ion exchange based. These
plants shall be fully automatic and r
un without human intervention. The plant
shall be equipped with all facilities (inc
luding electrical and instrumentation) for
producing required quality of Soft wate
r and material handling equipment.
The Soft water from Soft water plant to
the intermediate tank shall be transported
through seamless SS pipe of suitable size. Th
e units of Soft plant shall be modular
Filters
The selection and sizing of Filters shall be carried out by the Successful Bidder to
suit the requirement of the system
designed/ supplied by him. Technical
TECHNICAL SPECIFICATION FOR FILTER
Quantity 3 Nos. (2W+1S)
Installation In horizontal pipe
Pressure Drop As per requirement
C 40
Mesh Opening (mm) As per requirement
Body & Cover CI IS 210- 2009, FG 300
Spindle SS (AISI 410)
Companion flanges MS- IS 2062- 2006, Gr. B
Valve Disc CI (IS 210-2009, FG 300)

UPGRADATION OF B.F NO. 1 PAGE 3.139
O-ring of Nitrile Butadine
Accessories Two nos. plug type
valves, pressure equalising valve, changeover
mechanism with hand wheel, foundation bolts, nuts,

Main isolation valves for any
utility pipelines shall be ga
te type. Valves at suction
& delivery side of all pumps shall be motorised gate type.
Type Code Rating Test
(kg/cm
1. Gate Valve
Trim : SS-410/304
2. Tight shut-off
Butterfly Valve
Body & Disc :
graphite Iron
as per IS:
Body shall be Nylon
coated. Seat shall be
3. Double flanged
Butterfly Valve



UPGRADATION OF B.F NO. 1 PAGE 3.140
Type Code Rating Test
(kg/cm
Seals : PTFE
4. Ball Valve
BS-5159 Class
Ball & Trim : SS-
5. Swing check
Trim : SS-304/316
1. Gate Valve
API 600 PN 1.0
216 WCB)
Trim : SS-304/316
2. Swing Check
(Wafer Type)
API - 1868 Class -250Body : 24.0
(ASTM A 216 WCB)
Trim : SS-304 /316
3. Tight Shut off
Butterfly Valve
-do- -do-
With soft seal
4. Ball Valve
BS-5351 Class
Trim & Ball : SS-
Heat Exchangers
The selection and sizi
ng of Heat Exchangers shall be
carried out by the Successful
Bidder to suit the requirement of the syst
em designed/ supplied by him. Technical
TECHNICAL SPECIFICATION OF HEAT EXCHANGERS

UPGRADATION OF B.F NO. 1 PAGE 3.141
1. Quantity 4 Nos. (2W+1HS+1CS)
2. Type : Plate type
3. Type of flow : Cross flow (preferred)
6. Pressure drop (mWC) : 1.0 kg/cm
(max.)
7. Heat load : As per system requirement
8. Max. Operating pressure
Primary side
: As per system design
9. Test pressure
Both Primary and Secondary sides
: 1.5 times max operating pressure
10. Plate material : AISI 316
11. Plate thickness : 0.5mm (min.)
13. Frame : IS-2062-2006 (Gr. B)
14. Upper & Lower Carrying bar : IS
15. Tie Rods : IS 1367- Gr. 5.6
17. Fouling Factor 20% to be considered.
Expansion Tanks
Tanks shall be as per syst
em requirement. However, the MOC shall be MS (as per



UPGRADATION OF B.F NO. 1 PAGE 3.142
Emergency Tank
Minimum 1550 m
(useful volume) overhead Soft Water Storage Tank of steel
construction shall be provided for emergency situation. Height of the tank bottom
Minimum 1550 m
(useful volume) intermediate Soft water storage tank of RCC
construction shall be provided. The tanks
The pipes for different services shall be
as per the table given below. However,
for water pipes of size DN 600 & above may
be spirally welded
/ fabricated type.
In case of fabricated type, material shal
l be as per the note
indicated below the
Technical Specification of Piping System
Service Standard/Code Type Duty/ Schedule No.
Pipes
Water
IS : 1239-2004 (Part-1)
or IS : 1978-1982 (upto
ERW Heavy Duty
Water
IS : 3589 2001 Gr. Fe-
410 (above DN 150) or
ERW 6.4 thk. For DN 200-DN
7.14 thk. for DN 400-DN
Soft Water ASTM A 53, Gr. B Seamless Schedule 40
Soft Water ASTM A 312 TP 304 Seamless Thickness subject to
approval of Employer
Pipes of size above DN 500 may be fabricat
ed type. In that case material shall
be as per IS: 2062-2006(Gr. Fe410Cu WA).
The copper percentage in the
material to be used for manufacturing
the pipes and pipe fittings shall be 0.17

UPGRADATION OF B.F NO. 1 PAGE 3.143
In case of buried pipe the thickness of
pipe shall be 10 mm (min.) for size DN
400 to DN 600. It shall be 12 mm for pi
pe size above DN 600. It shall be
Supporting shall ensure freedom for expa
nsion and absence of movement as
well as restrict sagging to reasonable limits
Maximum permissible spacing
25 2.1 2.7
40 2.7 3.2
50 3.0 4.0
65 3.4 4.2
80 4.0 4.7
100 4.3 5.2
160 5.2 6.4
200 5.8 7.3
250 6.7 8.0
300 7.0 9.1
350 7.6 9.8
400 8.2 10.7
450 8.5 11.3
500 9.1 11.8
600 9.8 12.8



UPGRADATION OF B.F NO. 1 PAGE 3.144
Wherever no self-compensation can be used to cater for the
expansion/deformation of the pipelines,
expansion joints shall be provided
1 Upto DN50 0.4-1.0 m/s
2 DN65 to DN150 0.6-2.0 m/s
3 DN200 & above 1.0-2.4 m/s
Erection - General
All the pipelines shall be laid by the Successful Bidder on the basis of
approved drawings. The interfacing and
joining of the proposed pipe lines
with the existing pipe lines/ equipment/ fa
cilities are in the scope of work of
the Successful Bidder.
Before erection, pipes, valves, fittings

UPGRADATION OF B.F NO. 1 PAGE 3.145
For mitre bends on the pipelines, welded
butts shall be located at a distance
All G.I. pipes of sizes DN15 to DN50 sha
ll be screwed joints. All other joints
All field welding shall conform to BS-
4515. All other welding for pipelines shall
conform to BS 2633 (Class 1 welding) or
equivalent. Welding
of steam pipelines
shall be carried in conformity to IBR. However, the followings are to be
followed.
Assembly of elements shall be carried
out with devices that ensure correct
mutual location of such elements. Asse
mbled elements are kept fixed during
welding by the use of suitable clamps.
As a rule, butt welding shall be car
ried out without interruptions. No
interruption shall be allowed till at
least 50% of welding thickness is



UPGRADATION OF B.F NO. 1 PAGE 3.146
Welding Quality
All field welding of carb
on steel shall be executed by qualified welders using
qualified welding procedure as per
BS:4515. For steam pipe welding the
per the requirement of IBR.
Besides systematic operational control
in the process of pipelines erection,
the quality of welded joints shall also
be checked by visual inspection and
non- destructive testing as stipulated
in BS:4515. However, All the welded
joints shall be subjected to visual in
Pipes shall be arc welded with matchi
ng electrodes as per BS 2633 (Class- 1)/
Welded shaped parts shall have smooth outer and inner surface.
Only screwed and socket joints shall be
used on these pipes. Welding of these
pipes shall not be permitted. The Successf
ul Bidder shall be responsible for
the preparation of the thread
All joining and branching shall be done with screwed fittings.
Mating surfaces shall be coated with white lead after thread cutting.
All the joints sha1l be water tight.
sful Bidder shall ensure that:-

UPGRADATION OF B.F NO. 1 PAGE 3.147
All grit and foreign materials are rem
oved from the inside of the valves.
All machined faces are thoroughly cleaned
and coated with a thin layer of
mineral grease before erection (e
The erection of pump and equipment incl
udes leveling, alig
their appropriate locations as per
unloading, checking of equipment / items.
and moving them into storage site
with own tools, tackles, consumable
d from RSP before final coupling of



UPGRADATION OF B.F NO. 1 PAGE 3.148
cceptance of Pipelines
Manufactured / Fabricated items shall be presented for acceptance in
Acceptance & control tests of the items
shall be carried out in presence of
the engineers of Employer.
Prior to testing, pipes shall be cleane
d up by metal swab in order to remove
the grit, sand and other solids deposite
d on the inner pipe surfaces followed
Acceptance shall be carried out as follows:-
Documentary checking of the materi
als according to the drawings/
specifications / contract.
Checking of documents attesting the
satisfactory results of mechanical
tests.
Visual examination of the welding quality and checking of the result of
Checking of the dimensions and other t
then additional tests shall be
conducted as per the instructions of site engineers of Employer.

UPGRADATION OF B.F NO. 1 PAGE 3.149
Defective spots on welded joints sh
all be chipped off and re-welded.
Caulking is not allowed for repairin
g leaky stop in welded joints. Any
connections shall be eliminated.
Unless otherwise specifie
d in the working drawi
ngs, the hydrostatic test
r services shall be as follows:-
Test pressure shall be e
qual to 1.5 times the worki
ng pressure, but not less
Hydrostatic test pressure shall be
maintained for 30 minutes. At this
After testing and acceptance all the outside
surfaces of M.S. pipes, fittings and
ducts including supports shall be clea
red of loose substance and foreign
material i.e. dirt, rust, oil, grease, slag



UPGRADATION OF B.F NO. 1 PAGE 3.150
approved make and quality. Number of coats and film thickness shall be as
per manufacturers recommendations.
Existing Gas Cleaning System
The existing system of gas cleaning is co
mmon to BF No. 1 & 2.
It consists of 4
streams. Each stream consists of a washer
and an ESP in series. Each stream is
connected to clean gas network. In the ex
isting system, raw gas from dust catcher
enters a vertical cylindrical washer at th
e bottom. In the washer, water is sprayed
from top and gas is cooled and partially
cleaned. The gas then passes through
electrostatic precipitators (ESP). The clea
ned gas from ESPs then enters the BF
Raw gas from the new dust catcher sha
ll follow the existing route of raw gas
pipe. Wet scrubbing shall be carried out
in 2 stages in th
e scrubber. The gas
shall be saturated, cooled and partially cleaned in the first stage. Water shall
be sprayed through spray nozzles, ha
tapping along with an electrically operat
ed gate valve shall be provided from
the first stage for supplying gas for
equalization purpose at furnace top. The
tapping shall be suitably connected to
the semi clean gas pipe near the dust
catcher. In the second stage, final clean
ing and pressure reduction of the gas
shall take place through variable annul
ar gap type elements. Here, water is
age shall have three annular gap
elements. Automatic control of the a
nnular gap elements shall be achieved
The second stage shall be used to control top pressure. The water discharged
from the second stage shall be pumped back
to the nozzles in
the first stage.
Operation of these pumps shall be inte
rlocked with the level control in the
second stage. Capacity and the head developed by these pumps shall be
There shall be two pumps (1W+1S).
Level control in the first stage and second stage shall be achieved by a
mechanical level control valve actuated
mechanically by lever arms (or any
other means to be specified by the Bidde

UPGRADATION OF B.F NO. 1 PAGE 3.151
Main pump group (1W+1S)
Accumulator station
Valve stand
The dirty water generated in the GCP sh
all be discharged by gravity to the
existing water treatment system. Suspende
ith the following specifications:
Top pressure : 2.0 kg/cm
Gas flow : 1,80,000 Nm
2,10,000 Nm
: 16 18 %
CO : 24 26 %
: 4 5 %
: 56 58 %
Description %



UPGRADATION OF B.F NO. 1 PAGE 3.152
Description %
: 30.3
Insolubles : 16.5
: 9.7
CaO, MgO, ZnO : 17.8
O : 19.3
, Cl : 6.4
Particle size in microns % wt less than the size
150 : 100
104 : 97
75 : 90
60 : 80
40 : 65
30 : 55
20 : 45
15 : 38
10 : 30
7.5 : 26
5.0 : 20
2.5 : 12
Pressure of water at pump delivery : 7.5 kg/cm
Pressure of water at GCP : 6.0 kg/cm
Suspended solids : 150 ppm (maximum)
Temperature : 33
Type of Construction : Outdoor
Purging medium : Steam at 5-7 kg/cm
(g), temp.
220
kg/cm

UPGRADATION OF B.F NO. 1 PAGE 3.153
Battery Limits
Gas Input from dust catcher at the existin
Raw Gas Main
To carry raw gas from dus
t catcher to the new GCP
Pipe Size : To be indicated by Bidder
Pipe Thickness : 12 mm
Material of construction : Fabr
icated from steel plate as
Operating pressure & temperature : 2.0 kg/cm
g in the raw gas pipe
Purging : By Steam and Nitrogen
Dust loading : 200 kg/m for the proposed
arrangement
Arrangement for maintenance : Suitable ladder & walkway



UPGRADATION OF B.F NO. 1 PAGE 3.154
Type : Self contained construction

UPGRADATION OF B.F NO. 1 PAGE 3.155
Water supply : Clarified water spray in 2
stage discharge
pumped to first stage.
Discharge from first stage by
gravity into the existing
launder. Drain out connection
with valve for drainage.
Noise level : Less than 85dB (A) at 1.0 m
distance
Installation : Outdoor
Other facilities : Access platform & stair case
for operation & maintenance
Handling facility for throat &
Man holes for inspection
Semi clean gas shall be
tapped after first stage.
Size : To be indicated in by the
Thickness : 10 mm
Material / Standard : IS 3589 1991 or Fabricated
from plate as per IS-2062-2006
Isolation valve : Electrically operated gate
Purging : By steam and nitrogen
Size : To be indicated by Bidder
Thickness : 12 mm
Material / Standard : Spirally welded pipe as per IS
fabricated from plate as per IS-
Isolation : New water seal and existing
Purging : By steam and nitrogen by double
valve arrangement



UPGRADATION OF B.F NO. 1 PAGE 3.156
Bidder to give in the offer their cons
idered technical opinion regarding the
suitability or otherwise of the existi
ng DN 2800 clean gas pipe (w.r.t. the new
clean gas flow and the resultant velocity)
at the outlet of resp
ective goggle valves
as the same are to be utilised for new GCP.
Recirculating Pumps

UPGRADATION OF B.F NO. 1 PAGE 3.157
Raw Gas
Semi clean gas
Clean gas
Steam / Nitrogen
Water
Slurry
Compressed air (if required)
Design & execution of piping work and specification of its components and
Service pressure and temperature
Extreme and transient working condition
Hazardous, corrosive, abrasive nature of fluid if any



UPGRADATION OF B.F NO. 1 PAGE 3.158
Water and compressed air
: C.I. gate with flange
d end and rising stem
generally as per IS:14846-2000 in PN 1
Slurry
: C.I Self lubricated taper plug valve as per
BS 5158 PN 10 with PTEE based
antifriction agent impregnated.
CI swing check valve with SS internals,
flanged ends as per IS:5312-2004, 10
Valves - Material Construction
: Carbon steel ASTM A 216 Gr. WCB
: S.S. (AISI-410)
: S.S. 316 with stellite facing
: S.S. (AISI-410)


UPGRADATION OF B.F NO. 1 PAGE 3.159
: Forged steel ASTM A 105
: S.S. (AISI-410)
: S.S. 304 or 316 with stellite facing
: S.S. (AISI-410)
Location of new GCP for BF No. 1 is shown in
1) The design of the system shall be su
ch that 100% evacuation of fumes is
achieved from the tap hole (under ope
ration), skimmer and rocking runner
during tapping of hot metal. The system
capacity shall be optimized based on
PLC operated dampers in the system,
according to the operation of two tap
holes. The control of the dampers shall be from local control room as well as
from Furnace Mudgun Control Room. The PLC shall be hooked up to the
main Furnace PLC.
2) The system shall be designed ba
i) System capacity : 4,20,000 m
/h (minimum)
ii) Inlet dust content : 5 g/Nm
(max.)
During tapping operation, dust laden fume
s alongwith air shall be drawn out by
suitable collection hoods placed by the side/ and (or) above the tap hole and the
collected fumes shall travel to the fume
ducts laid below the cast house, where



UPGRADATION OF B.F NO. 1 PAGE 3.160
fumes from skimmers and iron runner areas
lly, the fumes from
the rocking runners along with the above
Fume Collection Hoods
i) Fume Extraction at Tap Hole Area
Necessary hood shall be placed by th
e side/ above of each of the tap
hole of each cast house below the Tuyere maintenance platform with
associated under floor ductwork leading to the main fume collection
header outside the cast house bu
ilding. One no. hood/ fume extraction
duct shall be provided for at skimmer.
ii) Fume Extraction at The Rocking Runner Area:
Necessary enclosure/hood of suitable
size and configuration above the
rocking runner area with duct atta
ched to it for aspirating fumes
generated during ladle pouring to th
e main header outside the cast
ESP
i) Brief Specification of the pr
1. Quantity 1 no
2. Type Dry, Horizontal
6. No. of fields 3 (minimum)
7. Gas Temperature Bidder to design
8. Max. design temperature Bidder to design
9. Collection Efficiency Bidder to design
10. Dust handling Rotary air-lock valves, drag
11. Specific collection ar
ea Bidder to design
12. Collector electrode spacing 400 mm
13. Collecting electrode thickne
ss MOC:CRCA, 1.2 mm thickness
(minimum)

UPGRADATION OF B.F NO. 1 PAGE 3.161
14. Emitting electrode Bidder to design
14. Dust Hoppers Pyramidal
Ductwork
Ducting shall be of welded construc
tion with mitre bends, required no. of
fabric expansion joints, flanges, associ
2. Capacity 4,60,000 m
/h (minimum)
3. Static pressure at in
5. MOC of blades Suitable for the application with
wear resistant lining
6. MOC of shaft EN-8, statically & dynamically



UPGRADATION OF B.F NO. 1 PAGE 3.162
7. Drive Direct with flexible coupling
8. RPM (max.) 1000
10. Fan & motor bearing temp.
11. Fan & motor vibration m
onitors To be provided
12. Drain plug To be provided
13. Noise level Less than 85 dB (A) at 1 m
distance from source
14. Handling facility Manually operated monorail
beam with chain pulley block of
required capacity for ID fan &
CA Fan & Auxiliaries
Design Condition
Operating ambient condition for design Combustion Air fan shall be
Composition of BF Gas
The analysis of BF gas available at Rour
kela Steel Plant is furnished below for
Chemical Analysis Composition by volume(%)
18.6
0.2
CnHm -
CO 24.2
4.0
-
53.0
Density 1.34 kg/Nm
CV 833 kcal/Nm3
Dust 20 mg/Nm
(max.)
Composition of Mixed Gas
The analysis of Mixed Gas available at
Chemical Analysis Composition by Volume(%)

UPGRADATION OF B.F NO. 1 PAGE 3.163
6.4
0.2
CnHm 1.6
CO 23.4
41.8
16.6
10.0
Density 0.7244 kg/Nm
CV 3636 kcal/Nm3
System Description for CA Fan Station
Air will be sucked through a suction
duct having a common suction filter for
both the fans. Each suction duct will be
of DN1400 and will be connected to
filter. The suction duct of each Fan
will be connected to CA Fan through
Area classification Usually dusty as normally prevalent in
steel plants
Dust content in the area 20 mg/Nm
(max.)
Fan Characteristics
Service Air
No. of fans Two (one
Capacity To be decided by the Bidder
Duty Continuous



UPGRADATION OF B.F NO. 1 PAGE 3.164
Discharge Pressure at exit of
Mode of connection Directly coupled
Noise level Not more than 85 dBA at 1m from
Not more than 40
Operation Parallel during changeover period
Fan Construction
Type Simply Supported Centrifugal, single
Rated Speed 1450 RPM
Casing type Suitable for easy approach for
maintenance
Impeller type Backward Curved
Connection Flexible connection at suction and
Flow control at inlet Inlet
Shaft sealing arrangement To suit the duty
Bearing lubrication Oil lubricated
Type of coupling Flexible
Fan Motor connection Direct
Material of Construction
Casing M.S. fabricated (IS: 2062 2011)
Impeller M.S (IS: 2062 2011)
Base plate M.S. fabricated (IS: 2062 2011)
Shaft coupling M.S (IS: 2062 2011)

UPGRADATION OF B.F NO. 1 PAGE 3.165
Companion Flange M.S (IS: 2062 2011)
Filter Body -M.S (IS: 2062 2011)
Filter element- Stainless Steel
Testing
Material test for Casing, Impeller, Shaft,
Shaft Ultrasonic
Dynamic Balancing test Required
Performance test Witnessed at manufacturers work
Performance Guarantee test Witnessed at site(RSP) after erection
Field test Required
Testing standard BS 848 Part-I ( latest)/IS 4894 :1987

Fan(s) shall be designed to have the best
efficiency at the specified duty point.
The fan(s) shall be suitable for conti
nuous operation at a
ny point within the
"Range of Operation". Under all circumst
ances, the 'range of operation' of the



UPGRADATION OF B.F NO. 1 PAGE 3.166
Impeller
The impeller assembly shall be statically and dynamically balanced and designed
with critical speed substantially above
the operating speed. The impeller shall be
backward curved
. The impeller shall be designed for heavy duty and having
non-overloading power characteristics. The
impeller shall be s
ecured to the shaft

UPGRADATION OF B.F NO. 1 PAGE 3.167
temperature of 500C and power supply
conditions shall is done before
calculating aforesaid margin of 10%.
The successful Bidder shall supply following accessories along with fans
This specification broadly covers the
chnical requirement
of main utility items required fo
r installation of CA Fan station.
All the services shall be tapped from
existing lines with the respective
The gas pipelines shall be provided
with compensators (for thermal
expansion of pipeline), drain
pot, vents with sampling point,
nitrogen/steam purging system as requi
red for safe and smooth functioning
ll generally conform to
Necessary supports, trestles, platforms,
hand railings, approach ladder as
required for maintenance and operation of equipment shall be in the scope
For approach to valve a direct stai
ting platform in



UPGRADATION OF B.F NO. 1 PAGE 3.168
The face of the hand wheel of each va
lve shall be clearly marked with
words open and shut of indicate the di
rection of the rota
tion. Arrangeemnt
for limiting the travel of valve in open and shut position shall be provided
All valves shall be provided with em
The total system/installation as well as individual items shall be checked/tested
according to the test procedure to be prepar
ed by the Bidder in the form of Quality
Assurance plan (QAP) and approved by the Employer.
The manufacturer shall conduct all tests
required to ensure
that the equipment
and material to be supplied conform to the specific requirements and the

UPGRADATION OF B.F NO. 1 PAGE 3.169
shut off head or 1.5 times the duty point
pressure or whichever is higher. Test
pressures to be maintained for a minimum of 30 minutes.
Fan shall be tested for full-scale full -speed performance test. Fan shall be
operated at constant speed to establish
the full head-capacity characteristics
using air as medium; a minimum of five
points are required to plot the curve.
The performance testing Standard / C
ode to be followed
indicated in the offer.
Fan shall be tested for vibration and noi
se level. Vibration in excess of 0.04
mm at each bearing housing and fan shaft
in all direction and noise level of
more than 85 dB (A), at a dist
ance of 1m, will not be acceptable.
Electric motors shall be tested in acco
rdance with the relevant Standards
mentioned in
Heat recovery system to heat BF gas &
Air from waste flue gas of stoves shall
be designed to minimize/eliminate the
requirement of mixi
ng of CO gas to
achieve the HBT of 1200 deg C. Succe
ssful Bidder shall submit the design
calculation for the same.
Isolation facilities for heating either BF
gas or Combustion Air shall also be
Heat Recovery System consisting of
heat exchangers and other auxiliary
equipment like ID Fan, Pilot Burner with
electrics & instru
mentation shall be
provided as per requirement
of the offered system.
Heat recovery System shall be of compact
design so that same can be installed
within limited space available at the site.
All rotating equipment in the Heat Rec
overy System shall be provided with



UPGRADATION OF B.F NO. 1 PAGE 3.170
Pipelines & Valves
Mixed Gas, BF Gas
Pipeline
DN 15 to 150 ERW, as per IS 1239 Part I- 2004,
DN 200 and above Pipeline roll
ed from plates to IS 1978-
1982 spirally weld pipe, Pipe
thicknesses shall be as per As per
Flanges : As per IS:6392-1971, Table 17 slip on
made from carbon steel, IS:2062-2011.
raised faced flanged ends to ANSI
Shut
Upto DN 300 Pneumatically operated gate valve with

UPGRADATION OF B.F NO. 1 PAGE 3.171
Coal Dust Injection System
The Coal Dust Injection(CDI) system w
ill consist of flue gas supply system,
Nitrogen supply system, BF/ Mixed gas supply system, Dust extraction system,
Ventilation and air conditioning system, fi
re fighting, cooling water system for
CDI unit. General descripti
on & technical specification
for the above systems is
Flue gases from Hot Gas Generator (HGG) w
ill be used to dry out the coal in the
grinding mill as well as safe transportation medium for coal dust to the bag filters.
Stove off Gas from the Chimney shall not
be used. Necessary arrangement for
recirculation of flue gases
such as moisture eliminator
, fans, valves, instruments
for flow, pressure & temperature measurem
ent , valves ducting shall be provided
as per system requirement base
BF gas goes into the combustion cham
ber of the hot gas generator for
generating flue gases
Mixed gas is used as igniti
ng gas and shall be burnt all
the time in order to avoid the die
out of BF gas flame. Simultaneously
combustion air is mixed with BF gas fo
Quantity 1 no.
Capacity As per requirement of the system
CO & O
content
2:-
Combustion air
Centrifugal with backward curved aerofoil type
impeller
Fuel BF gas with Calorific value (CV
) and Mixed gas (CV
) for pilot burner
Requirement of Combustion Air



UPGRADATION OF B.F NO. 1 PAGE 3.172
Pressure, kPa (Guage) ~ 3.0
nser (Eliminator) is given below:
Capacity & Gas As per requirement of the system
Gas cooled from As per requirement of the system
Cooling water requirement (flow &
As per requirement of the system
Mill Bag Filters
Purpose For cleaning & separating the coal dust and flue
gases as well as to minimize the dust particles in
the exhaust flue gases to the atmosphere
Capacity To be decided by the Bidder
Air to cloth ration 1.25m
(max.)
Type of Bag material Polyacrylic
Homopolymer to suit the design
temperature
Bag filter casing MS , 5mm thick( mininmum)
Dust content in flue
gas at the outlet
50mg/Nm

URPOSE
For sucking the coal dust laden gases from the coal
mill to push through bag filters and emit it to
atmosphere through stack
Quantity 1No.
Medium to handle Flue gases
Capacity At least 10% higher volume than the bag filter
capacity
Head As per requirement of the system
Type Centrifugal, direct dr
Impeller:- Backward Curved aerofoil type

UPGRADATION OF B.F NO. 1 PAGE 3.173
Stack MS construction and designed as per
IS/International St
andards. The height of the stack
shall not be less than 45m and also at least 4m
above nearest monitoring point/top of the
structure. Necessary port
holes, caged ladder with
platform will be provided as per statutory
requirement.
Dust content in flue gas
at the inlet
150mg/Nm
Testing As per IS 4894-1987
Nitrogen Supply System
Compressed nitrogen in the coal dust inje
ction system is used for coal conveying,
inertisation, instrumenta
tion, purging of gas pipe
lines and pollution control
equipments. The oxygen and carbon monoxide c
ontent of the flue gases, are also
controlled by nitrogen injecti
on. It is also used to m
A Centralised bag filter based Dust Extrac
tion (DE) system shall be provided to
extract fugitive dusts generated at va
rious transfer points (conveyors, ground
Type Pulse jet type (On line with compartments),



UPGRADATION OF B.F NO. 1 PAGE 3.174
Capacity To be decided by the Contractor
Air to cloth ration 1.25m
Type of Bag
material
Polyacrnitrile Homopolymer to suit the design
temperature
Bag filter casing MS
MM THICK
MINIMUM
Dust content in flue
gas at the outlet
50mg/Nm
4. I D Fan There will be two ID Fans (1 W+
1 S) for DE System with Bag Filters:
Purpose F
OR SUCKING THE FUGITIVE DUST PUSHING
THROUGH BAG FILTERS AND EMIT IT TO
ATMOSPHERE THROUGH EXHAUST DUCT
Quantity 1 no.for each coal Grinding Mill (i.e-Total -
Medium to handle Air
Capacity At least 10% higher
than the bag filter capacity
Head As per requirement of the system
Type Centrifugal directly driven through flexible
Impeller: Backward Curved aerofoil type
Exhaust Duct A fabricated duct
of 6mm thick and height of
duct will be 5m above top of the building.
Dust content in flue
Testing A
Cooling Water Re-circulation System
Industrial make up water will be tapped
from existing water header coming for
BF4, CDI within 50 m from existing
pump house. Recirculation system for
cooling water circuit (for the quantity wh
ich is required continuously) will be
provided including cooling tower, pump
s (1W+1SB), provision for makeup water
BF Gas & Mixed gas for CDI will be
tapped from existing DN800 & DN150
pipeline line going for CDI of B.F No. 4. Bo
th the lines will be provided with the

UPGRADATION OF B.F NO. 1 PAGE 3.175
isolation valves and BF gas line will be
provided with water s
eal in addition to
isolation valve at tapping point. Branch
pipe line for hot gas generator will be
taken with isolation valve and blanking
facility from this header as per
requirement. Both Nitrogen & steam purgi
ng shall be consider
ed as per existing
design followed in the plant. Nitrogen a
nd steam for purging will be available at
column A/28. Technical specification of ga
s piping and fittings shall be as per
Following fire fighting system shall be
to the electrical cables
Fire fighting system will be as per stat
The General layout of facilities envisage
d for coal dust injection unit for B.F No.



UPGRADATION OF B.F NO. 1 PAGE 3.176
Turbo-blower and Auxiliaries
The new Turbo Blower shall be in
stalled in place of existing Turbo
Alternator#1 (TA#1) at Captive Po
wer Plant-I as shown in enclosed
The Blower can either be centrifugal or
axial type. The stator shall be of
fixed blade / turning blade type for ax
ial type Blower. Blower shall work
safely below the choke line. The requi
rement of anti-choke valve shall be
The Blower and Turbine shall have th
e direction of rota
tion marked by an
The following information shall be provi
ded in a name plate in an easy-to-
see position
For Blower For Turbine
Manufacturers name.
Year of manufacture.
Discharge volume (Nm
continuous and maximum condition
Manufacturers name.
Year of manufacture.

UPGRADATION OF B.F NO. 1 PAGE 3.177
continuous and maximum condition
Rotating speed in normal and
maximum condition
Critical speed
Design vacuum condition
Rating of the Turbine in MW.
Critical speed
Steam consumption at Normal and
Maximum condition.

Blower casing shall be of horizontally
split type. The upper casing shall be
removable type to facilitate inspec
tion and maintenance without removing
suction, discharge and auxiliary piping.
The diaphragm shall be designed to
Steam turbine shall be horizontally split single cylinder condensing type.
Both blower and turbine casing shall be equipped with eye bolts / lifting lugs,
Rotor assembly
Blower & Turbine rotor shall be of solid forged construction
Both blower and turbine
rotor shall be dynamically
balanced independently
and compositely.
Both Blower and Turbine impeller/bladi
ng shall be of robust construction for
strength and reliability and longer servic
e life. The profile shall be designed
to have the best efficiency for the specified performance.
Bearings shall provide the best rotor st
ability and long vibration free operation.
replaced without moving the rotor.
Arrangement shall be so to mini
mize the axial thrust on bearings.
Shaft sealing devices
Labyrinth seals shall be suitably desi
speed.
The packing shall be steam sealed. Steam from all glands shall be taken to



UPGRADATION OF B.F NO. 1 PAGE 3.178
3.6.6.7

Coupling shall be capable of being
connected and disconnected without
Coupling shall not disturb
the inspection and maintena
nce of bearing and shaft
seals.
Coupling shall be dynamically balanced.
An electric motor driven slow speed turning gear will be provided which will be
engaged manually and disengaged automatically when the Turbine speed reaches
the pre-set value. The turning gear wi
A self contained oil system
for lubrication of blower
and turbine bearings and
for governing and regulation of turbine shall be provided which supplies oil
at a correct flow and temperature to
cool all bearings of Turbine and
The system shall comprising of:
capacity with automatic switching.
DC motor driven Emergency oil pump capable of supplying sufficient
Two nos. (120% each) shell and tube t
ype water-cooled oil coolers of
sufficient capacity to cool requ
ired amount of oil at a desired
temperature. Pressure drop shall be less than 0.5 bar.
Two nos. (100% each) oil filters with
changeover valves. Filters shall
be removable during operation.
Oil reservoir with manhole
Locally mounted oil pressure and
temperature gauges, Low lube oil
pressure switch.
2 nos. High pressure jacking oil pump
shall be provided if considered
Dedicated centrifuge will be fitted to cl
ear the oil in oil tank. The throughput of
Centrifuge will be suffici
total oil in the tank in 8 hours.
The oil pumps shall be rotary positive displacement type.

UPGRADATION OF B.F NO. 1 PAGE 3.179
Turbine Safety Devices

Blower performance tests shall be carri
ed out as per BS 2009 / API 617 / PTC
Turbine performance test shall be carri
Hydrostatic test pressure
shall be 1.5 times the design pressure for minimum
10 minutes for pressure parts.



UPGRADATION OF B.F NO. 1 PAGE 3.180
Dimensional inspection.
Dynamic balancing test.
Performance test.
All inspection and tests shall be perf
ormed in acceptance with the codes /
Specified performance data
Cold blast volume, Nm
Maximum
Pressure, bar (g):
Maximum
Turbine rating 15% more than Blower maximum power
requirement.
Rated Speed, RPM: Bidder to decide
Maximum continuous speed, RPM As per code
Steam Turbine trip speed, RPM As per code
Speed Range, RPM As per code


Condenser will be surface type, wate
r cooled and of twin pass design
for cleaning. A relief valve will be
provided for condenser pressure
relieving. Stainless steel will be used
as tube material. Automatic tube
The Condenser shell will be of welded
construction suitable for internal
pressure likely to develop during
operation. Sufficient drips, drains

UPGRADATION OF B.F NO. 1 PAGE 3.181
The water boxes shall be of divided
flow type with proper connections
so that one half of the Condenser
can be shut down for cleaning while
the other half is in operation. Th
e water boxes will be designed to
withstand the shut off head of ci
rculating water pumps. Removal of
water boxes shall be possible without disturbing the Condenser tube
Ejectors shall be steam operated. There
will be start-up ejector and two sets
of running ejectors each of 100% capacit
l have adequate
capacity to remove non-condensable a
nd associated water vapour from the
Condenser to achieve the required vac



UPGRADATION OF B.F NO. 1 PAGE 3.182
Condensate extraction Pumps
There shall be two Condensate Extraction Pumps (one working + one stand-
by). Pumps shall be supplied with electrical motor drives and all auxiliaries.
Each of the pumps will be capable
of delivering 125% of full condensate
load at maximum Pump Brake kW
curve shall be non-overloading type.
Pumps shall be vertical type. Pumps sha
ll be provided with mechanical seal.
Pumps speed shall be 1500 RPM maximum. NPSH
curve shall be
established during performance test of the pumps.
Suction air filter for Blower
Suction air filter for the Turbo-Blower shall be of pulse filter type having facility
of cleaning while Blower is in operati
on. Continuous on-line dust removal from
the filtration system shall also be provide
d. Approach for removal of dirty filters
during operation shall also be provided. 20%
margin on area shall be kept over
maximum Blower discharge.
Required compressors (1w+1s) along with dr
Sound level shall be limited to 85 dBA.
Suitable noise preventive measures such
as installation of sound-proof covers /
acoustic insulation fo
Piping system covered under this specifi
cation shall comprise of main and
auxiliary steam, condensate, cold air
blast, blow-off line, suction air duct,

UPGRADATION OF B.F NO. 1 PAGE 3.183
calculations, studies and results shall be submitted to the Purchasers for
reference / comments. This, however,
shall not relive the Bidder of the
in this regard. Expansi
on or contraction joints
at suitable interval shal
Main steam pipeline will be designed according to the acceptable forces and
the moments of the Turbine.
Material Specifications
Main stream ASTMA 335 Gr. P22
Aux. Steam ASTMA 335 Gr. P11
suction air duct
To be fabricated from IS:2062, 2006,
Fe 410 W-B
Cooling water Piping To be
fabricated from IS:2062, 2006,
Fe 410 W-B / IS-1239, 2004, Heavy
grade.
Lub Oil Piping To be fabricated from IS:2062, 2006,
Fe 410 W-B / IS-1239, 2004, Heavy





UPGRADATION OF B.F NO. 1 PAGE 3.184
Valves operating under vacuum conditions shall be provided with water
sealing arrangement as required. Valve
of 50NB and below in vacuum lines
The Blower discharge valves shall be
double disc gate valves of cast body
type. The end position status and openi
ng / closing status of these valves
shall be indicated in the PLC and Bac
kup control panel near the machine.
Two nos. each of 100% capacity globe type electro-hydraulically operated
Blow-off valves shall be provided. The position feed back of these valves
shall be provided in PLC.
For LO/CO line cast steel body Plug valv
es shall be used for isolation
For cooling water line flanged end, CI
body, SS trim gate / butterfly / NRV
shall be considered. Pressure class sh
all be PN 1.0. Gate
valves shall be
Blower discharge NRV shall be provided with servo system.
single large orifice type
. Ball material shall be
Ebonite Rubber Coated or Hard Vulcan
ite covered seasoned Timber Ball.
The air release valve shall maintain closed position to prevent the loss of
ting of a non-corrosive fl
oat against a smoothly
ground contact surface of the exhaust orif
ice. It shall automatically provide
for the escape of air to atmosphere
without the loss of water where the
special ball float moves away from th
e orifice seat. The float shall be free
floating within the valve body, linkages or
levers attached the float are not
acceptable.
For steam line valves forged steel body (ASTM A 182 Gr.22) and trim
(ASTM A 182 Gr. F6a, cl2) for size
(ASTM A 217 WC6) and forged trim and seat ring (ASTMA 182 Gr. F6a,
Flanges shall be raised faced type.
Thermal Insulation
Insulation shall be applied
to piping, valves, vessels,

UPGRADATION OF B.F NO. 1 PAGE 3.185
All insulating material, fixing cladding
and protection shall be new and best
of their quality. Insulation materials shall be non-corrosive to the surface
insulated, fire proof, free from asbestos



UPGRADATION OF B.F NO. 1 PAGE 3.186
All joints shall be
sealed with suitable sealant then secured with no. 8 x 12
mm cadmium plated self tapping scre
ws spaced 150 mm apart on both
longitudinal and circumferential joints.
Stainless steel bands 12 mm
wide x 0.5 mm thick (min.) with positive fixing
to prevent slipping shall be placed ci
rcumferentially at 250 mm centers.
Insulation shall be finished with su
itable metal end capping fully weather
Valves, fittings shall be insulated with
removable lined covers. Covers shall
comprise of two sections from plai
Furnace Control
Room
C and 50% +
Package AC with
accessories. with 50%
CLCS Control
Room
C and 50% +
Package AC with
accessories. with 50%
GCP Control
Room
C and 50% +
Package AC with
accessories. with 50%
33 kV Control
C and 50% +
Package AC with
accessories. with 50%
Drilling m/c
C and 50% +
Package AC with
accessories. with 50%
PLC, skip drive
C and 50% +
Package AC with
accessories. with 50%
C and 50% +
Split AC with minimum
The air-conditioning system
shall comprise of water
cooled package type air-
conditioners (PACs) consisting
of compressor, conde
ator, fan unit, filter,

UPGRADATION OF B.F NO. 1 PAGE 3.187
dehumidification and winter heating, humidi
fier, insulated G.I. ducting for supply



UPGRADATION OF B.F NO. 1 PAGE 3.188
Thermostatic expansion valves.
High pressure and low pressure cut out
Following premises shall be provided with
dry pressurized air ventilation system:-
Sl.
No.
Premises Internal
Temperature (
C)
1 Switch Gear room Ambient temp. + 2
permissible rise.
Dry Pressurized
Ventilation System
consisting of Tube
Axial Fan with drive
and accessories with

UPGRADATION OF B.F NO. 1 PAGE 3.189
2 Cable Basement Ambient temp. + 2
permissible rise.
3 Cable vault Ambient temp. + 2
permissible rise.
4 MCC room Ambient temp. + 2
permissible rise.
5 Stove MCC room Ambient temp. + 2
permissible rise.
6 Electrical room
Ambient temp. + 2
permissible rise.
7 CLCS Bldg Ambient temp. + 2
permissible rise.
8 GCP control Bldg Ambient temp. + 2
permissible rise.
9 Mud-gun Control
room (MCC room)
Ambient temp. + 2
permissible rise.
10 MCC room for CA
Ambient temp. + 3
permissible rise.
11 New CDI Elect. Bldg Ambient temp. + 3
permissible rise.
12 Electrical building for
Ambient temp. + 3
permissible rise.
2) Exhaust Ventilation System
Following premises (proposed) sha
Sl.
No.
Premises Internal
Temperature
C)
1 Primary Pump house Ambient
temperature + 2
permissible rise
(max.)
System using heavy duty
tube axial fans, wall
mounted type.
2 Soft water plant
3 33 kV Transformer
4 6.6 kV Transformer
5 Battery Room
6. CA Fan Building



UPGRADATION OF B.F NO. 1 PAGE 3.190
Sl.
No.
Premises Internal
Temperature
C)
7. Cooling Water Pump
Exhaust ventilation system shall comprise
of heavy duty tube axial fan along with
Air-Conditioning and Ventilation systems sh
all be provided for conditioning the
air to specified limits of temperature a
nd humidity and have adequate air changes
in the working premises for human comfort & equipment cooling as mentioned in
this chapter.
HVAC equipments capacity shall be
designed based on outside maximum DBT
and RH (i.e. summer condition), room insi
de equipment + lighting heat load and
inside temperature condition (as given).
The Successful Bidder shall select sizing
of air conditioners based on actual solar
& internal heat load (as per ASHRAE) of
different rooms. The Successful Bidder
shall submit heat load calculations and equipment sizing calculations for all air-
1) Pressurised ventilation
system envisaged in the sp
ecification shall comprise
of industrial heavy duty type tube
axial fan (RPM not exceeding 1000),
supply duct, wall cowl, HDPE- steel
wire reinforced- dry panel type-

UPGRADATION OF B.F NO. 1 PAGE 3.191
3) The Successful Bidder shall size ven
tilation equipment based on actual solar
& internal heat load of different room
s, or at least 25 air changes per hour,
which ever is higher. Extra 10% margin shall be considered for all
ventilation system. The Successful
Bidder shall submit heat load
calculations and equipment sizing calculations for all ventilated premises
1) Heavy Duty Tube Axial Fan
The tube axial fan shall be indust
continuous operation, statically and
dynamically balanced, single stage,
directly coupled with drive motor
and shall be manufactured, tested
according to IS:3588-1986.
2) Gravity Type Louvers
The gravity type louvers shall be fa
Electrical items shall be as
per specification stipulated under electrical chapter.
Civil and Structural Work
Civil & structural works shall be as per
specification stipulated under respective
Painting
All mild steel equipm



UPGRADATION OF B.F NO. 1 PAGE 3.192
Colors of the grills shall match with the in
terior decor of cont
rol room/ painting of
walls.
1) 1 PDB has been considered for
power supply to Air conditioning &
ventilation system. Power supply shal
l be obtained from the same PDB.
2) Make up water for condenser water c
ooling tower shall be made available
with in 25 m from the proposed cold water basin.
The inside conditions in the air-condi
tioned and ventilated rooms shall be
maintained throughout the year.
Dismantling of existing AC system (if a
ny) and handover to RSP concerned are to
The Successful Bidder shall furnish the following for approval / reference.
1) Heat load calculation and design criter
ia including duct-sizing calculation of
ll rooms / premises for approval.
Technical specification for reference.
Literatures /catalogues for record of
all the equipment covered under A/C &
Ventilation system
The Successful Bidder using various type of
fire fighting facilities like portable
The type, size and number of portable fire
extinguishers shall be planned as per
recommendation of Tariff Advisory comm
ittee in all the new premises under the
scope of this package. Some of the new
premises like Electrical Rooms, Cooling
water complex including Pump houses,
Control Room, Cable Vaults, Hydraulic
room, Fans, DM/ SOFT Plant, GCP area,
CO
(4.5 kg) DCP (10 kg) Foam (9 litre)
1. Primary Pump House 2 6 -

UPGRADATION OF B.F NO. 1 PAGE 3.193
Sl. No.Unit / Area with size Type of fire extinguishers
CO
(4.5 kg) DCP (10 kg) Foam (9 litre)
3. Soft Water Plant 2 2 -
4. All Control rooms 6 4 -
5. GCP Hydraulic room
1 1 2
6. Gas Booster House - 2 -
7. CA Fan Building 1 1 -
8 MCC Room 1 1 -
Note:-The type of portable fire extingui
shers envisaged for various units shall
conform to IS:15683-2006.
Fire sealing shall be considered
for all floor openings including conduit
openings, cable openings, below electr
ical panels / equipment and wall
llowing technical characteristics:



UPGRADATION OF B.F NO. 1 PAGE 3.194
The system shall not affect the curr
ent carrying capacity of the cables.
The system shall be single com
ponent and certified by CBRI Roorkee.
2) Coating of cables with fire retardant paints
The electrical cables shall be coated
with fire retardant coating compound
to minimum 2 mm dry thickness coating in
order to withstand severe fires
be done at strategic locati
ons such as straight thr
ough joints, internal side
of termination points and each side of
the fire sealing for a length of one
meter.
Fire retardant paint shall have the
following technical characteristics and

UPGRADATION OF B.F NO. 1 PAGE 3.195



UPGRADATION OF B.F NO. 1 PAGE 3.196
Requirement of Refractory & Auxiliary Materials
Bidder shall furnish BOQ of all refractory
& auxiliary materials required as per
Inspection & Testing of Refractory Materials
3.7.6.1 Bidder shall undertake the inspection of
all refractory & auxiliary materials at
manufacturer/supplier works as well as at pl
ant store to cross ch
eck the conformity
of the specification. The responsibility
of entire inspection management of
refractories shall lies with the bidder.
MARKING, PACKING & TRANSPORT
3.7.7.1.1 Each refractory brick / material
shall be clearly marked with
Manufacturers Name
Material Quality
3.7.7.1.2 Marking shall be done with water insolubl
e ink in English or
with indelible paint
by stenciling.
3.7.7.2.1 Dense and checker bricks shall be suitably packed in wooden box.
3.7.7.2.2 Insulation bricks shall be
supplied individually wrappe
d and packed
in cardboard
3.7.7.2.3 Insulation slabs shall be supplied shr
unk film packed in cardboard cartons.
3.7.7.2.4 Mortars shall be supplied packed
in 50 kgs single polythene lined gunny bags/
3.7.7.2.5 Castables shall be supplied packed in 50 kgs HDPE bags.
STORAGE OF MATERIALS
3.7.8.1 Proper storage, transportation, handli
ng and protection of the materials at all the
transit locations and at work site
3.7.8.2 Successful Bidder shall make his own
arrangement for loading, transporting,
unloading, stacking, sorting, st
orage and safe custody of th
e materials up to their
use in the stove complex. The refractory bric
3.7.8.3 Successful Bidder shall also be required
to develop suitable covered and open
space for storage of refractor
y & auxiliary materials. Insulation bricks, mortars,
castable, ceramic felt and all other auxiliary materials likely to be damaged in the
open shall be stored under cover in
dry conditions Ther
e shall be proper
arrangement for handling the materials.
Proper records of materials receipts, issu
ed and consumed shall be maintained and
balance materials shall be handed over
in proper manner to the Employer.

UPGRADATION OF B.F NO. 1 PAGE 3.197
ERECTION OF REFRACTORIES
Successful Bidder shall carry out the erec
tion of the refractory lining as per
Erection work shall be carried out as
per erectin drawings and erection
instruction manuals
Supervision of brick work erection shall be carried out by the experience
supervisors and expert of bidder. To en
sure the quality of work sufficient
Specification of all refractory & auxiliary materials.
33 kV+10%, AC 3-phase, 50 Hz +/- 5%
, solidly earthed system, short-
6.6 kV+10%, AC 3-phase, 50 Hz +/-
LT Power: 415 V + 10%, AC 3-phase, 4-wire, 50 Hz + /-5%, solidly earthed
system with 50kA (r.m.s) for 1 s.
For HT Board: 220 V DC



UPGRADATION OF B.F NO. 1 PAGE 3.198

For Solenoid coil: 48 24 V DC
ltages (AC, DC) as required for his
system from the above power supply.
For the purpose of equipment design, the am
bient conditions are to be considered
as 50 degree C for indoor & 55 Deg C for outdoor equipment and 100%
maximum relative humidity. All indoor equi
pment shall be de-rated for 50 degree
C if not designed for 50 de
gree C. Similarly, all outdoo
r equipment shall be de-
All the equipment & components shall be
located in hot,
humid, tropical and
dusty atmosphere in an adverse industrial environment as prevalent in Blast
Furnace zone of steel plant.
All equipment and accessories shall conform
to the latest revision of the Indian
The Blast Furnace no.1 will be reconstr
ucted and Existing Blast furnace no.2
will be dismantled. BLT system of exis
ting blast furnace no.-2 will be used in
upgraded Blast furnace no.1. The proposed
power distribu
tion arrangement

UPGRADATION OF B.F NO. 1 PAGE 3.199
for the various units/ installations of
Blast Furnace-1 has been described in
subsequent clauses. The Power Dist
ribution Arrangement in HT and LT
Following HT loads will be fed from new 6.6kV switchboard:
i) ID fan of Cast House defuming system.
ii) Skip winch drive motors: The existing Skip Winch Drive motors (DC
motors) of BF-1 (2 x 202 kW each) are fed from BF substation through
Thyristor converter system. The dr
ive motors of the proposed BF-1
Skip is envisaged with uprated
AC motors and shall be operated
(VFD) system. New Converter tr
ansformers will be fed from the
sformers for feeding LT loads



UPGRADATION OF B.F NO. 1 PAGE 3.200
iv) CA fans ( 1 W + 1S).
New HT pumps for Closed loop system
will be fed from 6.6kV switchboard at
BF 1, 2 & 3 by extending the switchboard
through bus trunk
ing arrangement.
New panels will be located at the space available in front of existing 6.6kV
Proposed LT Power Distribution system:
2MVA 6.6kV/433V transformers (3 nos.) will receive power from the new
6.6kV switchboard and these transforme
rs will feed new LT Switchboard
The envisaged LT switch board of BF-1
substation shall feed Motor Control
Centres (MCCs) and Power Distributi
on Boards (PDBs) of various new
installations. The Motor Control Centre/ PDBs catering to the following areas
have been planned with the abov
e LT Switch Board ( refer SLD no.
Drg

UPGRADATION OF B.F NO. 1 PAGE 3.201
3.8.3.2

The operation control for all drives in diffe
rent zones of Blast Furnace is to be
i. Stock House PLC
Instrumentation system
of Stock House, Skip
Winch Drive
Control room
at second
floor of BF-1
ii. BLT PLC
Instrumentation system
Control room
at second
floor of BF-1
iii. Stoves PLC
Electrical system of Hot
Blast Stoves, CA fan and
Control room
iv. Closed Loop Cooling System
Instrumentation system
of Closed Loop Cooling
Pump House
v. GCP PLC
Instrumentation system
vi PLC for CH defuming
system
Instrumentation system
of CH defuming system
Control room
at second
floor of BF-1
vii. CDI PLC
Instrumentation system
room for BF-1



UPGRADATION OF B.F NO. 1 PAGE 3.202
Area under Control Location
viii. PLC for New Turbo Blower
Instrumentation system
of New Turbo Blower
control room
for turbo
2. In addition to the above PLCs th
ere is one separate
Instrumentation PLC
at BF-1 for the controlling of various measurement values and process
parameters of BF-1. The Instrumenta
tion PLC is described in clauses
under Instrumentation system.
i. Stock House
Charging control
All HMIs are
ii. Stoves, Stock House
, BLT, GCP, CDI,
CH Defuming
system
iii. Closed Loop
Cooling System
Pump House Control
Room
iv. GCP GCP Control room
v. CDI CDI control room
vii. New Turbo blower Existing Turbo
Blower control room

UPGRADATION OF B.F NO. 1 PAGE 3.203
6) All equipment are considered to be
operated in one of the three following
i) Local Operation from the Local control (start /stop push button)
station near drive motor of indivi
dual equipment. This operation
will be only in de-interlocked mode and for testing only. However,
Stop PB shall always remain active
ii) Programmed operation through PLC
Operation through monitor key board (manual intervention
Layout drawing enclosed):
1) Building for BF-1 substation: One Three storied building with cable
basement has been considered tentatively for housing following
equipment. Exact configuration of the building will be finalised during



UPGRADATION OF B.F NO. 1 PAGE 3.204
- Other Substation auxiliaries
ii) First floor will be provided for cable vault
iii) Second floor will be provided
to install MCCs, PDB & PLCs
related to Stock house, BLT, CH defuming system, skip AC Drive
system and associated equipment, Augmentation of Slag disposal

UPGRADATION OF B.F NO. 1 PAGE 3.205
Motors rated 200 kW and below: 415 V ,3 ph, 50 Hz
AC induction motors rated 200 kW and
below shall be fed at LT, 415 V, 3
VFD system shall be provided for 415
V motor drives having requirement
Electronic Soft starters with DOL
bypass shall be prov
ided for drives
ratings ranging from 110 kW to 200 kW
where full torque load starting is
For conveyor loads from 110 kW to 200kW suitable VFD based soft
starting shall be provided. Conve
yors with LT motor less than 110kW
shall be started DOL.
Fine Coke breeze skip shall have VFD drive with redundancy. Close loop speed
and position feedback shall be provided for the same
Sinter fines disposal system with ne
w electrics shall be hooked up with stock
house PLC for smooth transportation of generated sinter fines.
All PLC and field termination sha
All outputs of PLC shall be consider
ed through interfac
important fault prone inputs (as require
For specific areas , where common PLC
is provided for both Electrical &
Instrumentation system, separate I
nput/ Output units for Electrical &
Instrumentation system shall be considered.
Epoxy based Insulated flooring shall be cons
idered in front of all new electrical
panels, except for the rooms wh
All Junction Boxes and Push button stations
shall be provided
with double door,
canopy. All Junction Boxes & Local contro
l stations shall be made of poly
All motor shall be provided with a power
JB (near the motor) for terminating the
All electrical equipment like panels, pus
h button stations, motors, receptacles,
light fittings, actuators, cranes & hoists



UPGRADATION OF B.F NO. 1 PAGE 3.206
frequency relays (with F & df/ dt feat
ures) shall be provided with necessary
auxiliary relays) Time re
IS:1866-1983 Code of practice for
maintenance and

UPGRADATION OF B.F NO. 1 PAGE 3.207
insulating oil in equipment.
1977) (Pt.3-
1981) (Pt.5-
Power transformer
IS:3639- 1966 Fitting & accesso
ries for power transformer
IS:6600-1972 Guide for loading of
oil immersed transformer.
Code of practice for se
lection, installation &
maintenance of power transformer
In addition to above Indian Standards tran
sformers shall also comply with IPSS :
Technical parameters of transformers .
1.
Voltage HV/LV 33/6.9 kV
2. Normal System
Voltage
3. Maximum System
Voltage
4. Rated frequency 50 Hz + 5 %
5. Duty Indoor installation in transformers pens
and suitable for heavily polluted area.
6. Type 3 phase, ONAN
7. Specification to be
complied with
IS 2026: 1977 & 1981, IS: 10028:1981 &
8. Continuous rating 12.5 MVA
10. Winding connection Delta/ Star
11. Vector group DYn 11
12. Winding Copper
13.
Insulation level
One minute Power
Voltage (kV)
70 kV rms (primary)
20 kV rms (secondry)
Peak impulse test 170 kV :peak (primary)



UPGRADATION OF B.F NO. 1 PAGE 3.208
withstand voltage (kV)
14. Neutral grounding 6.6 kV resistance grounded.
15. Termination 33 kV through insulated bus bars/tubes
16. 33 kV , 6.6kV CTs 33kV trafo differential CTs and , 6.9kV
CTs for REF should be mounted inside
bushing . CTs for other functions shall be
CT for differential
CT for protection Class 5P20
Neutral side CT PS class & 5P20
17. Permissible maximum
temperature rise over
50 deg C ambient
temp.
Top oil (by
thermometer)
Windings (by
resistance)
Hot spot temp. As per IS 2026 - Part II- 1977
18. Tap changer on 33 kV
Range + 10% at steps of +/- 1.25 %
Total tap positions 17
Tap change controls Local manual
19.
Impulse test withstand
20. One minute dry and
a) Induced over voltage
withstand voltage

UPGRADATION OF B.F NO. 1 PAGE 3.209
b) Withstand time
without injury for 3
phase short circuit
at terminals shall be
21. Short circuit level on
22. Auxiliary supply
23. Parallel operation Suitable
for parallel operation with
transformers of similar ratings
24. Overload capacity As per IS 6600-1972
26. Painting Shade 632 of IS 5: 1994.
Transformers shall be capable of deliver
ing rated current at an applied voltage
upto 105% rated voltage without exceedin
g the temperature limits specified
Transformers shall be operable at its rate
Transformers shall be designed to with
stand the thermal and dynamic stresses due
to short circuits at its terminals. The dur
The maximum temperature at the end of th
e specified duration
shall not be more
than 250
C with the temperature prior to s
ponding to maximum
permissible overload.
Transformers shall be designed for suppr
ession of harmonics especially 3rd and
Transformers shall be able to deliver rate
d power for 10 minutes even if the forced
ot temperature limited to 140oC.
i) Low loss CRGO silicon steel shall be used.
ii) Laminations shall be annealed in a no
n-oxidizing atmosphere to relieve stresses



UPGRADATION OF B.F NO. 1 PAGE 3.210
v) Core, framework and clamps shall be
arranged and tightened to securely hold
laminations in order to prevent any se
ttling of displacement in case of heavy
vi) Flux density under specified over voltage
or frequency shall be within the
maximum permissible for the lamination.
vii)Transformers shall be designed to
withstand 110% over fluxing corresponding
Windings
Material shall be electroly
tic grade work hardened c
opper of high proof stress
with more numbers of radial supports.
Windings shall be pre-compressed, pre
uniformly distributed throughout the wi
ndings under all operating conditions.
ii) 33kV and 11kV windings shall be fully insulated.
i) Welded thick gauge plates stiffene
d and reinforced to withstand without
deformation for all stresses applied dur
eration or short
ii) Oil tight weld and joints
iii) Fully assembled transformer with its ra
diators, conservator and other fittings
shall withstand for one hour a pressu
re corresponding to twice the normal
head of liquid or to the normal pre
ssure plus 35 kg/ sq.m, whichever is
higher, measured of the based of the tank.
iv) Plates shall be protected internally
v) Provided with inspectio
n opening and cover/with
handling equipment) to

UPGRADATION OF B.F NO. 1 PAGE 3.211
vi) Form of cover shall be such as to
prevent any stagnant water deposit and to
vii) Tank shall be capable of withst
anding of 760 mm of mercury vacuum.
viii) Diaphragm cover for divert
i) Conservator mounted on frame, integral with tank in such a manner that
under all conditions and the lowest oil
level in the bushings remain under the
ii) Conservator volume shall be sufficient
to maintain oil seal from ambient to
oil temperature of 90oC.
iii) Oil filling hole with cap, a drain valv
i) Double float relay as per IS 3637 - 1966
i) The cooling system shall be
Oil natural, air natural type.



UPGRADATION OF B.F NO. 1 PAGE 3.212

i) Valves of sluice type with hand wheels.
ii) Made of gun metal
iii) Clear indication of open and closed position
iv) Provided with blanking
v) Padlocking facility to lo
Terminations
i) It shall be possible to withdraw th
e transformer easily af
e busduct / line / terminations.
ii) For bus duct termination
iii) Flanged throat shall be provided to
suit the bus duct. Flange ends and
i) Conform to IS 3347 and IS 2099-1986
ii) Minimum rated current of line and bushi
ngs shall be 1.5 times rated current of
iii) Clamps and fittings made of steel or malleable iron shall be hot dip galvanised.

UPGRADATION OF B.F NO. 1 PAGE 3.213
i) 150 mm dial type thermometer with
i) Local winding temperature indicator (W
i) All outgoing connect
ions from the transformer i.e. buchholz relay, temp/ level
indicators, CT secondary fault contact fo
r annunciations, forced cooling system
i) All metal parts of the transformer with the exception of individual core
laminations, core bolts, and clamping pl
ates shall be maintained at fixed
ii) Two tinned copper earthing terminals.
iii) One end of bushing CTs shall be earthed.
i) Resistance type (PT 100) embedded



UPGRADATION OF B.F NO. 1 PAGE 3.214
The isolators shall comply with the following standard specifications and
, (pt.4-1985) H T Isolators
All isolators shall also conform to the latest Indian Electricity Rules as regards

UPGRADATION OF B.F NO. 1 PAGE 3.215
Design Criteria
The following system voltage and power
6.6 kV + 10% 3 phase 50 HZ + 5% AC, with 40kA for 3 sec s.c. withstand
capacity.
One minute Power frequency withstand Voltage (kV): 20 kV (rms)
Selection Criteria
The isolator shall be floor mounted
type within enclosure with IP 52
protection. HT isolator shall be trip
le pole, air break, manually operated,
quick break and make, load break type
and shall be designed as per IS:9920
(Pt 1-1981), (Pt 2,3-1982),
e poles shall operate
simultaneously by a operating handle.
On the outgoing side of th
e isolator, an earthing sw
itch shall be provided for
the earthing of the outgoing equipment. It
shall have interlock with the main
switch i.e. the earthing switch cannot be closed unless the main switch is
OFF.
Design and selection of isolators shall
be done taking into consideration the
fact that the isolators are called upon
to operate continuously and hence all
facilities to simplify inspec
tion, testing, maintenance,
cleaning can be carried
out at site without disrupting
Type Punched stainless steel
Applicable standards IEC-32 1972
Voltage rating 6.6 kV
1 minute power frequency
withstand voltage
Current rating
( Design calculation for the same shall be
submitted by successful tenderer.)
Design temp rise IEEE-32



UPGRADATION OF B.F NO. 1 PAGE 3.216
Degree of protection IP 33
Termination Suitable Earthing strip
The bus-ducts will be metal enclos
ed type conforming to IS: 8084-1976,
Reaffirmed 1987. Inspection covers will be
provided at the end and at points
Highest system
1minute Power
Frequency with -
stand capacity
20 kV rms
Impulse test 60 kV peak
current for bus
2000 Amp

UPGRADATION OF B.F NO. 1 PAGE 3.217
Fault with stand
capacity
Maximum
permissible Temp.
Rise including
ambient
6.6 kV Switchgear
The 6.6 kV Switchboard shall be totally enclosed dust and vermin



UPGRADATION OF B.F NO. 1 PAGE 3.218
The switch boards shall work on 3
phase, 50 Hz; unearthed system of
1 Normal system voltage 6.6 kV
2 Maximum system voltage 7.2 kV
3 System Frequency 50 Hz +5%
4 Rated current of
Incomer Refer SLD
Bus-coupler -do-
5 Degree of enclosure
6 Standard to be followed IS: 13118-1991 IS: 3427-1969 IEC:
7 Rated short circuit breaking
capacity
40kA rms for 3 seconds
8 Asymmetrical breaking
capacity (D.C. component)
9 Making capacity (peak) 100 kA
10 Rated insulated level:
Power frequency withstand
voltage for 1 minute (RMS)
Impulse withstand voltage
12 Type of Circuit Breaker 1250A,
Vacuum circuit breaker, metal
13 Location Indoor, floor mounted
14 No. of poles 3
15 No. of breaks/pole 1
17 Permissible temp. rise over
ambient for switch board
18 Operating voltages for
Spring charging Universal motor on 220V DC

UPGRADATION OF B.F NO. 1 PAGE 3.219
Closing & Tripping 220 V DC
Indications/ annunciation 220 VDC
19 Permissible opt. Voltage for
70% to 110% nominal
65% to 110% nominal
80% to 110% nominal
20 Min. size of earth bus bar 75 mm x 8 mm Supporting calculation
21 Special protection Surge suppressors shall be provided
for all VCBs
Protection (with numerical protective rela
ys) and metering requirement for 6.6 kV
S. No. Name of
1. Incomers Ammeter of appropriate range
with selector switch, close/
Trip circuit supervision relay,
with lamp, high-speed master
trip relay, aux. relay DC
for interfacing with RTU, 12
window annunciator, kWH &
kVRAH meter
IDMTL overcurrent relay
with instantaneous high
Sectionaliser
Ammeter of appropriate range
with selector switch, close/
Trip circuit supervision relay,
with lamp, high speed master
trip relay
for interfacing with RTU, 12
window Annunciator,
IDMTL overcurrent relay
with instantaneous high



UPGRADATION OF B.F NO. 1 PAGE 3.220
S. No. Name of
3. Motor feeder Ammeter of appropriate range
with selector switch, close/
Trip circuit supervision relay,
with lamp, high speed master
trip relay, aux. relay DC
relay as required and fault
for interfacing with RTU, 12
window annunciator, kWH
meter, aux, relays for
4. Transformer
feeders
Ammeter of appropriate range
with selector switch, close/
Trip circuit supervision relay,
with lamp, high-speed master
trip relay, aux. relay DC
for interfacing with RTU, 12
window annunciator, kWH
meter, aux, relays for
5. 6.6 kV Bus
All protective relays shall be state-of-the art numerical relays. Relays shall be
provided such that each relay shall have
multiple protection features in a single
relay ( composite type) to
the extent possible. Relays shall have IEC 61850
protocol and shall have
provision for connectivit
y to the RTU of SCADA
system.

UPGRADATION OF B.F NO. 1 PAGE 3.221
With all the meters provision shall be
kept for connecting transducers with 4-
20 mA output for data transfer to RTU.
The internal wiring from transducers
HT circuit breakers envisaged in the sp
ecification shall be designed to control
and protect the power distribution syst
em. The circuit breaker shall conform
The circuit breaker shall be mainte
nance free and shall have adequate
capacity, insulation and mechani



UPGRADATION OF B.F NO. 1 PAGE 3.222
Suitable sizes of channels are to be gr
outed in front of ea
ch HT cubicle for
smooth racking in and ra
The moving carriage of circuit breaker, whic
h shall also carry jaw contacts, shall
be provided with
earthing contacts continuously so
that the breaker remains
positively earthed in "service" position and during withdrawal operation "Test"
position. The breaker shall have anti-pumping features.
All circuit breakers shall have three opera
tional positions, such as "Service" "Test"
and "Draw-out" position. It
shall be possible to achie
ve all the above three
positions with cubicles front door closed. Mechanical indicators for all three
positions shall be provided. The circuit break
ers shall carry a single break per pole,
which shall be identical with the other 2 pole chambers of the breaker.
Simultaneous closing of the three poles
of a breaker on a single closing command
shall be ensured. All circuit breakers shall preferably be interchangeable.
The HT Breaker shall be provided with electr
ical and mechanical trip free features
and an emergency mechanical push to trip
the breaker. All the features of the

UPGRADATION OF B.F NO. 1 PAGE 3.223
Bus bar arrangement shall be as per IS: 5578-1985 & IS: 11353-1985. Bus
bar shall be sleeved with proper grad
e of insulating sleeves and of proper
colour code for each phase. Care shall
be taken to obviate corona formation
at the joints and connec
tions. All joints and connecting terminals shall be
Bus bar shall be housed in a separate bus bar chamber with adequate air
hing shall be cast resin type to
offer higher mechanical strengt



UPGRADATION OF B.F NO. 1 PAGE 3.224
Incoming PTs shall be provided in

UPGRADATION OF B.F NO. 1 PAGE 3.225
Temperature rise of winding.
Over load signal (CT operated)
Temperature rise of winding.
The integrated unit shall be operati
ng on DC control and DC signalling
r every transformer feeder.
Insulation of relays should withstan
d 2.5 kV A.C. (RMS) at 50 Hz for one



UPGRADATION OF B.F NO. 1 PAGE 3.226
Earthing bus bar shall be positively connected/ welded with different
sections of HT switchgear, indivi
dual functional units and non-current
carrying metallic units.
Hinged door shall be earthed through
stranded copper galvanized earthing
For positive earthing of with drawable
units, silver plated
copper strapping
earthing contacts of "make before" / "b
reak after" type shall be used
ensuring earth continuity from "service"
to "test" position of draw-out type
Earthing of the main bus (when only dead
) shall be feasible from PT panel
only and shall be properly interloc
ked with the incomer panel of the
Annunciation and Control Scheme
The signalling and annunciation scheme shall include the following:
ON-OFF-TRIP and spring charged
indications shall be provided
BER and WHITE signal lamps for every
panel. The green lamp shall be ener
gised through an auxiliary relay,
which shall also confirm to the read

UPGRADATION OF B.F NO. 1 PAGE 3.227
All other faults not mentioned above, but considered necessary may
also be included in the annunciation scheme.
me shall operate on 110 V DC.
Solid state audio-visual annunciato
r of minimum 12 windows shall be
provided however exact number of
windows shall be finalised during



UPGRADATION OF B.F NO. 1 PAGE 3.228
Incomer panels shall be painted
Mimic diagram shall be shown on the cubicle both sides.
Nomenclature of the relays and meters
shall be written
on panel by paint
In each panel one NO auxiliary contact
of breaker is to be brought at the
row of terminal and marked in the drawing for RTU
Other Accessories
Supply of each of the HT Switchgear sh
all necessarily include the following
accessories.
Earthing truck suitable for earthing the
bus side /cable side of each breaker
1 No. each for bus side
Device for hand charging of breakers
c) Breaker rack in / rack out device 1 no.
d) High voltage tester 1 no
e) Wheel mounted trolley for attending relays
and meters

3.8.12.1

Technical Particulars
Type Plante Lead Acid type
Output Voltage 220 V DC for substation
Capacity Minimum 200 AH for 10 hours
discharge capacity
Batteries shall be provided with metallic

UPGRADATION OF B.F NO. 1 PAGE 3.229
with end cell bypassing diode. An appropria
te circuit for end cell discharge shall
Supply voltage 415+10%, 3 phase
Frequency 50+6% Hz
Charge characteristic Constant
Degree of Protection IP-52
Output supply Output supply voltage will be suitable for

The mains supply for the chargers shall be 3 phase, 415 V. This input shall be
received necessarily prior to an isolat
ing transformer for each charger. The AC
input to the rectifier circ
uit shall be through a satura
ble core reactor and the
output shall be filtered in a filter ci
rcuit to minimise
the ripple content
(Maximum ripple content shall be
Output supply voltage shall be suitabl
e, for charging the battery. A permanent



UPGRADATION OF B.F NO. 1 PAGE 3.230
Purpose : DC power needs of all the protection, control and
annunciation of the system as well as for emergency
Type : IP 54, floor mounted, compartmentalized type.
Incomer : MCCB( 50 kA )
Outgoing feeder : MCB suitable for DC duty.
Enclosure : shall be made of
2 mm thick sheet steel.
Purpose : To cater to all LT auxi
rol requirement
for different switchgears, transformers at Substation.
All protective relays shall be mounted in the RCP.
RCP shall have following :
b) For Incomers

Ammeter at the RCP & Switchgear

UPGRADATION OF B.F NO. 1 PAGE 3.231
Breaker Control
Semaphore Indicating lamps
d) For Transformer Feeders

IDMTL Overcurrent and IDMTL earth
IDMTL Overcurrent and IDMTL earth



UPGRADATION OF B.F NO. 1 PAGE 3.232
Buchholz, oil temperature, wi
nding temperature protection
Busbar Differential Protection


Panels shall be arranged to form a
continuous board with the mimic and
control equipment.
Panels shall be vertical, free standing,
simplex type with rear hinged door,
side terminal blocks control signalli
ng circuit breakers, resistors, fuses,
Panels shall be wired with 1100 volt grade multi strand copper wire PVC
ea 1.5 sq. mm. CT connections and
external connection shall be made wi
th 2.5 sq. mm copper wires. The CT &
PT wiring shall be done with colour
coded wires with no lugs in CT
secondary termination.
Wire shall not be joined or ti
ed terminal blocks shall be used.
Stud type terminal blocks shall be provi
ded with brass studs of not less than

UPGRADATION OF B.F NO. 1 PAGE 3.233
Control Supply
vices with auxiliary contacts for
indication of control supply.
One number 220 V single phase 15 A pl
ug point in all panels for testing
Static type alarm annunciators for fault and alarm conditions shall be provided.
b) Enclosure IP- 54
c) Extendable feature Yes
d) Illumination with door switch Yes
e) Provision of cable glands Yes
f) Inscription Both sides, front and rear
g) Control supply 220 V DC
h) Signalling bus isolation
ON/OFF switch (stay put type)
i) Signalling supply isolation By switch
j) Base channel provision Yes
k) Control buses As per circuit requirement
o) Instrument size 144 mm square
p) Provision of test block for CT and
q) PT secondary voltage
r) CT secondary current 1 A

3.8.17.1

The Transformers shall in all aspects comply with the following standard
Power transformer
IS:2099-1986 Bushing of transformer



UPGRADATION OF B.F NO. 1 PAGE 3.234
IS:3639- 1966 Fitting & accesso
ries for power transformer
IS:10028 (Pt.1-1985)
Code of practice for Se
Maintenance of power transformer
IS:10561-1983 Application guide
for power transformer
IS:11171-1985 Dry type power transformer
Technical Specification
Specific Aspects Technical Features
kVA rating 2000kVA
Voltage Ratio HV/ LV 6.6/ 0.433 kV
Normal System Voltage 6.6 kV
Maximum System Voltage7.2 kV
Rated frequency 50 Hz + 5 %
Duty Indoor
Type 3 phase core type, Dry type, air cooled,
Vector group DYn 11
Winding Copper
Class of Insulation Minimum class F
Insulation level
a) One minute Power
Voltage (kV)
HV side: 20 kV rms
LV side: 2.5 kV rms
b) Peak impulse test
withstand voltage (kV)
Neutral grounding 415 V seconda
Percentage impedance
To be indicated by the Bidder at
Bushings Porcelain bushings shall be provided in
HV & LV side and shall confirm to IS:
Termination At HT primary side through XLPE HT
cable. HV cable box
( self supported

UPGRADATION OF B.F NO. 1 PAGE 3.235
Specific Aspects Technical Features
can be taken out without disconnecting
Neutral CTs 2 nos.
. CT for Backup earth fault
Protection
CT for restricted earth
PS class
Maximum Temperature
rise in winding after
continuous operation with
rated load
C ambient temp (Indoor)
(total temperature 110 deg C)
Tap changer on 11 kV
Tap changer shall be hand operated
through hand wheel. Padlocking facility
Range + 5%
Taps above nominal
Taps below nominal
Voltage per step variation 2.5%
Short circuit level on HV
As mentioned in design criteria
Short circuit withstand
Auxiliary supply voltage 240 V AC
Parallel operation
Suitable for parallel operation with
transformers of similar ratings
Overload capacity As per IS 6600-1972
Over fluxing withstand
(without heating) capacity
for one minute due to
combined voltage &



UPGRADATION OF B.F NO. 1 PAGE 3.236
Specific Aspects Technical Features
Degree of protection for
Transformer Enclosure
IP:21
Accessories
- Scanner with alarm and rip contacts for
Winding temperature
-- NeutralCTs
- surge arrestor al
ongwith earthing bar
for surge arrestor
- Roller ( bi directional)
-Warning plate
Marshalling box
Fabricated with
1.6 mm CRCA steel

All routine tests as per relevant standards
at the manufacturer's
Measurement of winding resistance

UPGRADATION OF B.F NO. 1 PAGE 3.237
Measurement of voltage ratio & chec
Measurement of impedance voltage
/ short circuit impedance & load
loss
Measurement of no load loss & current
Measurement of insulation resistance
Dielectric test
Type test certificate fo
r Temperature rise test
LT Bus Duct
Busbar trunking system
IS: 5350 (Part-1)-1970 Indoor
Post insulators
IS: 191 -2007 Copper busbar & flexible
IS: 3965 -1981 Dimension for aluminium alloy bar
IS: 1897 -1983 Copper strip for electrical purpose
IS: 5082 -1998 Aluminium alloy busbar
IS: 9431 -1979 Post insulators of organic material ,Insulators &
Seal off Bushing
IS: 13947 -1993 Busbar Assembly Clearances
IS: 5578-1984 Busbar marking colour code
IS:11353-1985 Identification of
terminals.
Sl. No. Specific aspects Technical features
1 Type Totally enclosed with Interleaved
Aluminium busbars
2 Rated voltage (V) 415 V + 10%
3 Current rating Bus Duct shall be rated for full
load (100%) of the terminating
4 Phase (Nos.) 3 phase and neutral
5 Frequency (Hz) 50 Hz + 5%
6 Power frequency withstand
2.5 kV rms for one minute



UPGRADATION OF B.F NO. 1 PAGE 3.238
Sl. No. Specific aspects Technical features
7 Maximum temperature rise
a) Bus Conductor
C 40
C under normal operating
b) At joints oC 55
C for other joints
8 Short circuit withstand ca
pacity 50 kA rms for 1 sec
9 Material of Enclosure
10 Material of busbar Aluminium (E91E WP grade)
black matt painted & colour coded
11 Bus insulator FRP type
12 Degree of protection for the
13 Earthing Two earthing pads for 50 mm x 6
end of duct
14 Other constructional features -
Flexible expansion joints for
Expansion joint with
aluminium strips for busbars
Silver faced Busbar and tap
joints or application of suitable
m-oxide contact grease at the
ends after thorough cleaning
before making the joints.
Non-inflammable, non-
hygroscopic, track resistant
and high strength porcelain or
Space heaters at suitable
15 Painting
a) Surface Treatment for Painting Seven tank process.
16 Paint shade
a) Outer surface Shade No.631 (light grey) of IS 5:

UPGRADATION OF B.F NO. 1 PAGE 3.239
Sl. No. Specific aspects Technical features
b) Inner surface Black paint matt finish
LT Switchboard
IS Code & Year Title
IS: 1248 (Part1-2003) (Part 2-
measuring instruments & their accessories
IS: 2705-(Part 1-4)-1992
Current transformer
IS: 3156-(Part 1-4)-2002
Voltage transformers
IS: 3231(Part 1-3)-1987 Electrical Re
lays for power system protection
IS: 5578 1984 Guide for marking insulated conductor.
IS: 11353-1985 Guide for uniform
of conductor and terminals
IS: 8623 (Part 1-3)-1993 Low volta
assemblies.
IS: 10118 (Part 1-4)-1982 Code of pr
gear.
IS: 11182 (Part 1,2-1984)
Guide for evaluation of insulation system of
Electrical Equipment.
IS: 13947(Part 1-5)-1993 Specificatio
Sl. No Specific aspects Technical features
Voltage 415 V + 10%
Phase 3 phase
Frequency 50 Hz + 5%
Neutral system Solidly Grounded
System Fault level 50 kA (RMS) for 1 second
Rated Insulation Voltage 2.5 kV rms for 1 min
Duty Continuous operation
Construction
Type of board Single Front, Compartmentalised,



UPGRADATION OF B.F NO. 1 PAGE 3.240
Sl. No Specific aspects Technical features
Mounting Vertical, Floor mounted, Free
base frame / base channel

Degree of protection of
Front access Hinged door
Back access & clearance Back access of LT panels shall be
minimum 800 mm
Future extension provision Provisi
new vertical section
Cabling Space Side Cable Alley or at the back
Height of panels Maxi
mum 2350 mm including base
(minimum) and 1800mm
(maximum) from floor level.
Busbar arrangement Top horizontal
Power feed to outgoing
s (bottom entry)

Busbar
Main horizontal busbar 3 Phase & neutral at top
Busbar Material (Make:
INDALCO/ HINDALCO)
Aluminium Alloy
Maximum temperature rise
including the specified
ambient temperature and
Short time withstand current
Short time withstand curre
nt 50 kA (RMS) for 1 sec

UPGRADATION OF B.F NO. 1 PAGE 3.241
Sl. No Specific aspects Technical features
Earth busbar G
ALVANISED STEEL EARTH
USBAR
OF ADEQUATE SIZE
RUNNING
THROUGHOUT THE LENGTH OF PANELS
AT BOTTOM
Insulation Heat Shrunk PVC Sleeve.
Colour coding IS 5578: 1984
Clearance between Phase &
25 mm (minimum)
Air Circuit Breakers
Type Electrically operated with closing
coil, tripping coil, motorised spring
charging mechanism for all circuit
breakers- incomer & outgoing
feeders.
Drawout type Yes
when ACB is in Isolated
position
(symmetrical)
Rated making Current 105 kA peak
Adjustable short circuit
releases
Adjustable over load releasesYes
Anti-pumping & trip free
features
Electrical anti-pumping & trip free
feature in addition to mechanical
anti-pumping feature.
Protection
-For incomers & and
microprocessor based release shall be
earth fault protec
tion. All ACBs
shall have 240 V AC shunt trip
releases.



UPGRADATION OF B.F NO. 1 PAGE 3.242
Sl. No Specific aspects Technical features
For Incomer In addition to above microprocessor
Incomer only by using IDMTL relay

Ammeter Ammeter with selector switch for
incomers & all outgoing feeders


Wiring
Power Circuit Insulated (1.1 kV) Flexible Copper
Wire/ strip
Control circuit Copper 2.5 mm2 multi strand PVC
wire, insulated
Inter panel Wiring To be completed in each
transportable Section. Provision for
inter shipping section wiring shall be
Control Transformer Adequate
ly rated (minimum 2 kVA)
Indication lamps LED cluste
r with luminous intensity
min. 100 mcd.
CT & PT As required
Painting
Surface Treatment for
Painting
Paint shade Shade No.631 (light gray) of IS 5:
Intelligent Draw-out type, Motor Contro
l Centres (MCC) shall be provided in
following areas for control of drives
of various technological units with
communication capability on Profi-bus

UPGRADATION OF B.F NO. 1 PAGE 3.243
Closed Loop Cooling system (CLCS) MCC
Cast House Defuming MCC
GCP MCC
CA fan auxiliaries MCC
Hear Recovery MCC
Each Intelligent MCC shall have two incomers one bus coupler and required no.
of outgoing feeders. 20 % spare feeders shall also be provided. All the incomers
and bus couplers shall have air circuit
breakers. For outgoing feeders,MPCB will
be considered upto 30kW. Above 30kW MCCB shall be considered. The
Intelligent MCC modules sh
all be draw out type.
Non intelligent conventional, fixed type
, Single front with two incomers & one
bus-coupler Motor Control Centres (MCC) shall be provided for Mud gun and
drilling machines, rocking runner, pus
system, Fire fighting system.
Non intelligent MCCs shall have two inco
mers, one bus coupler and required no.
of outgoing feeders with 20 % spares.
Air circuit breakers/MCCBs shall be
provided for all Incomers and buscoupler. . For outgoing feeders,MPCB will be
considered upto 30kW. Above 30kW
MCCB shall be considered..
Intelligent MCC modules shall have state of



UPGRADATION OF B.F NO. 1 PAGE 3.244
3.8.20.8

Technical Particulars
Specific aspects
1. Reference Standards IS 13947 (Part 1 5): 1993 Low
assemblies
2. Supply system & variation
a) Voltage 415 V + 10%
b) Phase 3
c) Frequency 50 Hz + 5 %
3. Neutral system Solidly grounded
4. System Fault level
5. Rated Insulation Voltage 2.5 kV for 1 min
6. Construction
a) Type of board Single Front Compartmentalised,
Maximum operating he
ight shall be
1800mm and minimum
shall be 300mm from floor level.
b) Degree of protection IP-54
c) Mounting Vertical, Floor mounted, Free standing
d) Front access Hinged door
e) Back access & clearance B
ack access shall be provided.
f) Future extraction provision Provi
h) Paint
i) Cabling Space Side Cable Alley
a) Main horizontal busbar

UPGRADATION OF B.F NO. 1 PAGE 3.245
Specific aspects
b) Busbar Material Aluminium Alloy
c) Max. temp. rise including the
specified ambient temp. and
d) Busbar arrangement Top horizontal
e) Power feed to outgoing
module Sleeved busbar dropper
f) Insulation Heat Shrunk PVC Sleeve.
g) Short time withstand current of
h) Short time withstand current of
i) Colour coding IS 5578 : 1984
j) Clearance between Phase &
25 mm (minimum)
8.1 ACB/MCCB for incomer &
Protection feature
For Incomer load current 400 A and
above ACB shall be provided and
below 400A shall be MCCB.
Rated Interrupting capacity
(symmetrical)
8.2 MCCB /MPCB for outgoing
Rated Interrupting capacity
(symmetrical)
Current limiting type Yes



UPGRADATION OF B.F NO. 1 PAGE 3.246
Specific aspects
Capacity to protect downstream
equipment
Type 2 Co-ordination IS13947 (Part 4/
8.3 Contactors (Power)
Utilisation Category AC3 for non reversible feeders
AC4 for all reversible feeder
Coil voltage (VR) 240 V
Drop out voltage 50% VR
Pick up 85 110% VR
Auxiliary Contacts & rating 2 NO + 2 NC, 10A, 240V AC.
8.4 Overload protection
Through microprocessor based
intelligent module at each cubicle
of intelligent MCC.
Through EMPR for non intelligent
MCCs of process areas
Through thermal o/L relays for non
process area MCCs like A/c,
8.4 Wiring
Power Circuit
Wire / strip
Control Circuit Copper 2.5 mm2 multi strand PVC
wire, Insulated
8.5 Control Transformer 2 nos. with auto changeover scheme.
8.6 Indication lamps LED cluster
8.7 CT & PT As required
8.8 Ammeters For incomers & all motor feeders
8.10 Surge suppressor Across all power contactors
Intelligence feature requirement in MCC:
Each incomer cubicle and each outgoing
feeder cubicle shall be provided with
dedicated inbuilt intelligence module
for Status, control, protection and

UPGRADATION OF B.F NO. 1 PAGE 3.247
ii) The motor feeders shall be provided
with Intelligent Motor control and
protection device, in place of overload re
lay, in the power circuit. All motor
protection and control functi
ons and interlocking schemes shall be implemented
with microprocessor.
iii) The Intelligent Motor control and pr
otection device sha
ll be provided with
interface communication cable
(The interface shall be an
integral part of the
iv) The intelligent motor control and pr
be provided with
current measuring module which shall be
Overload Protection



UPGRADATION OF B.F NO. 1 PAGE 3.248
Thermistor protection, with a facility
to choose among the binary & analog
Intelligent motor control and protection device shall offer parameterizable control
Intelligent motor control and protection device shall offer following
supplementary functions:
i) Signal matching
ii) Truth table
iii) Timer counter
Intelligent motor control and protection
device shall have standard function
control blocks for various functions ( e
.g. time graded restarting of drives after
main failure)
i) Check back signal test
ii) Operating
iii) Ready to start
iv) Under voltage off
v) Graded restart
vi) External fault
vii) External wiring
viii) Emergency start
ix) External check back signal
x) PLC / CPU fault
xi) DP fault
xii) Test 1 with shut down
xiii) Test 2 without shut down
Intelligent motor control and protection device shall provide following data:
i) Motor On / Off / open / close

UPGRADATION OF B.F NO. 1 PAGE 3.249
iv) Operating current
v) Operating hours
vi) Number of switching cycle
vii) Number of overload trips
viii) Current of last over load trip.
Technical parameters of Intelligent motor control and protection device:
Sl.No. Specific aspects Technical features
Ambient Temperature 50 deg C
Supply voltage 415 V +/- 10 %
Insulation voltage 1.1kV

Auxiliary circuit continuous current
Digital Inputs / Outputs Based on the control
requirement
Safe Isolation All circuits shall be safely
isolated according to IEC
Power Distribution Board (PDB)
Power distribution board (PDB) sha
Incomer 2 nos incomers and buscoupler of suitable rating
Outgoing feeders MCCBs (no. & rating as
required), 20% spare feeders shall



UPGRADATION OF B.F NO. 1 PAGE 3.250
Busbars 3 ph, 4 wire, electr
olytic grade Aluminium
MCCBs All MCCBs shall be of 50kA
breaking capacity with short
The soft starter shall be suitable for 415V
, 3 phase, squirrel cage rotor induction
motor for application having rating 110 kW
and above. The drives are required
to be controlled automatically through PLC.
The soft starter shall be designed for
reference from PLC.
The soft starter shall be microprocessor ba
sed using solid state
electronic devices.
The motors covered under this specifi
cation shall comply to the following
specification and to the specific standard
s mentioned in the respective clauses:
IPSS:1-03-001-95 General purpose squirr
el cage induction motor (third
IPSS:1-03-001-92
IPSS 1.03-004-93
NEMA Standard
MG1-1993 Part 31,
or latest

UPGRADATION OF B.F NO. 1 PAGE 3.251
IPSS:1-03-018-95 General purpose
HT Squirrel cage Induction motor
IPSS:1-03-004-95 AC Crane duty Squi
rrel cage Induction motors (second
IPSS:1-03-007-85 AC Roller table motors (with amendment 1 & 2).
IPSS:1-03-003-94 AC mill/ crane duty s
lip ring Induction motors (second
IS:325-1996 Three phase Induction Motors
IS:900-1992 Code of practice for
installation and maintenance of
IS:1231-1974 Designation of thr
ee phase foot mounted Induction
IS:2148-1981 Flame proof enclosur
IS:2253-1974 Designation of type
of construction and mounting
arrangement of Rotating electrical machine.
IS:3682-1966 Flame proof A C Motors for use in Mines
IS:6381-1972 Construction and testin
g of electrical
IS:9628-1980 Three phase Induction Moto
rs with type of protection
n.
IEC 34 & IEC 72
All motors shall also conform to the late
st Indian Electricity Rules and Indian
Design and selection of motors shall
be done taking into consideration the
fact that the motors are called upon
to operate continuously and hence all
facilities to simplify inspec
tion, testing, maintenance,
cleaning can be carried
out at site without disrupti



UPGRADATION OF B.F NO. 1 PAGE 3.252
2)

2. Variation in Rated

UPGRADATION OF B.F NO. 1 PAGE 3.253
3. Rated frequency 50 Hz
4. Variation in rated
5. Duty As per requirement
6. Speed (RPM) To be matched with the driven equipment
7. Time to withstand
2 minutes
8. Mounting Horizontal/ Ve
rtical mounting as per
application
10. Degree of protection IP 55
11. Class of insulation F
12. Temperature rise (over
ambient temp. of 50
13. Starting current in
percentage of rated
current (Ist / Ir)
600 % maximum
14. Power factor at rated
15. Starting time at 100%
and 85% rated voltage
with load
Not more than 10/ 15 sec for 100% voltage.
16. Safe stall time at 110%
rated voltage at Hot
5 10 Sec more than locked Rotor withstand
time
17. Thermal time constant,
in min.
45 min.
18. Margin on Hot thermal
withstand curve
Minimum 10% over full load current to
19. Minimum permissible
voltage at terminal for
starting (with full load)
20. Permissible running
time with full load at
minimum (75%)
allowable voltage.
5 min



UPGRADATION OF B.F NO. 1 PAGE 3.254
22. Transient recovery after
temporary system
The motor shall be capable to accelerate with
load to rated operating point from such
23. Fault withstand current
and time for terminal
6.6 kV motors : 40 kA
(rms) for 0.25 seconds
415 V motors : 50 kA (rms) for 0.25 sec.
24. Withstanding ability of
Switching Surge of (4U
+ 5kV) Where U is
rated line voltage.
175/2500 micro second
25. Direction of rotation Bi-direction
26. Winding Material Copper
27. Winding Insulation type Non-hygroscopi
c, oil resistant and resistant to
flame propagation
28. Winding connection Star: For HT motors
Delta: For 415 V motors
30. Motor terminal box type
(for HT motors)
Phase segregated type. An insulated barrier
shall be provided between the motor terminals
thus eliminating the possi
bility of direct short
circuit across the terminals. The outer case is
to be fabricated from heavy gauge steel plate.
It shall be suitable for termination of actual
no. and sizes of cables as per kW rating of the
31. Motor terminal box type
It shall be suitable for termination of actual
no. and size of cables as per kW rating of the
motor considering derating due to site
ambient temp. as well as method of
installation.

UPGRADATION OF B.F NO. 1 PAGE 3.255
32. Degree of protection for
terminal boxes
IP - 55
33. RTD for Winding and
Bearing temperature
measurement for HT
6 nos. RTD (Platinum wire having resistance
of 100 ohm at 0
C) for windings and 2 nos.
RTD for bearing temp.
(Temperature inputs shall be directly taken to
34. Space heater for HT
35. Supply system for space
heaters for HT motor
37. Bearing Self lubricated anti friction roller bearing
38. Earthing of motor body Each motor
frame shall have two distinct
39. The motor shall be
provided with adequate
& suitable lifting
devices and with the
40. Noise level The noise level
shall be as per IS 12065:1987
and shall not exceed 85 dBA at 1 m. from
415V Inverter Duty Motor:
1.0 Type -
AC Squirrel cage induction motor.
2.0 Constructional Features
Frame size & rating -
10:1 constant torque speed range motors



UPGRADATION OF B.F NO. 1 PAGE 3.256
may exceed frame standard by one frame
Protection for Motor &
Bearing
Motor Shaft Shall be provided with an external recessed
slinger at the drive end of the motor to
provide additional (minimum IP-54)
protection from moisture and foreign
material.
Shaft ends & Extension -
Cylindrical as per requirement
Shaft shall be extended for encoder /
tacho. mounting, accordingly suitable
Internal Encoder Motors with
speed variation of 1000:1 at
constant torque shall have internal builtin
encoder for speed feedback
Bearing -
Roller type bearing upto 5 kW .
Ball Bearing at NDE end for above 5
kW.
All motors shall have fully re-greasable,
anti-friction bearings.
All motors shall have cast iron inner
bearing caps.
All motors shall have a charged
lubrication system to
inhibit moisture
Standard motors shall have extended
grease fittings on the opposite drive-end
to facilitate re-lub
rication. Grease ports
shall be located on the periphery of the
Motor shall be fitted with a shaft slinger
or V ring seal on the drive end for a
minimum of IP-54 protection (to help
protection of bearing
from ingress of dust

UPGRADATION OF B.F NO. 1 PAGE 3.257

3.0 Terminal box
Location RHS viewed from DE / On top
Suitability -
4 Core Aluminium Cable
The terminal box shall be oversize as
compared to NEMA requirements.
Earthing stud Inside Terminal Block
Miscellaneous -
4.0 Cooling -
TEFC, Effective bi-directional
Motor with 1000:1 speed range and
constant torque shall have external fan.
External fan motor shall be 3 phase, 415
V AC
- Thermistors shall be provided in the
5.0 Quality of operation
Vibration intensity -
Shall be limited as per IS 12075-1986.
Shall not exceed .08 inches / second
velocity.
Noise level As per IS: 12065-1987
6.0 Electrical design
Power Supply 415 V +/-10 %, 50 Hz +/- 5%, 4-wire AC, ,
solidly earthed.



UPGRADATION OF B.F NO. 1 PAGE 3.258
Starting Variable Frequency Drive
Service factor -
Peak transient voltage 1600 V
Minimum rise time 0.1 microsecond
Starting Torque 200 % rated to
rque for 1 minute below base
speed
Constant horsepower
1.5 times base speed.
Duty Application dependent
Max speed permissible 150 % rated for 2 minutes
Derating for VFD As per above mentioned standard
Insulation Class H limited to class F.
Load Type Constant Torque / Variable Torque
Space Heater -
Out door motors above 45 kW
No. of Poles 4 / 6 / 8
7.0 Operating Characteristics
Operation with variation in
Motors shall operate successfully under
running conditions at rated load with
variation in the volta
ge or the frequency
not exceeding the following conditions:
+/-10% rated voltage at rated constant
V/f ratio except for specific torque
Motors shall operate successfully under
running conditions at rated load and V/f
ratio when the volta
ge unbalance at the
motor terminals does not exceed one
percent.

UPGRADATION OF B.F NO. 1 PAGE 3.259
7.2

Operating speed range -
Locked rotor (starting)
currents
Shall not exceed NEMA Design B values
for the specified rating on 5:1 constant
torque or less and variable torque motors.
NEMA Design A values are allowed for 6:1
constant torque or higher value constant
Motors shall be capable
of a 20 second stall
at six times full load current without
injurious heating to motor components.
Efficiency -
Shall have a nameplate minimum and
nominal full load efficiency for motors
when tested in accordance with NEMA
standard MG1 Part 12, IEEE Test
8.0 Motor location Outdoor
9.0 Nameplate -
Shall be of corrosion resistance stainless
steel.
In addition to standard nameplate
information following informations shall
Nominal efficiency.
Bearing identification numbers.
Torque values with speed range and
amps for that torque value.



UPGRADATION OF B.F NO. 1 PAGE 3.260
o



The tests to be carried
out on equipment are s
Factory tests (Routine te
Site tests
All routine tests as per relevant standard
s referred above shall be carried out by
the Successful Tenderer at the manufactur
er's works. However, the following
Routine test shall necessarily be carri
ed out in the presence of purchaser/
consultant unless otherwise waived
Insulation resistance test
No-load running of motor & reading
of voltage, current, power input &
speed.
Locked-rotor readings of
voltage, current & power
input at a reduced
Open-circuit voltage ratio
(for slip-ring motors only)
Temperature rise test
Momentary over load test
Over speed test: The motors shall be suitable to withstand 120% of rated
speed for specified duration (2 minut
es) without any mechanical damage.

UPGRADATION OF B.F NO. 1 PAGE 3.261
Switching surge test for HT Motors
: Motors shall be capable of
withstanding a 175/ 2500 micro second
switch surge of (4u+5)kV, where u
is the line to line voltage.
Temperature rise test listed under Type
Test, as per IS-325-1
be carried out on at least one motor of
each type, rating and category for which
The mode of operation of skip is as follows
Local mode
Remote mode (control desk)
Monitor mode (auto mode)



UPGRADATION OF B.F NO. 1 PAGE 3.262
Two separately excited DC motors ar
e coupled with the
winch rope drum
Local & Remote
mode selector
switch
From control desk
In Remote Auto mode through PLC and can be
Local operation Inching operation from Local control post
In auto mode skip operation is controlled
from operator consol
control room. PLC co-ordinates with the thyristor drives for operating the skip
operation of the mechanisms with other related
equipment.
When selection switch on control desk in
control room is put in auto mode
"permission to work" command goes from PLC as per the charging sequence and
system inter-lockings. PLC enables the t
the speed of the drives. Status feedback
will be sent to PLC continuously for
operational sequence of the charging system.
All the protection and safety switches are
hard wired and additional potential free
contacts have been made available to PLC for status monitoring.
Stop command
Drive stops at the end positions as per
track limit switch setting and withdrawing
reference, based on electrical sequencing
and interlocks. However emergency stop
button is also provided at the control de
sks /operator console to stop the operation
at any time for emergency. Rotating merc
ury switch is used for over speed
tacho-generator input to PLC/ thyristor.
Restart the operation
To restart the drive after a power failure
terruption the same
operation is carried out by the operator as in the case of monitor mode and drive

UPGRADATION OF B.F NO. 1 PAGE 3.263
accelerates from the same position where
it had stopped. In no case restarting of
drive is taking place automatically, it st
arts only after operators intervention.
Principal interlocks to start the skip drive
End limit switches in set position.
Permission from furnace charging system obtained.
The above mentioned interlocks are only i
the opening & closing of big bell &
small bell. The bell control winch mechanism is such that at any given time
either both the bells are in closed pos
ition or only one of the bells is in open
position. This is done to ensure that bl
ast furnace is not opened directly to
atmosphere. Raw materials are discha
rged into the blast furnace by co-
ordinated opening & closing of big bell & small bell. Small bell opening
discharges the material on the big be



UPGRADATION OF B.F NO. 1 PAGE 3.264
The opening and closing of small bell
and big bell are carried out in line
with furnace charging pattern. Norma
lly a big bell operation takes place
after three to five
small bell operation.
Speed control of the DC motor is ach
ieved through two nos. of reversible,
regenerative thyristor drives connected
in parallel, out of which only one
will be in operation while other
will be kept as hot stand by.
The above mentioned Bell winch system is to be replaced by Bell Less Top (BLT)
charging system.
Description of main BLT
components and of charging sequence as proposed by
The burden brought up by skip system is ch
arged into the static receiving hopper.
ed on the main BLT top structure.
A material gate is fixed to the lower
part of the static receiving hopper. The
material transfer is controlled by a materi
al gate in the static receiving hopper and
a seal valve (double motion type) in the
material hopper. The upper seal valve is
top of the material hopper.
The material hopper is supported via a
weighing beam assembly on a main
lumns, which are fixed to
and supported on the BF
The material hopper being empty and
under atmospheric pressure, burden
material is discharged from the static
valve and then the upper material gate.
After filling-up of the material hopper, the
upper material gate is closed, the upper
seal valve and the pressure relief valv
e are closed and the
material hopper is
pressurised with semi-clean BF gas by ope
ning the equalising va
lve. Once certain
pressure has been reached, the equalizing
valve is again clos
ed. Final pressure
If the BF is ready for charging, the se
quence for burdening will start by opening
the lower seal valve (double motion type
) and opening the material gate to a
precalculated position. For purpose of cont
rolling the flow for different kind of
materials, different material flow curves are stored in the PLC.
The burden material flows from the materi
al hopper through the material gate, the
bellow arrangement and the transmission
gearbox, wear protected by a feeder
able to carry out a rotation movement as well as a tilting movement around the

UPGRADATION OF B.F NO. 1 PAGE 3.265
When the material hopper is empty, the mate
rial gate and the lower seal valve are
closed. Furthermore the secondary
Prior to emptying the static receiving
hopper into the material hopper, the
material hopper is depressu
rised to the atmosphere by opening the relief valve.
During the emptying of the material hopper
into the blast furnace, the static
receiving hopper has been again filled, so
that the burdening sequence can start
again.
Specification of Electrical equipm
ent for Skip AC drive System
690V Inverter Duty Motor for Skip
Type -
AC Squirrel cage induction motor
Standard -
NEMA Standard MG1-Pt. 31
Constructional Features
Frame size & rating -
10:1 constant torque speed range
motors may exceed frame standard by
one frame rating.
Motor body Grey iron casting as per IS:210-1978
Motor Feet Integrally cast with the stator
Body Design -
Prevent breakage or other failures due
to vibrations normally encountered in
Motors will be of weather proof
Designed to operate in the humid air
stream.
Protection for Motor &
Bearing
IP - 55
Bearing insulation The motor shaft will have insulated
Shaft ends &
Extension
Cylindrical as per requirement
Shaft will be extended for encoder /
tacho. mounting, accordingly suitable
Absolute Encoders Combination for speed and position control
and monitoring
Bearing -
Fully re-greasable, anti-friction
Motors will have cast iron inner



UPGRADATION OF B.F NO. 1 PAGE 3.266
bearing caps.
Motors will have a charged lubrication
system to inhibit moisture
Motors will have extended grease
fittings on the opposite drive-end to
facilitate re-lubrication. Grease ports
will be located on the periphery of the
motor end shield.
Motor will be fitted with a shaft slinger
or V ring seal on the drive end for a
minimum of IP-54 protection (to help
protection of bearing from ingress of
Terminal box
Location RHS/ LHS viewed from DE
Suitability -
The terminal box will be oversize as
compared to NEMA requirements.
Rotation in steps of 90 deg.
Earthing stud Inside Terminal
Block and on either side o
Miscellaneous -
Cooling -
IC411 as per IS 6362: 1995 (IC4A1A1
Contractor to consider force ventilation
unit if required w.r.t. duty of the motor
Quality of operation
Vibration intensity -
Will be limited as per IS 12075-1986.
Will not exceed .08 inches / second
velocity.
Noise level As per IS: 12065-1987
Electrical design

UPGRADATION OF B.F NO. 1 PAGE 3.267
Power Supply 690 V +10 & - 10% , 50 Hz +/- 5%
Starting Variable Frequency Drive
Service factor -
Insulation Suitable for p
Minimum rise time 0.1 microsecond
Starting Torque 200 % rated torque
Duty Motors will be suitable for overload duty
cycle conforming to NEMA standards and
Max speed
permissible
150 % rated for 2 minutes
Derating for VFD As per above mentioned standards
Insulation Class H with temp rise limited to class F.
Load Type Constant Torque
Space Heater -
No. of Poles 8
Protections
PTC thermistors in stator winding
Winding temperature measurement/
Bearing temperature measurement/
Operating CharacteristicsTorque s
with existing moto
Operation with variation
in the voltage & the
Motors will operate successfully under
running conditions at rated load
Operating speed range Zero to rated speed
Locked rotor (starting)
currents
Will not exceed NEMA Design B values
for the specified rating on 5:1 constant
torque or less and vari
able torque motors.
NEMA Design A values are allowed for
6:1 constant torque or higher value
Motors will be capable of a 20 second
stall at six times full load current without
injurious heating to motor components.
Motor insulation Moto will be designed to withstand high



UPGRADATION OF B.F NO. 1 PAGE 3.268
switching frequency generated by AC
drive. The switching frequency data must
be given to the motor manufacturer.
Motor insulation will able to withstand
voltage of 2.4kV, rise tim�e0.1 microsec.
Motor location Indoor.
Painting Total thickness of painting will be 140
microns.
Variable Frequency Drive for Skip
Application
The variable frequency drive system
will have digital control technology
with vector control. The VFD
controllers will be IGBT
based with pulse width modulation (PWM) design
converting the input AC voltage and fr
equency to a variable voltage and
variable frequency output via two-st
age conversion (A
C to DC through
controlled IGBT rectifier and DC
to AC through IGBT based PWM
Inverter) for the speed control of
asynchronous motors. The VFD will be
The VFD System will conform to the following specification:
The latest applicable standard
s of IEC (IEC 146), IEEE (IEEE 519
Specification
Specific aspects Technical features

LT: 690 V +/- 10%, 50Hz +/- 5% , 3
System fault level 50 kA for 1 sec
Ambient temperature
humidity
Incoming power
As indicated above with Transformer
secondary voltage of 690V. Enclosed
VFD configuration drawing may please

UPGRADATION OF B.F NO. 1 PAGE 3.269
Specific aspects Technical features
VFD System be referred to.


AC drives will be latest generation 4
quadrant operational drives and active
front end (AFE) type VFD system.
VFD system will have digital control
The Inverter will be 3 phase, 6 pulse
32 bit microprocessor based voltage
source pulse width modulated type.
IGBT based with sine coded PWM
VFD will communicate to basic
automation system on system
Suitable for constant torque
The drive will have an internal EMC



UPGRADATION OF B.F NO. 1 PAGE 3.270
Specific aspects Technical features
the parameters of variable speed
drives when the AC power supply to
drive is OFF. Necessary power
supplies for this purpose will be
Synchronous supply &
supply will be taken from proposed
ACDB through suitable control
transformers.
For all other auxiliary supplies like
control voltage for relay logic, power
stack cooling fan, sk
ip brake supply
Selection criteria Characteris
tics of the VFD Inverters
matching the speed torque characteristics
of the AC motors a
ssociated with the
Blast Furnace Skip mechanisms will be
the prime consideration for selecting the
Duty The continuous rating of each AFE
Rectifier unit will be able at least 1.5
times the full load current drawn by both
the motors (both in operation).
Rated for continuous duty with frequent
intermittent overloads without exceeding
temperature limits.
Overload duty
Overload duty of AC motors will also
match with specified overload duty of
Control technique Pulse encoder feedback will be taken for
precise control. However, Sensorless
vector torque control technique will be

UPGRADATION OF B.F NO. 1 PAGE 3.271
Specific aspects Technical features
the integral part of control system.
Total voltage and
current harmonic
5% in accordance with the procedure
outlined in IEEE 519-1992
Torque ripple 2%
Efficiency 96 - 98%
Power factor 0.96-0.98
Speed control
accuracy
Torque accuracy +/- 0.5%
Output frequency
resolution
(of rated torque of
Features
Control panel will be dust and vermin
proof, free standing made of 2 mm thick
cold rolled sheet steel. Height of the
panel will not exceed 2200 mm. The
panels will have a collapsible shelf in the
Major equipment &
components to be
considered in total
The following major components to be
Converter transformers
AC power circuit isolating devices
circuit breaker, dis-connector with
semiconductor fuses for thermal



UPGRADATION OF B.F NO. 1 PAGE 3.272
Specific aspects Technical features
Pre-charging rectifier, pre charging
Regenerative AFE rectifier unit
Line filter accompanied by AFE
reactor ( LCL filter)
DC fuses
32 bit microprocessor based control
Line reactors input side and output
side to take care of capacitive
charging currents
Voltage limiting filters (dV/dt)
Parameterization unit
RS-485 multi-drop serial link for
connectivity to external controlling
devices (operators key pad, PLC , PC
based maintenance tool)
communication board for master
for fast deceleration and quick stop
(additional requirement for skip
operation to take care of
emergencies).
Cooling fan with air flow/ pressure
switch,
Control switches, push button,
Contractor is to note that standby
inverter unit of identical capacity will

UPGRADATION OF B.F NO. 1 PAGE 3.273
Specific aspects Technical features
be provided and will be connected to
each section of DC bus. In case of
failure of working inverter of a
particular secti
unit of that section will take over
automatically.
Connectivity to
external field
To be provided for connecting the
Inverter with external devices for
Reference command
to the drive
Parameterization through standard
control key pad mounted at the door
External devices like PLC, PC based
commissioning and maintenance tool
or from overriding computer system.
Control functions The VFD will be controlled and
monitored from a digital operators
keypad. The following functions will be
performed by the keypad as minimum:
Display the drive actual values.
Protection, switches
Protection The following protection features will be
Phase loss / Negative sequence trip
Missing run/ start permissive
Internal / external short circuit
Earth fault (in case of large motor)
Momentary power failure
Forward/ reverse current limit
Thermal overload
Under voltage trip with time delay



UPGRADATION OF B.F NO. 1 PAGE 3.274
Specific aspects Technical features
Inrush current limits
Over speed
short circuit protection
Motor temperature high

provided for:



Indication Clustered LED lamps will be provided
for incoming power supply ON, OFF and
LCD display 4 x 20 alphanumeric display unit to be
Actual speed
Motor current
Power factor of the motor
Operating time
Other technical parameters, various
Routine test:
Visual check up and disposition of
components and wiring, assembly
Dimension of the panel
Measurement of IR
tion of protective
Overload capacity check. However,
overload check shall be performed by

UPGRADATION OF B.F NO. 1 PAGE 3.275
Specific aspects Technical features
e of similar rating:
Temperature rise test
Harmonics analysis and torque ripple
Rigorous metal treatment, degreasing,
drying followed by two coats of red
oxide primer and two coats of finished
stove enamelled painting.
Paint shade as per IS:5, 1994

690V Power Distribution Board (PDB) for skip
Power requirement for the proposed AC drive system will be 690V and it
will be fed from the converter transformers. The proposed PDB will be
Type Indoor, Free-standing, Floor-mounted
Standards IS: 8623 (Pt: 1-3) -1993
Service voltage 690V+ / - 10%
Fault level in kA RMS 50kA



UPGRADATION OF B.F NO. 1 PAGE 3.276
Description Technical particulars
System Frequency 50 Hz [+ / - 5% ]
Degree of enclosure
IP -54
Permissible temperature rise
over ambient( for switch
Short circuit withstand
strength of busbar systems in
Asymmetrical breaking
current of circuit breakers
current of circuit breakers
Short- time current capability
Air Circuit Breaker
Air circuit breaker type Suitable for 690V, 3-phase, 4-wire,
Electrically operated dr
aw out type with
microprocessor based release for short
circuit, overload and earth fault
Bus bars three phase and
neutral busbars of high
conductivity aluminium alloy as per
grade E91EWP of IS:5082-1981
Quantity and rated current of
incomer, bus coupler &
Incomer- 1250A (minimum rating) - 2
Bus-coupler-1250A (minimum rating)- 1
Outgoing: feeders 1000A (minimum

UPGRADATION OF B.F NO. 1 PAGE 3.277
Description Technical particulars
Operating voltages for
Universal motor
Permissible operating
85% to 110% nominal
70% to 110% nominal
85% to 110%nominal
Earthing: Main earth ba
r extending throughout the
Connection for incoming and
Indicating instruments
Size: 144 mm x 144mm
The meters will have accuracy class of 2
Limit Switches and Brake for skip
The following type of Limit Switches w
ith mounting, fixing and driving are to
Cam operated rotary geared limit switc
The gear-cam limit switches shall be used for tracking the skip Car over
Track limit switches (Rotary cam type



UPGRADATION OF B.F NO. 1 PAGE 3.278
Limit switches shall be provided with
convertible type contacts. The
contact are rated for 2 A at 220 V
D.C. and 10 A at 240 V AC. Contact
development / actuation logic will
Each limit switch set enclosure will
have two separate grounding pads,
tapped holes and bolts suitable for
connection of Employers 8 SWG GI
Rope Slackness switch
The rope slackness switch shall be
provided with lever and roller
arrangement for operation of the limit switch contacts. The switch is fixed
just below the rope drum. In case of
slackness of the rope the lever will
actuate the electrical contacts through
which alarm and trip circuit will get
activated.
The other Limit switches such as Skip
in pit limit switch, Rope Tension limit
switch shall be similar to the above.
The Contractor shall provide merc
ury over speed switch having contact

UPGRADATION OF B.F NO. 1 PAGE 3.279
Multi-turn absolute encoder will also be provided for
position feedback
of
Control posts/ desk will be free
standing, floor mounted, totally
enclosed, dust & vermin proof, bench board type construction having
Control and selector switches will be
of rotary type
with escutcheon
plates clearly marked to show the function and positions. The switches
will be of sturdy construction suitable for mounting on panel front.
Switches with shrouding of live part
s and sealing of contacts against
dust ingress will be preferred.



UPGRADATION OF B.F NO. 1 PAGE 3.280
The Control posts/ desk
will have a Red mushroom head Emergency Stop
Indicating lamp assembly of LE
D cluster will be of the panel
mounting type and capable of clear
status indication to operator under
the normal room illumination intensity 100 mcd. Indicating LED
lamps will be suitable for continuous operation.
LED lamp assembles will have following colours:
All indicating meters will be flush mounted on panel front. The
instruments will be of at least 96
mm2 size with 90 degree scales and
will have an accuracy class of 2.0 or

UPGRADATION OF B.F NO. 1 PAGE 3.281
Terminal blocks will be of 650 volts
grade, rated for 10 Amps and in
one piece moulding. They will be co
All internal wiring will be carried
out with 650 V grade, single core,
2.5.mm2, stranded copper wires with
Internal termination of stranded conduc
tors will be made with solder less
crimping type tinned copper lugs which will
firmly grip the conductor. Insulating
Remote Terminal Unit (RTU)
RTU shall be provided for provision of
connectivity with existing SCADA system
of Purchaser. Communication link
Under normal conditions, both the system
UPS in parallel redundant mode shall
supply regulated AC power continuously to
share the loads. Th



UPGRADATION OF B.F NO. 1 PAGE 3.282
charger shall convert the normal AC incomi
and for float charge of the storage ba
ttery. When incoming AC power supply to
UPS system shall take full load immediat
ely to ensure un-i
nterruptible power
supply to critical loads. The
configuration of the UPS sy
stem shall be such that
the rectifier and inverter
section of both the UPS can
function in criss-cross
manner such that rectifier of one UPS can
feed inverter section of both UPS and
vice-versa.
If both AC incoming power supply fail or de
viate from specified tolerances , the
storage battery shall supply DC power to
the inverter of working UPS ensure
continuous AC Power supply to the loads.
Input power supply conditions shall be as below :
Voltage: 415 V + 10%, -10%, 3 phase 4 wire AC
Frequency: 50 Hz + 5%, -5%
Power factor: 0.8 lagging (minimum)
The UPS System shall be designed to function under the following design
Applicable standard: IEC 60146-4 (1986-09), IEC - 60146-5
Design ambient temperature: 50 deg C
Acoustic noise: 55 dBA at 1 M
Degree of enclosure: IP 42
Frequency 50 Hz
Voltage regulation + 1 % nominal for any of following conditions :

UPGRADATION OF B.F NO. 1 PAGE 3.283
1. No load to full load
2. 1.0 - 0.8 lagging power factor
3. Min to max DC input voltage
Voltage transient response 10% maxi
mum deviation (average over half-
cycle for 100% load ap
Voltage adjustability + 5 %
Voltage unbalance 5 % maximum line to line or line to neutral, with
Phase separation 1200 + 5% with 100 % load unbalance
Voltage wave form 5% total ha
rmonic distortion (THD) maximum
and 10 % fifth harmonic current
Frequency stability + 0.1 % free running
Frequency slew rate 1.0 Hz / second (maximum)
Frequency adjustability + 2 Hz
Overload capacity 100 % continuous
125 %for 15 minutes
150 % for 60 secs.
1000 % for 10 milliseconds
Battery recharge time 8-10 hours
Storage battery
Voltage As required by the inverter
Protection time
Type Inverter grade SMF ( VRLA)
The inverter section of the UPS system shall be IGBT based.
Each UPS of the parallel redundant system
shall have its own dedicated battery



UPGRADATION OF B.F NO. 1 PAGE 3.284
shall have data as well as I/O communi
cation with the PLC system. Necessary
hardware & software for the same shall be included.
UPS shall have battery health monitoring feature.
UPS shall have selectable feature of au
tomatic charging/ disc
The protection of the UPS system are to be
provided as suitable and required for
Rectifier
Current limiting to maximum value.
Auxiliary supply failure
The following meters shall be provided:-
Ammeters
Ammeters for battery
listed but need not be limited to :
Load on AC mains/battery
Rectifier on

UPGRADATION OF B.F NO. 1 PAGE 3.285
AC mains failure due to fuse blown
Overcurrent
Battery on load timer
Test at manufacturer's works
Routine Test
Assembly inspection/painting check
H.V test on main circuits.
Protective device co-ordination
Control desk shall have all switches (for
selection of mode
s & actuation), push
buttons for remote operation of the system through PLC, along with other
facilities.
Control desks shall be free standing,
floor mounted, totally enclosed, dust &
vermin proof, bench board type constr
of protection of



UPGRADATION OF B.F NO. 1 PAGE 3.286
Necessary number of fault annunciati
on Windows are to be provided on the
vertical facia at a convenient locatio
n. The annunciation system shall have
Control and selector switch
es shall be of rotary t
ype with escutcheon plates
clearly marked to show the function a
nd positions. The switches shall be of
sturdy construction suitable for moun
shrouding of live parts and sealing of

UPGRADATION OF B.F NO. 1 PAGE 3.287
3.8.30.4


Indicating lamp assembly of LED clus
ter shall be of the panel mounting
type and capable of clear status in
dication to operator
under the normal
room illumination intensity 100 mcd. I
ndicating LED lamps shall be rated
LED lamp assembles shall have following colours:
All indicating meters sha
ll be flush mounted on panel front. The instruments
shall be of at least 96 mm2 size with
90 degree scales and shall have an



UPGRADATION OF B.F NO. 1 PAGE 3.288
The Local Control Station shall be pr
ovided with DRIVE
ON, OFF & TRIP
or Valve OPEN, CLOSE, TRIP indica
ting lamps. Indicating lamps shall be
LED block type, and suitable for panel mounting.
Local control stations shall have require
d push buttons like
Power supply 415 Volts, 3 phase, 4 wire 50 Hz
Voltage variation + 10%
Frequency variation +5%
System short circuit
All equipment & components shall be su
itable for operation in a hot, humid,
tropical and dusty atmosphere as
prevalent in a steel plant.
1) Torque limit switches, one for each
direction of travel, self-locking,
2) End-of-travel limit switches, one for
each direction of travel, each having 2
3) Contact rating of each limit switch shall be 5 Amps at 240 V AC.

UPGRADATION OF B.F NO. 1 PAGE 3.289
4) The torque switch shall have a mi
nd wheel with limit switch for emergency
manual operation. The hand wheel shall declut
ch automatically when the motor is
energized. The hand wheel limit switch sha
ll disable energization of motor during
manual operation.
Actuator Terminal Box
All terminals of limit and torque switche
s, space heaters shall be brought to a
common terminal box. There shall be at le
ast five (5) spare terminals for spare
Electric motor for actuator
The drive motor shall conform to
IS 325:1996. The motor shall be with class
F insulation for stator winding with te
mperature rise limited to class B.
The motor shall be designed for high
torque and reversing service.
Thermostats shall be placed in the st
ator winding for thermal protection of
motor. The motor shall be suitable for S2 duty cycle.
The motor shall be designed for full voltage direct on line. The motors shall
be capable of starting at 85% of rate
d voltage and running
at 80% of rated
voltage at 33% excess rated torque for a period of 5minutes each. Earthing
terminals shall be provided on either side
of motor. The torque capability of
the motor shall match the requirement of the load.
Control rooms 300 0.6 Decorative CFL type
Electrical rooms
PDB, MCC, VFD
200 0.6 Decorative CFL type
Staircases, cable 70 0.6 Industrial well-glass



UPGRADATION OF B.F NO. 1 PAGE 3.290
basement integral type luminaire
suitable for 70W
HPSV lamps
Pump house 200 0.6 Industrial well-glass
integral type luminaire
suitable for
70W/150W HPSV
lamps
Area lighting 70 0.6 W
eather proof flood
light fittings for
1x400W HPSV lamps
70 0.6 Industrial well-glass
integral type luminaire
suitable for 70W
HPSV lamps
Well glass integral
1x70W HPSV
1x150W HPSV
250/400W HPSV
Well glass integral
1x70W HPSV
1x150W HPSV
250/400W HPSV
100 0.6 Industrial well-glass
integral type luminaire
suitable for 70W
HPSV lamps
Aviation obstruction
light fittings, flame

UPGRADATION OF B.F NO. 1 PAGE 3.291

For maintenance lighting, power suppl
y shall be fed from 240/26.5V small
capacity step-down transformers



UPGRADATION OF B.F NO. 1 PAGE 3.292
3.8.33.7

Flood lights for area lighting shall be
mounted on towers/ poles or building
Power factor of all the light fittings sha
ll be improved so that it is not less than
0.90. Power factor shall be improved by pr
oviding capacitor banks with discharge
resistor in the light distribution or by
providing capacitors with individual fittings.
Illumination wiring from SLDBs upto li
ght fittings shall be through 1.1kV PVC
insulated, PVC sheathed, 2.5 sq.mm coppe
r unarmoured cables in GI conduit/
armoured cables in trays for Tec
hnological areas and through 1.1kV PVC
insulated 2.5sq.mm wires in GI conduits at
rooms. For offices and control rooms,
The switches shall be provided for contro
lling lighting circuits. The rotary or
toggle switches provided will
be of sturdy design. The
unit will be housed in cast


UPGRADATION OF B.F NO. 1 PAGE 3.293
The MLDB shall have enclosed busbar ch
amber at the top, vertical busbars for
outgoing feeders and cable compartments
separately. Maintenance access shall
be provided from front only afte
MLDB shall have two nos. TPN MCCB incomers & one bus coupler and TPN
MCCBs as outgoing feeders.The MCCBs sha
ll have Short circuit, overload and
Each outgoing feeder will feed lighting power to the respective Sub
30% spare outgoing
provided for MDB with minimum of 2 nos.
Cable entries shall be made from the bo
SLDBs shall be metal-enclosed, cabine
Fixtures shall be suitable for 20 mm
conduit entry and 16 SWG GI earth wire



UPGRADATION OF B.F NO. 1 PAGE 3.294
connection. Necessary conduit to pipe adap
ters shall be furnished for fixtures
High bay fixtures shall ha
ve provision for vibration damper to ensure rated
lamp life.
Fixtures shall be fully wired up to the
respective terminal blocks, suitable for
Flame proof fittings and control gearboxes
will be provided as per relevant IS
The receptacles to be installed
- 5A, 240V AC, 2 pole, 3 pin with
third pin earthed, decorative type
suitable for flush mounting in offi
ce areas and control rooms. The
switch shall also be flush mounted piano type.
- 16A, 240 V AC, 2 pole, 3 pin with
third pin earthed, decorative type
suitable for flush mounting in offi
ce areas and control rooms. The
switch shall also be flush mounted piano type.
- 20A, 240 V AC, 2 pole, 3 pin with
third pin earthed, industrial type

UPGRADATION OF B.F NO. 1 PAGE 3.295
and outgoing feeders as per requiremen
t. Earth fault protection shall be
provided in each feeder.
WDB shall be floor mounted type, dust
and vermin proof, weather proof with



UPGRADATION OF B.F NO. 1 PAGE 3.296
The Electric hoist shall be provided w
ith Pendant Switch Push Button (P/B)
control. Pendant Control switch shall
be adequately protected to prevent
accidental contact with live parts. Th
e P/B station shall be of momentary
contact type and shall turn to off positi
on when pressure is
released (spring

UPGRADATION OF B.F NO. 1 PAGE 3.297
3.8.36.2

The general design parameters for the cranes are outlined in the IPSS 2-02-
004-97. The Bidder shall refer to the sta
ndard for selection of electrical
equipment for the cranes.
The main down shop leads for the crane travel shall be supplied and
erected by the Bidder. The Bidder shall calculate the maximum
continuous current (on the basis of
30 min maximum demand) that the
down shop leads shall be required
to carry. Adequate screening &
protection of down-shop power conduc
tors and live parts shall be
provided to avoid accidental contac
t. The permissible voltage drop on
the DSL shall not be more than 3%.
The no. of runs and size of feeder
cables in the bay shall also be
decided on the basis of the computed maximum continuous current
es in the respective bays.
For EOT cranes with VFD, the ma
in current collecting arrangements
shall be as per the VFD manufacturers recommendations.
Collector Shoes
The main current collectors with
double collector shoes (tandem
collectors i.e., in 2 different frames) with adequate current carrying
capacity shall be provided for all the three phases and single shoe for
the earth conductor. Th
ere shall be minimum chance of jamming at
the hinge point due to accumu
The width of the shoe shall be sufficient to cover the permissible
lateral movement of the crane.
Current carrying shunts on all the colle
ctors shall be designed so that
there is no danger of contact with adjacent collectors. The shunts shall
be easily replaceable.
l be mounted on rigid steel st
Collectors shall be suitable for easy maintenance and access. Electrical



UPGRADATION OF B.F NO. 1 PAGE 3.298
All crane motors shall
be a.c. induction motors. The motor shall be
suitable for Crane duty i.e., for plugging / reversible type of operation
and suitable duty class (S4) with 150 starts per hour and Cyclic
Duration factor (CDF) not less than
40%. For Cast house crane hoist
mechanism shall have S5 duty motor.
The squirrel cage induction motors w
ith VFD operation. In addition to
control from Cabin the remote cont
rol operation to be provided. The
control shall also conform to all
the requirements specified in IPSS:1-
Motor Power
The motor kW shall be computed on
the basis of guidelines given in
IPSS: 2-02-004-97, IS 4137:1985
The motors shall be in I.E.C. frame
devices shall be ergonomically sited
on the armchair-unit in the Oper
ator cabin. Cam type master
switches/controller with joysticks ty
pe levers shall be provided along
with radio remote control for control
of different motions of the crane.
The contact shall be of double-break
type. Master controller shall
conform to IPSS: 1-10-005-81
Salient technical parameters of the master switches to be used on
required Motors
Employers Requirement
1 Application To provide
directional and speed
control of hoist,
travel/traverse &
slew mechanisms of EOT cranes
and shall be suited for outdoor
and dusty environment.
2 Enclosure IP-54
3 Drum Controller
4 Contacts Double break contact block

UPGRADATION OF B.F NO. 1 PAGE 3.299
required Motors
Employers Requirement
5 Electromechanical life Induc
tive: 1 million operations @
For only Cast House Crane the wire
less remote control operation of
e platform shall be provided.
Resistance (wherever applicable)



UPGRADATION OF B.F NO. 1 PAGE 3.300
shall be mounted in respective panels

UPGRADATION OF B.F NO. 1 PAGE 3.301
Heavy-duty, roller-lever operated
track limit switches shall be provided to limit the travel and traverse motion
of the cranes. Limit switches operated by projecting arms fitted on the crane
shall be provided to prevent collisio



UPGRADATION OF B.F NO. 1 PAGE 3.302
All EOT cranes shall be with tr
ailing cable arrangement for cross
movement.
Type : 3 core, 33 kV, earthed, XLPE insulated PVC sheathed
armoured aluminium conductor cables.
Size : Size 240 mm
Standard : IS: 7098 (Part-II)-1985
3 core 33kV, XLPE cable shall be compact circular stranded (rm/V), aluminium
conductor, provided with conductor sc
reening of semi-conducting compound,
XLPE insulated, provided with insu
lation screening over individual cores
consisting of extruded semi-conducting compound, followed by lapped semi-
conducting tape and copper tape, cores
Specific aspect of
Specification
1. Grade 6.6 kV (UE)
2. Type XLPE ( dry cured )
3. Conductor Circular conduc
tor made of stranded and
compacted electrical grade aluminium wires as
4. Maximum conductor
temperature with
6. Shielding
(Screening)
be made by extruded semi-conducting
7. Inner Sheath Extruded PV
C inner sheath with non-
hygroscopic fillers for suitably holding the cores

UPGRADATION OF B.F NO. 1 PAGE 3.303
8. Armouring galvanised steel round armoured
as per IS 7098
(Part-II-1985)
9. Outer Sheath Extruded type/ PV
C outer sheath (type ST2 as
Minimum size of 6.6kV(UE)cable
s shall be 3 core 185
sq.mm and shall have
LT power cables shall be 1.1 kV grade
multicore heavy duty PVC insulated, PVC
inner and outer sheathed, steel round/fl
at armoured with stranded aluminium
conductor as per IS: 1554 (Part-1) -1988.. Th
e insulation of inner and outer sheath
shall be of extruded PVC (ST2) as pe
r IS: 5831-1984. Minimum size of multicore
stranded aluminium LT power cables sha
ll be 6 sq.mm. For motor rated 2.2kW
copper cable shall be considered.
LT control cables shall be 1.1 kV grad
e multicore heavy duty PVC insulated,
PVC inner & outer sheathed, steel r
ound armoured with 2.5 sq. mm stranded
copper conductor as per IS: 1554 (Part-1)
-1988. The inner & outer sheaths shall
33kV(E) XLPE Al cable from CPP-I
up to the new 33/6.6kV substation will
be laid through existing cable tunnel. 33kV
cable from MSDS-V shall be laid
in buried cable trench in soil up to ex
isting cable tunnel near CRM and then it
will be laid in the existing cable tunnel.
The 6.6 kV grade unearthed XLPE Aluminium armoured and 1.1 kV grade
PVC Aluminium armoured cables shall
be laid generally along the existing
Cable route of BF-1. In addition to the ex
isting route, Cables may also be taken
in Structure/ galleries (overhead cabl
e routes), underground cable trenches



UPGRADATION OF B.F NO. 1 PAGE 3.304

UPGRADATION OF B.F NO. 1 PAGE 3.305
All cables shall be provided with iden
tification tags indicating cable numbers
in accordance with the cable/circuit schedule.
Tags shall be fixed at both ends
of cable, at joints and at 20 m spacing
for straight runs. When a cable passes
through a wall, tags shall be fixed at both
sides of the wall. The tags shall be of



UPGRADATION OF B.F NO. 1 PAGE 3.306
Cable racks shall be mounted ver
tically to the extent possible.

UPGRADATION OF B.F NO. 1 PAGE 3.307
shall be of galvanised steel, sc
rewed type conforming to IS:9537-1981
(part-II). Conduit accessories and f
ittings shall be of standard types
conforming to IS:3837-1976 and IS:2667-1988.
All GI pipes/conduits shall be provided
with pull wires to facilitate cable
GI pipe/conduit runs shall not have more than three 90
bends (270
total)
including bends immediately



UPGRADATION OF B.F NO. 1 PAGE 3.308
PVC hose may be used with matched adapters.
All fabricated pull/junction boxes shall

UPGRADATION OF B.F NO. 1 PAGE 3.309
through RC pipes at minimum depth of
750 mm from finalised ground level



UPGRADATION OF B.F NO. 1 PAGE 3.310
for cross members placed at an inte
rval of 300 mm along the length of the
rack with a provision of double cross
members at a distance of 600 mm for
cable clamping. Length of single piece
of cable rack shall be 3 metres.
1. Main Earthing ring/ grid below
75x10 mm Flat Galvanised
2. Sub grid above ground 50x6 mm Flat -do-
3. Riser/ Pigtail from earthi
ng grid/ Mat 50x6 mm Flat -do-
4. Earth Electrodes 100 mm dia,
5. Conductors to be used for ground
connection of various equipment/
structures as listed below:-
a) HV Equipment 50x6 mm Flat Galvanised

UPGRADATION OF B.F NO. 1 PAGE 3.311
Description Size Material
b) Structures, Bus Duct, Cable Trays
c) 415V Power Control Centre/ Motor
d) Mimic cum control desk, Control
e) Local Panels 25x6 mm flat -do-
6. Motors:
a) Above 90 kW 50x6 mm flat -do-
b) Above 30 kW upto 90
kW 25x6 mm flat -do-
c) Above 5 kW upto 30
kW 25x3 mm flat -do-
d) Upto 5 kW 8 SWG Wire -do-
e) Miscellaneous items, viz. Push
The sizes of copper flat/ copper conductor/
copper strip/ copper
wires for earthing
of electronic equipment shall be ba
sed on recommendation of PLC/ VFD
manufacturers.
Lightning protection system shall
Lightning mast shall be provi
ded on structures and if
required separate earthing
masts of steel structure shall be provided
to protect all the equipment / structure.
The vertical Air termination rods shall
be of 25mm dia galvanized steel rods.
Whereas the horizontal air termination conductor and down conductor from air
terminals (mast) to earth electrode shal
l be of 50x6mm2 size galvanised steel
Lightning Protection system sh
all have separate dedicated
earth pits i.e other than
equipment earthing system earthpits.



UPGRADATION OF B.F NO. 1 PAGE 3.312
3.8.40.1

figure of braking torques. In the absence
of power supply the brakes shall remain
applied, thereby achieving a fail safe feat
ure in the event of power failure. The
brake opening shall be well coordinated wi
th the development of motor torque.
Braking torque depending on the spring force shall remain constant at all speed of
the drum.
The panels shall be finish painted as
per shade no. 631 (light
grey) of IS: 5-1994

UPGRADATION OF B.F NO. 1 PAGE 3.313
Type/ routine test certificates for all
items not specifically co
Site Tests
Insulation test with 500 V megger
Downloading of Application software
and checking of
all I/O channels,



UPGRADATION OF B.F NO. 1 PAGE 3.314
Testing & Commissioning
The testing and commissioning of the e
quipment supplied & installed under the
present package shall be carried out by the present package .
Site Tests for Commissioning


UPGRADATION OF B.F NO. 1 PAGE 3.315
Phasing out test of the transformers
be operated in
st with 1000 V megger for main circuits.
st with 500 V megger for control circuits.



UPGRADATION OF B.F NO. 1 PAGE 3.316
Elimination of defects found during testing

UPGRADATION OF B.F NO. 1 PAGE 3.317
If relevant IPSS/IS is not available
for a particular application, the IEC
(International Electro-technical Commi
3.9.1.3 All plans, design, manufactur
e, installation and cabling wo
rk shall be based on the
ISO metric system.
IS 13947-1993 Part 1, Enclosure for
IS 1554, 1988 Part-1 PVC insulated elec
tric cables for working voltages
IS 513, 1994 Cold rolled carbon
IS 2848, 1986 Industrial platinum re
sistance thermometer sensors
IS 2054, 1962 Reference table for nickel/chromium- nickel-
aluminium thermocouples
IS 2055, 1962 Reference table for platinum/rhodium-platinum
thermocouples.
IS 5, 1994 Colours for ready mixed paints and enamels
IS 6392, 1971 Steel pipe flanges
IS 8945, 1987 Electrical measuring instruments for explosive gas
atmospheres
IS-12754, 1989 Process measurement control functions and
instrumentation
Orifice design calculation
IS-2189, 2008 Selection, Instal
lation and maintenance of
All instrumentation & automation equipm
ent shall be designed for continuous
duty operation in steel plant environment.



UPGRADATION OF B.F NO. 1 PAGE 3.318
System shall be designed with inbuilt safety system for operating and
maintenance personnel. Facilities for
inspection, testing, maintenance and
adjustment at site shall be pr
System shall be of modular design fo
r future expandability/modification.
Necessary redundancy shall be considered
for reducing extent of abnormality
and Mean Time To Repair (MTTR).
All analyser PLCs shall be of the same make and model.
Instruments and field equipment shall be e
xplosion proof or intr
insically safe in
hazardous locations.
All control valves shall have smart va
lve positioners for sending position signal

UPGRADATION OF B.F NO. 1 PAGE 3.319
Vibration monitoring system shall
be provided for all HT motors.
All control valves shall be pneumatically



UPGRADATION OF B.F NO. 1 PAGE 3.320
BF gas temperature distribution profile
with over burden probe thermocouples
and multiple point gas analysis (CO, CO
& H
Hearth temperature monitoring including
foundation temperature, Hearth cooling
medium temperature & hearth wear profiles with isotherms.
Runner refractory temperature: Inserted
MI thermocouple in refractory with local
& remote temperature displays.
Differential pressure (permeability) measurement across various furnace zones.
Radar type stock level indicator (SLI)- 2 nos. and absolute encoder based
mechanical type- 2 nos.

UPGRADATION OF B.F NO. 1 PAGE 3.321
Pressure and temperature of hot
blast- Redundant measurement
Pressure measurements of different locat
ions of furnace like furnace top pressure
control, bin pressure, intermediate pr
Taphole periphery temperature monitoring system.
Measurement & control of other utilit
ies required for furnace e.g. Steam,
Top gas analysis of se
mi-clean gas for CO, CO
and H
Suitable gas leakage detec
tion in analyser room.
Under hearth cooling water flow, pre
ssure and temperature measurements.
Ambient CO monitoring system (30 points) for BF complex
Online measurement of stack emission in cast house
Water level measurement in OH tank
- DP measurement or ultrasonic.
Pressure & temperature measurement at
inlet & outlet of heat exchangers.
level & water flow meas
urement to surge tank.
Nitrogen pressure measurement to surge tank.
Water level, temperature & pre
Water flow, pressure & temperature measurement at inlet & outlet of each tuyere.
Cooling water temperature of stave coolers.
Staves body temperature measurement.
Measurement of water pressure to stoves,
stack/belly/bosh, tuyere, hearth coolers,
Trough temperature monitoring with application software



UPGRADATION OF B.F NO. 1 PAGE 3.322
Pressure at suction and discharge of each pump.
Temperature at discharge of each pump
Flow measurement for each supply headers
Position limit switches for each valve
Level measurements at each tank
Pressure, temperature and flow measuremen
ts (Total flow of Industrial water) in
Automatic sump pump operat
Pressure & temperature before and after Bag filter
Level monitoring in Bag filter hoppers
Bearing and winding temper
ature of ID fan motor
Flow measurement after bag filter
DP measurement across filter
Flow measurement and control of oxyge
n to stoves- Vortex flow meter
Pressure measurement of oxygen to stoves
Incoming and semi-clean BF gas pressure & temperature
temperature to scrubber
Re-circulating water pressu
re, flow and temperature
Emergency water pressure

UPGRADATION OF B.F NO. 1 PAGE 3.323
Pre-scrubber and AG element water level measurement and signalling
Note: There shall be redundancy for water level measurements in scrubbers
Top pressure measurement.
Bin pressure measurement
Gear box temperature measurement
Nitrogen pressure measurement
Temperature measurement and flow control in Nitrogen
Water flow measurement to Gear box
Water level measurement in
BLT Gas & water circuit instrumentation
Hopper weighing system for coke, sinter,
ore, additives and intermediate bunker
Radar based level measurement in bunkers for Iron ore, Additives, Coke and
Coke moisture measurement near each screen
after vibro feeder Infrared type.
Level measurement in Sinter & c
Turbo Blower
Blower
Suction Air Pressure / Temp. / Flow Measurement
Discharge Air Pressure & Temp. Measurement
Pressure / Temp. / Flow Measurement of Steam to Turbine
Extraction Steam Pressure / Temperature Measurement



UPGRADATION OF B.F NO. 1 PAGE 3.324
Wheel Chamber Pressure
Condenser vacuum Measurement
Condensate Pump Discharge Pressure Measurement
Condensate Temp. Before & After Heaters
Bearing Oil Pressure Measurement
Control Oil Pressure Measurement
Cooling Water Temp. Before & After Oil Cooler
Oil Temperature Before & After Oil Cooler
Circulating Water Temp. Before & After Condenser
Condenser Level Measurement & Control
Turbine Casing Temp. Measurement
Exhaust Hood Temperature Measurement
Axial shift
for Turbine & Blower
Hot blast pressure measurement
Combustion air header pressure control
Dome temperature measurement- Re
Pressure measurement of com
Temperature of combustion
Pressure of mixed Gas
Temperature of mixed Gas to Individual Stoves
Flow of mixed gas to individual stoves
Air-Gas ratio control
Temperature measurement and high temp
Temperature measurement and high temp
Waste Gas Temperature
Combustion Chamber Temperature
DP across hot blast valve
DP across chimney valve

UPGRADATION OF B.F NO. 1 PAGE 3.325
temperature compensation- Redundancy in
measurements (Transmittes- PT, FT & TT)
except Ventury which shall be one.
Steam humidification control
in cold blast : Dew cell based humidity measurement
Redundancy w.r.t flow transmitter, pr
essure transmitter and temperature
transmitter. Orifice and dew cell measurement shall not be redundant.
Silica interface temperature
Silica brick temperature monitoring
EEDBACK CONTROL LOOPS
OT BLAST TEMPERATURE CONTROL
TOVE DOME TEMPERATURE CONTROL
AFT CONTROL
GAS RATIO CONTROL
Discharge pressure control with the help
Pressure switching and pressure
measurement for purging Nitrogen line
Pressure and temperature m
easurements in outlet header
Gas mixing station & CA fans
Mixed gas pressure measurement in head
Mixed gas flow measurement & control in gas mixing station
BF gas flow measurement in gas mixing station
BF gas pressure measurement in gas mixing station
Temperature measurement at discharge header of CA Fans
Pressure measurement at the discharge end of CA fans
Motor bearing & winding temperature
DP across filter
EEDBACK CONTROL LOOPS
CA Fan discharge pressure control
Mixed gas pressure control
Coal Dust Injection



UPGRADATION OF B.F NO. 1 PAGE 3.326
Raw coal silo
Coal weight measurement
High & low level monitoring
Mill DP control
Temperature hot spot measurement
Level monitoring in bag filter (High) in hoppers
HGG (Hot gas generator)
CO pressure in main CO gas line
Gas pressure measurement in CO line
Air-Gas ratio control
Level monitoring(high & low)-
analysis-
Pressure measurement-

UPGRADATION OF B.F NO. 1 PAGE 3.327
Pressure measurement in injection vessels & control of N
pressure in
Level monitoring(High & low)
Flow measurement & control of N
Flow measurement & control of N
in carrier lines
Weight measurement (Total fl
Flow measurement in main coal carrier
DP measurement across individu
al tuyeres and basal main
Low flow monitoring(Radar type flow ja
m switches) in indi
vidual lines from
lines
Flow monitoring (Flow switches)
Pressure monitoring
Flow measurement / Totalisation / Total N2 consumption
Feedback control loops
Automatic control of the differential pressure across the mill
Coal mill outlet temperature control
Differential pressure control across the bag filter by controlling the
Air-Gas ratio control
in Hot gas generator
Smart Pressure/Flow Transmitter
Type Smart type
Range As required
Output 4-20 mA dc
Power Supply 12-48 V dc



UPGRADATION OF B.F NO. 1 PAGE 3.328
Load limit 600 Ohms
Accuracy +/- 0.25% of span
Ambient temp. limit 0-75 deg C
Sensitivity +/- 0.05% of span
Elevation/Suppression -50% of LRL to 100% of URL
Zero adjustment Required
Dead band +/- 0.05% of span
Temperature effect Maxm. Zero shift +/- 0.5%
Response time Less than 0.1 sec
Housing IP-65 as per IS 13947 : 1993
Mounting 2 NB pipe mounting
Universal HART Calibrator for Smart
transmitters (of same make as that of transmitter)
Accessories Diaphragm seal for dirty/corrosive media
Note: Shall include 2 way/3 way valve manifolds and other fitting
accessories

Standard IS-2848:1986
Protective tube MgO filled
SS 316 tube of min. 8 mm OD
Terminal Head/block
Brass screw type/silver plated on ceramic head
Cable connection with cable gland

UPGRADATION OF B.F NO. 1 PAGE 3.329
Insulation resistance Min
100 M Ohms at 100 V dc
Accessories -Extension nipple with thermowell connection
-3 mtr long flexible conduit of SS
Thermocouples
Element Chromel Alumel (K type),
Standard IS-2053:1974
Wire gauge 3.2 mm dia for
K-type (1.6 mm for duplex)
0.5 mm dia for S type or B type
Thermowell OD 21 mm
Sheath material 316 SS / Inconel
Thermowell material Inconnel-60
0 (barstock), minimum 5 mm wall
thickness
Thermowell junction Spot welded & ungrounded
Filling material MgO filled (Purity above 99.4%)
Terminal Head/block
Brass screw type/silver
plated on ceramic head
Cable connection 1/2 with cable gland
Process connection 11/2 RF Flanged
Note: All S type thermocouples sha
ll be installed under lock & key to



UPGRADATION OF B.F NO. 1 PAGE 3.330
Temperature Transmitter:
Type Smart configurable
Input T/C (K, S, B) mV to Current converter /
Output 4-20 mA dc
Power supply 12-48 V dc
Ambient temperature 0-75 deg C, Cold junction compensation for T/C
Accuracy +/- 0.25%
I/O Isolation Isolated Input, Output & Power circuit
Range adjustment Field adju
stable within the range
Mounting Shall be DIN rail mounted
Housing These transmitters shall be installed inside the
instrument panel to be located in control room.
For transmitters which cannot be installed in the
control room, the same shall be installed at site
Pressure Switch / DP Switch
Type Bourdon/Bellow type
Sensing material SS 316
Casing Die cast aluminum alloy
Over range protection 150%
Switch Two nos SPDT suitable for 240 V ac, 5A or 220
Accuracy + 0.5% of span
Repeatability + 0.5% of span
Enclosure class IP-65
Accessories
-Remote Chemical seal with 5 mtrs. Capillary
-Valve manifold

UPGRADATION OF B.F NO. 1 PAGE 3.331
Orifice Plate
The orifice plate shall specifically be
designed as per B.S. 1042 section 1.1:
1981, 1.2 & 1.4: 1992. Orifice plat
e shall in general be
of square edge type
with flange tapping. For line sizes of
500 mm and less, the orifice plate shall
be an integral unit comp
mbly, tapping arrangement on
both upstream as well down stream side.
For line sizes more than 500 mm, the
All orifice plates shall be supplied with
matching flanges of suitable rating not
less than three times the maximum lin
e pressure. All tapping arrangements
Type Square edged concentric
Tapping Flange tapping
Orifice plate material SS316 (Min. 3mm thickness)
Flange material/ type ASTM-A-105/ WNRF
Accessories CS nipple & shutoff valve for tapping with CS
companion flanges

shall preferably be microprocessor base
d with self diagnos
tic functions and
auto zero adjustment functions. Re
mote mounted electronics will be
considered for all transmitters to be
installed on or near furnace body. The
remote electronics will be suitably in
stalled on platforms with proper access.
Type Matched pair type
Excitation Pulsed dc type or dual frequency
ND CONNECTION
Flanged



UPGRADATION OF B.F NO. 1 PAGE 3.332
Matching flanges Required (Carbon Steel)
Power supply 220 V, 50 Hz
Output signal 4-20 mA Linear
Accuracy + 0.25 %
Measuring tube SS
Electrodes Hastealloy / SS
Liner material Teflon
Remote electronics Required
Housing Die cast Aluminium alloy
Local display Flow rate
Protection class IP-65, IS 13947 : 1993
Alarm Annunciator
Type Microprocessor based
Window
Mounting Flush panel
Power Supply 220 V ac, 50 hz
Power consumption 1.5 W per window
Interrogation voltage 24 V dc
First up feature Required
Displays White translucent (black engraving)
Hooter assembly Required with mounting accessories
Enclosure IP-30 as per IS-13947:1993
Input 4-20mA dc/1-5 V dc
Output 4-20 mA dc/ 1-5 V dc
No. of outputs 2/3
Mounting DIN Rail mounted
Isolation Isolation be

UPGRADATION OF B.F NO. 1 PAGE 3.333
Power supply 24 V DC
The Hopper Weighing System has been en
visaged for Iron Or
e, Coke, Sinter,
Limestone & Manganese hoppers in
Stock house area. Load cell based
weighing shall also be used for measurement in raw coal silo and injection
vessels of CDI. The system comprise
s of load cells, fixed bearing type
supports, electronics, control panel, indi
cators, monitoring unit, field junction
Load cells
Type Compression strain gauge
Capacity As required
Maximum usable load 200 %
Maximum load without
damage
Destructive load � 500 %
Rated output 1 mV/V
Tolerance on rated output 0.25 %
Repeatability
Creep after 30 min 0.03%
Creep after 4 hrs. 0.05%
Non-linearity 0.05%
Hysteresis 0.03%
Power supply To be de
rived from weighing
electronics
Protection IP-68 as per IS-13947:1993
c) Weighing electronics
Function Weighing & controlling the charging
weight of raw materials
Type Microprocessor based
Mounting Panel mounted
Overall system accuracy 0.05% of FSD
Power supply 230 V ac



UPGRADATION OF B.F NO. 1 PAGE 3.334
Display Digital display of actual weight, set
weight & cumulative weight
Programming Fully programmable through Key pad
& alpha numeric display
bus communication
Auto taring, auto calibration
& auto zero features
Out put 4- 20 mA dc with 4 DI & 4DO
Overall monitoring of
PC based system with SCADA
Location Stock house control room
Panel protection IP-30 as per IS-13947:1993
Cables Screened & armoured cables with
inner & outer PVC insulation for 11
Junction boxes Field mounted
weatherproof junction
Redundancy 1 no. additional weighing electronics
shall be provided for offline
Communication with PLC Both with conventional I/Os and
Radar Type Level Transmitter
Radar type level sensors shall be used
for measuring the level of ore, coke,
Level measurement type Continuous

4-20 mA with HART protocol


UPGRADATION OF B.F NO. 1 PAGE 3.335

Antenna type Parabolic or horn type
Mounting Flange mounted
Degree of protection IP 65
Operating temperature 20
Maximum measured error
Burden Level measurement through Radar ba
sed sensors: This shall be used in
addition to the conventional absolute en
coder based Stock level measurement.
External surge/Lightning protection de
vice at both transmitter and control
room ends. Regulated N
supply with quick shut-off
type isolation valve shall
be considered for these instruments for isolation in case of low N
Service Stock level in Blast Furnace
Type Micro wave RADAR, Antenna type
Output 4-20 mA, dc with HART protocol
Process connection Flanged
Measuring View A
Measuring range 2.00 to 30.00 mtrs.
Accuracy
F.S.
WHEN THE OBJECT
TO MEASURE IS METALLIC
M
MM
M TO
M
MM
Resolution 1 mm
Sensor material 316 L
Max. Process temperature As required
Housing material Cast al. Alloy



UPGRADATION OF B.F NO. 1 PAGE 3.336
Cable entry 1/2" NPT
Enclosure class IP67(IS13947:1993)
Vortex Flow meter:
The vortex type flow meter shall be used
to measure the flow in steam and N
Flow range 0-14 T/hr
Steam pressure 8-12 kg/cm
Steam temperature 0-300
Measuring uncertainty 1 %
Power supply 24 V dc
Output 4-20 mA
Local display Yes, LCD
External surge &
Analyser
circuit of CDI. The system shall be comp

UPGRADATION OF B.F NO. 1 PAGE 3.337
Type Non dispersive Infrared absorption type;
IR spectrum 2.5 to 12 micron-m
component
% in sample gas
Callibrated range CO: 0 40 % ( by Volume)
Outputs 4-20 mA dc
Linear zero drift 1 % of span/month
Linear sensitivity
1 % of measurement span/month
Auto purging Required with so
lenoid valves & programmable
logic controller
Auto-calibration
facility
Mounting In 19 rack/mounted in panel
Accessories Pump, filter, flow monitor
Type Thermal conductivity type
Application % H
measurement in the BF gas
Range 0-10%
Zero-point drift 1 % of span per 6 months
Linearity deviation 1 % of span per 6 months
Alarm output 2 nos. (L & H ) adjustable
Display Digital
Output 4-20 mA DC, lo



UPGRADATION OF B.F NO. 1 PAGE 3.338
Auto Calibration Zero & span calibration with gas cylinders &
Mounting In 19 rack/mounted in panel
Accessories Probe, Pump, filter, solenoid valves, flow
Note: Effect of CO & CO2 analysis
shall be considered for correction
Process temperature 150-600
Ambient temperature 50
Measuring range 0 5 % O
Response time T
= 10 seconds
Display resolution 0.1% O
Auto Calibration Zero & e
Power supply 220 V ac + 10%, 50 Hz, single phase
O/P signal 4 20 mA dc
Alarm output Relay type w
ith potential free contact
Sampling system To be provided as required.
Enclosure IP 54 (IS13947:1993)
Type Direct
Mounting On line (Local)
Dial size 150 mm
Case Cast Aluminium
Blowout protection Required
Moving parts matl. SS 316
Accuracy + 2%

UPGRADATION OF B.F NO. 1 PAGE 3.339
ROCESS
ONNECTION
Temperature Gauge
The specification of the temperat
Type Direct
Range 0-150
Mounting On line (Local)
Dial size 150 mm
Case Cast Aluminium
Accuracy + 2%
Process Connection 1/2 " BSPT(M)
Paperless Recorder
The recorder shall be multipoint and mu
ltifunction and shall record and display
Screen size 144 mm x 88 mm (minimum)
Resolution 640 x 640 pixels (minimum)
Update rate 1 second (minimum)
Trend time base 5 min to 24 hrs/screen
Data storage Shall automa
tically calculate storage
time base on storage schedule
Input type mV , V, mA, Thermocouple, RTD
No. of channels As men
Level Switch
Liquid Level in water sumps
Maximum working temperature 60
Ambient temperature: 55



UPGRADATION OF B.F NO. 1 PAGE 3.340
Mounting Vertical
Probe material SS316 flexible wire, (PTFE) teflon
Probe length: As required
Type Capacitance
Cable entry 1/2" NPT
Enclosure class IP66(IS2147,1962)
Reference electrode Earth probe(Tube/Plate)
Switching unit IP66 encl.
Relay output 2 No.(For low level & high level)
Contact rating 5A,230V AC,resistive
Switching accuracy +/- 1% of FSD
Repeatability +/- 1% of FSD
Power supply 24V
The carbon monoxide (CO) monitoring syst
em shall be microprocessor based
and shall monitor the % of CO in the ambient in case of any leakage of gas
Sensor Probe Solid state el
ectrolytic type (no cross
sensitivity with hydrocarbon & other
Range 0 - 500 ppm
Display Digital for each channel
Power supply 230 V, 50Hz AC or 24V DC
Output 4-20 mA DC, isolated
Alarm Output Potential
free contact (5A at 240V
AC, 5A at 24V DC)
Protection class IP-65
Ambient temperature 0 - 70

UPGRADATION OF B.F NO. 1 PAGE 3.341
It shall monitor the vibration for ro
tating equipment. The specification of
vibration measuring system shall be
as per IPSS-2-07-027-88. Additional
Displays Digital display
for measured vibration
value on rack mounted cards with
alarm lamps for all rotating
machinery
Alarms Potential free contact for alarm at pre
vibration limits shall be provided
Configuration: Split arch
itecture, Rack mounted
signal processing cards, video
Output signal: 4 - 20 mA DC, pulse
Enclosure IP-54 as per IS-2147:1962
Intelligent Control valves: The valves
Line size As required



UPGRADATION OF B.F NO. 1 PAGE 3.342
Guiding/points Cage / Top guided, V-port,
Body material ASTM-A21
6 WCB (Carbon steel)
Packing material Grafoil
Valve action Energy failure to stay-put
Seat & Trim
material
Leakage Class IV as per ANSI-B16.104 (1976).
Actuator Pneumatic actuator (suitable for control air
pressure 4 kg/cm2) with smart HART
positioner.
I / P Converter Required (suita
ble for 4-20 mA input signal
from controller & 0.2 to 1.0 kg/cm2 air
Air lock relay Required
Enclosure IP-65, IS 13947 : 1993
Position Indicator Required (Local )
Transmitter
Handwheel Required
Valve type Butterfly
Service Gas, air & cold blast
Actuator Pneumatic cylinder type
Input 4-20 mA dc from DCS
Position transmitter Required
Packing Teflon
Disc material CS A216 WCB
Body material CS
Duty Regulating (0-60 deg)

UPGRADATION OF B.F NO. 1 PAGE 3.343
Accessories Required
The CCTV system shall be CE/UL certified and shall be designed,
manufactured, assembled, tested and inst
alled in accordance with the latest
standards of International Radio consultative committee (CCIR-B) & PAL as
applicable. The scope shall include
coloured cameras with vary-focal
length/motorized lenses, remote controlled
pan & tilt units, receiver drier unit,
key board unit, digital video recorder cum multiplexer, control consoles,
coloured video monitors, interconnecti
distribution amplifiers/video cable e
qualizers, alarm annunciators and other
auxiliary equipment, connectors,
erection accessories as required.
System features:
The cameras shall be of charged c
ouple device (CCD) type and these
should be mounted in such a manner as
to provide continuous monitoring
The system should provide clear a
nd sharp picture on monitors in
itions at any time of the day or night.



UPGRADATION OF B.F NO. 1 PAGE 3.344
recovery of approx. 100usec.
It shall have recovery
within regulation band for
a load change from 10% to 90% and th
e output adjustability from 20.4V to
32.4V. The ripple and noise shall be
within 1mv rms. The unit shall be
Microphone & receiver Dynamic with high sensitivity
Line amplifier High sensitivity with 200 hz to 12 khz with
Power amplifier Required with tone control & SC protection
Power supply 240 v ac
Loudspeaker 40W with IP-55 protection
Signal & Control Cable
all be conforming to IS : 1
554 (part-II), latest version
or relevant Indian standards as appli
cable. The cables wherever applicable
The power wiring within the cubicl
e shall done with minimum 2.5 sq. mm
Cable entry to the panels/junction
boxes shall be through suitable gland

UPGRADATION OF B.F NO. 1 PAGE 3.345
The Compensating cable shall be suitable for K or, S type thermocouple
conforming to IS 8784/78.
Following cables shall be considered for instrumentation system:-
Signal cables Armoured, Individu
al pair & overall screened
(1.5 Sq.mm)
Compensating cable Armoure
Control cables 1.5 sq. Mm
, Armoured, unscreened
Armoured, un-screened
(1.5 sq. mm)
Power cable Armoured, unscreened
(2.5 sq. mm)
FDA system cable Armoured, FRLS
(1.5 sq. mm)
Special cables




UPGRADATION OF B.F NO. 1 PAGE 3.346
Nitrogen / steam purging f
acilities shall be provided for impulse pipe
cleaning.
Each impulse line shall have minimu
m three valves; SS ball valve (root
All impulse piping in general shall be gi
ven a slope of not less than 1 in 12
except where otherwise specified. The sc
ope of impulse pipe work shall be
done from the tapping point for li
quids, steam and condensable and up
from the tapping points for gases unless specific provisions are made for
2) Vents and drains shall be ensured at
the highest or lowest of piping run
respectively. Impulse pipelines sha
ll be kept as short as possible
consistent with good practice and acce
ssibility. Piping and tubing shall
distances not exceeding as follows-
Copper tube 12 mm or less - Continuous support
Steel tube 10 mm to
20 mm - 1.5 m.
Steel tube 25 mm - 2.0 m.
Steel pipe 40-50 mm - 3.0 m.
3) The following colour code shal
l be used for impulse lines -
Green Water
Red Blast (Hot)
Blue Oxygen line , Steam line
Yellow BF Gas line
The R.F. earthing system shall conform to
I.E. rules and latest revision of
Minimum two separate grounding stations
each comprising of two earth pits at
minimum distance of 3 meters shall be
provided. Earthing resistance of the pit
should not be more than 0.5 ohms.
mm) shall be provided as logical

UPGRADATION OF B.F NO. 1 PAGE 3.347
30)




UPGRADATION OF B.F NO. 1 PAGE 3.348
AUTOMATION SYSTEM
General
1) This specification is intended to define the basic requirements for Automation
(Level-1) system for BF-1 of Rourkela
Steel Plant (RSP) with a view to
achieve smooth, efficient, safe and
2) Automation equipment to be supplied fo

UPGRADATION OF B.F NO. 1 PAGE 3.349
CPU of PLCs shall be OPC compliant.
LED based mimic shall be connected
to HMIs simultaneously through
switching facility. This shall ensure th
at in addition to the normal monitors,
the LED mimic shall keep working at the same time.
All output shall be considered throu
gh interfacing relay and only important
All the monitors (operator station , serv
tion) shall be of
standard & same size of 20/21 TFT color monitor.
Redundancy level in the HMI
server system as a whol
e shall be such that
failure/malfunction of any of the sub
system shall not cause interruption
in the function of other system.
Hardware based hot redundancy of
CPUs, communication modules, I/O
bus, power supply shall be inbuilt
in to the PLC system with
automatic/manual changeover provisions
. However, PLCs for auxiliaries
like analysers shall not be hot standby,
but shall be of the same make as
that of main process PLC.
The PLC and HMI bus shall have bus
or ring topology. In case it is bus
The two servers shall work in such a way that if one fails the HMI shall
continue to take data from the othe
r server without any break. The hard
disk of each server shall have
RAID 0+1 feature which shall be
implemented through separate RAID controller cards.
Area I/O redundancy
BLT PLC 100 % + 10 % spar
e points in each
card and and 20%
spare cards of
each type will be considered
Stock house PLC 100 % + 10 %
spare points in each
card and and 20%
spare cards of
each type will be considered
GCP PLC 100 % + 10 % spar
e points in each
card and 20% spare cards of each
For all other areas, the I/O redundancy has been explained in the design
conditions mentioned earlier.




UPGRADATION OF B.F NO. 1 PAGE 3.350
All switches shall be of Layer 2 managed type.
Hardware based firewall shall be considered for connecting the new PLC
based control system with plant wi

UPGRADATION OF B.F NO. 1 PAGE 3.351
c) Sequential and in
c) Graphical display of process information
d) Diagnostic and alarm generation
e) Events and report generation for MIS
f) Interfacing with the control syst
em of CDI for exchange of process
parameters like cold blast flow, pres



UPGRADATION OF B.F NO. 1 PAGE 3.352
Programmable logic controller (PLC) shall be designed based on open
architecture configuration for eff
ective control and monitoring of the
process. The I/O system and the CPU shall of the same series and same
make. The system shall have flash memo
ry to facilitate upgrades (instead
of replacing an EEPROM chip or cartridge). The system shall be

UPGRADATION OF B.F NO. 1 PAGE 3.353
System configuration:- The proposed
system configuration is shown in



UPGRADATION OF B.F NO. 1 PAGE 3.354
All inputs and outputs shall be isolate
d. All I/Os shall also be isolated
from each other and protected against electrical noise. The analog
input and output modules shall be of differential type.
PC based Human Machine Interface (HMI) system
PC based HMIs and HMI servers shall be provided with latest
configuration at the time of appr
oval. The HMI servers shall have
minimum RAID- 0+1 implementation and shall have Xeon processors.

UPGRADATION OF B.F NO. 1 PAGE 3.355
Alarm summary display: - This s
hows all current alarms in the
system. Alarms, which are not related, the current operating
conditions are out of service automatically.
Historical alarm display: - This shows the process alarm, device
alarm, and parameter changes in the time sequence.
Historical trend display: - Con
tinuous process variables of all
process signals shall be recorded
in a historical data file for 24
hours or more up to one month
Minimum 8 process variables can
be accommodated in one screen.
Loop structure display: - This shows input/output allocation,
The system shall have provisions
and capability to process all
the analog and digital signals wi
th scan rate of 250 msec for
Capability to include new tags fo
r scanning as well as to delete
tags from scanning and to restor
e scanning or to substitute a



UPGRADATION OF B.F NO. 1 PAGE 3.356
value in place of de
available.
on compensation square root
extraction, pressure and temperature compensation of flow
All algebraic, logic a
nd comparison functions.
Lead-lag compensation, dead-time compensation.

UPGRADATION OF B.F NO. 1 PAGE 3.357
Feed forward, ratio and adaptive
control, cascade control with
The switches shall be Managed switch to be
installed in suitable rack at various
shops and office buildings
The switches shall have fo
llowing specifications /
features:
Characteristic Specification
Required Port Density Required GBICs
Switching Bandwidth /
Throughput Performance throughput s
hould be 6.5 Mpps or higher for
Interface Supported GBIC/Mini-
GBIC/SFP, 1000BaseSX, 1000BaseLX
Functionality Functionality at Half
VLAN IEEE 802.1Q VLAN support for at least 250 VLANs
RMON Embedded RMON: 4 groups of RMON (Statistics, Alarm,
Standards Supported IEEE 802.1p prioritizati
on with min. four priority queues



UPGRADATION OF B.F NO. 1 PAGE 3.358
Management
capability
Management through Web View (Web Based Management)/
Others Features Rack Mountable
with rack mounting hardware
Quality of Service Four Egress queues per port
Traffic prioritization
Manageability Managed along with embedded management software.
Security Security: 802.1x, MA
(Access Control List)

Item description Specification
Processor 2 * Intel Xeon 64-Bit Quad core Processor with
minimum 2.0 GHz processor speed with 12 MB Level-
Main Memory 16 GB DDR3 Regi
stered ECC 1333 MHz with 32 GB

HDD Integrated dual channel ha
rd disk controller with
3 x 300 GB hot pluggable SAS Hard Disk Drives at

UPGRADATION OF B.F NO. 1 PAGE 3.359
minimum 10K RPM
Graphics Onboard Graphics Controller
Combo Drive CD-RW/
DVD Combo drive
Monitor 20/21 TFT LCD Monitor
Keyboard Multi media USB Keyboard
Mouse USB Optical Mouse (2- Buttons With Scroll)
Ports Minimum 4 USB Port, 1 Serial Port
Expansion slots Minimum 2 Mezzanine/PCI-X/PCI-E Slots
Power Supply Redundant Power supply
Operating System Windows server 2012 standard
Anti-virus software The software shall
be able to protect the system from
any kind of virus infecti
on. Should have three years
certification ISO 9001, ISO 14001, Windows, Red Hat certified,
Compliance & Support
Warranty 3 years comprehensive
warranty Expandable up to 5
years
LED Monitor/Mimic
Diagonal screen size 63 inch or more
Optimum resolution 1920 x 1080
Contrast ratio
Viewing angle (vertical) 178 degree
Display colors 1.07 Billion or more
PC: VGA-in D-Sub 15HD, VGA-out D-
RS232 D-sub9 output, 3.5 mm PC audio
AV input: Component (BNC) x1



UPGRADATION OF B.F NO. 1 PAGE 3.360
Out, USB, HDMI
Temperature range (operation): 0 - 40 C
Relative humidity: 5 - 90 %
Consumption (On mode): 150W
Built-in speakers: 2 x 10W (RMS)

UPGRADATION OF B.F NO. 1 PAGE 4.1
4.1.1 The Successful Bidder shall guarantee opera
tion and performance of each erected
equipment/ items and systems in B.F No. 1 with respect to the following:-
i) For design, material
s, workmanship, erection & commissioning of the
equipment, civil & structural, utilitie
s and other facilities manufactured/
fabricated & erected by him based on the
1. Hot Metal Production
ii) Heat loss through
Cooling System
specified by
Successful Bidder
As recommended
Not more than
recommended



UPGRADATION OF B.F NO. 1 PAGE 4.2
i) Dust content in
clean gas
5 mg/Nm
(Dry) 9 mg/Nm
0.025% of Contract
price for every
1 mg/Nm
or part
thereof increase in
dust content in clean
ii) Clean gas
temperature
C (Max.) 44
C 0.025% of Contract
increase or part
thereof in clean gas
temperature
3. Cast House Defuming System:
The successful Bidder shal
performance of each equipment/items and systems for Cast House De-fuming System.
i) Work Zone dust
Maximum of 3
mg/Nm
(RSPM) (size less
than 10 microns)
PM10 at a
distance of 5 m
from the dust
source over and
above ambient
dust level. The
ambient dust level
shall be defined
as work zone dust
level when the
Cast House is not
No Deviation -----
ii) Stack Emission 50 mg/Nm
with all fields
hot metal tapping
75 mg/Nm
0.025% of Contract
Price for every 5
mg/Nm
or part
thereof increase in
Stack emission
iii) Duration of PG Test: 72 hours (min. 4
samples in 24 hours with gap of 4 hour
iv) The test for work zone dust content
shall be done as per IS:5182(part4)-1999

UPGRADATION OF B.F NO. 1 PAGE 4.3
4. Turbo Blower
i) Blowers
continuous output
volume
/hr No tolerance
ii) Blower discharge
pressure at Blowers
continuous output
volume
3.7 bar(g) No tolerance
iii) Steam consumption
output volume and
To be quoted by
See note vii)
iv) Maximum
combined vibration
maximum output.
2.5 mm/s as per
No tolerance
i) Injection Rate/
100 kg 75 kg 0.075% per 5 kg
ii) Coke/ Coal
replacement ratio
0.92 0.075% for each
replacement ratio
iii) Coke/ Coal
replacement ratio
1.00 for imported
0.95 0.075% for each
replacement ratio
iv) Variation in
uniformity in
+/- 5% +/- 8% 0.075% for every
v) Maximum
Emission dust
100 mg/Nm
No increase ----
vi) Moisture Content
in sized and dried
1.5 % max. No increase ----



UPGRADATION OF B.F NO. 1 PAGE 4.4
vii) Range of injection
in stepless mode
25 t/hr to 5 t/hr No deviation ----
viii) Max. sound level
measured at 1 m
from source
85 dBA No increase ----
ix) Ambient air quality
SPM 5 mg/Nm
(max.) above
ambient
No increase ----
i) Hot Blast Temp 1200
C 0.5% for every 10
decrease in HBT
Note: In accordance with the SBD clause 4.2.1
, the Contractors aggregate liability to
pay LD for failure to attain the perf
ormance guarantee parameters above the
minimum acceptable levels of performan
ce guarantee parameters specified shall
not exceed 7.5% of the Contract Price.)
by Bidder and approved by Employer)
For heat loss through cooling system,
the system shall be designed for
Ferrous burden, flux, coke & coal will be
as per raw materials quality given
at Clause No. 3.1.7.4.
The Employer & the Bidder will jointl
y prepare the procedure to be
followed in the Performance Guarantee Test.
Other terms & conditions of the PG te
st shall be as s
tipulated in the
Standard Bidding Document (SBD).
Bidder to also demonstrate the Bl
ower maximum output
volume 181 000
/h at maximum discharge pressure
of 3.7 bar g, steam consumption of
the Turbine. Bidder to demonstrate and
establish the characteristic curve of
the Blower.

UPGRADATION OF B.F NO. 1 PAGE 4.5
4.3.2 Cold test shall be performed on the indi
vidual sub-assemblies on the unit. Cold tests
shall be designed to conduct systematic
check of the components and of the
4.3.3 The Instrumentation and automation equipment shall have uptime of 99% during PG
parameter test.

UPGRADATION OF B.F NO. 1 PAGE 5.1
5. SPECIAL INSTRUCTIONS TO THE BIDDER
5.1.1 1 no. soft copy of complete offer shall be submitted along with the Bid with hard
5.1.2 All materials / equipment / machinery /
fabricated items used in the subject
package shall be according to the speci
and any deviation
should be clearly brought-out in the offer.
No mention of deviation will mean that
the bidder has accepted the specification given herein.
5.1.3 The Bidder shall include in his supply



UPGRADATION OF B.F NO. 1 PAGE 5.2
necessitating removal of othe
r parts. All like parts of
the equipment supplied shall
be inter-changeable.
5.1.9 After erection, all equipment, pipes, stru
en approval/clearance from the Employer
at each stage or before start of the next
stage of site work. The Bidder with the
approval of the Employer shall decide the stages.
5.1.13 The Successful Bidder shall ensure deput
ation of well experienced engineers and
technical staff from various disciplin
es including mechanical, technology,
refractory electrical, instrumentation,
automation and process control (as per
requirement) for erection, testing and co
mmissioning of plant and equipment.
5.1.14 All the manufacturing / fabr
ication works shall be carri
ed out only on the basis of
approved drawings and schemes or as directed by the Employer. It is solely the
responsibility of the Successful Bidder to
ensure that all working drawings
prepared by him bear the stamp of a
pproval of the Employer / his consultants
prior to start of work. A
ll other drawings shall bear
the acceptance stamp of
Employer / his consultant fo
5.1.15 For issue of steel from Employer, kind
ly refer commercial terms and conditions.
DRAWING/DOCUMENTS/DATA TO BE FURNISHED
5.2.1 The offer shall be accompanied with various layout drgs. showing the major

UPGRADATION OF B.F NO. 1 PAGE 5.3
5.

RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 1 OF 21

Annexure
2.12-1
LIST OF PREFERRED MAKES (MECHANICAL ITEMS)
SL.NO.
ITEMS MAKE
A. MECHANICAL
GENERAL
1.
Copper Stave Coolers Imported
2.
SGI Stave Coolers Imported
3.
Tuyere and Tuyere Coolers Imported
4.
Drill machine (Hydraulic) TMT
5.
Mud gun (Hydraulic) TMT
6.
Trough cover manipulator
(Hydraulic)
TMT
7.
Drain pot drill machine TMT/Imported
8.
Dust Catcher Dust valve TMT/Imported
9.
Stock level Indicator TMT/Imported
10.
Expansion Joint FLEXATHERM / METALLIC BELLOWS /
LONESTAR / SUR INDUSTRIES/
FLEXICAN
11.
EOT Cranes (class III & IV
duty)
JESSOPS, HEC, MUKAND, BRAITH-
WAITE, ARDEC, WMI BOMBAY, L&T
12.
Jib Cranes BATLIBOI / ARMSEL / BOMBAY CRANES
/ ARDEC INDIA / AARCO / SIMPLEX / BEC
/ BEEKAY / VOLTAS
13.
Electric Winches BOMBAY CRANES / MECHANICAL
MOVEMENT / TOOLS / BATLIBOI /
PULLMAN / ELECTRO MECHANICAL
ENGGINERING / AARCO / EDDY CRANE /
SIMPLEX / BEC / BEEKAY / NEW
CAPITAL
14.
EOT Cranes (class II duly) HEC, JESSOP, MUKAND, B
RAITHWAITE,
WMI, ANUPAM
15.
Electric Hoists REVA ENGG, HERCULES HOISTS,
VOLTAS, ARMSEL, ROBIN ENGG, INDEF,
BRADY & MORRIS, BOMBAY CRANES,
CENTURY CRANES.
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 2 OF 21
SL.NO.
ITEMS MAKE
16.
Erection Trolley VOLTAS / IDC / BOMBAY CRANES /
ARDEC / REVA ENGG / HERCULES HOIST
/ ELECTROTHERAPY / AARCO / ARMSEL
/ EDDY CRANE / ROBIN ENGG. / AVON /
INDEF/CENTURY CRANES
17.
Passenger cum Cargo lift OTIS / KONE ELEVATOR / MI
TSUBISHI /
ECE
18.
Chain pulley blocks and hand
operated travelling cranes
BATLIBOI, W.H. BRADY & CO., TRACTEL
TRIFOR, ARRCO, REVA ENGG., MORRIS,
TAK MACHINARY
19.
Motors BHARAT BIJLEE / NGEF / KIRLOSKAR /
SIEMENS
20.
Gearboxes ELECON / NAW / FMG / SHANTHI /
PREMIUM ENERGY TRANSMISSION /
SUMI-CYCLO DRIVE INDIA PVT.LTD.
21.
Geared coupling NAW / HICLIFF / CONCORD / FMG /
ELECON / WELLMAN WACOMA / GBM /
LOVEJOY /ROMA
22.
Fluid Coupling VOITH INDIA / PEMBRIL / FLUIDOMAT
23.
Resilient Coupling WELLMAN (BIBBY)/NAW/NU-TECK /
ELECON / GBM/ LOVEJOY / FENNER /
HICLIFF ROMA/ SELECTION DRIVE
24.
DC Brakes BCH / ELECTRONIC & POWER CONTROL
/ ELECTROMAG
25.
Limit switches BCH / EPCC / ESSEN / INDUSTRIES
SYNDICATE / JAI BALAJI / JAI SHREE /
SCHNEIDER / SIEMENS / STROM KRAFT
26.
High Tensile Fasteners GKW / FIT TIGHT / UNBRAKO /
SN
FASTNERS / TVS
27.
Fork Lift VOLTAS / GODREJ / ESCORTS / L&T /
JOIST ENGG. / MACNEILL & MAGOR
28.
Wire Rope MUMBAI WIRE ROPE / USHA MARTIN /
FORT WILLIAMS / J K STEELS / GLOSTER
29.
Hydraulic System REXROTH/ VICKERS/ YUKEN/ PARKER
30.
Over burden probes TMT
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 3 OF 21
SL.NO.
ITEMS MAKE
31.
Hooks (above 10t) HERMAN MOHTA/ FREE TRADING
CORPORATION
32.
Hooks (upto 10t) HERMAN MOHTA/ FREE TRADING
CORPORATION/ MACHINE TOOLS/ OM
ENGG./ ESKAY MACHINERY
33.
Brake Drum HICLIFF/ RUPEX/ RISHI/ KAPSEK
(COMBINED BREAK DRUM & COUPLING
SHALL NOT BE USED)
HYDRAULICS SYSTEM
1.
Hydraulic Cylinder BOSCH REXROTH/ VICKERS/ WIPRO/
USHA TELEHOIST/ OSCAR/ PARKER
YUKEN
2.
Hydraulic Systems with
Accessories
BOSCH REXROTH/ VICKERS/ YUKEN,
PARKER/ HYDAC
3.
Accumulators BOSCH REXROTH / EATON / YUKEN /
PARKER / EPE/ HYDAC
4.
Hydraulic Fitting & Clamp HYDAC / HYTECH / PTS / HY
DAIR
HYDAC / EPE
5.
Hose HYDROKRIMP / HYDROLINE / INDO
INDUSTRIAL SERVICES / AEROLEX /
SUPERSEAL / PSI HYDRAULICS
6.
Pressure / Temperature
gauges & Switches
BELLS. H. GURU/ AN INSTRUMENTS/
SWITZER/ DANFOSS/ WIKA
7.
Level Switches float type BELLS/ LEVCON/ SWITZER/
SRIDHAR/
TECHTROL/ SIGMA INSTRUMENTS/
CRYSTAL
8.
Level Gauges BELLS/ LEVCON/ SWITZER/ SRIDHAR/
TECHTROL/ SIGMA INSTRUMENTS/
CRYSTAL
9.
Flow switches SWITZER/ LEVCON
10.
Hydraulic Fittings & Clamps HYDAC/ HYTECH/ PTS./ HY
DAIR
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 4 OF 21
SL.NO.
ITEMS MAKE
11.
Servo Valve MOOG
12.
Filter INTERNORMEN/ DONALDSON/ PALL/
PARKER/ HYDAC/ EPE
13.
Hydraulic motor HAGGLUNDS/ VICKERS/ REXROTH/
YUKEN/ PARKER
PNEUMATIC SYSTEM
1. Valves Various Types NUCON/ SCHRADER SCOVILL/
ROSS
INDIA LTD./ SMC/ ROTEX
2. Filters NUCON/ SCHRADER SCOVILL/ ROSS
INDIA LTD./ SMC/ ROTEX/
SHAVONORGEN
3. Regulators NUCON/ SHAVO NORGREN / SCHRADER/
ROSS/ SMC
4. Lubricators NUCON/ SHAVO NORGEN/ SCHRADER/
ROSS/ SMC
5. Moisture Separator NUCON VELJAN/ SCHRADER/ ROSS/
SMC
6. Silencer NUCON VELJAN/ SCHRADER/ ROSS/ SMC
7. Pneumatic Cylinder WIPRO/ FESTO CONTROLS/ NUCON/
VELJAN/ GABRIEL PNEUMATICS/
SHRADER/ SMC
LUBRICATION SYSTEM
1. Grease Lubrication System LINCOLN/ BIJUR DELIMON
2. Screw Pumps TUSHACO/ ALWEILER/ ROTO/ ALEXTON/
UT PUMPS & SYSTEM
3. Gear Pumps AIRAUTO/ ROTO/ TUSHACO/ ROTODEL
4. Filter Strainers OTOKLIN/ SUPERFLOW FILTERS/ SPA
N
ASSOCIATES PUNE/ MULTITEX
FILTRATION.
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 5 OF 21
SL.NO.
ITEMS MAKE
5. Heat Exchangers RELIANCE/ ALFA LAVAL/ IDMC/ APV/
SWEP/ GEA
6.
Valves
: Plug Valves L&T/ CRESCENT/DEZURIK/KSB
Cat Steel / Forges Steel Gate
Valves
L&T/ FOURESS/ M&M/ CRESCENT/ NECO/
KSB/ BDK
Cast Steel, Forges Steel Globe
Valves
L&T/ FOURESS/ M&M/ CRESCENT/ GVD/
NECO/ BDK/ KSB
Cast Steel/Forged Steel N/R
Valves
L&T/ FOURESS/ M&M/ CRESCENT/ BDK/
KSB
GB / Bronze Gate / Globe
Valves
BOMBAY METAL/ M&M/ JNM/ ILK/ BHEL
Safety Valves FOURESS/ ILK/ JNM/ BESTOBEL/ BHEL,
Control Valves BESTOBELL/ ILK/ L&T/ JNM/ M&M/ DE
ZURIK/ FOURESS/ IL PALGHAT/ FORBES
MARSHALL
Ball Valves L&T/ CRESCENT/ AKAY/ BHEL/ M&M/
JNM/ KSB/ DEZURIK/ BDK/ VIRGO
7. Centrifuge VALCAN/ LAVAL, ALPHA LAVAL
8. Oil Mist/Mist Cool & Spray
Lube Systems
SHAVONORGEN/ LINCOLN HELIOS/
DELIMON/ AFMC/ OILAIR LUBRICATION
9. Automatic Grease Lubrication
System / Comprising of :
Reservoir
Grease Pumps
(motorised)
Distributors
Changeover Valves
Filters
Piping and
Electrical Control Panel
LINCOLN/ AFMC/ DELIMON PROTOS/
LUBIN ENGG.
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 6 OF 21
SL.NO.
ITEMS MAKE
10.
Manual Grease Lubrication
System Comprising of :
Reservoir
Hand operated Grease
Pumps
Distributors
Changeover Valves
Filters
Piping
HYDROLUB AIR/ LUBCON/ LINCOLN
HELIOS/ ELGI/ LUBIN ENGG./ AFMC
11. Grease Spray Systems SHAVO NORGEN LINCOLN/ AFMC
/
LUBIN ENGG.
12. Flexible Hose SUPERSEAL/ COSMOS/ DUNLOP/
SWASTIK/ MAXWELL
13. Lubricants IOC/ BALMER LAWRIE/ ASIAN OIL
CO./BPCL/ HPCL/ SHELL
14. Hose Assembly HYDROKRIMP/ HYDROLINE/ INDO
INDUSTRIAL SERVICES/ AEROLEX/
SUPERSEAL/ PSI HYDRAULICS
15. Tube fitting HYTECH/ HYDAIR/ PTS/ HYDRO
TECHNIC
FLUID SYSTEM
1. Centrifugal Pumps KIRLOSKAR/ MATHER & PLATT./ KS
B/
BEACONWEIR
2. Submersible Pumps SU PUMPS/ DARLING/ KSB/ KIRLOS
KAR/
KISHORE PUMPS/ M& PLATT.
3. Sludge Pumps AKAY/ BEACON WEIR/ KSB/ SAM/
KIRLOSKAR/ U.T PUMPS
4. Valves (Gate, Globe, Non
Return)
KORLOSKAR/ BDK/ AUDO/ CRESCENT/
BHEL/ TYCO VALVES,
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 7 OF 21
SL.NO.
ITEMS MAKE
5. Butterfly valve FOURESS ENGG./ AUDCO/ FISHER
XOMOX/ KSB/ BDK/ INTERVALVE/ IVC/
TYCO VALVES & CONTROLS/ VIRGO
6. Diaphragm valve DE ZURIK/ FLUID SYSTEM/ SAUNDER
S/
BDK/ GEORGE FISCHER/ POLY VALVE
7. Ball Valve (CS/FS/CI) AUDCO/ KSB/ FISHER XOMOX/
VIRGO/
BDK/ TYCO VALVES
8. Compressor (centrifugal) ATLAS COPCO/ KIRLOSKAR/
SULZER
9. Compressors (reciprocating
and screw)
KG KHOSLA/ KIRLOSKAR PNEUMATIC/
HOLMAN/ CLINEX/ ELGI/ I-R/ ATLAS
COPCO/ INGERSOLL
10. Heat Exchanger ATLAS COPCO/ BAKUBHAI AMBALAL/
APV/ L&T/ ALFA LAVAL/ BHPV/
THERMAX/ RELIANCE/ IDMC
11. Air Drier DELAIR INDIA/ DRY HYPHEN/ ARCTIC/
M&M/ LLOYD STEEL/ INDCON/ MIRCH/
MIREX
12. Air Blower INGERSOL RAND/ SLM/ MANEKLAL
INDUSTRIES/ CHEMICAL PROCESS EQPT.
KAY INT. TLT ENGG./ INDOCON/ C
DOCTOR/ BATLIBOI
13. Pressure Filters RESIN/ INDIA/ ION EXCHANGE/
OTTOKILN/ ING-TECH ENGG. CO./
THERMAX/ ARUDA/ VASMYL
14. Activated Carbon Filter RESIN INDIA/ ION EXCHAN
GE/
OTTOKILN/ ING-TECH ENGG. CO./
THERMAX/ ARUDRA/ VASMYL
15. Drain traps (steam &
compressed air)
DRAYTON GREAVES/ J.N. MARSHALL/
UNIKLINGER
16. Strainer OTOKLIN/ DRAYON-GREAVES/ J.N.
MARSHALL/ UNKINGER/ SUPERFLOW
17. Steel Pipes SAIL (RSP)/ ITC/ JINDAL/
MAHARASHTRA SEAMLESS/ BHEL
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 8 OF 21
SL.NO.
ITEMS MAKE
18. HDPE Pipes, PVC pipes &
fittings
POLYFIX/ CHEMPLAST/ EMOCOHENE/
PLYOLEFINS/ PIL
19. Stainless steel pipes CHOKSY, ZENITH/ STANDARD/
(INDIA),
BHEL/ STERLING/ MISHRA DHATU
NIGAM/ AMARDEEP STEEL CENTRE
20. Expansion joints (non
metallic)
HINDUSTAN FERODO/ BESTOBEL/ ANUP
ENGG./ PRECISION ENGRS/ GBM/ D
WREN/ CORI ENGG./ KE BOGMAN
21. Expansion joints (metallic) LONE STAR/ METALLIC
BELLOW/
FLEXATHERM/ FLEXICAN
22. Steel Pipe Fittings JINDAL/ AJANTA/ ITC/ BHEL/
TUBE
BEND/ S&L/ MS FITTINGS
23. Steel Pipes (Traders) M.J. PATEL/ SIVMONI & CO.
SOOR NEOGI
24.
Vibrating Feeder
IC / SCHENK PROCESS / TRF / METSO/
MSEL/ELECTROMAG
25.
Vibrating Screens
IC / SCHENK PROCESS / TRF / METSO/
MSEL/ELECTROMAG
26.
Conveyor Belting PHOENIX YULE / DUNLOP /
SIMPERLRANS NIRLON /
HILTON / NORTH LAND RUBBER / MRF /
ORIENTAL
RUBBER / HINDUSTAN RUBBER
27.
Idlers L & T / ELECON / TRF / TECPRO /
BENGAL TOOLS /MSEL
28.
Gear Boxes ELECON / NAW / FMG / SHANTHI /
PREMIUM ENERGY TRANSMISSION /
SUMI-CYCLO DRIVE INDIA PVT.LTD.
29.
Geared Couplings NAW / HICLIFF / CONCORD / FMG /
ELECON / WELLMAN WACOMA / GBM /
LOVEJOY /ROMA
30.
Pull cord,
EPCC / IND SYNDICATE / STROM KRAFT
/ AG-MECH
31.
Belt Sway switch
EPCC / IND SYNDICATE / JAYASHREE /
STROM KRAFT / TELE MECHANIC
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 9 OF 21
SL.NO.
ITEMS MAKE
32.
Proximity switches AB CONTROLS / BCH / ROCKWELL
AUTOMATION / SIEMENS / SCHNEIDER
33.
Brakes BCH / ELECTRONIC & POWER CONTROL
/ELECTROMAG / EMCO PRECIMA /
TURFLEX / STROMCRAFT
34.
Bearings

a) For Idlers SKG / FAG / NTN / TATA TIMKEN / KOYO
/ NEI (NBC) / GPZ / ZKL
b) For Pulleys & others
SKG / FAG / NTN / TATA TIMKEN / KOYO
/ NEI (NBC) / GPZ / ZKL
c) Adopter Sleeves SKEFCO /FAG / NTN
35.
Belt Scraper HOSCH / KAVERI
36.
Electric Hoist VOLTAS / IDC / BOMBAY CRANES /
ARDEC / REVA ENGG / HERCULES HOIST
/ ELECTROTHERAPY / AARCO / ARMSEL
/ EDDY CRANE / ROBIN ENGG. / AVON /
INDEF
LIST OF PREFERRED MAKES FOR TURBO BLOWER
S. NO.
ITEMS MAKES
1.
Blower SIEMENS/MANTURBO/MES/BHEL/KAVASAKI
2.
Turbine BHEL/SIEMENS/MANTURBO/MES/ALSTOM/G
E/KAVASAKI
3.
Condenser GEI GODAVARI / GEA/ Turbine Manufacturer
s
Own Make
4.
Condensate extraction
pumps
KSB/ SULZER-/ BHEL
5.
Steam Ejectors MAZDA CONTROLS
6.
Oil Centrifuge ALFA-LAVAL / WESTFALIA SEPARATOR
7.
Suction filter AAF LIMITED / ANFILCO LIMITED / DEL
BAG
LUFTFILTER / D I FILTER SYSTEM / FILTER
MANUFACTURING / LOCKER AIR-MAZE
LIMITED/ CAMFIL
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 10 OF 21
S. NO.
ITEMS MAKES
8.
Blower Discharge Gate
Valve
AUDCO/ FOURESS
9.
HP / LP Valves AUDCO / BHEL / KSB
10.
PRDS BTG KALLE / DEWRANCE / HOPKINSONS / JN
MARSHALL
11.
Steam Traps JN MARSHALL / MAZDA
12.
Blow Down Valves BHEL / LEVCON
13.
Insulation CHEMTECH / LLOYDS / MURUGAPPA / ROCK
WELL
LIST OF PREFERRED MAKES FOR CA FAN
S. NO.
ITEMS MAKES
1.
CA Fan TLT / FLAKT / ANDREW YULE / BHEL /
BOLOROCCHI
LIST OF PREFERRED MAKES FOR HOT BLAST SYSTEM
SL.NO. ITEMS MAKE
1.
GENERAL
i)
Gearbox (other than crane) ELECON / NAW / FMG / SH
ANTHI /
PREMIUM ENERGY TRANSMISSION /
ii)
Geared Motor IC BAUER / ROSSI MOTORS / POWER
BUILD / BONFIGLIOLI / SHANTHI /
NORD / SEW / CYCLO
TRANSMISSION / AUMA / ROTORK
iii)
Coupling (other than fluid) NAW / HICLIFF / CONCO
RD / FMG /
ELECON / WELLMAN
INCANDESCENT / GBM / LOVEJOY
/ROMA
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 11 OF 21
SL.NO. ITEMS MAKE
iv)
Transmission Chain & Sprocket ROLCON / ROLON / RE
YNOLD /
DIAMOND /
v)
Brake BCH / ELECTRONIC & POWER
CONTROL / ELECTROMAG /
STROMCRAFT
vi)
Paint ASIAN / J&N GARWARE / BERGER /
SHALIMAR / ICI /GOODLASS
NEROLAC / BRITISH PAINTS
vii)
Bearing SKG / FAG / NTN / TATA TIMKEN /
KOYO / NEI (NBC) / ZKL
viii)
Hook (up to 10 t) HERMAN MOHTA / FREE TRADING
CORPORATION / MACHINE TOOLS /
ESKAY MACHINERY
ix)
Hook (above 10 t) HERMAN MOHTA / FREE TRADING
CORPORATION
x)
Wire Rope MUMBAI WIRE ROPE / USHA
MARTIN / FORT WILLIAMS / JK
STEELS / GLOSTER
xi)
EOT Crane & its gear box (up to
50 t)
JESSOP / HEC / MUKAND / WMI /
UNIQUE INDUSTRIAL HANDLERS /
FURNACE & FOUNDRY EQUIPMENT
CO. / VOLTAS / IDC / BOMBAY
CRANES / REVA ENGG / ARMSEL /
EDDY CRANE /ROBIN ENGG. /
TOUBRO FURGUSON / DEMAG
CRANES / CENTURY CRANE
/ELECTRO THERAPY / ANUPAM
INDUSTRIES
xii)
Electric Hoist VOLTAS / IDC / BOMBAY CRANES /
ARDEC / REVA ENGG / HERCULES
HOIST / ELECTROTHERAPY /AARCO /
ARMSEL / EDDY CRANE / ROBIN
ENGG. / INDEF
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 12 OF 21
SL.NO. ITEMS MAKE
2.
HYDRAULICS SYSTEM
i)
Hydraulic Power Pack BOSCH REXROTH/ EATON / YUKEN
/
PARKER
ii)
Hydraulic Cylinder BOSCH REXROTH / EATON / WIPRO /

PARKER / VELJAN HYDAIR
iii)
Accumulator BOSCH REXROTH / EATON / YUKEN /
PARKER / EPE / HYDAC
iv)
Hydraulic Fitting & Clamp HYDAC / HYTECH / PTS / H
YDAIR
v)
Filter INTERNORMEN / DONALDSON /
PALL / PARKER/ HYDAC / EPE
vi)
Hydraulic Motor HAGGLUNDS / EATON / REXROTH /
YUKEN / PARKER
vii)
Hose HYDROKRIMP / HYDROLINE / INDO
INDUSTRIAL SERVICES / AEROLEX /
SUPERSEAL/ PSI HYDRAULICS/
HYDAC
viii)
Heat Exchanger ALFA LAVAL / SWEP / GEA /
TRANTER
3.
STOVE VALVES
FOURESS, AUDCO (L&T), Z & J
4.
EXPANSION JOINT

i)
Expansion Joint (metallic) LONE STAR / FLEXATHERM
/
FLEXICAN BELLOWS
5.
REFRACTORY
SUPPORTING STRUCTURE
i)
Columns, Grids & Girders SIMPLEX CASTINGS/BEEKAY E
NGG./
BEC/ NECO CASTINGS/HEC
6.
PNEUMATIC SYSTEM
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 13 OF 21
SL.NO. ITEMS MAKE
i)
Pneumatic Cylinder
WIPRO / FESTO CONTROLS / NUCON /
VELJAN HYDAIR/ GABRIEL
PNEUMATICS / SHRADER /
ii)
Hose
HYDROKRIMP / HYDROLINE / INDO
INDUSTRIAL SERVICES / AEROLEX /
SUPERSEAL / PSI HYDRAULICS
7.
LUBRICATION SYSTEM

i)
Grease Lubrication System LINCOLN HELIOS
ii)
Hose HYDROKRIMP / HYDROLINE / INDO
INDUSTRIAL SERVICES / AEROLEX /
SUPERSEAL / PSI HYDRAULICS
LIST OF PREFERRED MAKES (ELECTRICAL ITEMS)
SL.N ITEMS MAKE
1.
33kV GIS Switchgear ALSTOM(AREVA)/ SIEMENS /ABB
2.
6.6kV Circuit Breakers with
switchboard
ALSTOM(AREVA)/ SIEMENS
/ABB/CGL/BHEL
3.
33kV & 6.6kV Insulator and
bushing
JAYSHREE INSULATORS/OBLUM/WSI /
MODERN
4.
6.6kV CT CGL/ JYOTI/ ALSTOM(AREVA)/ KAPPA/
AE/ PRAGATI
5.
6.6kV PT CGL/ KAPPA/ AE/ ABB / PRAGATI
6.
6.6kV Surge arrestor RAYCHEM/TYCO/ELPRO
INTERNATIONAL /CGL/OBLUM /
ALSTOM(AREVA)
7.
Oil filled transformer ALSTOM(AREVA)/ABB/ BHARAT B
IJLEE/
BHEL/ CGL/ KIRLOSKAR ELECTRIC
COMPANY/ EMCO
8.
OLTC EASUN MR/CTR/ABB/BHEL
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 14 OF 21
SL.N ITEMS MAKE
9.
Dry type transformer KIRLOSKAR ELECTRIC COMPANY/
VOLTAMP/CGL/INTRAVIDYUT/ ABB
10.
33kV & 6.6V Isolator A BOND STRAND/ SIEMENS/ DRESC
HER
& PANICKER/ TRANSELECTRICALS/
PROJECT ELECTRICAL INDUSTRIES/
ALLIANCE / ELPRO INTERNATIONAL /
GR POWER/ SWITCHGEAR &
STRUCTURES
11.
Numerical relays ABB/SIEMENS/ ALSTOM(AREVA)
12.
Relay & Control Panel ABB / ALSTOM(AREVA) / SIEME
NS/ OR
THEIR SYSTEM HOUSE
13.
Ammeter/ voltmeter/
wattmeter/ VAR meter
AEL/ LANDIS & GYR /IMP POWER LTD/
L&T./ RISHABH /DUKE ARNICS /MECO
INDUSTRIES PVT.LTD
14.
Watt-hour meter LANDIS & GYR
/AEL/ALSTOM(AREVA)/BHEL/ LANDIS &
GYR / IMP / SECURE (SEMS) / RISHABH
15.
Power factor meter AEL/LANDIS & GYR /IMP POWER
LTD./KAPPA
MECO INSTRUMENTS PVT LTD. /
RISHABH
16.
Frequency meter AEL/LANDIS & GYR /IMP/ RISHABH
17.
Digital Meters POWER MEASUREMENT /ROCKWELL
AUTOMATION / L&T/ LECTROTEK/ GE/
DUKE ARINCS (HAVELLS)/
SATEC/CONZERV/ SECURE METER
18.
Semaphore indicators ABB/ALSTOM(AREVA)/BINAY
19.
Winding and oil temperature
indicator for transformers
OSMADIAL//PERFECT CONTROLS/SKII
20.
Buchholz relay AREVA/SUKRUT/ ATVUS
21.
Battery Charger CHABI ELECTRICALS / NELCO/ HBL
NIFE/ AEL/ APLAB /CALDYNE/ AMARA
RAJA
22.
Intelligent MCC L&T/SIEMENS/ABB/GE/SCHNEIDER
/ROCKWELL
23.
Non Intelligent MCC & PDB ABB/GE/SCHNEIDER/C&S/L&T
/SIEMENS/
SWITCHING CIRCUIT/MEDITRON/BCH
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 15 OF 21
SL.N ITEMS MAKE
24.
Programmable Logic
Controller(PLC) alongwith
panel
ROCKWELL AUTOMATION / SIEMENS
/ABB/ GE FANUC/SCHNEIDER
25.
VFD alongwith panel ABB/ SIEMENS/VACON/GE/ROCKWELL

AUTOMATION/SCHNEIDER
26.
UPS HITACHI-HIREL/EMERSON/ DB POWER
27.
VRLA Battery for UPS EXIDE/ AMAR RAJA/ HBL NIFE
28.
AC motors ABB/MARATHON(ALSTOM)/BHARAT
BIJLEE/CROMPTON/KIRLOSKAR/SIEMEN
S/BHEL/CONVERTEAM/WEG
29.
Ammeter/ voltmeter/
wattmeter
AEL/DUKE ARNICS/IMP POWER
LTD/MECO INDUSTRIES PVT.LTD./
LANDIS & GYR/L&T
30.
Control switches/Selector
switches
ALSTOM/BCH/EPCC
/KAYCEE/L&T/SIEMENS/ ABB/C&/S
31.
Push Buttons ALSTOM/BCH/CONTROL &
SWITCHGEAR/ L&T/S&S POWER
SWITCHGEAR LTD /SCHNEIDER
/SIEMENS/VAISHNO
32.
Timers/Time Delay Relay ALSTOM/BCH/ELECTRONIC
AUTOMATION PVT
LTD./L&T/SIEMENS/SCHNEIDER/EAPL
33.
Control contactors ABB/BCH/BHEL/CONTROL &
SWITCHGEAR (TM)
/L&T/SCHNEIDER/SIEMENS
34.
Control transformers AEL/BCH/INTRAVIDYUT(INDCOIL)/
KAPP
A/SIEMENS
35.
Indicating lamps LED type BINAY/ESSEN/VAISHNO
36.
Hooter/buzzer/bell EPCC/KHERAJ/ GETCO/EDISON
37.
Solid state annunciator ADVANI OERLIKON/ALSTOM/ AP
LAB/
BHEL/CONTROL & DYNAMICS/DIGICON/
INSTRUMENTATION
LIMITED/L&T/MINILEC
38.
Lamps BAJAJ/CROMPTON GREAVES/GE
LIGHTING/PHILIPS/ SURYA ROSHNI LTD
39.
Light fittings (fixtures) BAJAJ/CROMPTON GREAVES/G
E
LIGHTING/PHILIPS / SURYA ROSHNI LTD
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 16 OF 21
SL.N ITEMS MAKE
40.
Lighting wire(PVC) CCI/DELTON/FINOLEX/FORTGLOSTER/
G
OVIND/INCAB/NICCO/RPG
CABLES/UNIVERSAL
41.
Miniature Circuit Breaker
(MCB)
HAVELLS/INDO
KUPP/MDS/S&S/SCHNEIDER/STANDARD
42.
5A/15 A Piano switch ANCHOR/ELLORA/PRECISION
43.
Switch socket outlet
(240/24V)
ALSTOM/ANCHOR/BCH/CGL//ESSEN
44.
Switch socket outlet (415V) ALSTOM/BCH/CGL
45.
Ceiling Fans USHA/CROMPTON/BAJAJ/KHAITAN
46.
Winding temperature
indicator
OSMADIAL//PERFECT CONTROLS/SKII
47.
HT XLPE cables CCI/ NICCO/RPG Cables (ASIAN)
/UNIVERSAL /HAVELLS
48.
PVC Power cables CCI/ GLOSTER//NICCO/RPG Cables
(ASIAN) /UNIVERSAL /HAVELLS
49.
PVC control cables CCI/ GLOSTER/LAPP/NICCO/ RPG
cables(ASIAN)/UNIVERSAL /HAVELLS
50.
Heat shrinkable jointing &
termination kit
REYCHEM/MAHINDRA CHEMICALS
51.
Screened cable TOSHNIWAL/DELTON/CCI
/FINOLEX/LAPP KABEL / DOWELLS
52.
Cable lug DOWELLS/ISMAL/JAINSON
53.
Cable gland CCI/DOWELL'S ELECTRO
WERKE/ELECTROMAG
54.
Terminal block CONNECT WELL/CONTROL &
SWITCHGEAR/ELMEX/ESSEN/PHOENIX/
WAGO
55.
LT Isolators ALSTOM/CONTROL & SWITCH
GEAR/L&T/SIEMENS/STANDARD
56.
LT Air circuit breaker (ACB) ABB/ C&S/ L&T/SCHNEID
ER/SIEMENS/GE
57.
Moulded case circuit breakers
(MCCB)
ABB//L&T/SCHNEIDER /SIEMENS
/GE/C&S
58.
AC power contactors ABB / C&S/L&T/ SCHNEIDER /
SIEMENS/GE
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 17 OF 21
SL.N ITEMS MAKE
59.
EMPR (O/L Relays) SIEMENS/ABB/GE/ C&S(TM)/L&T/
SCHNEIDER / AY/BCH
60.
Fuse switch unit ALSTOM/CONTROL & SWITCHGEAR/
HAVELLS/L&T/SIEMENS/STANDARD
61.
H.R.C. fuses ALSTOM/HAVELLS/L&T/SIEMENS/
STANDARD (INDO ASIAN)
62.
LT SWITCHBOARD ABB/ C&S/ L&T/SCHNEIDER/SIEMENS/GE
63.
SOFT STARTER SIEMENS / L&T/
SCHNEIDER/ABB/ROCKWELL
AUTOMATION/VACON
64.
BUS-DUCT STARDRIVE/A-BOND/ECC
65.
NGR RSI/RESITECH
66.
DC Motor BHEL/IEC/KEC
LIST OF PREFERRED MAKES (INSTRUMENTTAION)
Sl. No. ITEMS MAKES
1.
PRESSURE/DIFFERENTIAL
PRESSURE/LEVEL/FLOW
TRANSMITTERS
EMERSON / E&H / YOKOGAWA / HONEYWELL
/ ABB / FUJI
2.
PRESSURE / DP SWITCH WIKA / WAREE / SWITZER / IFM /
ASHCROFT
3.
PRESSURE GAUGE /
DIFFERENTIAL PRESSURE
GAUGE
BUDENBERG /ANI / WIKA / FIEBIG / WAREE /
GENERAL INSTRUMENTS
4.
TEMPERATURE GAUGE
ANI / GENERAL INSTRUMENTS / WIKA /
FIEBIG / WAREE
5.
RTD / THERMOCOUPLE GENERAL INSTRUMENTS /TEMPSEN /
PYROELECTRIC / WAREE / TOSHNIWAL /
NAGMAN
6.
TEMPERATURE
TRANSMITTER
EMERSON / HONEYWELL / YOKOGAWA / ABB
/ FUJI
7.
TUNING FORK TYPE
LEVEL SWITCH
ENDRESS & HAUSER / VEGA / CHEMTROL /
SIEMENS / P&F
8.
ULTRASONIC / RADAR
ENDRESS & HAUSER / CHEMTROL(VEGA) /
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 18 OF 21
Sl. No. ITEMS MAKES
TYPE LEVEL
INSTRUMENT
YOKOGAWA / EMERSON (ROSEMOUNT)/
KROHNE MARSHALL
9.
ELECTRO MAGNETIC
FLOW METER
EMERSON / YOKOGAWA / ENDRESS &
HOUSER / HONEYWELL / ABB / KROHNE
MARSHALL
10.
ROTAMETER ROTA INSTRUMENTS / INSTRUMENTATION
ENGINEERS / FORBES MARSHALL / WAREE /
CHEMTROLS
11.
FLOW ELEMENTS
ENGG SPECIALITIES / EMERSON / MICRO
PRECISION / EMERSON / UNICONTROL
12.
FLOW SWITCH IFM / KOBOLD / KROHNE MARSHALL
13.
VORTEX FLOW METERS
EMERSON / E&H / YOKOGAWA / FORBES
MARSHALL / VORTEX INSRUMENTS
14.
MASS (CORIOLIS) FLOW
METER
EMERSON / E&H / YOKOGAWA / FORBES
MARSHALL
15.
ANNUBAR ENGG SPECIALITIES / EMERSON / SWITZER
16.
INFRARED PYROMETER LAND / RAYTEK / IRCON / CHINO /
KELLER
17.
THERMOWELL AND
THERMOCOUPLE
ASSEMBLIES
TEMPSENS / TEMCON / WAAREE / GENERAL
INSTRUMENTS / PYROELECTRIC
18.
TEMPERATURE SWITCH IFM / WIKA / OMEGA / E&H / KOBOL
D
19
a)
PROGRAMMABLE LOGIC
CONTROLLER
SIEMENS (PCS 7+ S7400H) / ROCKWELL
(CONTROL LOGIX) / ABB(AC 800XA)
/
SCHNEIDER( QUANTUM)
19
b)
DISTRIBUTED CONTROL
SYSTEM
SIEMENS (PCS 7+ S7400H)/ROCKWELL
(CONTROL LOGIX) / ABB(AC 800XA)
/
YOKOGAWA(CS 3000)
20.
LEVEL GAUGE
CHEMTROL/EMERSON/FORBES
MARSHALL/WAAREE INSTRUMENTS
21.
LEVEL SWITCH
E&H / P&F / CHEMTROL(VEGA) / EMERSON /
FORBES MARSHALL
22.
LEVEL TRANSMITTER
EMERSON / SIEMENS(MILITRONICS) / E&H /
P&F / FORBES MARSHALL / YOKOGAWA /
ABB
23.
CONTROL VALVE
FISHER / IL / SAMSON CONTROLS / FORBES
MARSHALL(ARCA) / DEMBLA / IL
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 19 OF 21
Sl. No. ITEMS MAKES
24.
PNEUMATIC ACTUATOR
FISHER / IL / SAMSON CONTROLS / FORBES
MARSHALL(ARCA) / DEMBLA / FLOWSERVE
25.
ELECTRIC ACTUATOR INSTRUMENTATION LTD(BERNARD)
26.
SELF REGULATING
CONTROL VALVE
SAMSON CONTROLS/FORBES
MARSHALL/IL/FISHER-XOMOX
27.
I/P CONVERTERS
FORBES MARSHALL / ABB / EMERSON /
HONEYWELL / SIEMENS
28.
ELECTRO PNEUMATIC
POSITIONER (SMART)
SIEMENS
29.
THERMO COUPLE
COMPENSATING CABLES
TOSHNIWAL CABLES/MEM
INDUSTRIES/BELDON/LAPP/PARAMOUNT
CABLES
30.
LOAD CELL CABLES SIEMENS / SARTORIUS / SEHENCK / IP
A
31.
INSTRUMENTATION
CABLES
TOSHNIWAL CABLES / DELTON / FINOLEX /
LAPP CABLES / MEM CABLES / BELDEN
32.
DIGITAL INDICATOR
YOKOGAWA / MASSIBUS / ABB / HONEYWELL
/ LECTROTEK / EUROTHERM
33.
PAPERLESS RECORDER
YOKOGAWA / ABB / HONEYWELL /
EUROTHERM / PENNY&GILES
34.
SIGNAL ISOLATOR P&F / MTL / YOKOGAWA / PHONEIX
35.
FLAME DETECTOR
HONEYWELL / DURAG INSTRUMENTS /
YAMATAKE / ENDEE
36.
HOPPER WEIGHING
SYSTEM
SEHENCK / SARTORIUS / SIEMENS /
TRANSWEIGH / IPA
37.
LOAD CELL
SARTORIOS / SEHENCK / HBM / VISHAY
TRANSDUCERS / PRECIA - MOLEN
38.
CCTV HONEYWELL / SIEMENS / ECIL / TOSHNIWAL
39.
SOLENOID VALVE ROTEX / SCHRADER SCHOVILL / AVCON /

ASCO / BURKERT / HERION
40.
AIR FILTER REGULATOR
SHAVO NORGREN / PLACKA / DELAIR /
SCHRADER SCHOVILL
41.
ZENNER BARRIER P&F / MTL / STAHL
42.
PANEL / ENCLOSER /
RACK
RITTAL/ HOFFMANN/ SIEMENS/ IL/ APW
PRESIDENT/ VALRACK
43.
PC / LAPTOP IBM / DELL / HP / LENOVO
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 20 OF 21
Sl. No. ITEMS MAKES
44.
SERVER IBM / HP / SUN / DELL
45.
NETWORK SWITCH
CISCO/ HP / BROCADE / EXTREME /
HIRSCHMANN
46.
SECURITY APPLIANCES
LIKE FIREWALL/ UTM
ETC.
CISCO / JUNIPER / CHECK POINT / CYBEROAM
47.
ROUTER CISCO / JUNIPER
48.
WIRELESS NETWORK
EQUIPMENT
CISCO / BROCADE / EXTREME / D-LINK
49.
PASSIVE NETWORK
COMPONENT /
ACCESSORIES
MOLEX/ TYCO(AMP) / SYSTIMAX / DIGILINK
50.
DATA STORAGE SYSTEM HP / IBM / EMC
51.
FO CABLE / UTP CABLE MOLEX / TYCO(AMP) / SYSTIMAX
/ DIGILINK /
LUCENT
52.
LASERJET PRINTER HP / CANNON / SAMSUNG
53.
DOT MATRIX PRINTER EPSON / TVSE / SAMSUNG
54.
UPS
EMERSON / IL / DB / RITTAL / GE/ NUMERIC /
APC
55.
SMF BATTERY
EXCIDE / AMRON / PANASONIC / FURUKAWA
/ AMAR RAJA
56.
REGULATED DC POWER
SUPPLY UNIT / SMPS
APLAB / COSSEL / PHOENIX / SIEMENS
57.
ALARM ANNUNCIATOR IIC/ IL/ MINILEC / PROCON
58.
FLOW TOTALISER
YOKOGAWA / HONEYWELL / MASIBUS /
PYROTECH
59.
GAS ANALYSER
ABB(H&B) / EMERSON / YOKOGAWA /
SIEMENS / SICK MAIHAK / FUJI
60.
OPACITY ANALYSER
CODEL / SICK MAIHEK / DURAG / EMERSON /
CHEMTROL
61.
GAS DETECTORS BEILER & LANG / DRAGGER / OLDHAM
62.
VIBRATION MONITORING
SYSTEM
BENTLEY NEVADA( for power plant & critical
application)/ SHINKAWA
63.
CALORIFIC VALUE
ANALYSER
REINEKE / YOKOGAWA / CHEMTROLS
64.
MOISTURE ANALYSER
FUJI / MOISTECH (EARTH TEKINK) /
RSP ANNEXURE 2.12-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 21 OF 21
Sl. No. ITEMS MAKES
INFRARED ENGG
65.
PH / CONDUCTIVITY / ORP
ANALYSER
PHILIPS / FORBES MARSHAL / EMERSON /
YOKOGAWA / ABB / E&H
66.
SOX / NOX ANALYSER EMERSON / YOKOGAWA / ABB / HONE
YWELL
67.
INSTRUMENTATION
CABLE
INCAB / FINOLEX / CCI / POLYCAB / CORD /
MEM/ LAPP / THERMOCABLES
68.
COMPENSATING CABLE
UNIVERSAL CABLES / RPG / THERMOCABLES
/ GENERAL INSTRUMENTS / CORD
69.
FIRE DETECTION SYSTEM
SIEMENS BUILDING TECHNOLOGIES /
HONEYWELL (NOTIFIER)
70.
COMPUTER FURNITURE GODREJ / USHA LEXUS / ZUARI
71.
GPS MOTOROLA / ERICSSON
72.
LCD / TFT MONITOR SAMSUNG / SONY / PANASONIC / HITA
CHI
73.
LARGE DISPLAY SCREEN
(LED)
SAMSUNG / SONY / PANASONIC / HITACHI
74.
RADIO COMMUNICATION
EQUIPMENT
MOTOROLA / STAHL / RADIUS / CIRRONET /
SATELLINE
75.
WEIGHING SYSTEM
SCHENCK PROCESS INDIA LTD / SARTORIUS /
SIEMENS / TRANSWEIGH INDIA LTD / PRECIA
MOLEN INDIA LTD / IPA PVT LTD
76.
CONVEYOR RUPTURE
DETECTION SYSTEM
PNF / PROTO CONTROL / SAI CONTROL
SYSTEM / JAYSHREE
RSP
ANNEXURE 3.2.1-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF BF-1 PAGE 1 of 37
ANNEXURE 3.2.1-1
1.0
SPECIFICATIONS FOR CIVIL WORKS
1.1
GENERAL
1.1.1
Design Specifications
1.1.1.1
This specification covers the design criteria for C
ivil Engineering work
for the Rourkela Steel plant (RSP)
. The term Design Criteria includes
loading standards, permissible stresses, functional
requirements and
quality standards to be adopted as a basis for prep
aration of designs and
drawings by the Bidder. These designs and drawings
will cover buildings
for production and non-production facilities, auxil
iary facilities, ancillary
buildings and structures, foundations for buildings
and equipment, roads,
drains, sewers and other miscellaneous civil engine
ering items of work to
be provided and/or to be modified/ rectified by the
Contractor.
1.1.1.2
The designs prepared by the Contractor shall not on
ly provide for the
requirements indicated in this specification but al
so consider the overall
process requirements, service conditions and provis
ions to be made for
future expansion. The designs shall be compatible w
ith the operating
conditions in the plant and the atmospheric conditi
ons prevalent at
Rourkela
1.1.1.3
Standards and unification shall be carried out to t
he maximum extent
possible and in the interest of standardisation. RS
P
reserves the right of
selecting a particular make of materials and compon
ents. The Contractor
shall supply materials/components of the particular
make, if so required.
1.1.1.4
The work is to be carried out in an operating plant
and hence design &
execution of work shall be carried out in such a ma
nner to cause
minimum or no disturbance to the normal day-to-day
operations of the
plant.
1.1.2
Standards
1.1.2.1
The design criteria for civil engineering work shal
l be in accordance with
this specification. Detailed instructions on such a
spects as are not
indicated herein shall be as per the latest standar
ds & BIS codes. In the
absence of suitable IS specification and codes of p
ractices other
recognised international standards and codes may be
followed with the
prior approval from Purchaser.
1.1.2.2
In respect of pollution control, safety, sanitary a
nd hygienic requirements
the stipulations of the Department of Environment o
f the Government of
India, stipulations of the Indian Factories Act, Or
issa
Government
Factories Rules, RSP
s Safety Rules, notification of Orissa
Government
Department of Science, Technology and Environment o
n Water and Air
Pollution and other statutory authorities shall be
satisfied.
1.1.2.3
This specification covers design of major Civil Eng
ineering items of
work. Other items of work shall be designed accordi
ng to the relevant
standards, recommendations and stipulations referre
d above. This design
specification shall also be read in conjunction wit
h the General
specifications for Civil Engineering Work.
1.1.2.4
In case anything mentioned in this specification is
at variance with IS or
other codes of specification mentioned herein, the
provisions of this
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UPGRADATION OF BF-1 PAGE 2 of 37
specification shall prevail.
1.1.3
Concrete and Reinforced Concrete for Structures and
Foundations
1.1.3.1
Concrete work shall be a dense, homogenous, smooth
mass including
required finishes, possessing required strength and
resistance to
weathering and abrasion for the structures and foun
dations.
1.1.3.2
Design of all reinforced concrete structures shall
be as per the latest IS:
456 2000. The structural safety of all foundation
s on soil shall, in
general, be based on IS: 1904 1986. The allowable
settlement of
foundations shall be as per technological / system
requirement. For
building structures allowable settlement shall not
exceed 50mm.
1.1.3.3
For calculation purpose Limit State Design method
s shall be adopted.
1.1.3.4
The minimum grade of RCC shall be M25 and PCC shall
be M10.
However, PCC of grade M5 shall be used for mass fil
ling
1.1.4
Load Condition
1.1.4.1
All foundations and concrete structures shall be de
signed to resist full
operating dead and live loads, with appropriate com
bination of wind and
seismic forces and with due allowance for impact, i
nertia loading,
vibration etc. as secondary affects of live loads,
temperature variation etc.
While designing structures and foundations either t
he effect of seismic
forces or wind loads, whichever produces the worst
effect, shall be
considered along with usual load conditions. Requir
ement of seismic
load analysis shall be based on type & importance o
f structure, mass
concentration etc. and shall be decided at the time
of detail engineering.
1.1.4.2
Concentrated and uniformly distributed live load on
floors and platforms
shall be considered depending upon the usage and in
accordance with a
maximum expected process requirements, to be indica
ted by the
equipment manufacturers. When the loads are movable
, they shall be so
placed as to get worst effect in moment, shear, axi
al loads etc. for which
the elements shall be designed. The effect of conce
ntrated load shall not
be reduced. Due allowance shall be made, wherever n
ecessary, for
installation and operation of any equipment as per
equipment
manufacturers data and recommendations. The design
shall be based on
the maximum loading due to uniform live load and /o
r equipment loading
including impact, vibrations etc.
1.1.4.3
Wherever applicable, seismic forces & wind forces s
hall be considered
according to the provisions of IS: 1893 (Part 1
) 2002, IS: 1893
1984 and IS:875-1987.
1.1.4.4
Design of structures shall provide for temporary ma
intenance of plant
and equipment. Consideration shall be given in the
design of structures to
the contributing loads form piping and cabling incl
uding provisions for
piping anchors and dead ends of electrical conducto
rs.
1.1.4.5
In case of moving loads, full load under worst oper
ating condition
together with minimum 25 percent vertical impact fa
ctor shall be
considered for vehicles and machinery travelling /
mounted on tracks
(rails). Horizontal forces along and transverse to
the rails as per
equipment manufacturers data and recommendations s
hall be considered
in design of the track supporting structures and fo
undations.
1.1.4.6
The design of buildings and structures shall take i
nto account the
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loadings due to future extension of units and insta
llation of additional
equipment, where necessary, in future in the units.
1.1.5
Permissible Stresses
Allowable stresses for all reinforced concrete stru
ctures shall be as per
IS: 456 2000.
1.1.6
Soil Conditions
Soil investigation & survey for the areas under con
sideration shall be
carried out through separate package.
The preliminary report / results of tests on sample
s shall be made
available to the Bidders during Tender Discussions.
1.1.7
Foundations
1.1.7.1
The foundation for structures and equipment shall b
e proportioned to
resist the worst conditions of loadings and shall b
e generally designed as
per the provisions of IS: 1904 1986.
1.1.7.2
Equipment requiring special foundations as a result
of dynamic,
unbalanced forces, shall be designed as per IS: 297
4 (Part-1) 1982,
(Part-3) 1992 & (Part-4) 1979. The contractor i
s required to design
and construct such foundation free of objectionable
resonance, vibration
or rocking. In the event that such equipment is ins
talled above ground
level, the supporting structure and foundation shal
l be investigated also
for natural frequency and designed properly to avoi
d resonance and
amplitude shall be within allowable limits as speci
fied by equipment
Manufacturer.
1.1.7.3
Selection of type of foundation shall be based on t
he recommendations of
soil investigation & survey report, supported loads
, system requirements
and site constraints.
1.1.7.4
The design, construction & testing of RCC pile foun
dations shall be in
accordance to the provisions of latest relevant IS:
2911.
1.1.7.5
For open foundations, the depth of foundation shall
be determined based
on loading on foundations and bearing capacity at t
he founding level,
constructional and technological requirements. Howe
ver, in no case shall
be the foundation is taken down to less than 600 mm
below natural
ground level in case of soil and 200 mm in case of
rocky strata.
1.1.7.6
However in no case foundation shall be placed on th
e filled up soil
and the depth of the foundation shall be taken upto
the depths where
the virgin soil strata /HDR is found
.
Extra depth shall be filled with
PCC M5B
1.1.8
Requirements of Durability
1)
This shall be as per the provisions of IS: 456-2000
. (Clause 8.2).
2)
In general, the exposure condition shall be Moderat
e for normal
type of structures (open foundations and production
buildings) and
shall be severe for underground cellars, water-reta
ining structures
etc. Moreover, as per the recommendations of soil i
nvestigation
report, other harsher environmental conditions shal
l be considered
as per the aggressiveness of the soil / ground wate
r.
3)
The minimum cement content, maximum water cement ra
tio and
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UPGRADATION OF BF-1 PAGE 4 of 37
minimum grade of concrete shall be as per Table 5 o
f IS: 456-2000
for different exposure conditions.
4)
The requirement of fire resistance shall be as per
IS: 1641 1988
and as per Clause 21 of IS: 456 2000. The members
shall be
designed for fire resistance for a period of 2 hrs.
(Refer Fig. 1 of IS:
456 2000)
5)
The crack width for underground cellar type structu
res shall be
restricted to 0.2 mm and for water retaining struct
ures to 0.1 mm.
1.1.9
External Cladding, Internal Partitions & Finishes
1.1.9.1
This section deals with cladding, internal partitio
ns and finishes for
production buildings and associated ancillary and a
uxiliary buildings.
1.1.9.2
External cladding shall be constructed of brick mas
onry. The thickness of
brick masonry walls shall be minimum 230mm. Design
of masonry walls
shall conform to IS: 1905 1987.
1.1.9.3
Cement sand mortar shall be 1:6 for external walls
having minimum
thickness of 230mm and also for brick work in prote
ction walls to
waterproofing membrane in tunnels, basements etc.;
for walls of
thickness 110mm mix shall be 1:4 with HB wire netti
ng reinforcement at
every third layer.
1.1.9.4
All brick and rubble masonry walls shall be plaster
ed on both sides.
Thickness of plaster shall be minimum 20mm for exte
rnal surfaces and
15mm for internal surfaces of walls. Thickness of p
laster for ceiling shall
be upto 10 mm.
1.1.9.5
Cement sand mortar mix for all plasters, shall be 1
:4.
1.1.9.6
All outside plastered surfaces of masonry walls sha
ll be applied with
weatherproof paint of approved make and quality and
to be applied as per
manufactures specification.
1.1.9.7
Inside surfaces of masonry walls shall be treated w
ith white wash/colour
wash or acrylic emulsion paints of approved quality
, make and colour, or
to be tiled as the case may be, on the basis of tec
hnological and/or
aesthetic requirements. Necessary surface preparati
on shall be done prior
to application of paints.
1.1.9.8
Depending on technological considerations, walls of
some premises may
be made of reinforced concrete and finished appropr
iately.
1.1.10
Floors and Floor Finishes
1.1.10.1
In general, all floors on ground except in areas li
ke offices and toilets,
shall be made of minimum M15 reinforced concrete of
150mm minimum
thickness. However, for the production buildings, t
he design of floor
shall be done taking into consideration technologic
al requirements,
imposed loading and other service conditions etc.
1.1.10.2
The sub-grade below the floor slab shall be minimum
250 mm thick
stone boulder soling blinded with moorum. Building
paper shall be
provided on top of sub-grade before casting the con
crete slab.
1.1.10.3
All sub-grade shall be laid on compacted earth.
1.1.10.4
In specific areas of production buildings where con
crete floor is not
required at ground floor level, the flooring shall
consist of minimum
250mm thick compacted stone boulder soiling with mo
orum blinding.
1.1.10.5
Floor finishes for the production buildings shall b
e provided according to
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technological and functional, service and duty requ
irements and as per
manufacturers instruction where applicable.
1.1.10.6
Anti skid / glazed tiles in the floor of offices &
toilets shall be provided
as per approved make, shade & manufacturers specif
ications.
1.1.11
Water-Proofing and Damp-Proofing
1.1.11.1
All underground structures and water retaining stru
ctures shall be water-
proofed with by injections of non-shrink polymeric
water proof grouting
compound from inside as per approved manufacturers
specification.
1.1.11.2
The roof of all buildings which are open to sky sha
ll be applied with
4mm thk. APP (Atactic Polypropylene modified plasto
meric bitumen
based membrane with polyester fibre reinforcement a
nd mineral finish)
over the screed concrete laid in slope as per manuf
acturers
specifications.
1.1.11.3
All other water proofing & Damp-Proofing works shal
l be strictly in
accordance with IS:3067-1988 unless otherwise state
d elsewhere in this
document
.
1.1.12
Drainage
1.1.12.1
All the storm water drainage shall be laid in servi
ce aisles close to the
road. Crossings with other services shall be kept t
o a minimum. Where
the new lines are to be connected to the existing o
nes, the contractors
shall carry out the required interconnections.
1.1.12.2
Generally minimum earth coverage of one meter shall
be provided over
underground drainage pipelines unless the same is p
rotected by concrete
encasing for otherwise and adequately designed for
the imposed loads
from soil, water, operational and construction traf
fic.
1.1.12.3
RC pipes of class NP2 of IS: 458 1988 shall be us
ed for diameter
ranging from 300mm to 1200mm and beyond that box dr
ains shall be
provided. However, pipes under road/rail crossings
shall conform to class
NP3 and NP4 respectively of IS: 458 1988.
1.1.12.4
The material used for jointing of underground pipes
shall be such as to
make the joints watertight for preventing ingress o
f sub-soil water by
infiltration and escape of inside matter to the sur
rounding areas. In this
connection IS: 783 1985 for drainage shall be ref
erred to.
1.1.12.5
Relevant provisions of IS: 1172 1993, IS: 1230
1979, IS: 458 1988,
IS: 783 1985 and IS: 1742 1983 and other releva
nt Indian standards
shall be applicable for the design of the system.
1.1.13
Storm Water Drainage
1.1.13.1
The design of storm water drainage system shall be
based on maximum
hourly precipitation for a storm of duration of 20
minutes. Roof drainage
system shall be designed on the basis of an hourly
precipitation for storm
duration of 5 minutes.
1.1.13.2
Gully, traps, inspection pits, junction pits, colle
cting pits etc. as well as
other facilities shall be located suitably and desi
gned considering easy
access, maintenance and safety.
1.1.13.3
For the purpose of calculation of run-off from catc
hments area of any
drainage line, the contractor shall estimate areas
of buildings, paved area,
roadways, parking areas and open areas within tree
catchments area.
Run-off coefficients for design shall be as follows
:
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a)
Open areas : 0.50
b)
Roads and paved/parking areas : 0.70
c)
Roof surface : 1.00
1.1.14
The pipes shall be so designed as to give a velocit
y of flow not less than
one metre per second when running half full. The ma
ximum velocity
shall not exceed 2.5m per second.
1.1.15
Metal Doors, Windows, Ventilators & Rolling Shutter
.
All doors, windows, ventilators & rolling shutter s
hall be provided based
on functional, system & safety requirements. For no
n-standard & air tight
metal doors, bidder shall submit the detail drawing
s with schedule of
materials. For standard sizes, the steel doors shal
l be provided as per
provisions of IS:1038-1983. For rolling shutters pr
ovisions of IS:6248-
1979 shall be followed. For steel and aluminium win
dows, IS:1361-1978
& IS:1949-1961 shall be followed. For glazing of me
tal doors, windows
& ventilators, IS:1081-1960 shall be followed.
1.1.16
Paved Areas
1.1.16.1
All service and utility lines crossing under the pa
ved areas shall be taken
through concrete pipes/ ducts and designed for impo
sed loading. Number
of such crossings shall be kept to a minimum.
1.1.16.2
All paved areas shall be with flexible type of cons
truction. Thickness of
different layers of materials shall be adequate for
traffic intensity and
imposed loading. Generally the thickness of differe
nt layers to be
provided shall be as follows :
Sub-base 150mm thick consolidated moorum filling on

compacted soil
Base 250mm thick boulder soling blinded with
moorum
Water bound
Macadam (WBM)
150mm thick water bound moorum above
base
1.1.16.3
Surface storm water from the roadways shall be drai
ned by provision of
drain network.
1.1.16.4
Sufficient areas shall be paved around plant buildi
ngs so as to facilitate
parking of vehicles. Paved areas shall have same ty
pe of construction as
roads and the top level shall be flushed with crown
of the connecting
roadways with a cross slope of approximately one pe
r cent.
1.1.16.5
Around all plant and ancillary buildings minimum 15
00mm wide
concrete apron shall be provided.
1.1.16.6
For Road works, DBM shall be provided as per MORTH
specifications.
1.1.17
Survey Work
1.1.17.1
The surveying shall be done in the areas within the
battery limits
.
Additional information such as the layout of existi
ng facilities , Roads,
pump house, various buildings, shops, sheds, Bench
Mark Locations
(along with its value) manhole locations, trestle s
upport location,
pipelines etc., within the battery limits & 15m bey
ond the boundary
limits shall also be indicated. Survey drawings sha
ll be prepared to show
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the location of the existing buildings / equipments
/ trestles, towers, units
etc.
1.1.17.2
The surveying shall be done by modern three dimensi
onal
technological equipment ,Total Station or equivalen
t and data shall
be downloaded from the same and necessary survey ma
ps/ drawings
shall be prepared both in digitized and Auto CAD fo
rm in 2D (i.e Z
coordinates shall be zero for each entity).
1.1.17.3
The level of all the overhead lines (pipes and cabl
es, if any) shall also be
indicated. While measuring the exact level of the o
ver head lines, if due
to safety consideration the measurement is not poss
ible / feasible; the
tentative location with approximate location of the
same shall be
indicated in the Survey Drawing.
1.1.17.4
The location and level of the existing Culverts/wat
er cross-over and the
existing cable tunnel / pipe lines in the area shal
l also to be surveyed and
indicated in the drawing. For this available existi
ng drawings shall also
be referred.
1.1.17.5
At least three permanent bench mark statue at suita
ble location within the
plot shall be established & constructed for each si
te. Determination of the
bench mark elevations with reference to the existin
g bench mark and
determination of plant north with respect to magnet
ic north shall be done
and marked hereby on the permanent benchmarks..
1.1.17.6
Determination of the location & elevation of all ex
isting features inside
the area marked in the layout drawings and as direc
ted by Engineer.
1.1.17.7
In addition to permanent benchmark local bench mark
s/co-ordinate
pillars at suitable places shall be constructed. Th
e co-ordinates & spot
level shall be painted on the top of each of this b
ench mark respectively
.
1.1.17.8
Pedestals for Permanent Bench Marks of 1.0m height
from proposed
Finished Ground Level; shall be constructed in RCC
with top MS plate &
Steel Peg. The direction & coordinates of two ortho
gonal axes shall be
punched on the MS plate fixed at top of concrete pe
destals. The level of
top of MS peg shall be painted on the pedestals. PC
C Apron of atleast
500 mm width all around the concrete pedestal for p
ermanent bench
mark shall be provided along with barbed wire fenci
ng supported on MS
angles.
1.1.18
Design Calculations, Drawings And Documents
The design calculations shall be submitted by the c
ontractor for approval,
prior to submission of construction drawings shall
include but not be
limited to, the following.
1.1.18.1
Geotechnical / confirmatory works
The methodology, bore logs, testing procedures and
results of all
geotechnical investigation / confirmatory works sha
ll be submitted to
Purchaser for reference.
1.1.18.2
Building structure and foundation design
a)
The design calculations for all the buildings and f
oundations
including cellars, basements, water retaining struc
tures,
equipment foundations, tunnels, miscellaneous struc
tures, all
miscellaneous equipments foundations etc. The desi
gn
calculations shall include static design calculatio
ns for all
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structures and foundations, dynamic analysis for al
l important
structures and foundation subjected to impact, vibr
ations etc.
induced by equipment and other external forces,
b)
Building data shall include specifications of mater
ials, design
standards followed, load data assumed including the
loading
on roof, walkways, different floors, bulk material
density,
crane and hoist loading, wind and seismic loading,
wind
thrusts and vibration considerations, deflection, r
ainfall and
run-off data assumed and type of frame work etc. Al
so, type
of flooring, roofing and sheeting and type of const
ruction to
be indicated. The loading combinations and other
assumptions made in the design are to be furnished.
c)
Methods to be followed for (a) waterproofing, (b) c
orrosion
resistance, (c) thermally insulation of the superst
ructure,
foundation, underground cellars, basements, tunnels
shall be
mentioned etc.
d)
Measures required for the safety of the buildings a
nd
foundations shall also be given.
1.1.18.3
Drawings
a)
The contractor shall prepare general layout drawing
s giving
salient levels and dimensions of the whole area sho
wing all
over ground and underground services and facilities
,
buildings, roadways, railways etc. provided for co-
ordination
with the other areas of the plant. Detailed working
drawings
shall be prepared on the basis of the general layou
t drawings
considering overall foundation layout for the equip
ment,
building, services, etc. space requirement and clea
rances as
necessary. The contractor shall submit a comprehens
ive and
complete unit wise classified list of drawings in r
eproducible
form/softcopy.
b)
The Contractor shall submit for approval / referenc
e of the
Purchaser general arrangement and detailed working
drawings for all concrete, reinforced concrete and
other civil
work, as follows:
i)
Area Survey Drawings
ii)
General Layout of the new facilities / units
iii)
General arrangement of all new facilities / units
iv)
Excavation drawings
v)
Foundation plans and sections for building
columns and equipment incorporating services
/utility tunnels, trenches, pipes etc.
vi)
Loading drawings indicating superstructure
loading, equipment loading, floor loadings, etc.
vii)
Comprehensive anchor hole plan along with
complete details of anchor bolts and anchor
pockets for foundation for building columns and
equipment etc. including schedule for bolts and
anchor plates. Design of anchor bolts should be
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such that it should be possible for any
replacement of the same in future, if required.
viii)
Reinforcement details with bar bending schedules
for all reinforced concrete works.
ix)
Drawings for all types of bolts, inserts,
embedments, covers, miscellaneous steel works
etc.
x)
All drawings for masonry work, flooring, floor
finishes, partitions, etc.
xi)
Underground / over ground storm water drainage
drawings for areas and buildings within the
battery limit.
xii)
Drawings for paved areas / Roads as required.
1.1.18.4
The design criteria mentioned above is not exhausti
ve. However, the
same shall be discussed and detailed during detail
engineering stage
1.2
WORKMANSHIP & MATERIAL SPECIFICATION
1.2.1
General
1.2.1.1
Local conditions
The Bidder, before submitting his tender, shall vis
it the site and ascertain
the local conditions, labour rules, availability of
construction materials,
traffic restrictions, and all obstructions in the a
rea and also ascertain all
site conditions including the sub-soil conditions a
nd shall allow for any
extras likely to be incurred due to all such condit
ions in his quoted prices.
After the award of work no additional claims will b
e entertained on these
accounts under any circumstances, whatsoever, from
the Bidder.
1.2.1.2
Setting out and levelling
The Bidder shall set out and level the work and wil
l be responsible for
the accuracy of the same. He is to provide all inst
ruments and proper
qualified staff with labour for getting his work ch
ecked by Engineer, if so
desired by the Engineer. Such checking, if any, sha
ll not, however,
relieve the Bidder in any way, of his responsibilit
y for correct setting out.
1.2.1.3
Safety
The Bidder shall take adequate precautions to ensur
e complete safety and
preventions of accidents at site and shall be respo
nsible for the same. The
safety precautions shall conform to the safety regu
lations prescribed by
the Safety Code for constructions and relevant Indi
an Standard Codes,
some of which are stated below:
IS 3764-1992 : Safety Code for excavation work
IS 4014-1967 : Safety Regulations for scaffolding w
ork
IS 4081-1986 : Safety Code for drilling and blastin
g
operations
IS 4138-1977 : Safety Code for working with compres
sed air
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IS 7923-1985 : Safety Code for working with Constru
ctions
machinery
1.2.1.4
Keeping work free from water
The Bidder shall provide and maintained at his own
cost, pumps and
other equipments to keep the works free from water
and continued to do
so until the handing over of the works
1.2.1.5
Rubbish
The Bidder shall keep the site clear on a continuou
s basis of all rubbish
etc. which may arise out of the work executed by hi
m and dispose them
suitably in allotted areas.
1.2.1.6
Bench Marks, Reference Pillars etc.
The Bidder shall protect all bench mark, and refere
nce pillars /lines
including ground water gauges from damage or moveme
nt during
working. In case of any damage the Bidder shall hav
e to restore the same
to its original condition at his own cost.
1.2.1.7
Standards
Unless otherwise mentioned in the specifications, a
ll applicable codes
/standards as published by the Bureau of Indian Sta
ndards on the date of
award of contract shall governed the work in respec
t of design,
workmanship, quality and properties of materials, m
ethod of testing and
other pertinent features. In case of variance betwe
en this specifications
and IS Codes /Standards, the provisions of this spe
cification shall prevail
upto the extent of such variance.
1.2.2
Dismantling Work
1.2.2.1
No dismantling work shall commence without prior ap
proval of
Purchaser on the dismantling plan prepared by the B
idder.
1.2.2.2
The successful Bidder will have to arrange all type
s of equipments for
carrying out the dismantling work satisfactory incl
uding hire charges &
running charges with all labour, tools, tackles etc
. complete as per
direction of Engineer & I/c.
1.2.2.3
The structures shall be dismantled with due care so
that no structure &
equipments are damaged. If the same gets damaged th
en successful
Bidder have to change/modify/strengthen the items w
ithout any extra
cost. Care shall be taken during dismantling so tha
t maximum quantity of
dismantled material can be reused.
1.2.2.4
Care shall be taken to maintain the stability of re
tained structures for
which necessary structural supports are to be provi
ded without any extra
cost.
1.2.2.5
The Successful Bidder shall assess the entire disma
ntling work
independently and decide accordingly the resource t
o be deployed by him
so that the work can be executed in the stipulated
time frame.
1.2.2.6
The Successful Bidder shall obtain the necessary cl
earance certificates
from Safety department of the Plant for the arrange
ment of dismantling
work at every stage.
1.2.2.7
All debris collected due to dismantling shall be tr
ansported and disposed
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off as per direction of Engineer-In-Charge.
1.2.2.8
All serviceable material shall be stacked and trans
ported to designated
place within a lead of 10 Km including unloading &
stacking.
1.2.2.9
The stacking shall be done for various categories o
f dismantled items.
Such categorisation shall be worked out in consulta
tion with engineer in
charge.
1.2.2.10
Dismantling of structures including sheeting shall
be done preferably in
such a way that the items are easily identified and
can be modified and or
re-erected at the new location. The dismantled item
s which are not to be
re-used shall be cut in such pieces, sizes & length
s which will facilitate
easy transportation and disposal of those items to
dumping yard /storage
yard.
1.2.3
Excavation and Back Filling
1.2.3.1
Stripping
The Bidder shall strip the surface of the site prio
r to the commencement
of excavation to remove vegetable soil and carry su
ch soil to separate
spoil dumps in the allotted site/areas.
The Bidder shall not remove any
tree without permission of the Engineer
.
1.2.3.2
Excavation for foundations and Trenches
a)
The Bidder shall excavate at various levels includi
ng hard
rock to remove materials of any nature or descripti
on, which
may be encountered. Side slopes, benching and/or
shoring/strutting for excavation work shall be sole

responsibility of the Bidder. The bed of the excava
tion shall
be properly dressed and made level. All mud and slu
sh shall
be removed before taking up concreting work. The la
st 150
mm of excavation shall be done just prior to laying
of
concrete. The excavated materials shall not be plac
ed within
1.5 m from the edge of any excavation. The Bidder s
hall take
suitable precautions to prevent ingress of water in
to the
excavated areas during construction.
b)
The Bidder shall account for all excavated rock, if
any. He
shall stack excavated rock and if the Bidder for hi
s works
requires serviceable boulders, it may be issued bas
ed on stack
measurement less 40% for voids at the rate to be de
cided by
the Employer.
c)
The surplus excavated materials and excavated unser
viceable
materials from rock excavation shall be transported
and
disposed off by the Bidder in spoil dumps or fill a
reas as
directed by the Purchaser.
d)
If the Bidder excavates to levels lower than those
shown on
the drawings, he shall fill up such extra depth at
his own cost
to the proper level with lean concrete of grade M-1
0B.
e)
Should the bottom of any excavation appear to be so
ft,
unsound or unstable, the Bidder shall excavate the
same to
required depths and the extra depth shall be filled
up by the
Bidder with lean concrete of grade M-5B.
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f)
The Bidder shall take all precautions against slips
and falls in
the excavation. No extra payment will be made for r
emoval
of slips and for back filling the space with materi
als as
directed by the Purchaser.
g)
The excavation shall be kept free from water by pum
ping. In
small pits water may be bailed out with buckets. Pu
mping of
water shall be carried out either directly from the
excavation
or from sumps made outside the excavation as direct
ed.
Adequate care shall be taken to prevent movement of
water
through freshly laid concrete or masonry work.
h)
If any excavation for foundation gets filled up wit
h water due
to rain, seepage or for any reason, the water shall
be removed
and bottom of the excavation shall be completely cl
eared of
all silt/slush by the Bidder at his own expense.
i)
All water pumped or bailed out during de-watering o
f pits
and trenches shall be disposed off suitably through
properly
laid channels or pipes. Disposal of water shall be
carried out
in such a way that no inconvenience or nuisance is
caused to
the work in progress in the area or to other agenci
es working
in the area or cause damage to property and structu
res nearby.
1.2.3.3
Back Filling
a)
Materials
Suitable materials obtained from excavation of foun
dations
shall be used as far as possible for back filling.
Earth used for
filling shall be free from organic and other object
ionable
matter. All clods of earth shall be broken or remov
ed. If
sufficient amount of suitable materials are not ava
ilable at
site to complete filling work, then earth shall be
brought to
site from outside by the Bidder as directed by the
Purchaser
at his own cost.
b)
Filling around foundations with earth
Before commencement of back filling, the Bidder sha
ll
remove from the space around foundations all accumu
lated
water and slush, shoring and formwork, all debris,
brickbats,
bits of timber, cement bags and all other foreign m
aterials.
Filling shall be carried out in uniform horizontal
layers, each
layer not exceeding 200 mm in thickness. Each layer
shall be
watered, rammed, and thoroughly compacted before th
e next
layer is deposited.
c)
Plinth filling and special compaction with earth
Plinth filling or filling where special compaction
is required
shall be carried out in uniform horizontal layers,
each layer
not exceeding 150 mm in thickness. Each layer shall
be well
watered and compacted by mechanical means. The Bidd
er
shall take core samples for each layer, determine t
he dry
density and maintain logs. The minimum dry density
to be
achieved shall be 95% of maximum dry density as obt
ained
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by Standard Proctor Test. Tests shall be conducted
by the
Bidder as directed by the Purchaser at his own cost
.
d)
Removal of heaps & Mounds
Immediately upon completion of each phase of work,
the
Bidder shall at his own cost clear the mounds or he
aps of
earth which may have been raised or made and remove
all
earth and rubbish which may have become surplus in
the
execution of works, as directed.
e)
Filling with sand
Filling with sand shall be carried out in uniform h
orizontal
layers, each layer not exceeding 200 mm in thicknes
s with
approved river sand and each layer to be watered an
d
compacted mechanically to a well compacted mass.
1.2.4
Pile and pile foundation
1.2.4.1
The material, workmanship, construction & testing o
f RCC pile
foundations shall be in accordance to the provision
s of latest relevant
IS:2911
1.2.5
Plain & Reinforced Concrete Work
1.2.5.1
Materials
a)
Cement
Cement: Ordinary Portland cement shall conform to I
S:269-
1989 / IS 8112-1989 and Portland blast furnace slag
cement
shall conform to IS:455-1989. Soundness test is to
be carried
out on cement samples from time to time. Frequency
of these
tests shall be increased during monsoon period.
b)
Aggregates
All aggregates shall conform to IS:383-1970. Test o
n
aggregate shall be carried out from time to time to
ascertain
the suitability of the aggregates.
c)
Reinforcement
Reinforcement in general shall be of tested quality
. TMT bars
conforming to IS:1786-2008 & shall be free from oil
paint
and rust coatings. However, IRC mesh fabric reinfor
cement
conforming to IS:1566-1982 can also be used if spec
ifically
required and shown in the drawings. The binding wir
e shall
be 20 SWG approved annealed iron wire.
d)
Shuttering
The material for shuttering shall be steel plates a
s per
IS:2062-2006 or wooden planks as per the requiremen
t.
e)
Jointing materials
All rubber and PVC water stops joint fillers, seali
ng materials
etc. used in concrete work shall be of standard man
ufacture
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as per relevant IS codes. Usage of these materials
shall be in
accordance with the manufacturer's instructions.
f)
Admixtures
Admixtures, if required, to be used shall be of app
roved
quality and make and shall conform to relevant IS c
odes.
g)
Water
Water shall be clean and of potable quality as per
clause 5.4
of IS:456-2000.
1.2.5.2
Workmanship
a)
Concrete
i)
Production and control of concrete shall be as per
IS 456-2000. The Bidder shall at his own cost,
grade the aggregates and control the water cement
ratio, design the different mixes to required
strength and workability. The designed mix shall
conform to the requirement of IS 456-2000 and
recommended guidelines in SP: 23-1982. All
concrete shall be machine mixed, and no hand
mixing shall be permitted.
ii)
The maximum size of aggregates used shall be as
indicated in the drawings and IS:456-2000.
iii)
Where nominal mixed concrete as defined by
IS:456-2000 is permitted by the Purchaser for any
specific reason, the proportion of the materials
shall be as indicated in IS:456-2000.
b)
Mixing
Except where nominal mix concrete as defined in IS
456-
2000 is permitted by the Engineer to be used, all c
omponents
of concrete shall be proportioned by weight using w
eigh
batches for each grade of concrete. Mixing shall be
carried
out in mechanical mixers and preferably a batch mix
ing plant
shall be used. Batches shall not exceed the capacit
y, which
can be mixed efficiently as determined by the mixer

efficiency test, and peripheral speed shall conform
to the
manufacturer's recommended rate but should not vary
by
more than 10%. Mixing shall continue until the mas
s is
uniform in colour and consistency but in no case ne
t
minimum mixing time shall be less than 1.5 minutes.
Net
minimum mixing time shall begin when all ingredient
s
including water is in the mixer. Excessive mixing s
hall be
avoided. Mixers shall be operated only by trained o
perators.
Weigh batches shall be placed level during use and
the
hoppers shall be loaded evenly.
c)
Consistency
Consistency of concrete shall be controlled as per
IS:456-
2000 and the Bidder shall carry out slump tests in
accordance
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with IS:1199-1959.
d)
Work tests
Over the full period of construction, the Bidder sh
all carry
out works tests of concrete cubes at his own cost.
Sampling,
making up, curing and testing of specimen shall con
form to
IS:456-2000, IS:516-1959 and IS:1199 -1959. The num
ber of
specimen & the frequency of tests shall be in accor
ding to
IS:456-2000.
e)
Reinforcement
i)
Workmanship shall conform to IS:456-2000 & IS
2502-1963.
ii)
Reinforcement bars shall be placed and
maintained accurately in the position as shown in
the drawings. The correct cover to the
reinforcement shall be maintained by use of pre-
cast concrete blocks.
iii)
All intersections of longitudinal and transverse
bars of stirrups and all laps shall be securely tie
d
together with approved binding wire in
accordance with IS:2502-1963.
iv)
Welded joints shall be strictly in accordance with
IS:456-2000.
f)
Embedments
i)
All embedment shall be accurately set and rigidly
fastened. Anchor bolts shall be set to template
and firmly secured in vertical and horizontal line
at required positions. Water stops shall be secured

against displacement during the placing of
concrete. The joints for G.S. sheet water stops
shall be soldered watertight and those of PVC and
rubber shall be joined by cementing and
vulcanizing. Expansion joint fillers shall be for
the full depth of slabs or full width in walls and
shall be cemented with bituminous cement
against previously placed concrete. The ends shall
be butted tight and the upper edge set flush with
finished slabs.
ii)
Anchor holes and anchor bolts shall be protected
by covering suitably with brickwork in lean
cement mortar after thorough cleaning.
g)
Placing of concrete
i)
Transporting concrete
Concrete shall be transported from the mixing
plant to the forms as rapidly as possible by means
that will prevent segregation or flash set in the
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concrete during hot weather. The containers shall
be such as to prevent large evaporation. At the
time of placing concrete in very hot weather, care
shall be taken to see that the temperature in wet
concrete does not exceed 38C. Before placing
the concrete, all formwork, embedment and
reinforcement shall be checked for completeness,
location, dimension, square and plumb. All chips
and sawdust or other foul matter shall be removed
from within the forms. The base surface shall be
well moistened and puddles wiped out. Placing
equipment and accessories shall be kept clean and
free of partially set grout and concrete, and
maintained in proper working order. Suitable
walk cradles shall be placed over the
reinforcement when the concrete is placed by
manual transportation.
ii)
Placing
Concrete shall be placed within a maximum
period of 25 minutes of its removal from mixer.
No concrete shall be placed until the place of
deposit has been inspected and approved by the
Engineer. In general, placing shall be direct, by
transporting buckets. Where it is necessary to
deposit the concrete at level differences of more
than 1.5 m, short chutes shall be used. Short
chutes and hoppers shall be so designed and
installed that segregation will not take place. In
cases where chutes are impracticable due to
excessive drop to placing level, hoppers and
sectional tubes (elephant trunks) shall be used.
Concreting in open shall not be allowed during
rains unless all precautions have been taken by
the Bidder and permission has been given by the
Engineer.
a)
Construction joints
Construction joints shall be provided as per provis
ions of
IS:456-2000 & IS:3414-1968.
b)
Expansion joints
Expansion joints shall be provided as per provision
s of
IS:456-2000 & IS:3414-1968.
c)
Compaction
Concrete in general shall be consolidated by vibrat
ion using
high frequency mechanically driven vibrators. Concr
ete shall
be placed in layers at least 300 mm deep in walls a
nd
approximately 450 mm in mass pours. Vibrators shall
not
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penetrate more than 50 mm into the surface of previ
ously
placed layer but shall completely vibrate the worki
ng layer.
Care shall be taken not to over vibrate any concret
e and
especially those with higher slumps. Under no circu
mstances
vibrator shall be attached to or allowed to touch
reinforcement. Spare vibrators in good operating co
ndition
shall be in hand during placing operations.
h)
Curing and protecting
Curing of concrete with water shall comply with IS:
456-
2000.
i)
Repairing and patching
Pockets honey combing and other defects, which may
be
formed due to segregation, improper vibration and a
ny other
reason whatsoever shall be completely repaired to t
he
satisfaction of the Engineer. The voids, if any, sh
all be
properly keyed and reinforced, if necessary. The fa
ce shall be
tightly formed and arranged for providing a head in
the
concrete. The cavities shall be filled with the sam
e concrete
as used for the structure and thoroughly rodded or
vibrated
where possible. The filled hopper shall be left in
place until
shrinkage has taken place and the concrete sets suf
ficiently to
stay in place. While still `alive', the upper part
of form hopper
shall be removed and excess concrete struck off and
finished
with wooden flat or trowel to match existing concre
te. Any
fins or unsightly grout runs or bulges shall be rem
oved from
the surfaces exposed to view. The rod holes shall b
e finished
with cement or grouted to match the existing surfac
e as
closely as possible. No cement wash shall be used u
nless
particularly called for in the drawings.
j)
Tolerances
Tolerance is a specified permissible variation from
lines,
grades or dimensions given in drawings. Tolerances
shall be
as per provisions of IS:456-2000 or as specified fo
r the
system, whichever is minimum.
1.2.6
Grouting Bases of Machine, Columns, Foundation bolt
s, etc.
1.2.6.1
Level pads
For preparing the level pads, the top of the founda
tion concrete shall be
chipped off to remove laitance formed on the concre
te surface, and all
loose materials shall be thoroughly cleaned and the
surface is wetted
before the grouting. In case level pads are constru
cted they shall be of
cement concrete with one grade higher than the moth
er concrete with
6mm nominal size stone aggregates in conformity wit
h the grouting
requirements with 6 mm size ballast. The top of the
level pads shall be
finished & fine and true to level.
1.2.6.2
Grouting:
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a)
Cementatious grout of minimum grade M-30 with 10mm
&
down coarse aggregate shall be used for grouting th
e
structural steel column bases.
b)
For grouting of equipment bases, High strength, non
-shrink,
free flow, ready-mix grout of approved manufacturer
shall be
used.
c)
Before placing the grout, the concrete surface shal
l be
thoroughly cleaned, preferably with compressed air
and the
surface shall be thoroughly wetted with water for s
everal
hours. Grout concrete shall be of non-shrink strand
ed ready
mixed cement-based grout of approved make as per it
em of
work/drawing. The grouting shall be prepared and pl
aced as
per manufacturers instructions. Before placing the
grout all
free water shall be removed and the flat surface sh
all be
coated with thin cement slurry.
d)
The quantity of mixing water shall be minimum
commensurate with the workability, compaction, and
filling
of the grout in all corners and crevices. The grout
shall be
evenly spread and compacted by rodding or a vibrato
r until
the whole of the space is completely filled with co
ncrete. The
grout shall be carefully observed for initial settl
ement. If any
settlement is observed, further grout is to be pour
ed and
rodded.
e)
For base plate having ribs underside the base plate
, proper
care is to be taken to ensure filling of the caviti
es between the
ribs.
f)
In case of wide base plates or bedplates having rib
s
underside, it may be necessary to do pressure grout
ing.
g)
Non-shrinking grout:
Non-shrinking grout where required shall be used in

accordance with the method specified by the manufac
turer.
Material shall be as approved by the Engineer.
1.2.7
Form Work
1.2.7.1
Shuttering For Concrete
a)
The term `shuttering' shall include all centering a
nd form
work required to support the concrete during the pr
ocess of
laying, compacting and setting and all items such a
s planking,
lagging, walling, moulds, covers, cross bearer, str
uts, props,
bracing, etc., shall be covered by the term `shutte
ring'.
b)
Shuttering shall be strong and constructed rigidly
so that
there shall not be any deformation under weight and
pressure
of wet concrete, constructional loads, wind and/or
other
forces. It shall be constructed in such a manner th
at it can be
easily removed afterwards.
c)
Devices shall be provided in the shuttering for for
ming
openings, holes, pockets, chases, recesses etc., wh
erever
required.
d)
Cutting of holes etc. in the concrete after casting
shall be
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avoided. Corner fillets shall be provided in the fo
rmwork to
obtain chamfered edges to beams, columns, etc. wher
ever
required.
e)
All Shuttering / form work & its removal shall conf
orm to
IS:456-2000.
1.2.7.2
Supports
Props or Supports shall be provided as per IS:456-2
000.
1.2.7.3
Setting
Panels and units shall be set to true dimensions an
d alignment and rigidly
tied, walled and braced to prevent distortion and d
isplacement during
concreting and shall confirm to the provisions of I
S:456-2000.
1.2.7.4
Ties
Standard form ties, clamps, bolts, inserts etc., sh
all be of adequate
strength. Spreader, either removable or embedded ty
pe, shall be used to
maintain the wall thickness in accordance with prov
isions of IS:456-
2000.
1.2.7.5
Cleaning and treating of forms
All rubbish shall be removed from the interior of t
he formwork, and
inside of the formwork shall be wetted with water b
efore commencing
the concreting strictly in accordance with IS:456-2
000.
1.2.8
Pre-Cast Concrete Work
1.2.8.1
General
The formwork and/or mould for Pre-cast concrete uni
ts shall be made of
metal and true to shape and dimension of the finish
ed product as
indicated on the drawings. The moulds shall be clos
e jointed and
perfectly smooth with joints caulked to prevent lea
kage of cement slurry.
The moulds shall be of rigid construction to preven
t distortion and
bulging of sides and base. The moulds shall be desi
gned with suitable
fastening to allow them to be struck off without in
jury to the casting. The
moulds shall generally be vibrated on a mechanicall
y operated vibrator.
1.2.8.2
Marking of units
All pre-cast members shall be marked in a manner ap
proved by the
Engineer in a conspicuous place, with date of manuf
acture and marking
number. The upper part of the member shall be marke
d distinctly for
proper handling.
1.2.8.3
Erection
Erection of pre-cast units shall be carried out as
per the approved
sequence.
1.2.9
Mortar for Masonry & Plaster Work
1.2.9.1
Materials
a)
Cement
Cement used shall conform to IS:269-1989 / IS:8112-
1989 or
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IS:455-1989.
b)
Sand
The sand used shall be of approved quality river or
pit sand
and it shall conform to IS:1542-1992 for plaster an
d to
IS:2116-1980 for masonry mortar. Sand for the morta
r shall
be evenly graded from coarse to fine and shall be f
ree from
loam, clay, dust and any other organic or foreign m
atter.
c)
Admixtures/Plasticisers
Admixtures/plasticiser of approved make and quality
may be
allowed in the mortar, if permitted by the Engineer
.
d)
Water
Water shall be clean and of potable quality.
1.2.9.2
Mortar Proportion
The proportion of cement and sand for mortar shall
be as specified in the
technical specification/drawing.
1.2.9.3
Workmanship
a)
The workmanship shall conform to IS:2250-1981 for
preparation of masonry mortars and to IS:1661-1972
for
plaster.
b)
The cement and sand shall be proportioned by volume
in
gauge boxes and thoroughly mixed dry. The water sha
ll be
added by sprinkler just sufficient to make a stiff
and
workable paste. In case of mechanical mixing, the m
ortar
shall be mixed back and forth for at least 10 minut
es with
addition of water.
c)
Mortars shall be used within one hour of the first
contact of
cement with water. All materials remaining after th
is period
shall be discarded. Mortars, which have started to
set, shall
not be re-tempered.
1.2.10
Brick Masonry Work
1.2.10.1
Materials
a)
Cement Mortar
Cement mortar shall be as specified as per relevant
clause of
this specification
b)
Brick
The brick used shall be of class 5 designation conf
orming to
IS:1077-1992. Brick shall be whole, sound, well bur
nt, and
free from cracks, square and well shaped, uniform i
n size and
shall emit a clear ringing sound when struck. The
compressive strength of brick shall be minimum 5 N/
mm
.
1.2.10.2
Scaffolding
a)
Scaffolding shall conform to IS:2212-1991 and shall
be
designed to withstand the loads and to ensure compl
ete safety
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of workmen and materials.
b)
The scaffolding should be double, i.e. it shall hav
e two sets of
stands to avoid putlog holes. Where this is not pos
sible, the
inner end of the scaffolding poles shall rest in a
hole provided
in a header course only. Only one header for each p
ole shall
be left out. Holes, if provided, shall be filled in
and made
good by the Bidder to ensure that the surface does
not give
any unsightly appearance.
1.2.10.3
Cleaning
The Bidder shall carry out work in as clean a manne
r as possible and
shall remove excess materials and mortar droppings
and rubbish, daily.
Where brick walls and stone masonry are to receive
plaster, the joints
shall be cleaned of excess mortar and raked to a de
pth of 12 mm and the
surface shall be brushed clean.
1.2.10.4
Workmanship
a)
The Bidder shall carry out the whole of the brickwo
rk in a
uniform manner according to IS:2212-1991. All the b
rick
shall be kept under water till they are completely
soaked and
used on the work on their becoming skin dry.
b)
The Bidder shall set out and build all brickwork to
the
dimensions, thickness and heights shown in the draw
ings.
The Bidder shall build all brickwork in English bon
d and half
brick walls and casing to pipes, chases etc. in str
etcher bond.
Brickbats shall not be used except where required f
or bond.
c)
The Bidder shall lay bricks in full mortar beds wit
h shoved
joints. The joints shall not exceed 10 mm in thickn
ess and
shall be full of mortar, close, well finished and n
eatly struck.
The vertical joints in any course shall not be near
er than a
quarter of a brick length from those in the course
below. All
joints shall be of same width except for small vari
ations to
maintain bond. The brickwork shall be laid plumb an
d true to
line and level. No portion of brickwork shall be ra
ised more
than 1.0 m above another at one time. If the mortar
in any
course has begun to set, the joint shall be raked o
ut before
another course is laid. The top most course of bric
kwork
under a reinforced concrete beam shall be wedged ag
ainst
reinforced concrete surface and the joint well fill
ed with
mortar. The Bidder shall flush up all joints thorou
ghly with
mortar as the work proceeds.
d)
The brickwork as it progresses shall be thoroughly
watered
on its faces and top. New work shall be properly bo
nded with
the old work. New surface of unfinished work shall
be
cleaned and thoroughly watered before joining new w
ork to
it.
e)
Walls whose thickness is less than a full brick len
gth shall be
reinforced with wire netting of width equal to that
of the wall
at every third layer. The laying of wire netting sh
all be
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continuous. Wire netting shall be as per IS 3150-19
82.
1.2.10.5
Curing
The Bidder shall keep wet all brickwork for seven (
7) days after laying.
1.2.11
Plaster Work
1.2.11.1
Materials
Mortar for plasterwork shall be as specified as per
relevant Clause of this
specification.
1.2.11.2
Workmanship
a)
All plasterwork shall be carried out according to I
S:1661-
1972. The thickness and proportion of cement plaste
r shall be
as specified in the drawing. Where the thickness of
plaster is
20 mm or more, it shall be done in two operations (
coats).
b)
The surface to be plastered shall be cleaned of all
extraneous
matter and rubbish. Brickwork joints shall be raked
and
concrete surface shall be roughened by chipping or
hacking.
Any shuttering materials adhering to the concrete s
hall be
removed. The surface shall be thoroughly watered an
d
soaked, aerated and all putlog holes shall be close
d before
starting plastering operation. Plaster pads of requ
ired
thickness of plaster for the Bidder shall establish
correctness
of plumb, line and level before starting plasterwor
k.
c)
For one coat plaster work, the plaster shall be lai
d slightly
thicker than the specified thickness and the surfac
e then
levelled with a flat wooden rule to the required th
ickness. The
plaster shall be well pressed into the joints and t
he surface
finished for getting smooth and even surface.
d)
Where two coats plaster work is specified, the firs
t coat shall
be applied as described above except that the surfa
ce shall be
left rough and keys formed for the application of s
econd coat.
The second coat shall be applied a day or two after
the first
coat has set, but the first coat shall not be allow
ed to dry. The
second coat shall consist of mortar ground very fin
e and shall
be laid on with a wooden rule to specified thicknes
s, rubbed
smooth and levelled and the surface plastered compl
etely the
same day. The levelling shall be continued till the
plaster is
dry and all moisture which exudes from the plaster
shall be
wiped out with fine cloth. The surface shall be kep
t dry until
exudation of moisture ceases, during the process of
rubbing.
1.2.11.3
Curing
After the completion of plasterwork, it shall be cu
red by adequate
watering for a period of seven (7) days.
1.2.12
False Floor (Cavity Floor)
1.2.12.1
Materials
a)
Floor Jacks
The jack shall be made out of 24 mm diameter MS bas
e rods
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welded to 10 mm thick MS plate of size 100 mm x 100
mm.
The top part of the jack shall be threaded and prov
ided with
double check nuts and washers to provide for level
adjustment of 50 mm minimum. The jack head shall be

fabricated with 30 NB MS socket and 10mm thick 100
x 100
mm cap plate as per detail fabrication drawing.
b)
Stringers
The stringers for supporting the false floor panels
shall be
made of 40 mm x 40 mm 3.15 mm thick section be fini
shed
with 2 coats of synthetic enamel paint over a coat
of red-
oxide primer coatings of conforming to IS:1572-1986
.
Floor panels shall be 35 mm thick un-veneered teak
wood
particle board bonded with BWP type phenol formalde
hyde
synthetic resin generally conforming to IS:3087-198
5 similar
to `Anchor Nova Teak Super' or any other approved
equivalent.
All the four edges of the floor panels shall be fit
ted with edge
lipping made of teak wood or rigid PVC of suitable
thickness
or in combination of teak wood lipping and hard PVC
Z
beading to protect from damage during installation
and
removal of panels, and also to protect from moistur
e
absorption.
22 gauge galvanized iron sheets shall be fixed to t
he
underside of floor panels for moisture resistance a
s well as to
further improve fire resistance quality.
Top of the floor panels shall be provided with 2 mm
thick
homogeneous PVC sheets conforming to IS:3462-1986 a
nd
having anti-static property similar to Vinyl Floori
ng of
Premier Vinyl Flooring Limited / Wonder Floor or an
y other
approved equivalent.
1.2.12.2
Workmanship
Entire workmanship shall be carried out in strict a
ccordance with the
specification. Rigidity, steadiness and levelling o
f the false floor system
shall be ensured. Painting work for wood surfaces,
floor and walls, fixing
of PVC sheets on floor panels shall be in accordanc
e with the instructions
of the relevant manufacturers.
1.2.13
Granolithic Bedding and Floor Hardener Finish
1.2.13.1
Materials
a)
Cement: Cement shall conform to IS:269-1989 or IS:4
55-
1989.
b)
Coarse aggregates: It shall be of approved broken g
raded
stone of size 10 mm and down, conforming to IS:383-
1970.
c)
Sand: The sand shall be approved river or pit sand
shall
conform to IS:383-1970.
d)
Floor hardener: It shall be of best quality heavy d
uty metallic
hardener -Ironite or approved equivalent.
e)
Water: Water shall be clean and of potable quality.
1.2.13.2
Workmanship
a)
Proportion of Mix
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The proportion of mix for granolithic bedding shall
be 1 part
of cement, 1 part of sand and 2 parts of granite ch
ipping. The
mix for the floor hardener shall be in accordance w
ith the
manufacturer's specification.
b)
The thickness of granolithic finish shall be 25 mm
and shall
be laid in accordance with IS:5491-1969 -Code of Pr
actice
for laying in-situ granolithic concrete floor toppi
ngs. The
surface of the base concrete shall be thoroughly ha
cked or
chipped to remove laitance, well saturated with wat
er and
cleaned. Immediately before laying granolithic fini
sh, any
excess water shall be removed and the surface of th
e base
concrete shall be covered with a thin layer of ceme
nt slurry
well brushed in. Just sufficient water shall be add
ed to the
ingredient of granolithic mix to obtain enough plas
ticity. The
mix shall be laid over the freshly grouted base in
suitably
divided panels and evenly well tamped into place, s
creeded
and lightly floated to required levels. No dimensio
ns of a
panel shall exceed 2 m.
c)
When the granolithic finish has partially dried, ap
proved
floor hardener mix shall be applied on the granolit
hic finish
in two or more coats and finished evenly with a tro
wel. Each
coat shall be applied before the previous coat drie
s.
Workmanship for floor hardener finish shall conform
to
manufacturer's specification. The thickness of the
floor
hardener topping shall be 15 mm minimum.
d)
Curing
The finished surface after hardening shall be cured
for a
minimum period of seven (7) days by impounding wate
r on
the finished surface.
1.2.14
White Washing and Cement Painting
1.2.14.1
Materials
a)
Lime
White wash shall be prepared from shell (fat) lime
conforming to IS:712-1984.
b)
Gum and blue pigment
Gum and blue pigment for white wash shall be of bes
t quality
and of approved one.
c)
Water
Water shall be clean and of potable quality.
d)
Paint
Paints shall conform to relevant Indian Standards a
nd shall be
of approved brands. Only ready mixed paints shall b
e used
for the work, unless otherwise approved by the Engi
neer. The
materials for succeeding coats on any one surface s
hall be
product of the same manufacturer supplying the firs
t coat for
that particular surface. Aluminium paint shall conf
orm to IS:
2339-1963.
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e)
Brushes
Brushes shall be of type and size suitable for the
work,
conforming to IS:487-1985. Rags or inferior quality
brushes
shall not be used on the work.
1.2.14.2
White Washing And Colour Washing
a)
Slaking
Slaking of lime shall conform to IS:1635-1992. The
lime
shall be placed about 300 mm deep in a drum with ab
out
1200 mm deep water standing in the drum. Lime shall
be
added to the water and not water to the lime. The l
ime in
water shall then be vigorously stirred. Lime shall
be
considered to be completely slaked when the tempera
ture of
the lime and water shall cease to rise and any furt
her addition
of water shall not produce any further chemical act
ion or
heat. Water shall then be allowed to stand on for 1
2 hours or
more until the normal temperature is restored.
b)
Mixing
The slaked lime shall be dissolved in a tub with su
fficient
quantity of water and shall be well mixed to give a
thin
creamy consistency. It shall then be strained throu
gh a clean
coarse cloth and gum dissolved in hot water shall b
e added to
it at the rate of 2 kg for each cubic metre of lime
and
ultramarine blue added to the mixture in small prop
ortion just
sufficient to give a very light bluish tint.
Colour wash shall be prepared in the same way as fo
r the
white washing except that necessary amount of colou
ring
matter shall be added to lime mixture in this case.
No blue
shall be added to lime mixture in case of colour wa
sh.
c)
Preparation of surface
Before the wash is laid, the surface shall be well
cleaned and
brushed. After cleaning the surface, all holes, cra
cks and
patches shall be made good with approved materials.
d)
Application
i)
Whitewashing
White wash shall be applied with brush, each coat
consisting of vertical stroke from top downwards
followed by opposite stroke upwards over the
first stroke and horizontal stroke from left to rig
ht
followed by stroke from right to left. Each coat
must be allowed to dry, before the next coat is
applied. On completion, the surface when it
becomes dry, shall present a uniform white
appearance. When dry, no coat of white wash
shall show any patches, hair cracks or strokes nor
shall it come off when rubbed with hand. White
wash shall be done in three coats. Doors and
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windows, floors etc., must be protected from
whitewash splashes. Any splashes and droppings
shall be removed and cleaned immediately.
ii)
Colour washing
Colour wash shall be applied in the same manner
as specified for white wash. During application,
the solution shall be stirred continuously and
wash shall be applied with care to avoid any cut
shade or brush marks on the walls when the work
is completed. For all new work, the surface to be
colour washed shall first be treated with a
priming coat of lime wash. Unless otherwise
specified, two coats of white wash shall be first
applied before colour wash is applied. The colour
wash, whether applied inside or outside of a
building shall be of uniform tint and shade. Any
splashes and droppings shall be removed and
cleaned immediately.
1.2.14.3
Painting
a)
Ready mixed paint
Only ready mixed paints of approved brands shall be
used.
The product shall be such, when applied, it shall s
pread
evenly in a thin coat and flow on smoothly and shal
l dry
quickly forming a tough durable film without showin
g any
brush marks or cracks.
b)
Preparation of surface
i)
The surface of steelwork to be painted shall be
cleaned free of dirt, oil, rust, mill scale and be
thoroughly dry before painting. Cleaning,
degreasing, de-rusting and de-scaling wherever
necessary shall be carried out as specified in
IS:1477(part 1)-1971.
ii)
The surface of woodwork to be painted shall be
cleaned and rendered dry, free of dirt, grit and
grease and shall be rubbed smooth with the
appropriate quality of sand paper. All knots
patches and sappy spot shall be touched up with
shellac varnish.
iii)
The plastered / concrete surface shall be painted
after making it smooth by sand papering, wall
putty & other necessary preparatory works as per
manufacturer specifications.
c)
Painting steel work
Painting of steel work shall be carried out as per
general
specification for painting and as approved by the E
ngineer.
d)
Painting woodwork
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After the primer coat has dried, nails, holes, crac
ks and the
like shall be filled up with approved wood putty an
d the
surface finished smooth. The type of intermediate a
nd finish
coat shall be as specified in the technical specifi
cation or on
drawing. The surface shall be rubbed smooth before
application of each coat. Each coat shall be allowe
d to dry
before the succeeding coat is applied. Finished sur
face shall
have no brush marks and shall be uniform in colour.
e)
Painting Plastered / Concrete Surfaces
Painting shall be carried out as per manufacturers

specifications.
1.2.15
Acid Resisting Ceramic Unglazed Tile Flooring, Skir
ting and Dado
1.2.15.1
Materials
a)
Acid proof tiles
All acid proof unglazed ceramic tiles shall be of a
pproved
quality and shall conform to IS 4457-1982 and be of
different
sizes like 100 mm x 100 mm, 150 mm x 150 mm etc. as

required with a thickness around 38 mm to 40 mm.
b)
Bitumen primer
The bitumen primer coat to be applied on thoroughly
cleaned
and dry concrete and/or masonry surface shall be he
avy grade
bituminous corrosion resisting black paint conformi
ng to IS
158-1981, Type 2. Primer shall be applied at least
in two
coats.
c)
Bitumastic impervious liner
The bitumastic impervious inter-liner material to b
e applied
over bituminous primer described above shall consis
t of a
mixture of straight run bitumen of softening point
145+5
C
and clean dry coarse quartz powder free from lumps.
This
mixture at a temperature around 180
C or above shall be
sufficiently plastic to be poured into place and co
mpacted by
wooden trowel or by other suitable means to provide
a
compact, lean tight resilient membrane. The specifi
c gravity
of mastic shall be approximately around 2 and penet
ration at
25
C (100 gms/ 5 mm) shall be above 1. The liner thick
ness
shall be at least 12 mm to 15 mm.
d)
Bedding and jointing cement
For bedding and jointing, K-silicate cement (two pa
ck self
hardening) conforming to IS 4832 (Part-1)-1969 shal
l be
used. The bedding and jointing shall be at least 6
mm thick.
e)
Pointing cement
Furacin cement used for pointing purpose shall be a
self
hardening cement - a two pack product conforming to
IS
4832 (Part-2)-1969. In case of hydrofluoric acid se
rvice,
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carbon fillers shall be used. In case of concentrat
ed sulfuric
acid having temperature not exceeding 40
C, sulphur cement
conforming to IS 4832(Part-3)-1968 shall be used.
f)
Hydrochloric acid
The hydrochloric acid for cleaning concrete surface
or
washing tiled surface shall be not more than 10% (w
eight by
weight) unless otherwise specifically required.
1.2.15.2
Workmanship
a)
Line, level and water tightness of concrete and mas
onry work
shall be checked prior to starting of acid resistin
g tiling work.
Acid resisting tiling work shall follow the constru
cted slopes
and contours.
b)
The concrete and masonry surfaces on which tiles wi
ll be laid
shall be made free from laitance, dust, oil and gre
ase by
means of chemical treatment and/or by mechanical me
thods
such as sand blasting, grinding etc. as required fo
r the
specific surface. Dust and loose particles resultin
g from the
pre-treatment shall be totally removed, preferably
by vacuum
cleaning or oil free air blast.
c)
After proper surface preparation two coats of bitum
en primer
shall be applied and when touch dry 12 mm to 15 mm
thick
bitumastic liner shall be applied uniformly maintai
ning slopes
and contours. After mastic liner gets dried up on o
vernight
stay, tile lining work shall be taken up with speci
fied bedding
cement keeping uniform joints of 6 to 8 mm wide. Th
e tiles
shall be placed properly by tapping gently with a w
ooden
mallet. After laying of tiles the joints shall be s
ealed with
pointing cement mortar and all the mortar spill ove
r shall be
wiped off from the surface. The tile lining work th
us
completed shall be left in an unused condition for
a week and
washed with dilute hydrochloric acid solution (10%)
for
bright finish. Tile lining work shall be governed b
y IS 4441-
1980, IS 4442-1980 and IS 4443-1980, unless otherwi
se
specified herein.
1.2.16
White Glazed Vitreous Tile in Dado
1.2.16.1
Work Included
The Bidder shall furnish materials, labour, plant,
equipment and tools to
complete the work as specified and/or as shown in t
he drawings.
1.2.16.2
Materials
a)
White vitreous tiles: The white vitreous tiles shal
l be flat and
glazed on the top surface. They shall be generally
150 mm x
150 mm in size with a thickness of about 5 mm unles
s
otherwise approved by the Engineer. They shall conf
orm to
IS 777-1988 in all other respects. The Bidder shall
submit to
the Engineer for his approval samples of tiles whic
h he
proposes to use in the work and all tiles used shal
l be similar
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to the approved samples.
b)
Ordinary or white portland cement: The cement shall

conform to IS 269-1989 and IS 455-1989.
c)
Sand: The sand used shall be of approved river or p
it sand,
conforming to IS 383-1970.
d)
Water: Water used shall be clean and of potable qua
lity as per
Clause 4.3 of IS 456-2000.
1.2.16.3
Workmanship
The tiles shall be laid on 19 mm thick bedding of (
1:3) cement sand
mortar. Before laying each tile shall be covered on
the back side with
neat cement slurry and glue (araldite) and fixed to
the bedding mortar.
The tiles shall be gently tapped to the bedding mor
tar with a wooden
mallet. The fixing shall be done from bottom upward
s. Each tile shall be
fixed as close as possible to the one adjoining and
any difference in the
thickness of the tiles shall be evened out in the c
ushioning mortar so that
all the tile faces are set in conformity with one a
nother. All joints shall be
filled and white cement grout and surface shall be
cleaned and cured.
1.2.17
Timber Doors, Windows, Joinery and Ironmongery
1.2.17.1
Work Included
The Bidder shall furnish materials, labour, plant,
equipment and tools to
complete the work as specified and/or as shown in t
he drawings.
1.2.17.2
Materials
a)
Timber: Unless otherwise specified, all timber used
in the
work shall be as specified in IS 1003-1991 and IS 4
021-1983
and shall be of Class-1, Grade-1 only.
Timber shall be of specified type, properly seasone
d and shall
be sawed square, straight and true and shall be fre
e from
decay or insect attack, unsound sapwood, shakes, ch
ecks,
waned edges, pitch pockets and knots. Cutting and p
lugging
of knots either sound or unsound will not be allowe
d.
b)
Fixings: Nails, screws and bolts for use as fixings
shall
comply with the following standards:
IS 723-1972 : Nails
IS 451-1999 : Screws
IS 1363-1992 : Bolts
IS 1120-1975 : Rag bolts and coach screws
IS 4907-1968 : Timber connectors
c)
Adhesive: Adhesives used for jointing shall comply
with IS
848-1974, type BWP.
d)
Plywood: Plywood shall conform to the requirements
of IS
303-1989, BWP bonded type and shall be of thickness
not
less than 4 mm. Plywood face veneers shall conform
to IS
1328-1996, Grade-1. Plywood adhesives shall conform
to IS
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848-1974.
Plywood shall be obtained from an approved manufact
urer to
the correct thickness specified. The Successful Ten
derer will
not be permitted to make up the required thickness
by gluing
together sheets of thinner thickness.
e)
Face Veneers: Face veneers shall be hard, durable a
nd
capable of being finished easily to a smooth surfac
e. They
shall be free from knots, beetle holes, splits, dot
s, glue stains,
filling or any other defects.
f)
Face veneers shall be applied to one or more sides
as shown
on the drawings.
g)
Block board and Lamin board: Block board and lamin
board
shall comply with IS 1659-1990, Grade-1. The face v
eneer of
boards selected for varnishing or staining shall co
nform with
the requirements for a Grade-1 veneer on the expose
d faces.
In other cases the boards shall be finished on both
faces with
a Grade-2 veneer. Grades of veneer shall be as desc
ribed in
IS 1328-1996
h)
Decorative laminated plastic sheets: Decorative lam
inated
plastic sheets shall comply with IS 3794-1966, Clas
s-1 sheet.
i)
Hardboards: When used for panelling in door shutter
s, the
hardboards shall be of tempered quality conforming
to the
requirements of IS 1658-1977.
j)
Builder's hardware: Builder's hardware shall confor
m to the
relevant Indian Standards. They shall be of the bes
t quality
and complete with all necessary screws, bolts, plug
s and
other fittings. The finish on all the exposed faces
of lever
handles, plates and fittings shall be of anodised a
luminium.
k)
Locks: All locks shall differ and locks shall be su
ited to
provide an overall master key and individual keys,
in
duplicate.
l)
Flush doors: Solid core flush door shutters shall b
e 35 mm
thick and shall comply with IS 2191-1983 and 2202-1
991.
Flush doors shall be faced both sides with teak ven
eer.
m)
All doors shall be shop prepared for taking mortise
locks and
latches.
n)
Lining, architrave and skirting: These shall be of
timber to
suit the locations and finishing conditions under w
hich they
are fixed. The locations and sizes shall be as indi
cated on the
drawings.
1.2.17.3
Moisture Content
The moisture content of all timber fixed shall be s
uitable for the
conditions and locations in which it is fixed (air-
conditioning systems
which may be employed in certain areas are to be ta
ken into account).
The limits of moisture content should not exceed th
ose specified in
clause 4.1.2 of IS 1003-1991 generally and those sp
ecified in clause 5.1.3
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of IS 2191-1983 when used for manufacturing flush d
oors.
1.2.17.4
Workmanship
a)
General
i)
All work shall be fixed straight and true.
Construction and workmanship, dimensions,
tolerances, finish, inspection and test for all doo
rs
and windows and ventilators and any other
woodwork shall be as specified in IS 1003-1991.
ii)
Timber buried in ground and the portions of
woodwork embedded in or resting on walls shall
be treated with boiling coal tar or other approved
protective materials. All steel work embedded in
masonry or exposed shall be suitably protected
against rust.
iii)
All woodwork must be inspected and approved
before being put into place. In no case shall the
woodwork be painted or otherwise treated before
it is approved.
iv)
All woodwork in building shall, after it has been
approved, be treated with a priming coat of
approved paint before being fitted in position.
The succeeding coats of paint or other finish shall

be applied after the woodwork is fixed in
position.
b)
Door frames and linings
i)
Timber door frames and linings shall be properly
framed and glued together with through tenon
joints.
ii)
Door frames built into walls shall be secured by
means of holdfasts made of 40 mm X 6 mm
galvanised mild steel flats 225 mm long, one end
bent up and twice drilled for wood screw fixing
and the other end split and fish tailed. The
holdfast shall be screwed to the frames with
sheradized (zinc coated) screws. Galvanised mild
steel dowels 12.5 mm diameter shall be provided
at the foot of all door frames. The dowel shall be
housed 50 mm into the timber and their length
shall be sufficient to ensure a minimum of 50 mm
penetration into a pocket formed in the concrete
slab irrespective of floor finishes.
c)
Fittings
In connection with all fittings such as counters an
d cupboards
the doors, frames, drawers, rails, framing, etc. sh
all be
properly and accurately framed together.
d)
Sundries
Architraves and cover beads where required shall be
wrought
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and rounded and pinned on to frame. Rails for hat a
nd coat
hooks and the like shall be wrought and chamfered,
plugged
and screwed to walls. Glazing beads where required
shall be
wrought splayed and rounded and shall be neatly mit
red and
fixed small bradsor lost-head nails.
e)
Scribing
All joinery such as architrave, beads, etc. require
d to fit
against the contour or irregular surfaces shall be
accurately
scribed to ensure a close butt connection.
f)
Surface continuity
Continuity must be maintained throughout, in partic
ular, in
jointed panels each piece shall be of the same spec
ies. Joinery
for staining and polishing shall have all surface o
f the same
species and character of grain.
g)
Fixing to walls
This shall be carried by the following means:
i)
An approved patent fibre plug fixed in
accordance with the manufacturer's instructions.
ii)
An approved plastic filling used in accordance
with the manufacturer's instructions.
iii)
Hardwood plugs set in the wall so that fixing to
them is across the grain. Softwood plugs shall not
be used.
h)
Jointing
All carpentry shall be properly framed and glued to
gether and
all timbers shall be jointed by housings, mortising
, tenoning
in an approved manner.
i)
Preservative treatment
All sawed softwood or hardwood and all grounds and
plugs
together with all wrought softwood and hardwood sha
ll be
impregnated with an organic solvent or water borne
type
preservative complying with the recommendations of
IS 401-
1982 for pressure impregnating. All timbers shall b
e
impregnated following final machining and cut ends
of all
timbers shall be effectively sealed with an approve
d sealant.
j)
Joiner's work
i)
Joinery shall be manufactured in such a manner
that the workmanship conform with IS 1003-1991
for doors and windows and IS 3845-1966 for
furniture except where varied by this
specification. Joinery timber shall be sawn out as
early as possible so that the shrinkage may take
place before being jointed and fixed in the work.
The timber shall be accurately worked to details
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and put together in the best possible manner.
ii)
Framed work shall be properly mortised and
tenoned, wedged, glued and cramped together
and doweled where necessary.
iii)
The use of nails for fixing any item of joinery
will not be permitted. Springs may be used for
glazing where necessary.
iv)
All screws and bolts shall be countersunk and
pelleted and all springs punched and puttied.
v)
Planed surfaces which are to be polished or
painted shall be finished smooth and hand
finished with fine sand paper.
k)
Surface finish
Surface shall be prepared, painted, stained, and/or
polished
and finished in accordance with the relevant clause
s of this
specification.
l)
Ironmongery
i)
All fittings shall conform to relevant IS
specifications and shall be of approved make and
quality.
ii)
Ironmongery shall be fixed solidly to all doors,
cupboards and panels and in accordance with the
manufacturer's instructions.
iii)
Hinges shall be carefully housed or let into doors
and frames. Door stops shall be plugged and
screwed to floors.
iv)
Ironmongery shall be carefully wrapped and
protected until completion.
v)
The Successful Tenderer shall allow for removing
and re-fixing of fittings during any painting
operations.
vi)
Metal sockets shall be provided to all tower,
barrel and drop bolts where the shoots enter brick
masonry, stone masonry or concrete. These shall
be securely fixed flush with the surface into g and

cemented. Mortise plates shall be used over holes
in woodwork.
vii)
On completion, all locks, catches and similar
items of ironmongery shall be properly cleaned,
tested and oiled. All keys shall be clearly labelle
d
with metal or hardboard tags of approximate size
50 mm X 20 mm securely fixed to the keys and
handed over to the Employer. Keys shall be
handed over in duplicate.
1.2.18
Glazing
1.2.18.1
Materials
a)
Sheet glass
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Unless otherwise specified, all glass used in the w
ork shall be
of quality approved, distortion free, transparent s
heet glass
conforming to IS 1761-1960 and shall be free from
specks,
bubbles, smokes, wanes, air holes and other defects
. Unless
otherwise specified, for sizes of glass above 900 m
m X 900
mm plate glass shall be used. Glazing to doors shal
l be done
with 6.3 mm thick sheet glass weighing about 15 kg/
m2.
Glazing to windows and ventilators shall be done wi
th 4 mm
thick sheet glass weighing about 10 kg/m
.
b)
Plate glass
Where plate glass is specified for the work, it sha
ll be of
thickness as specified with a permissible tolerance
of 0.5 to
0.8 mm for polished plate glass. The transparent ty
pe glass
shall have polished surface giving clear and undist
orted
vision.
c)
Putty
Putty for use on wooden frames shall conform to IS
419-
1967 and putty for use on metal frames shall confor
m to IS
420-1953.
d)
Mastic
Mastic shall be of approved quality.
1.2.18.2
Workmanship
a)
Glazing of metal doors, windows and ventilators sha
ll
conform to IS:1081-1960 and glazing of timber doors
,
windows and ventilators shall conform to IS:1003-19
91.
b)
All glass shall be cut according to the sizes requi
red as per
drawings. Glass shall be delivered to site in cut s
izes bearing
the manufacturer's name/trade mark and the quality,
thickness
and unit weight shall be clearly marked on the pack
ages.
c)
The method of glazing in each case shall be accordi
ng to the
details as shown on the drawings. For glazing woode
n doors
and windows, the wooden rebate shall be well oiled
to
prevent oil from putty being absorbed by wood. The
frame
shall be cleaned thoroughly and sufficient compound
applied
to the rebate so that when glass is pressed into it
, a back putty
of not less than 2 mm thick remains. Surplus compou
nd
squeezed out at the back shall be stripped at an an
gle so that
water is shed away. Unless otherwise specified, gla
ss shall be
secured with approved glazing clips. Where shown in
the
drawings, aluminum or timber glazing beads with alu
minum
screws shall be used.
1.2.19
Waterproofing of underground structures:
1.2.19.1
Material
Non-shrink polymeric water proof grouting compound
of
SIKA/CICO/FUSROC or equivalent shall be used
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1.2.19.2
Workmanship
a)
The concrete for vertical wall shall be at least M-
25C grade
as per IS 456-2000 having a maximum water cement ra
tio of
0.45. Approved super plasticiser-cum-cement water p
roofing
agent shall be added to the concrete as per the man
ufacturer's
specification. Adequate precaution shall be taken t
o keep the
nozzles horizontal during concreting.
b)
The exterior surface of the concrete shall be plast
ered with 12
mm thick cement sand plaster 1:3 & mixed with appro
ved
cement waterproofing compound conforming to
manufacturer's specification. The plastered surface
shall then
be finished smooth with a neat coat of cement slurr
y and
painted with two (2) coats of approved solvent less
resin to
form a thick resilient and flexible resinous membra
ne over
the plastered surface. Approved non-shrink polymeri
c
waterproof grouting compound mixed with cement slur
ry
shall be injected through the nozzles under pressur
e by pump
as per the manufacturer's instruction. When the inj
ection
operation is over the nozzles shall be sealed with
a sealing
compound as per manufacturer's specification and in
struction
c)
Waterproofing shall be carried out as per the manuf
acturer's
specification and as stated below:
Raft
i)
The sub-base of the underground structure shall
be cleaned of all dirts and kept dry by continuous
pumping of water. 20 mm thick plaster with
cement sand mortar 1:3 mixed with cement
waterproofing compound as per manufacturer's
specification shall be laid on top of the sub-base.
ii)
The plastered surface shall then be painted with
two (2) coats of approved solvent less resin to
form a thick resilient and flexible resinous
membrane over the plastered surface.
iii)
Threaded nozzles of 12 mm diameter and of
suitable length shall be placed and fixed in a grid

pattern of maximum 1.5 m centre to centre over
the whole raft, prior to casting of RCC raft.
Similar nozzles will also be placed along the
construction joint, if any, at regular intervals no
t
exceeding 1.5 m c/c. Adequate precaution shall
be taken to keep the nozzles plugged at both ends
to prevent them from getting clogged by concrete.
Similar nozzles shall also be post fixed at critica
l
points, if required. Approved super plasticiser-
cum-cement waterproof shall be added to the
concrete for the raft as per manufacturer's
specifications. The concrete shall be at least M-
25C grade as defined by IS 456-2000 and the
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water cement ratio of the concrete shall not
exceed 0.45. Adequate precaution shall be taken
to keep the nozzle vertical while concreting.
iv)
Approved non-shrink polymeric waterproof
grouting compound mixed with cement slurry
shall be injected through the nozzles under
pressure by pump as per instruction of the
manufacturer. When the injection operation is
over, the nozzle shall be sealed with a sealing
compound as per manufacturer's specification and
instruction.
Vertical wall
i)
12 mm diameter threaded nozzle of suitable
lengths shall be placed and fixed in a grid pattern

of maximum 1.5 m centre to centre over the
entire surface prior to concreting of the vertical
wall. Similar nozzles are to be also fixed at
construction joints, if any, at regular intervals n
ot
exceeding 1.5 m c/c. Adequate precaution shall
be taken to keep the nozzles plugged at both the
ends to avoid clogging of the nozzles by concrete.
Similar nozzles shall also be post fixed at critica
l
points, if required.
1.2.20
Waterproofing Work on Roof of Buildings
1.2.20.1
Material
b)
4mm thick Atactic Polypropylene modified plastomeri
c
(APP) bitumen based membrane with polyester
reinforcement of approved make with a thermo fusibl
e high
molecular high density polyethylene (HDPE) film and

mineral finished on top surface.
c)
Screed Concrete of grade M20 with 10mm & down size
coarse aggregare.
d)
wire mesh with 2mm dia wire and 50X50 mesh size jus
t
below the screed surface
e)
The solvent based bitumen primer of compatible make

(Shalitex from STP or eqivalent)
1.2.20.2
Workmanship
f)
Screed concrete of minimum thickness 25mm shall be
laid on
the RCC slab of roof in gradient towards drain pipe
s. Wire
mesh shall be placed just below the screed surface.
g)
Placing, Curing etc of screed concrete shall be don
e as per
specification of concrete.
h)
Bitumen primer of APP compatible make shall be appl
ied
over the screed surface as per manufacturers speci
fication
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i)
Laying of the membranes over bitumen primer shall b
e done
by manufacturers authorized applicators only.
j)
Prior to taking up screed or bitumen primer work, c
leaning of
the roof surfaces and filling of the joints, micro-
leveling, etc
shall be done to remove any loose particle & to mai
ntain
proper gradient.
k)
Termination of membrane shall be carried out by cut
ting &
filling of chases in brick wall / RCC on vertical f
aces. The
filling of chases shall be done as per manufacturer
s
specifications.
l)
Necessary overlaps of the membranes at the joint as
per
manufacturer specifications shall be provided. Extr
a Care
shall be taken for waterproofing in drain mouth and
in gutter.
1.1.2
Road Works
All material, workmanship & testing for road works
shall be as per
MORTH specification. All tests of material shall be
carried out by Bidder
at his own cost.
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Annexure 3.8.5-1
TECHNICAL SPECIFICATION FOR GIS SUBSTATION
Gas insulated sub-station (33kV)
1.1
This specification applies to the design, fabricati
on, inspection, testing, delivery
at site and installation of three phase, 36kV, 50Hz
Indoor gas insulated
switchgear as specified in the following sections o
f this document and as
indicated on the referenced documents.
The assembled equipment shall be capable of withsta
nding electrical,
mechanical and thermal ratings of the specified sys
tem. All joints and
connections shall be able to withstand the forces o
f expansion, vibration,
contraction and specified seismic requirements with
out deformation,
malfunction and leakage.
Optimized arrangements are required to reduce insta
llation time, provide ease
of operations, minimize maintenance and repair cost
s and facilitate future
expansion.
The apparatus shall include but not be limited to t
he following:
1.
Circuit breakers
2.
Disconnector switches (Bus / Line)
3.
Maintenance earthing switches
4.
Fast acting line earth switches
5.
Bus PTs
6.
Line PTs
7.
Current transformers
8.
Bus and elbow sections
9.
Cable end enclosures / SF6 Bus - duct
10.
SF6 to air bushings / cable terminations
11.
Ground connection to the station ground grid
12.
Auxiliary material to complete the GIS installation
(like density switches,
auxiliary power/control cable and bolts)
13.
Support structures for the GIS
14.
Insulating SF6 gas
15.
Local Control Cubicle
16.
Special tools for installation , monitoring, testin
g & maintenance
17.
Commissioning spares
1.2
Standards and codes
All electrical switchgear, the components of the co
ntrol system, the
protection scheme shall be conforming to the releva
nt I EC standards and
publications of the latest issue.
The following standards are applicable in the relev
ant parts to the individual
components of the gas insulated switchgear.
IEC 62271-203: High-voltage metal enclosed switchge
ar for rated voltage of
72.5 kV and above
IEC 62271-100 & 200: High-voltage alternating-curre
nt circuit breakers and
panels
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IEC 62271-102: Alternating current dis-connector an
d earthing switches
IEC 60694 : Common clauses for high-voltage switchg
ear and control gear
standards
IEC 60044: Current and voltage transformers
IEC 60060: High voltage test techniques
IEC 60071: Insulation coordination
IEC 60099: Surge arresters
IEC 60137: Bushings for alternating voltage above 1
000V
IEC 60255: Electrical Relays
IEC 60265: High voltage switches
IEC 60270: Partial discharge measurement
IEC 60376: Specification and acceptance of new sulf
ur hexa-fluoride
IEC 60480: Guide to checking of sulphur hexafluorid
e (SF6)
IEC 60529: Degrees of protection
IEC 60815: Pollution levels
IEC 60859: Cable connections for GIS
IEC 61000: Electro-magnetic compatibility (EMC)
IEC 61634: Use and handling of SF6
IEC 61639: Direct connections Transformer GIS
IEC 60364/60479/60621/IEEE Std. 80: Standards for s
tation grounding
CENELEC/SVDB: Pressure vessel codes
CIGRE 44: Earthing of GIS - an application guide
1.3
Electrical ratings
Three phase enclosure shall be provided for 36kV GI
S equipment. The apparatus
shall have the following basic electrical and desig
n characteristics
Phase design: 3ph
Rated voltage: 33kV
Rated withstand voltage
-
Impulse voltage: 170 kV (peak)
-
Power frequency withstand voltage: 70 kV (rms)
Rated frequency: 50 Hz
Short circuit withstand capacity: 40 kA for 3 secon
ds
Partial discharge level, complete bay 1.5 x UA/3: p
C 10
Enclosure: Aluminium alloy
1.4
EQUIPMENT SPECIFICATION
1.4.1
Specification of Gas Insulated Switchgear

The GIS shall be made of tubular Cast Aluminum encl
osures and filled with SF6
gas for insulation. Enclosures shall be of single p
hase encapsulation for 36kV for
both the bus bars and the feeder section bays.
The switchgear shall be modular in design. Future e
xtensions shall be easily
accomplished by adding extra feeders without disman
tling any major parts of the
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equipment. As much as possible the parts shall be o
f standard manufacture with
similar parts and assemblies being interchangeable.
Shipping sections which are tested in the factory s
hall be jointed in the field by
using bolted and sealed flange connections only. Fi
eld welding of enclosures is
not acceptable. The size of the pre-assembled shipp
ing sections shall be as big as
practical for transportation. Complete station asse
mbly in the factory for testing
purpose and disassembly for shipping is not preferr
ed.
The flanged connections shall have gas seals betwee
n the flange surfaces. For
outdoor application, suitable means shall be used t
o protect the gas seal from the
external environment. Connections including bolts a
nd nuts shall be adequately
protected from corrosion and easy accessible with t
he proper tools.
1.4.2
Sectionalization
The switchgear must be sectionalized, with gas tigh
t barriers between sections or
compartments. The sections shall be designed.
i) To minimize operational shut down when the ga
s pressure is reduced due to
leakage or for maintenance purposes
ii) To minimize the quantity of gas that has to be
evacuated and recharged
before and after maintaining any item of equipment.
Each breaker bay shall consist of as minimum of the
following gas tight individual
monitored zones:
i) Circuit breaker
ii) Bus section
iii) Feeder section
iv) Potential transformer
v) Common point for both buses.
vi) Bus disconnector.
Sectionalization shall ensure that Circuit breaker
enclosure will not include any
other equipment in its gas compartment. Continuous
bus lengths without gas
segregation shall not be acceptable.
For double bus-bar arrangement, equipment redundanc
y shall be maintained by
way of selective mechanical arrangement of the gas
compartments.
Each section shall be provided with necessary valve
s to allow evacuation and refill
of gas without evacuation of any other section. To
reduce the probability of leaks,
connections with pipes between gas compartments are
not acceptable.
The gas system proposed shall be submitted with the
proposal. External fixtures
shall be of non-corrosive material and be capped wh
erever required.
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For the purpose of gas monitoring and maintenance,
the GIS shall be provided
with gas density monitoring device along with tempe
rature compensated gas
density switch having two stage contacts in each ga
s compartment.
Pressure relief devices shall be used where ever re
quired.
Bendoscope suitable for view ports shall be used wh
ere ever required.
1.4.3
Conductor Type and contacts
Conductors shall be made of extruded aluminum suita
ble for the specified voltage
and current ratings. The electrical connections bet
ween the various gas sections
shall be made by means of multiple contact connecto
rs (plug-in type) so that
electrical connection is automatically achieved whe
n bolting one section to
another. Field welding of the conductor is not acce
ptable. The surface of the
connector fingers and conductor tubes on such conne
ctions shall be silver plated
or silver inserts.
1.4.4
Support insulators and section barriers
Support insulators shall be used to maintain the co
nductors and enclosure in
proper relation.
Barrier insulators which are employed to isolate ga
s compartments as well as
support insulators shall be manufactured from high
quality epoxy resin, free of all
voids and be designed to reduce the electrical stre
ss on the insulators to a
minimum. The support insulator shall have holes on
both sides for proper flow of
gas.
The insulator cones shall be embedded in full retur
n current carrying metal fixing
rings in order to avoid mechanical stresses to the
cast resin part and to impart full
conductivity across the flange connection.
The mechanical strength must be sufficient to ensur
e the conductor's space
requirements and clearances when short circuit faul
ts occur. In addition, the gas
barrier insulators sealing to the conductors and th
e enclosure wall shall be
designed to withstand the maximum gas pressure diff
erential under normal
operating condition and maximum pressure differenti
al with one of the adjacent
enclosures at three times operating gas pressure an
d the other at atmospheric
pressure for five minutes.
Tests shall be carried out during the manufacturing
of the switchgear to ensure
that all insulators are free of partial discharge a
t a voltage which is at least 10%
higher than the rated voltage.
1.4.5
Gas system
The GIS shall be furnished with sufficient sulfur h
exa-fluoride (SF6) gas to
pressurize the complete system in a sequential appr
oach, one zone or
compartment at a time to the rated nominal density.
Maximum water content of SF6 -gas in GIS, within gu
arantee period: CB
50 PPM (weight)
Others: 75 PPM (weight)
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The Gas loss of the switchgear shall be in no case
higher than 1%
per year. Components may be filled with N2 for tran
sportation and
refilled with SF6 on site.
1.4.6
Gas Seal
All gas seals shall be designed to ensure that leak
age rates are kept to an
absolute minimum under all normal pressure, tempera
ture, electrical load and fault
conditions. All gas seals located in the flanges of
the equipment enclosures shall
be of the O-ring type.
1.4.7
Gas Filters / Treatment
Each gas compartment shall be fitted with gas filte
rs, driers or desiccants for the
absorption of moisture and the gaseous products of
switching. The filter shall be
effective for the duration of time between major ov
erhaul. It shall be possible to
replace the active material of the filter without e
xtensive dismantling and
preferably without taking disconnectors or circuit-
breakers out of service.
The absorbent shall be located in an easy accessibl
e location.
1.4.8
SF6 gas density and pressure
The rated pressure of the SF6 insulating gas in the
GIS equipment shall be as low as
possible while still meeting the requirements for e
lectrical insulation and space
limitations to reduce the effects of leaks and to e
nsure that there is no chance of
the gas liquefying at the lowest ambient temperatur
e. The initial gas pressure or
density at the time of charging the equipment shall
provide a 10% margin above
the minimum allowable operating pressure for the pl
ant to be safely operated for a
reasonably long period before recharging is necessa
ry.
1.4.9
SF6 gas quality
The GIS shall be designed for use with SF6. All SF6
gas supplied as part of the
contract shall comply with the requirements of IEC
60376 at a minimum.
1.4.10
Gas monitoring devices
Temperature-compensated gas density monitoring devi
ces shall be provided for
each gas compartment. Any pipe-work connection betw
een the various gas
compartments and a centralized measuring device sha
ll be strictly avoided. The
devices shall provide continuous and automatic moni
toring of the density of the
gas. It shall have the facility for calibration whi
le in service. The monitoring device
shall have two alarm settings. These shall be set s
o that:
a)
Advanced warning can be given that the gas density
is approaching an
unacceptably low level
b)
After an urgent alarm, measures can be taken to imm
ediately isolate the
particular compartment electrically by tripping cir
cuit breakers and by opening
disconnect switches if the gas pressure or density
continues to drop below
functional pressure or minimum density.
High pressure interlock and monitoring device shall
be provided.
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1.4.11
Switchgear enclosures
The metal enclosures for the GIS equipment modules
shall be made from
Aluminum alloy and tubular in construction. All fla
nges shall be directly bolted
together with good metallic contact to make enclosu
res equi-potential. Insulators
or insulating material between flanges shall be avo
ided in order to get the best
electrical connection between the different enclosu
re modules. Flange
connections via external cross-bonding are not allo
wed.
Enclosures shall withstand normal and transient pre
ssure in operation. They shall
be designed and manufactured according to the relat
ed standards to guarantee
safety and reliability of material, construction, w
elding technology and testing.
Enclosures shall be designed to withstand any burn-
through for a period long
enough to enable the back-up relay protection to cl
ear the fault i.e. the enclosure
must with stand short circuit � 40 kA (r.m.s) for 0
.3 s without any burn-through.
The gas-filled enclosures shall comply to the press
ure vessel code applied in the
country of manufacturer and shall be suitable for p
urchaser's environmental
condition.
1.4.12
Expansion joints and flexible connection
Expansion and installation alignment shall be consi
dered in the design of the bus
and enclosure. The continuity of service during the
rmal expansion / contraction
and vibrations shall be ensured. The switchgear sha
ll be fixed to the floor with
minimum requirement on floor preparation. If requir
ed, expansion joints shall be
provided with compensators for the enclosure and sl
iding plug-in contacts for the
conductors. Expansion joints and flexible connectio
ns shall be considered in the
design of the bus and enclosure to take care of the
rmal expansion / contraction
and vibrations during service and to absorb the rel
ative movement between the
switchgear equipment and its fixing structure / flo
or. The number and position of
expansion joints or flexible connections are to be
determined by the manufacturer
to ensure that the complete installation will not b
e subject to expansion stresses
which could lead to distortion or failure of any pi
ece of the SF6 equipment, support
structures or foundations.
Also, expansion joints, flexible connections and ad
justable mountings shall be
provided to compensate for reasonable manufacturing
and construction tolerances
in the associated equipment to which the GIS may be
connected. This is to ensure
that unreasonably excessive accuracy is not require
d when installing such
equipment and constructing the associated foundatio
ns or support structures, e.g.
transformers or the interconnection of isolated sec
tions of switchgear by means of
long GIS bus bar or duct installations. Flexible jo
ints may also be provided to allow
more efficient maintenance and future extensions of
the GIS.
1.4.13
Corona Shield
Corona shield, if necessary, shall be located at ap
propriate location inside the
enclosure. Minimum 3 spring loaded bolts (preferabl
y), or other approved
arrangement should fix each corona shield.
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Material of the corona shield should be Copper/ Bra
ss/ Alloy of Aluminium and
Steel.
1.4.14
TECHNICAL SPECIFICATION OF THE HIGH VOLTAGE COMPONE
NTS
OF GIS
1.4.14.1
Circuit Breaker
i)
General
The GIS circuit breakers shall comply with the foll
owing general requirements
for circuit breakers and the latest revisions of th
e relevant IEC specifications.
Circuit-breakers shall be the SF6 gas insulated typ
e of single phase design with
the specified ratings. The breaker shall be Self-Bl
ast / Puffer type principle and
consist of one interrupting arcing chambers.
Each circuit-breaker including the drive mechanism
shall be completely factory
assembled, adjusted and tested. The breaker shall i
nclude a suitable operating
mechanism to assure proper opening and closing, and
shall permit checking
adjustments and opening characteristics. Each mecha
nism shall include dual trip
coils in redundant design. The mechanism shall be c
apable of re-closing within
the range specified in the applicable standards. Th
e breakers are to be re-strike-
free.
The breaker layout arrangement shall be preferably
horizontal to provide higher
mechanical stability and ease in maintenance. The o
perating principle of the
breaker shall ensure minimized dynamic floor loadin
g. Low reaction forces on
foundations especially dynamically, are favorable a
nd considered in the
evaluation.
ii)
Technical Particulars:
Nominal operating Voltage:33kV
Highest system Voltage: 36 kV
System earthing: Solidly earthed
Rated withstand voltage with respect to eart
h:
Lightning: 170 kV (peak)
Power frequency: 70kV
Rated short-circuit breaking capacity : 4
0 kA for 3 sec
Number of breaks per pole: 1 no.
First pole to clear factor: 1.3
Rated operating sequence Time for recharging CO cyc
le: O-0.3s-CO-3 min-
CO/ CO-15sec- CO
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Type: Spring / Hydraulic- spring
Number of trip coils:2
Number of closing coils Rated control: 1+1
Control voltage : 220 V DC
iii)
Constructional features
All making and breaking contacts shall be designed
to have adequate thermal and
current carrying capacity for the duty specified an
d to have a life expectancy so
that frequent replacements due to excessive burning
will not be necessary.
Provision shall be made for rapid dissipation of he
at generated by the arc on
opening.
Main contacts shall be first to open and last to cl
ose so that there is little contact
burning and wear. Contacts shall be kept permanentl
y under pressure of SF6 gas.
Arcing contacts shall be first to close and last to
open. These shall be easily
accessible for inspection & replacements.
Any devices provided for voltage grading to damp os
cillations or to prevent re-
strike prior to the complete interruption of the ci
rcuit or to limit over voltage on
closing shall have a life expectancy comparable to
that of the beaker as a whole.
Breaker shall be so designed that when operated wit
hin its specified rating, the
temperature of each part is limited to the values c
onsistent with a long life or the
material used. The temperature shall not exceed the
values indicated in IEC
60694 under specified ambient conditions.
The gap between the open contacts shall be such tha
t it can withstand at least the
rated phase to ground voltage for eight hours at mi
nimum operating pressure of
SF6 gas due to its leakage.
The material used in the construction of the circui
t breaker shall be such as to be
fully compatible with SF6 gas decomposition product
s.
Provisions shall be made for connecting an operatio
nal analyzer to record travel,
speed and making measurement of operating timings e
tc. after installation at site.
All gasket surfaces shall be smooth, straight and r
einforced.
iv)
Breaking capacity
The total breaking time from energizing of the trip
coil at rated control voltage to
final arc extinction shall be as short as possible.
The circuit breaker shall be capable of breaking al
l currents from zero up to the
specified maximum fault current in accordance with
the relevant IEC publications.
Official test reports shall be submitted with the t
ender as evidence that the offered
circuit breaker meets the specific rating.
v)
Interrupting Duty:
Circuit breakers must be capable of coping with the
interrupting duties produced
by the switching of transformer magnetizing current
s, line charging currents, cable
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charging currents, capacitor banks, short-line faul
ts and out-of-phase switching
duties.
vi)
Auto-reclosing:
The circuit-breakers shall be capable of tripping a
nd reclosing according to the
specified duty cycle.
vii)
Closing devices
All electrically operated closing devices and any m
echanism charging motors or
devices shall be suitable for operation at any volt
age between 110% and 85% of
the nominal control voltage measured at the device
terminals.
The breaker shall close correctly when an electrica
l closing pulse of 50 ms
duration is applied to the closing coil.
The total power drawn by the closing coil at nomina
l control voltage during closing
operation shall not exceed 300 W per circuit breake
r.
viii)
Tripping devices
All electrical tripping devices shall be suitable f
or operation at any voltage between
110% and 50% of the nominal voltage, measured at th
e device terminals.
An emergency hand tripping (mechanical) device shal
l be provided in the
operating mechanism.
ix)
Operating mechanism
One operating mechanism shall be supplied for each
single phase circuit-breaker.
Electric motor for the spring / hydro-spring mechan
ism shall be DC operated to
allow operation in case of AC failure and thus of h
ighest reliability. Mechanism
housing shall have IP 54 degree of protection.
In order to reduce maintenance work and outage time
pneumatic operating
mechanisms will not be accepted. The mechanism shal
l be strong and rigid and
shall be suitable for high speed auto re-closing an
d other duties specified.
The mechanism shall be anti-pumping and trip free u
nder every method of closing.
Spring operated mechanism shall be complete with mo
tor, opening spring, closing
spring and all the necessary accessories to make th
e mechanism a complete unit.
Breaker operation shall be independent of motor whi
ch shall be used solely for the
purpose of charging the closing spring. Motor ratin
g shall be such that it requires a
maximum of 15 seconds for fully charging the closin
g spring.
'Closing' operation shall charge the 'opening' spri
ng and keep it ready for tripping.
When closing spring is discharged after closing a b
reaker, it shall be automatically
charged for the next closing operation. A mechanica
l indicating device shall be
provided to indicate the state of charge of the spr
ing and shall be visible with the
doors of the cubicle closed.
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The mechanism shall be such that failure of any aux
iliary spring will not prevent
tripping and will not cause trip operation of the p
ower operating devices.
The spring shall be fully charged before it can be
released to close the circuit
breaker. It shall not be possible for the breaker t
o close while the spring is not fully
charged. An alarm shall be provided to indicate "sp
ring charge failure" by a preset
time after circuit breaker closing.
In case of failure of aux. supply the mechanism sha
ll have sufficient energy stored
to perform one O-CO cycle.
Electric motor for the driving mechanism shall be D
C operated to allow operation
in case of AC failure and thus of highest reliabili
ty.
Hydraulic loaded spring operated mechanisms shall b
e complete with all control
equipment. The only external requirement for operat
ion shall be electrical supply.
Hydraulic pipe working on site or common system for
substation shall not be
acceptable.
Low stored operating energy shall be detected by so
me suitable method and
dependent on the position of the spring shall initi
ate one or more of the following
operations:
Block auto-reclosing if stored operating energy is
insufficient to complete a break-
make-break operation
Block closing if stored operating energy is insuffi
cient to complete a make-break
operation
Block tripping if stored operating energy is insuff
icient to complete a break
operation
Charging of the operating mechanism shall be possib
le in the event of failure of
the motor drive. This can be possible by connecting
an external mobile pump with
an electrically operated motor.
The mechanism shall be in a dust and vermin proof b
ox for indoor installation or in
a weatherproof box for outdoor installation.
Each breaker shall have sufficient auxiliary switch
es all wired to terminals located
in the local control cubicle.
Position indicating devices: Position indicators sh
all be provided to clearly indicate
whether a circuit-breaker is open or closed.
Operation counter: Each circuit -breaker shall be p
rovided with an operation
counter per mechanism to record the number of tripp
ing operations performed.
The counter may be located at the local control cab
inet.
Discrepancy circuit shall be provided which shall d
etect pole position discrepancy.
Design of circuit breaker shall ensure that the con
tacts will not 'close' / 'open'
automatically upon loss of gas/ hydraulic oil press
ure. The circuit breaker shall
retain and continue to remain in the position prior
to the loss of pressure.
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Circuit breaker operation shall be independent of t
he motor, which shall be used
solely for the purpose of compressing the 'closing'
spring'.
Each breaker shall have sufficient auxiliary switch
es all wired to terminals located
in the local control cubicle.
x)
Anti pumping
All circuit-breaker mechanisms shall be provided wi
th means to prevent pumping
while the closing circuit remains energized, should
the circuit breaker either fail to
latch, or be tripped during closing due to the oper
ation of the protective relays.
Position indicating devices
Position indicators shall be provided to clearly in
dicate whether a circuit-breaker is
open or closed. Each circuit-breaker shall be provi
ded with an operation counter
per mechanism to record the number of tripping oper
ations performed. The
counter may be located at the local control cabinet
.
1.4.14.2
Current transformers
i)
General
The current transformers shall be supplied in accor
dance with the following
general requirements and the latest revisions of th
e relevant IEC or ANSI
specifications. The CT's shall be positioned on bot
h sides of the circuit breaker
such that two cores are available on one side and t
hree cores are available on the
other side to ensure proper overlapping of protecti
on zones. Each current
transformer shall be arranged so that the enclosure
current does not affect the
accuracy or the ratio of the device or the conducto
r current being measured.
They shall be ring type multi ratio with fully dist
ributed secondary windings with
accuracy as per IEC 185 (1987), incl. IEC 44-6 (199
2) or ANSI / IEEE C57.13-
1978.
Current transformer secondary cores shall be termin
ated to shorting terminal
blocks.
It shall be possible to test each current transform
er without the removal of gas
through the insulated grounding switches.
Position of the Current Transformers and Cores, Rat
ios and Characteristics.
The number and position of the current transformers
relative to the circuit-
breakers, disconnecting switches and ground switche
s shall be as detailed in the
attached single line diagram.
The rating, ratio, accuracy class etc. for the indi
vidual current transformer
secondary cores shall be as specified. Where multi-
ratio current transformers are
required, the various ratios shall be obtained by c
hanging the effective number of
turns on the secondary winding.
ii)
Rating and Diagram Plates:
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Rating and diagram plates shall be as specified in
the IEC specification
incorporating the year of manufacture. The rated ex
tended current rating voltage
and rated thermal current shall also be marked on t
he name plate.
The diagram plates shall show the terminal markings
and the relative physical
arrangement of the current transformer cores with r
espect to the primary terminals
(P1 & P2). The position of each primary terminal in
the current transformer SF6
gas section shall be clearly marked by two plates f
ixed to the enclosure at each
end of the current transformer.
iii)
Constructional Details:
The current transformers incorporated into the GIS
will be used for protective
relaying and metering and shall be of metal enclose
d type. The secondary windings
shall be air insulated/Gas insulated with terminals
brought out for
secondary connection.
All the current transformers shall have effective e
lectromagnetic shields to protect
against high frequency transients.
Each current transformer shall be equipped with a m
arshalling box with terminals
for the secondary circuits, which are connected to
the local control cubicle. The
star/ delta configuration and the inter connection
to the line protection panels will
be done at the CT terminal block located in the loc
al control cubicle.
Current transformers guaranteed burdens and accurac
y class are to be intended as
simultaneous for all cores.
The rated extended primary current shall be 150% at
all ratios.
The instrument security factor at all ratios shall
be less than five (5) for metering
core. ISF shall be verified without use of any auxi
liary reactor.
The wiring diagram, for the interconnections of the
three single phase CTs shall be
provided inside the marshalling box.
The current transformers shall be suitable for high
speed auto re-closing. Provisions
shall be made for primary injection testing either
within CT or outside.
Electromagnetic shields to be provided against high
frequency transients typically
1-30 MHz.
The bidder will take care for the compatibility of
the CT vis--vis burden of
relay and connecting leads.
iv)
Technical Particulars
Core number per phase:2 + 3 nos.
Accuracy:
Metering-0.2
Protection: PS/5P30
Rated secondary current: 1A
Continuous Thermal rating:120
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1.4.14.3
Voltage transformers
i)
General
The voltage transformers shall be supplied in accor
dance with the following
general requirements and the latest revisions of th
e relevant IEC and ANSI
standards.
Each voltage transformer shall be an electromagneti
c, dry type SF6 -enclosed
single phase unit with the specified ratings.
The voltage transformers are to be connected as sho
wn in the attached single line
diagram.
Voltage transformers shall be attached to the gas-i
nsulated system in such a
manner that they can be readily disconnected from t
he system if required for
dielectric testing. The metal housing of the voltag
e transformer shall be connected
to the metal enclosure of the GIS with a flanged, b
olted and gasketed joint so that
the transformer housing is thoroughly grounded to t
he GIS enclosure. Adequate
measures shall be provided to prevent any unaccepta
ble impact on the secondary
control and protection circuits which might result
from very fast transients (VFT) or
ferro-resonance.
ii)
Ratios and Characteristics
The rating, ratio, accuracy class, connection, etc.
for the voltage transformers shall
be as specified below.
The voltage transformers shall have 2 secondary win
dings, each winding with one
tap.
iii)
Rating and diagram plates
Rating and diagram plate shall be provided complyin
g with the requirements of the
IEC specification incorporating the year of manufac
ture and including turns ratio,
voltage ratio, burden, connection diagram etc.
iv)
Secondary Terminals, Earthing and Fuses
The beginning and end of each secondary winding and
all secondary taps shall be
wired to suitable terminals accommodated in the loc
al control cabinet for the
feeder bay. Fuses shall be also located in the loca
l control cabinet.
All terminals shall be stamped or otherwise marked
to correspond with the
marking on the diagram plate. Provision shall be ma
de for earthing of the
secondary windings inside the terminal box.
The transformer shall be able to sustain full line
to line voltage without saturation
of transformer.
The accuracy class will be at maximum tap.
v)
Constructional Details of Voltage Transformers:
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The voltage transformers shall be located in a sepa
rate bay module on the bus
and will be connected phase to ground and shall be
used for protection, metering
and synchronization.
The voltage transformers shall be of inductive type
, nonresistant and shall be
contained in their own-SF6 compartment, separated f
rom other parts of
installation. The voltage transformers shall be eff
ectively shielded against high
frequency electromagnetic transients. The voltage t
ransformers shall have three
secondary windings
Voltage transformer's secondary shall be protected
by HRC cartridge type fuses
for all the windings. In addition fuses shall be pr
ovided for the protection and
metering windings for fuse monitoring scheme. The s
econdary terminals of the
VT's shall be terminated to the stud type non-disco
nnecting terminal blocks in the
secondary boxes via the fuse.
The voltage transformer should be thermally and die
lectrically safe when the
secondary terminals are loaded with the guaranteed
thermal burdens.
The accuracy of 0.5 on secondary III should be main
tained through out the entire
burden range upto 100VA on all the three windings w
ithout any adjustments
during operation.
The diagram for the interconnection of the VTs shal
l be provided inside the
marshalling box.
vi)
Technical Particulars:
Rated voltage: 33kV
Rated withstand voltage with respect to eart
h:
Lightning: 170 kV (peak)
Power frequency: 70kV
Secondary winding (volts): 110/V3
No of secondary windings:3 nos.
Class: 0.5/3P
Burden: 100VA
Partial discharge level at 1.5 UA/3: 5 pC
Test conditions for tests at site: Power frequency
tests for the completed GIS at site
shall be possible without removing the voltage tran
sformers. The power frequency
test voltage for at site tests shall be 80% of the
factory test voltage, for 1 min., and
at 100 Hz.
1.4.14.4
SF6 Gas Insulated Bus Tube
SF6 gas insulated bus tube is used to connect trans
former and incoming over
head line. All construction of the tube shall be si
milar to the 'enclosure' and
'conductor' of the main equipment specified earlier
in the specification.
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The requirement of SF6 tube will be shown in the Si
ngle Line Diagram and
Layout.
The enclosure shall be connected by use of bolted
and gasketed joints. The bus
conductor shall be connected with plug in contacts
with silver plated contact
surface. The bus system shall be capable of withsta
nd the mechanical and thermal
stresses due to short circuit currents, as well as
thermal expansion and
contraction created by temperature cycling.
SF6 tube for outdoor installation shall have additi
onal O-ring as specified in the
specification earlier sections.
Flexible joints and termination shall be supplied f
or termination of equipment.
The galvanized support structures and other accesso
ries as required shall be
supplied.
vii)
GIS to Over Head Line Connection
For connection to OHL by SF6 tube bus, SF6 to Air t
ermination shall be provided.
1.4.14.5
SF6/Air bushings
i)
General
Outdoor SF6 to air bushings, for the connection bet
ween the GIS and overhead
lines or conventional air insulated equipment shall
be furnished where specified.
Bushings shall comply with the relevant IEC standar
ds.
The bushings shall be preferably made of plastic co
mpound and with all surfaces
free from imperfections.
Bushings with porcelain insulators must be designed
to cause negligible damages
in case of porcelain rupture, having either a low p
ressure volume or a small SF6-
gas volume next to the porcelain.
Insulation levels and creep age distances:
The insulation levels are applicable to normal sea
level atmospheric conditions.
The creep age distance over the external surface of
outdoor bushings shall not be
less than 25 mm/kV.
Mechanical forces on bushing terminals:
Outdoor bushings must be capable of withstanding a
cantilever force applied to
the terminal of at least 2500 N.
Interface definition
The flange and conductor connection between bushing
and GIS component shall
be the standard of the GIS supplier.
1.4.14.6
HV-Power Cable connection
i)
General
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The design of the cable end box shall fully comply
with the I EC 60859 standard.
The high voltage power cables. The type and size of
cables shall be as per
requirement. The final connection of the high volta
ge cable circuits in the GIS will
be by means of individual single-phase cables, with
one cable per phase.
All cable end modules shall be suitable for connect
ing single core, XLPE solid
dielectric cable type for maximum Continuous voltag
e withstand.
The cable end unit design shall include a facility
for high voltage DC testing of
the connected power cable on site. The design of th
e link and connections
shall ensure that when removed the resulting gap ca
n withstand the impulse and
power frequency test voltages applicable to the swi
tchgear and the cable high
voltage DC test voltage.


RSP
ANNEXURE 3.
7.4
CET/05/RN/
3170
/TS/IR/0
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UPGRADATION OF
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Annexure 3.5.7.4-1
GENERAL TECHNICAL SPECIFICATION FOR
ELECTRICALLY OPERATED HOIST
1.0
SCOPE
This specification covers the general requirement of el
ectrical operated hoists
required for various purposes in steel plants.
2.0
GENERAL
2.1 The hoist shall be designed, manufactured, erected,
tested and commissioned as per
standards laid down in this specification. Wherever such st
andards are not indicated,
the system shall be as per the codes and practices adopte
d by IS or IPSS.
2.2 In general , the hoist shall be designed as per IS 3938:
1983.
2.3 Hoist shall include all necessary equipment and compone
nts to perform the
specified function.
2.4 The Equipment shall be provided with suitable safety prote
ctions and necessary
maintenance platforms.
The offered electric hoist shall be of rugged design suit
able for long life under
specified duty and site conditions, trouble free operation
and easy maintenance.
Name plates with the following description shall be attac
hed to the hydraulic
equipment and/or component at a place easy to be read.
a) Name of equipment and/or component
b) Manufacturing serial No. and/or type
c) Specification of rating
d) Date of manufacture
e) Name of manufacturer
3.0
MAIN COMPONENTS OF HOIST
3.0
ROPE DRUM
Rope drum shall be designed in accordance with IS 3938:1983.
3.2
HOIST ROPES
Hoist Rope shall conform to IS 3938:1983.
3.3
ROPE SHEAVES
All Rope sheaves shall be of cast or forged steel an
d shall conform to IPSS 1-08-002-
90 and IS 3938:1983.

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ANNEXURE 3.
7.4
CET/05/RN/
3170
/TS/IR/0
/R=
UPGRADATION OF
BF
PAGE
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3.4
WHEEL

Hoist wheel shall be designed as per IS 3938:1983. Track whee
ls may have
cylindrical or straight tapered or spherical tapered tread
to guide hoist trolley
effectively to prevent derailment. The wheel shall b
e mounted in such a manner as to
facilitate removal or replacement during maintenance.
3.5
GEARING, GEAR BOX, COUPLINGS
Gearing, Gear Box and Coupling shall conform to IS 3938:1983. S
traight and helical
spur gearing shall normally be used for all motions. All ge
ar boxes shall be oil tight
and sealed with compound or gasket. All gear shafts shall be
supported in bearings
mounted in gear box. The gear boxes shall be fabricate
d or of cast steel. All couplings
shall be of cast or wrought steel and shall be designed t
o suit the maximum torque
that can be developed.
3.6
BEARINGS
Ball and roller antifriction bearing in accordance wit
h IPSS:2-02-003-84 and
IS3938:1983 shall be used throughout except where specified otherw
ise or mutually
agreed.
3.7
LIFTING HOOKS
Lifting hook shall be plain shank type as per IS:8610-1977 an
d IPSS:1-08-004-94 and
also it shall be radiographically tested to check interna
l defects. It shall be swivelling
type mounted on antifriction thrust bearings.
3.8
SHAFT
Shafts shall be as per IS 3938: 1983.
3.9
LUBRICATION
Provision shall be made for all moving parts and bearings,
while the hoist is in
service except where life lubricated bearings are used. Bal
l and roller bearings shall,
in addition, be lubricated before assembly. Lubricating
nipples and adapters shall be
easily accessible and shall generally comply with the
relevant Indian Standards. All
exposed bearings shall be suitably sealed or shielded.
All gear drives with the exception of travel runner wh
eels of geared type and their
driving pinions, shall be enclosed and provided with means
for ample lubrication.
The oil bath lubrication shall be preferred.
Equipment shall be supplied along with first fill of lu
bricating oil.
4.0
OTHER TECHNICAL REQUIREMENTS
4.1
POWER SUPPLY ARRANGEMENT
One no feeder outlet of adequate rating for the electr
ical power at 415 V, 3ph 4 wire,
50Hz shall be provided for the power cum control panel of th
e hoist.

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4.2
PENDANT CONTROL SWITCH
Hoist shall be provided with pendant switch push button c
ontrol. Pendant control
switch shall be adequately protected to prevent accidenta
l contact with live parts.
These P/B station shall be momentary contact type and s
hall return to off position
when pressure is released. Suitable arrangement shall be
made for (2) two speed
(Forward/Reverse) control and they shall be electric
ally & mechanically interlocked.
The weight of pendant shall be supported independent of the e
lectric cable by means
of main chain / wire rope . Pendant push buttons shall be o
perative from 1.5 M above
floor level. The push button station shall be clearly ma
rked with marking
UP
and
DOWN
for hoist,
LEFT
and
RIGHT
for trolley movement.
4.3
MOTORS
i)
All the motors of electric hoist shall be totally enc
losed and fan cooled
induction motor. The motor shall conform to IPSS 1-03-004-95 &
1-03-007-85.
The class of insulation shall be H and temperature rise
limited to class B and
type of protection IP - 55 as per IS:4691-1985 and shall be suit
able for plugging
/ reversible type of operation and duty cycle not less th
an 40%.
ii)
Pull out torque of the offered motor shall be 2.75 times r
ated torque at normal
voltage and frequency.
iii)
Motors of LT and hoist shall be of class of duty S4 .
iv)
In hazardous locations flame proof motors conforming to IS:2148
-1981 shall be
provided
4.4
CONTROL PANEL
i)
All control panels shall comprise of electromagnetic o
perated contactor, relays
etc. There should be provision of electrical and mechanic
al interlock for the
hoisting / lowering and long travel movements.
ii)
Provision for creep speed, of 10-20 % of normal speed should b
e made as per
requirement
iii)
Electrical control panels shall be as per IPSS-1-10-010-84 (
General requirement
for control panels for hoists).
iv)
All power and auxiliary connectors and individual overload
relays shall be
mounted in sheet steel cubicle with provision of lock.
4.5
LIMIT SWITCHES
i)
Limit switches shall be provided at both ends of the monor
ail to stop the hoist
before hitting the mechanical buffer.
ii)
Hoist motion shall be provided with limit switches to
prevent over hoisting and
over lowering. These offered limit switches shall be as
per relevant clause of

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IS3938:1983. These limit switches shall be automatically reset
when the hook
is returned to normal operating zone.
4.6
EMERGENCY STOP PUSH BUTTON

Lockable off push button shall be provided to cut off/tr
ip main power in case of any
fault or emergency. It shall be provided on the pendant s
witch board. The colour of
the push button shall be red.
4.7
BRAKES
The offered electric hoists shall have shoe type Ele
ctromagnetic (A C / D.C.) Brakes
for hoisting / lowering motion and long travel motion.
4.8
CABLING AND EARTHING
All wiring for power and control shall be carried out w
ith 1.1 kV Grade PVC
armoured cables. All power cables shall be of minimum 6 s
q.mm. copper (refer
specific T.S.) and control cable 2.5 mm sq. cu only. Cables
selection and routing on
the hoist shall form part of electric hoist scheme.
The hoist structure , motor frames and metal cases o
f all electrical equipment,
including metal conduit or cable guards shall effectively be
connected to earth.
4.9
HOISTING MECHANISM
4.9.1
The operating speed shall be 2 - 4 m/min , if not specific
ally mentioned in TS.
Maximum speed shall be considered for motor power calcula
tion purpose .Creep
Speed shall be 10-20 % of normal speed .
4.9.2
Hoist shall be electric wire rope trolley suspended type
. The design and operation of
the hoist shall conform to IS 3938:1983.
4.9.3
Electrical hoist shall be fitted with an automatic loa
d brake to prevent self lowering of
the load in all working position and it will engage automa
tically in case of power
failure.
4.9.4
Load brake shall allow smooth lowering of the load and a
rrangement shall be such as
it can not be released accidentally. Brake shall confor
m to IPSS:1-08-005,86.
4.9.5
Service class of motor shall be '4' as per IS3177:1977. Conditi
ons given in
IS3938:1983 for hoist motor shall be followed. The motor shal
l be suitable for
plugging operation and duty cycle shall be 40 %.
4.9.6
Hoist shall be designed so that remote control can be
effected by means of push
button pendant switch operation. Arrangement of pendant push
button switch shall
conform to IS 3938:1983.
4.9.7
The power collection to the hoist shall be through fle
xible trailing cable system
mounted on retracting supports (Festoon type). The flexible
trailing cables shall be as
per IPSS:2-02-005-85 .

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4.9.8
Earthing terminals in the motor control panel and motor inc
luding pendant switch
shall be suitably provided, preferably at two different points
.
4.9.9
Speed of LT

mechanism shall be 10 -15 m/min, if not specifically ment
ioned in TS.
4.10
MOTOR CONTROL PANEL
The panel shall be made out of 2mm sheet steel clad, box
type by construction. The
panel shall be of wall/column type mounting.
The panel shall contain necessarily the following item
s :
i)
One three pole 415 V AC, 50 HZ MCCB having inbuilt over curre
nt & short
circuit release
ii)
3-pole electromagnetic contactors suitable for hoistin
g and lowering operation
with 230V/110V A.C.operating coil. One thermal over load rel
ay with single
phase preventer shall be incorporated in series with co
ntactors. The power
contactors rating of drives shall be 60% more over and a
bove the full load
current of the respective drives or rated 30A which ever is
more.
iii)
The incoming and out going cables of the panels shall be t
erminated at the
lower part of the panel on the terminals consisting of c
admium coated bolts
mounted on atleast 15 mm thick fiber insulating sheets. Al
l the control cables
shall be terminated in one clip on type of terminal board
and both end of cables
shall properly be ferruled and identified .
iv)
Following indication lamps shall be provided at the panel
door .
a)
Power supply ON
b)
Drive ON
c)
Drive trip
Control panel shall be as per IPSS-1-10-010-84. The supplie
r shall submit Data sheet
of MCC duly filled.
4.11 All the electrical & mechanical equipment shall be
procured as per the list of the
preferred makes of the Purchaser.
4.12 Following drawings shall be submitted:
i)
The general arrangement drawings containing all informat
ion like clearances ,
hook approaches, lift, wheel base, wheel loads, wheel dia
, motor ratings, speeds
etc.
ii)
Assembly drawings of individual drives like hoists, long t
ravel etc.
iii)
Drawings indicating details of lubrication system.
iv)
Circuit diagram showing the wiring for the electric hoi
st including the
following:

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a)
Speed torque characteristics of each drive.
b)
Electrical equipment layout drawing.
c)
Electrical schematic diagram.
Power supply arrangement to the Hoist and attachments.
v)
Approved Quality Assurance Plan (Q.A.P.)
vi)
In addition to the above, the Purchaser may ask for subm
ission of other
drawings, documents, structural, mechanical and electrical
calculations of the
electric hoist for approval, if required.
4.13 Following break-up of weights of the electric hoist
shall be furnished
i)
Total weight of electric hoist including electrical equi
pment.
ii)
Weight and name of individual heaviest mechanical component
for electric
hoist.
iii)
Total weight of structural, mechanical and electrical e
quipment separately
4.14 A tool-box containing all necessary tools like torque wr
ench, portable hydraulic
jacks, hand grease gun, set of spanners, screw drivers et
c. required for the
maintenance of the electric hoist, shall be supplied w
ith the electric hoist.
4.15 Test certificates for all electrical equipment, c
ables and all parts used in handling
loads as for instance wire ropes, chains, load hooks et
c shall be submitted.
4.16
Material test certificates for structural steel and me
chanical component such as
couplings, gears, gear boxes, rope drums, brake drums, pulley
s, shafts, wheels etc
shall be submitted.
4.17
Supplier shall ensure that minimum amount of assembly at s
ite is necessary for early
commissioning of the electric hoist after delivery. Site
welding and riveting shall be
avoided as far as possible. The Supplier before proceedi
ng with design details shall
satisfy himself about the site conditions so as to a
void any difficulty in erection
arising out of design.
4.18
INSPECTION AND TESTING
4.18.1 The electric hoist may be inspected and tested durin
g different stages of its
manufacture starting from raw materials, till the com
pletion of the electric hoist by
the Purchaser or his authorised representative at the sub
-supplier's works as per the
inspection procedure mutually agreed between the Purchaser or
his authorised
representative and the supplier. Inspection shall be regarde
d as a check up and shall
be in no way binding on the Purchaser.
The technical instructions in respect of the inspection
testing shall be strictly
followed.

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The particulars of the proposed test and the procedure of
the test shall be submitted to
the Purchaser for approval prior to conducting the test. T
he Supplier shall inform the
Purchaser well in advance about the program for the tes
t so that Purchaser's
representative can witness the same. All tests shall
be carried out in presence of the
Purchaser's representative. The equipment in no case sha
ll be dispatched without the
certificate of acceptance from the Purchaser's inspect
or and dispatch clearance.
The electric hoist shall be completely assembled in
the Supplier's works and no-load
testing shall be carried out in presence of Purchaser's
representative.
4.18.2 The electric hoist after erection shall be tes
ted as follows:
1) SPEED TESTS
i)
All the motions of the electric hoist shall be test
ed with 25% overload in which
case the geared speeds need not be attained but the electr
ic hoist shall show
itself capable of dealing with the overload without diffi
culty.
2) BRAKE TESTS
i)
The hoist brakes shall be capable of breaking the moveme
nt under conditions of
Speed Tests.
ii)
The long travel brakes shall be capable of arresting the
motion within a distance
in meters equal to 10% of the speed in Metres/min.
3) INSULATION AND OTHER TESTS
As mentioned in IS3938:1983 shall also be carried out.
4) DIMENSIONS of all parts USED on electric hoist sh
all conform to metric
standards.
4.19
PAINTING
Painting shall be done as per Plants standard.

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Annexure 3.5.7.3 1
GENERAL TECHNICAL SPECIFICATION FOR
HYDRAULIC SYSTEMS
1.0
SCOPE
This specification covers hydraulic systems including anc
illary equipment such as
filters, heaters, hoses, accumulators, etc., with th
e exception of hydraulic servo-systems
which shall generally conform to the manufacturer's stan
dards.
The hydraulic systems covered herein are intended for actua
tion of components of
various production and ancillary equipment in the steel p
lant to achieve specific
functions such as application of pressure / force / tor
que, generation of linear or rotary
motion etc.
2.0
GENERAL
1) The hydraulic systems shall be designed, manufactured,
erected, tested and
commissioned as per standards laid down in this specificatio
n. Wherever such
standards are not indicated, the system shall be as per
the codes and practices
adopted by IS or IPSS.
2) Hydraulic systems supplied shall include all the necessar
y equipment and/or
components to perform the specified functions.
3) In the designing and installation of each system and pip
ing, attention shall be
paid to guard against oil leakage.
4) All the equipment and/or components shall be provided wit
h protection such as
a cover against splashed water or other liquids considerin
g their environmental
conditions.
5) When fire-resistant hydraulic fluids are used in the
system, the material of
mechanical parts shall be selected taking the chemical a
nd physical property of
such fluids into consideration.
6) Trenches and pits shall be provided for each classifie
d section of the hydraulic
system to make collection of drained oil possible.
7) All the components shall be installed taking into con
sideration accessibility and
easy maintenance.
8) Provisions of IS 5107-69, Recommendation on nominal pressure
for oil
hydraulic system elements; IS 5108-69 Recommendation on nomi
nal rates of
flow for oil hydraulic system elements; and IS 5109-69, Reco
mmendation on
nominal bores for oil hydraulic system elements shall be
complied with.
9) Operational parameters and circuits shall be displaye
d at easily accessible
places.

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10) Name plates with the following description shall be at
tached to the hydraulic
equipment and/or component at a place easy to be read.
a) Name of equipment and/or component
b) Manufacturing serial No. and/or type
c) Specification of rating
d) Date of manufacture
e) Name of manufacturer
3.0
RESERVOIRS
1) The bottom plate of a rectangular type reservoir sh
all have approx. 3 to 4 %
inclination in the direction of oil drain (generally to t
he front side) and shall be
equipped with a valve to drain oil.
2) Reinforcing ribs shall generally be attached at the ou
ter surface of the reservoir.
Cleaning and inspection of the reservoir shall be done ea
sily for a large capacity
reservoir which structurally requires reinforcing ribs at
its inner surface.
3) Material for reservoirs shall be selected from amo
ng those given in the table
below according to the kind of working fluid.
Hydraulic fluids Material
Phosphate ester Stainless steel or anti-weathering ste
el
W/O type emulsion
Water + glycol
Rolled steel for general engineering
purpose
Mineral oil (including fatty
acid ester)
4) Reservoirs shall have a working volume adequate to cont
ain all the fluid that
may return when the system is at rest and to feed the
system for a minimum of 5
minutes at the rated working capacity.
Reservoir capacity, for small systems shall, howeve
r, be at least 7 times the
delivery amount (lpm) of the pumps.
They shall be designed for adequate heat dissipation and s
o as to allow
unhindered air flow over all surfaces.
5) The inside of the reservoir shall be sand blasted to r
emove rust and detrimental
matter.

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6) An anti-corrosive treatment shall be given to reser
voirs made of steel except for
those made of stainless steel.
7) Air breather, oil supply and drain holes, oil sampling
hole, oil level gauge,
manhole, oil temperature gauge, and other necessary items
shall be installed for
which fitting mounts shall be arranged at proper places.
8) Name plates describing the hydraulic circuit for the re
lated equipment and/or
component with a reservoir shall be attached at a sui
table place in addition to the
name plate on reservoir itself. Material for plates
shall generally be aluminum or
stainless steel, and the description should remain clear
for long term operation.
9) Baffle plates shall be attached at suitable places in
reservoirs with large capacity.
10) More than one manhole shall be provided at both the top
and side plates.
Manholes on the top shall be provided with elevated seat a
t least 20 mm above
the top plates to protect against dirty oil or dust enteri
ng the reservoirs. The
bottom surface of the manhole for the side plate shall
be at the same level as the
bottom of the reservoir in order to be used as a cleani
ng hole.
11) The suction pipe for the pump shall be installed not less
than 100 mm above the
bottom plate of the reservoir and more than 100 mm below
the lowest oil level.
The outlet of the return pipe shall be arranged so as no
t to blow off the sediment
at the bottom.
12) The bottom plate of the reservoir shall be locate
d at a place at least 150 mm
higher than the floor where the reservoir is installe
d in consideration of the
draining of oil from the reservoir unless otherwise specifi
ed.
13) The visual oil level gauge for local service to be insta
lled on the reservoir shall
be of direct indication type with absolute values, an
d shall be made so as to
prevent any damage to the glass.
14) The oil inlet holes of the reservoir shall be provi
ded with a wire net filter of 40
to 150 mesh according to the working condition of the equi
pment and/or
component.
4.0
HYDRAULIC PUMPS AND MOTORS
1) Unless otherwise specified, the number of standby pumps s
hall be in accordance
with the following instructions:
Number of normally operating
pumps
Number of standby pumps
1 1
More than 1 50% of the total no. of pumps

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2) Operation mode for standby pumps
Standby pumps shall be started automatically in case of
failure of any operating
pump. However, a positive lockout system shall be provided
to avoid any
unexpected starting of the standby pumps due to a pressure dro
p resulting from
the motion of some large capacity actuators or due to the
normal starting
duration of a series of pumps.
3) Pumps shall, in principle, not be installed on the re
servoir.
4) The length of the suction piping shall be as short as
possible and its diameter
shall be as large as practicable.
5) Each pump shall be arranged so that it can be removed
for maintenance even
while the corresponding hydraulic system is in operation.
6) Oil flow and shaft rotation direction shall be indica
ted on the pumps.
7) Electric motor and pump shall be installed on a common bas
e.
8) The type of pump for fire-resistant fluids shall be se
lected in accordance with
the table below, considering the type of hydraulic fluid. H
owever, selection of
hydraulic fluid other than mineral oil shall be subject t
o prior consent of the
Purchaser. In such cases, compatibility of the equipmen
t/ components with the
type of oil selected shall be ensured.
Hydraulic fluid Type of pump Hydraulic pressure
O/W type emulsion Piston pump Less than 210 kgf/cm
2
W/O type emulsion Piston pump
Vane Pumps
Less than 210 kgf/cm
2
Less than 70 kgf/cm
2
Water + glycol
Piston or vane
pump
Less than 140 kgf/cm
2

Phosphate ester
Piston or vane
pump
No pressure limitation
9) The hydraulic motor shall be mounted on a rigid base
plate which is capable of
withstanding the hydraulic shocks likely to be imposed.
10) Where possibility of over-running or complete stalling of
the hydraulic motor is
present, suitable relief arrangement shall be provided to a
llow oil to circulate
without overheating.
5.0
VALVE STANDS
1) Each valve stand shall have sufficient rigidity again
st vibration during operation.

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2) Stop valves shall be installed for the maintenance of
each item of equipment
and/or component.
3) Each valve stand shall be provided with a circuit diagram
plate which will
include its related actuator. Name plates describing the nam
e, use, etc. shall be
attached to each valve.
4) Pipe connections to the manifold block and valves at the
valve stand shall, in
principle, be flanged connections.
5) Valve stands with large capacity shall be of an indepe
ndent type, separate from
the pump unit and reservoir.
6) Valve arrangement shall be designed to facilitate its
inspection and replacement
without disturbing the adjacent components.
7) Collecting pans, or small trenches and pits around the v
alve stands shall be
provided for the discharged oil.
8) Valves shall be mounted at a level higher than the hig
h fluid level in the
reservoir.
9) Internal leakage shall be separately drained to reservo
ir or to vented manifold to
prevent locking of plunger type controls.
10) All valve porting shall be identified adjacent to ports
by International Standard
Organisation (ISO) thread designations.
6.0
ACTUATORS
6.1
HYDRAULIC CYLINDERS
1) An air breather shall be provided in the head cover an
d rod cover, respectively.
2) According to the surrounding conditions, cylinders shall
be protected against
dust, heat, water, etc.
3) The internal surface of the cylinder and the rod surface
shall be plated with hard
chromium with a minimum thickness 0.05 mm for O/W emulsi
on and a
thickness of 0.02 mm for other hydraulic fluids.
4) Surface of pistons shall be of bronze coated steel i
n principle.
5) A cushion shall be provided at both ends unless otherwise
noted. Lock nuts
shall, in principle, be adopted for locking the piston rods
and end pieces.
6) Cylinders shall be installed so that no side or radial
load shall occur on the
piston rod or ram. Cylinders shall be easily replaceabl
e.
7) Port connections shall have pipe threads to ISO standa
rds.
8) Cylinder shall have metal name plate stating manufact
urer's name, bore, stroke,
pressure rating, model and serial number.

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9) Hydraulic cylinders shall be tested as per IS 10585-83. Provi
sions of IS 11003-
84, IS 11146-84 and IS 13102-91 shall also be complied with.
6.2
HYDRAULIC MOTORS
1) Hydraulic motors shall generally be in accordance with J
IS B 8359 or
equivalent.
2) External drain of hydraulic motors shall drain oil thr
ough an exclusive pipe to
avoid harmful back pressure on the hydraulic motor.
7.0
AUXILIARY APPARATUS
7.1
PRESSURE GAUGES
1) Pressure gauges shall be located so as to facilitate ea
sy readability.
2) Gauge cocks shall be so designed to permit gauge changing whi
le the hydraulic
system is in operation.
3) Adequate protection against surge pressure shall be provided.
4) Pressure gauges which are required to be watched continuousl
y shall be
protected by certain shock absorbing equipment.
5) The gauge shall have a range of 1.7 to 2.0 times as high
as the maximum
working pressure.
7.2
FILTERS
1) Suction filters shall be installed outside the reservoi
r, except for special reasons,
and a stop valve shall be installed at its primary side.
However, suction filters may be located inside the res
ervoir when their
inspection and cleaning can be done without draining fluid fro
m the reservoir.
2) Line filters shall, in principle, be installed in the
return line.
3) Line filters shall be equipped with an indicator for clo
gging.
4) Mesh for the suction filter shall be 120 mesh or finer.

5) Due consideration shall be given so that filters can b
e maintained easily during
operation.
7.3
COOLERS
1) Oil coolers shall be provided so that oil temperature at
normal operation may not
rise more than 50oC.
2) Oil cooler shall be provided in auxiliary cooling and filt
ration circuit only.
3) Operation of the cooler shall be automatically contr
olled according to the oil
temperature.

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4) Suitable thermometers shall be provided for checking inl
et and outlet
temperature of oil.
7.4
HEATERS
1) A heater shall be installed when the hydraulic fluid
is of a phosphate ester
straight type or when the viscosity of the hydraulic fl
uid becomes higher than
the value given in the table below under a combination of
pump types.
Type of pump Viscosity
Vane pump 850 cSt (4,000 SSU)
Gear pump 1,600 cSt (7,000 SSU)
Axial piston pump 630 cSt (3,000 SSU)
Screw pump 850 cSt (4,000 SSU)
2) Operation of the heater is automatically controlled
according to the oil
temperature.
3) When hydraulic fluid of a phosphate ester straight type
is used, the material of
the heating pipe shall be stainless steel.
4) When an electric heater is used, an electric heater
having a power density of
more than 2.3 W/cm2 for stagnant oil and 3.0 W/cm2 for flow
ing oil shall not be
used to prevent cracking of fluid due to localised overheat
ing.
5) Suitable thermometers/ thermostats shall be provided f
or checking inlet and
outlet temperature of the hydraulic fluid.
7.5
FLEXIBLE HOSES
1) Suitable material shall be selected for the flexible
hoses, considering type of the
hydraulic fluid and surroundings.
2) Flexible hoses shall be connected so that excessive l
oad may not occur on the
connection part.
3) Flexible hoses shall be properly installed avoiding sha
rp bends and excessive
flexing. Proper supporting means shall be provided with suitable sl
eeves, where
required, for protection against external abrasion.
4) Hoses which are used in a corrosive environment or in an
environment where
the outer surfaces of hoses can easily be damaged shall
be protected by some
appropriate means such as stainless wire braid, etc. accor
ding to the working
conditions.

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5) Hoses used in circuits where surge pressure may occur sh
all have sufficient
strength to overcome the expected maximum surge pressure (1.
5 times the
maximum working pressure).
6) Hoses fittings shall be stamped with normal working pr
essure at a place where it
is easy to be read.
7) While selecting hose assemblies and fittings, Plants
standards (if any) shall be
adhered to. Consideration shall also be given to latest
practices and standards in
use.
7.6
SEALING DEVICES
1) All sealing materials shall be selected taking the kin
d of hydraulic fluids and
working environment into consideration. Latest developme
nts and practices in
this area shall be kept in view.
2) Detailed manufacturing drawings, along with component pa
rt nos. for easy
identification, shall be provided for the sealing devices.
7.7
ACCUMULATORS
1) Materials, construction, dimensions, etc. of the ac
cumulator shall be in
accordance with IS 2825-69 or the code for unfired pressure ves
sels
(Amendment 5) prevailing in the country of origin. Accumul
ators shall
preferably be of bladder type.
2) Paint shall not be applied but a rust resisting treatm
ent should be applied to the
inner surface of bladder type accumulators.
3) Means shall be provided for safely relieving the accumulat
or gas and liquid
pressure before the accumulator can be disassembled. Sui
table equipment shall
be provided for charging the accumulator.
4) The following information shall be indicated on each
accumulator:
i) Manufacturer's name and address and serial no.
ii) Rated operating pressure
iii) Charging medium
iv) Total fluid capacity
5) Details of accumulator bladders, sealing elements, fil
ling and testing devices and
safety devices shall be provided along with nomograms/ cha
rts.
8.0
PIPING
8.1
MATERIAL AND WALL THICKNESS OF STEEL PIPE
1) Materials for hydraulic piping shall be Stainless Stee
l seamless pipe.

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2) Safety factors for the calculation of pipe strength
shall be in accordance with the
following:
Pressure range,kgf/cm
Safety factor
Less than 70 8
70 - 175 6
More than 175 4
3) Excessive hydraulic shock shall be considered in additio
n to the safety factors.
8.2
VELOCITY OF FLUID IN THE PIPE
1) The hydraulic circuit pipework shall be designed to m
inimize generation of heat
in the system.
2) In principle, the diameter of the pipe shall be decide
d to permit the following
maximum velocity of the fluid:
Delivery lines : 4 to 6 m/sec
Return lines : 1.5 m/sec
Suction lines : 1 m/sec
8.3
PIPE JOINTS
1) For pressure side piping, slip-on welding type pipe joints
shall be used.
For the places where those joints cannot be used due to
the restriction of
installation work, and places where frequent disassembly
is required for
maintenance, flanged joints with O-rings may be used.
Pipe flanges for pressures of 210 kgf/cm
and under shall conform to IS 6392 :
1971 or equivalent.
2) For return piping, flanged joints shall be used. For th
e places where joints do not
need to be disassembled for maintenance and flushing wo
rk, butt-welded joints
may be used.
8.4
OTHER TECHNICAL REQUIREMENTS
1) Intervals between pipelines shall be large enough for
easy installation and
maintenance.
2) Pitches of pipe supports shall be as follows:
Nominal diameter L
1
, near bends L
, on straight length
Less than 65 mm 500 mm 1,500 mm

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More than 80 mm 500 mm 3,000 mm
3) Block type pipe clamps shall be applied for pipe supports
in principle.
U-bends, if used, shall be equipped with cushion rubber to ha
ve sufficient
vibration-resistance.
4) Stainless Steel pipes shall be cut by machine.
5) Pipes shall be bent by mechanical bending and not by heat
bending.
6) Air vents with plug / valve shall be provided at proper plac
es.
7) All valves shall have frame sizes, ports etc. conform
ing to ISO standards.
8) All hydraulic equipment shall be accessible, have adequa
te working clearance
and be mounted in a position that will not interfere wi
th maintenance of the
equipment and shall not require use of portable platforms
and ladders.
9.0
SAFETY AND CONTROL SYSTEM
1) Centrally monitored and controlled hydraulic systems
shall be equipped with the
following devices:
a) Alarm for low oil level in reservoir
b) Alarm for lowest oil level in reservoir (signal t
o be used to shut down
pumps)
c) Alarm for low pressure of main hydraulic circuit
d) Alarm for high oil temperature in reservoir
e) Alarm for filter clogging in main hydraulic circuit
2) Hydraulic circuits shall be designed to withstand all
possible sudden load
variations. An accumulator for absorbing such shock shall
be installed, if
necessary.
3) In designing circuits, necessary fail-safe measures sh
all be taken so that the
actuator may not cause damage to plant equipment and operat
ors in case of an
electric power failure.
4) It shall be possible to change over from automatic to
manual mode, whenever
necessary.
5) When a positive displacement pump is used, relief of t
he circuit shall be
provided.
6) Wherever cylinders, actuators, or motors may experience
externally induced
forces, the circuitry shall include protective devices, such
as suitable cushioning
and relief valves, to prevent detrimental pressures on t
hese equipment.
7) Hydraulic motor speeds shall be controlled by suitable
flow control valve.

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8) Sequence control shall be primarily governed by mechanical
ly actuated limit
switches, electronic timers, sequence valves or any othe
r position sensing
device.
9) When loss of working pressure on the discharge side of the
pump may result in
damage to equipment or danger of injury to personnel, means sha
ll be provided
to prevent operation under these conditions.
10) An emergency stop shall be provided and shall be readily
accessible from the
operator's normal working position.
10.0
OIL CELLARS
1) The following shall be taken into consideration when an
oil cellar is provided for
hydraulic systems.
a) Entrance stairs shall be provided at least at two pla
ces.
b) Trenches and pits for collecting oil shall be provided
around tank and
valve stands.
c) Suitable fire fighting facility shall be provided.
d) An electric / manual hoist shall be installed for ma
intenance.
2) A ventilator of not less than 15 m3/min capacity per 100 m
3 of cellar capacity
shall be provided.
11.0
PICKLING AND FLUSHING
11.1
PICKLING
1) Pickling shall, in principle, be done after final weldi
ng.
2) De-greasing and water washing should be done prior to pickli
ng, if necessary.
3) Water washing and neutralization shall be made immediat
ely after pickling.
4) Proper anti-corrosive treatment shall be given to pi
pes which will require being
left for long periods of time after pickling.
11.2
FLUSHING
1) The entire system shall be flushed.
2) When flushing is performed with the use of a reservoir,
the reservoir shall be
thoroughly cleaned after flushing.
3) Draining of flushing oil shall be performed immediatel
y after the completion of
flushing. Attention should be paid so that oil is not left in
the lower part of the
piping.
In order to return oil completely to the reservoir,
nitrogen gas or dry air can be
used.

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INSPECTION AND TESTING
Inspection and testing shall be as specified in TS. Howev
er, following are to be
necessarily take care of:
1) A hydrostatic test of the reservoir shall generally
be performed prior to
shipment. However, large-scale reservoirs to be assem
bled at site shall be tested
at the site.
2) After completion of flushing, oil shall be fed into th
e piping system and pressure
increased up to 1.5 times the working pressure to check oil
leakage in each
section.
3) The hydraulic system shall be commissioned as per reco
mmendations of IS
13053-91.

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RSP ANNEXURE 3.5.7.5-1 CET/05/RN/3170/TS/IR/02/R=1
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Annexure 3.5.7.5-1
GENERAL TECHNICAL SPECIFICATION FOR
LUBRICATION SYSTEMS
1.0
SCOPE
This specification covers the general requirements
of lubrication systems for the
forced circulation oil and grease lubrication.
2.0
FORCED CIRCULATION LUBRICATION
2.1
GENERAL
1) The systems shall be designed, manufactured, ere
cted, tested and
commissioned as per standards laid down in this spe
cification. Wherever
such standards are not indicated, the system shall
be as per the codes and
practices adopted by IS 8593: (Part1) - 77.
2) Lubrication systems supplied shall include all t
he necessary equipment
and/or components to perform the specified function
s.
3) In the designing and installation of each system
and piping, attention shall be
paid to guard against oil leakage and protection ag
ainst external damage.
4) All the equipment and/or components shall be pro
vided with protection such
as a cover against splashed water or other liquids
and also to prevent dust
accumulation considering their environmental condit
ions.
5) Trenches and pits shall be provided for each cla
ssified section of the
lubrication system to make collection of drained oi
l possible.
6) All the components shall be installed taking int
o consideration accessibility
and easy maintenance.
7) Details concerning each lubricant shall be furni
shed indicating system
reference, consuming point reference, oil type and
grade, detailed
specification, quantity for first fill, expected co
nsumption rate and all other
relevant data.
8) Unless otherwise specified, lubrication equipmen
t for centralised systems
located in unattended areas, basements etc., shall
have remote control
facilities to ensure safety of the equipment served
by such lubrication.
9) Centralised oil lubrication systems shall be pro
vided for applications where
lubrication is needed for a large number of use poi
nts located reasonably
close and needing the same grade of oil lubrication
.
10) Name plates with the following description shal
l be attached to the
lubrication equipment and/or component at a place e
asy to be read.
a) Name of equipment and/or component
b) Manufacturing serial no. and/or type
c) Specification of rating
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d) Date of manufacture
e) Name of manufacturer
11) All schematic drawings and GA drawings shall be
approved by the
Purchaser/consultant.
12) All units to be packed properly in wooden boxes
to project the equipment
against damages due to long outdoor transit. All in
struments to be packed
separately in wooden boxes.
13) Power units to be filled with system fluid to p
revent corrosion/rusting due to
long storage. Openings of all the units to be blank
ed for air tightness.
2.2
RESERVOIRS
1) The bottom plate of a rectangular type reservoir
shall have approx. 4%
inclination in the direction of oil drain (generall
y to the front side) and shall
be equipped with a valve to drain oil. An additiona
l drain point with valve
shall be provided at a height of 150 mm above the b
ottom of the reservoir to
facilitate the pumping out of oil excluding the slu
dge deposited at the
bottom.
2) Reinforcing ribs shall generally be welded at th
e outside face of the
reservoir.
Cleaning and inspection of the reservoir shall be d
one easily for a large
capacity reservoir which structurally requires rein
forcing ribs at its inner
surface.
3) The reservoir capacity shall, in principle, be a
t least 20 times the volume of
oil circulated per minute through the system. The t
otal volume of the
reservoir shall be at least 20% more than the usefu
l volume, the rest being air
space.
4) For facilities such as an oil-film bearing into
which a large amount of water
may enter, two reservoirs shall be provided so that
they may be used
alternatively.
5) Pump suction pipe with a float shall be provided
for reservoirs with a
capacity of 15 m3 or more. Suitable strainer shall
be provided at the suction
point.
6) The oil sampling hole shall be positioned at abo
ut one tenth of the reservoir's
height from the bottom and near the pump suction to
permit the sampling of
flowing oil.
The sampling hole shall be provided with necessary
valve and stopper.
7) Centrifuges shall be installed in lubrication ci
rcuits where water may enter
into large-size gear drives and large-size journal
bearings.
8) An anti-corrosive treatment shall be given to re
servoirs made of steel except
those made of stainless steel.
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9) Air breather, oil supply and drain holes, oil sa
mpling hole, oil level gauge,
manhole, oil temperature gauge, and other necessary
items shall be installed
for which fitting mounts shall be arranged at prope
r places.
10) Name plates describing the oil circuit for the
related equipment and/or
component with a reservoir shall be attached at a s
uitable place in addition to
the name plate on reservoir itself. Material for pl
ates shall generally be
aluminum or stainless steel, and the description sh
ould remain clear for long
term operation.
11) Baffle plates shall be attached at suitable pla
ces in reservoirs with large
capacity.
12) More than one manhole shall be provided at both
the top and side plates.
Manholes on the top shall be provided with elevated
seat at least 20 mm
above the top plates to protect against dirty oil o
r dust entering the reservoirs.
The bottom surface of the manhole for the side plat
e shall be at the same
level as the bottom of the reservoir in order to be
used as a cleaning hole.
13) The suction pipe for the pump shall be installe
d not less than 100 mm above
the bottom plate of the reservoir and more than 100
mm below the lowest oil
level.
The outlet of the return pipe shall be arranged so
as not to blow off the
sediment at the bottom.
14) The bottom plate of the reservoir shall be loca
ted at a place higher than the
floor where the reservoir is installed in considera
tion of the draining of oil
from the reservoir.
15) The visual oil level gauge for local service to
be installed on the reservoir
shall be of direct indication type with absolute va
lue, and shall be made so as
to prevent any damage to the glass.
16) The oil inlet holes of the reservoir shall be p
rovided with a wire net filter of
40 to 150 mesh according to the working condition o
f the equipment and/or
component.
17) The complete lubrication system shall drain by
gravity to the reservoir. Drain
lines shall slope down to the reservoir at about 4%
to the horizontal.
18) Side ladder shall be provided on tanks more tha
n 1.5 m in height.
19) After manufacture, the tanks will be tested for
leakage by kerosene swab and
chalk application. Spot dye penetration test will a
lso be carried out on
random basis to check quality of welding. Static lo
ad test will be done with
water filling of tanks.
20) GA drawing of tank shall be approved by the Pur
chaser/consultant.
These provisions shall not apply to casings for equ
ipment such as a reducer
which is lubricated.
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2.3
OIL PUMPS
1) The endurable pressure shall be at least 150% of
the maximum working
pressure.
2) Unless otherwise specified, the number of standb
y pumps in a system shall
be in accordance with the following instructions:
No. of normally operating
pumps
No. of standby pumps
1 - 2 1
3-4 2
5-8 3
3) Operation mode for standby pumps
Standby pumps shall be started automatically in ca
se of failure of any
operating pump. In such a situation an indication w
ith audio-visual alarm
shall be available at the control panel.
4) The length of the suction piping shall be as sho
rt as possible.
5) Each pump shall be arranged so that it can be re
moved for maintenance even
while the corresponding oil system is in operation.
6) Oil flow and shaft rotation direction shall be i
ndicated on the pumps.
7) Electric motor and pump shall be installed on a
common base.
8) The pump shall be of screw type. Pump & motor sh
all be aligned and
assembled on a common base frame and coupled by axi
ally split flexible
bibby coupling complete with coupling guard. The mo
tor will have an in
built 20% extra power. The pump shall be capable of
handling the increased
viscosity of oil corresponding to ambient temp of 6
oC. The normal system
working temperature will be around 500C.
2.4
AUXILIARY APPARATUS
1)
Pressure gauges
a) Pressure gauges shall be located so as to facili
tate easy readability.
b) Gauge cocks shall be so designed to permit gauge
changing while the
lubrication system is in operation.
c) Adequate protection against surge pressure shall
be provided.
d) Pressure gauges which are required to be watched
continuously shall be
protected by certain shock absorbing equipment.
e) The gauge shall have a range of 1.7 to 2.0 times
as high as the
maximum working pressure.
f) Pressure gauges shall be installed at the oil fe
ed side of facilities such
as an oil-film bearing etc.
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g) Filters and coolers shall be provided with diffe
rential pressure gauges
for monitoring pressure drop of oil and water.
2)
Filters
a) Self cleaning type filters shall be used in all
oil systems. Filtering
elements shall be of stainless steel.
b) Filter element shall be of 100 micron rating.
c) Lubrication systems, in which interruption of oi
l may cause a stoppage
of the plant, shall be so designed that the filter
at the delivery side of
the pump can easily be cleaned and replaced without
interruption of
lubrication.
d) Filters shall be equipped with an indicator for
clogging. The indication
shall be available on the control panel.
e) The filter should be capable of handling full fl
ow of oil at a pressure
differential of 0.2 kg/cm
in clean condition. The total filtering area and
the net open area shall be indicated.
3)
Coolers
a) Oil coolers shall be provided so that oil temper
ature at normal
operation may not rise more than 60
C. Plate type coolers shall be
preferred.
b) When an oil cooler is installed, a by-pass circu
it shall be provided so
that maintenance of the cooler can be performed eve
n during operation
of the oil system.
c) Operation of the cooler shall be automatically c
ontrolled according to
the oil temperature.
d) Suitable thermometers shall be provided for chec
king inlet and outlet
temperature of oil.
e) The cooler shall be designed with 20% reserve ca
pacity. The
performance data sheet of the cooler as per the enc
losed format shall be
furnished.
4)
Heaters
a) Heaters shall, in principle, be installed when t
he lubrication system is
operated under the following conditions:
Ambient temperature is 40 deg.C or below.
Water may enter into the system.
Viscosity of the oil is 460 cSt or higher at 40
C.
b) Operation of heater shall be automatically contr
olled according to the
oil temperature.
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c) When an electric heater is used, heater having a
power density of more
than 0.8 W/cm
shall not be used.
d) Thermostat shall be provided to maintain oil tem
perature at any desired
value from 35
C to 85
C.
5)
Flexible hoses
a) Flexible hoses shall be used only where steel pi
pes are not suitable due
to system vibrations etc. Suitable material shall b
e selected for the
flexible hoses considering compatibility with the o
il used and expected
ambient conditions.
b) Flexible hoses shall be connected so that excess
ive load may not occur
on the connection part.
c) Proper supporting means shall be provided for lo
ng hoses.
d) Hoses which are used in a corrosive environment
or in an environment
where the outer surfaces of hoses can easily be dam
aged shall be
protected by some appropriate means such as stainle
ss wire braid, etc.
according to the working conditions.
e) Hoses fittings shall be stamped with normal work
ing pressure at a place
where it is easy to be read.
6)
Sealing devices
All sealing materials shall be selected taking the
kind of lubrication fluids
and working environment into consideration. They sh
all conform to IPSS 1-
02-013-81 (Rotary shaft oil seal units).
7)
Pressure tanks
a) Pressure tanks shall be provided for lubrication
systems such as for oil-
film bearing in which instantaneous interruption ma
y cause serious
damage to the equipment.
b) Pressure tanks shall have the capacity to keep t
he required oil volume
supplied to important lubrication points for a cert
ain time period after
the oil pump stops.
c) Materials, construction, dimensions, etc. of the
pressure tank shall be in
accordance with the code for pressure vessels preva
iling in the country
of origin.
d) Paint shall not be applied but a rust resisting
treatment should be
applied to the inner surface of the vessel.
e) Means shall be provided for safely relieving the
pressure tank of gas
and liquid pressure before the accumulator can be d
isassembled.
Suitable equipment shall be provided for charging t
he vessel.
f) A name plate with the following descriptions sha
ll be attached to the
pressure tank.
Type
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Name of Manufacturer
Oil supplying capacity
Working pressure
8) Back Pressure regulating valve
This shall be provided to maintain constant system
pressure by
diverting varying amount of system flow back to res
ervoir.
2.5
PIPING
1) All pipes shall conform to seamless Sch 40 ASTM
53. Gr A Black pipe upto
150 NB & ERW Black standard weight pipe to IS 1978:
1982 or spirally
welded to IS 3589:1991 for size beyond 150 NB.
2) The return pipe shall have an inclination of app
rox. 1/40.
3) A water leg to discharge water with easy valve o
peration shall be provided in
the return pipe for the lubrication systems of the
main equipment into which
large amounts of water may enter.
4) Consideration shall be given so that no air is l
eft in the return piping.
5) Joints to be used shall be of the slip-on weldin
g, butt-welded, or flanged
type.
6) Spray nozzles for gear lubrication shall general
ly be provided on the gearing-
in side, and shall be prevented from dropping into
the gearing part.
7) In principle, the diameter of the pipe shall be
decided to permit the following
maximum velocity of the fluid:
Delivery lines : 2 m/sec
Return lines : 0.75 m/sec
Suction lines : 1.5 m/sec
8) For pressure side piping, slip-on welding type p
ipe joints shall be used.
For the places where those joints cannot be used du
e to the restriction of
installation work, and places where frequent disass
embly is required for
maintenance, flanged joints with O-rings may be use
d.
9) For return piping, flanged joints shall be used.
For the places where joints do
not need to be disassembled for maintenance and flu
shing work, butt-welded
joints may be used.
10) Intervals between pipe lines shall be large eno
ugh for easy installation and
maintenance.
11) Pitches of pipe supports shall be as follows:
Nominal diameter L
, near bends L
, on straight length
Less than 65 mm 500 mm 1,500 mm
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More than 80 mm 500 mm 3,000 mm
12) Block type pipe clamps shall be applied for pip
e supports in principle.
U-bands, if used, shall be equipped with cushion ru
bber to have sufficient
vibration-resistance, as shown below.
13) Steel pipes shall be cut by machine or grinder
and shall not be cut by gas.
14) Pipes shall be bent by mechanical bending and n
ot by heat bending.
15) Pipe fittings (Tee, elbow, reducer, coupling et
c.) will conform to 3000 Lb
forged steel ASTM A105. Gr A socket welds ends ANSI
B 16.11 for sizes
upto 50 NB & Sch 40 butt weldends ASTM A-234 Gr B s
eamless ANSI B-
16.9 for sizes 65 NB & above.
16) Flanges will conform to weld neck/slip-on. Clas
s 150 Lb forged steel to
ASTM AISI Gr I, ANSI B16.5 flat face.
17) Unions will conform to 2000 Lb forged steel AST
M A-105 Gr II socket weld
ends ANSI B2.1.
2.6
SAFETY AND CONTROL SYSTEMS
1) Centrally monitored and controlled oil lubricati
on systems shall be equipped
with the following alarm devices:
a) Alarm for highest oil level in reservoir
b) Alarm for lowest oil level in reservoir
c) Alarm for low pressure of main oil circuit
d) Alarm for high oil temperature in reservoir
e) Alarm for filter clogging in main oil circuit
2) It shall be possible to change over from automat
ic to manual mode,
whenever necessary.
3) As a positive displacement pump is to be used, r
elief of the circuit shall be
provided. All relief valves shall be piped directly
to the reservoir. Check
valves shall be provided on the discharge side of a
ll pumps to check back
flow.
4) A sight flow indicator shall be installed for th
e lubricant supply pipe of each
high-speed slide bearing.
5) An interlock shall be provided between the lubri
cation system and equipment
requiring an oil-film bearing which may be damaged
if equipment is
operated without the required oil supply pressure a
nd amount.
6) For automatic lubrication systems, all main equi
pment served by the system
shall be suitably interlocked with the lubrication
control circuit with a
suitable time delay relay to ensure positive lubric
ation before starting.
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3.0
GREASE LUBRICATION
3.1
GENERAL
1) Grease systems supplied shall include all the ne
cessary equipment and/or
components to perform the specified functions.
2) In the designing and installation of each system
and piping, attention shall be
paid to guard against grease leakage.
3) All the equipment and/or components shall be pro
vided with protection such
as a cover against splashed water or other liquids
considering their
environmental conditions.
4) All the components shall be installed taking int
o consideration accessibility
and easy maintenance.
5) Hand operated dual line centralised lubrication
system shall be used for
separate machines and mechanisms which have a small
number of
lubrication points and require an infrequent supply
of lubricant.
6) Automatic dual line centralised lubrication syst
em shall be used for
lubricating a large number of points requiring freq
uent supply of lubricant
for long and uninterrupted operation.
7) Lubrication points which are not covered by cent
ralised lubrication systems
shall be provided with lubrication nipple conformin
g to IS 4009(Part-1)-:
1981. The connector for the hand lubrication device
shall suit the
connections provided at the lubrication points.
8) Provisions of IS 8593(Part 2):1988; Recommendati
ons for Centralised
Lubrication as applied to plant and machinery shall
be complied with.
9) Name plates with the following description shall
be attached to the grease
equipment and/or component at a place easy to be re
ad.
a) Name of equipment and/or component
b) Manufacturing serial no. and/or type
c) Specification of rating
d) Date of manufacture
e) Name of Manufacturer
10) Grease station shall be located on the mill flo
or.
3.2
RESERVOIRS
1) Reservoirs for a centralized grease lubrication
system shall have sufficient
capacity to supply grease for one week under normal
operating conditions.
2) Reservoirs shall, in principle, be of the cylind
rical type and shall be provided
with an indicator for the amount of remaining greas
e.
3) The inside of the reservoir shall, in principle,
not be painted.
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4) The reservoir shall be complete with a heavy ine
rtia follower plate and tell-
tale rod for indication of grease content in the re
servoir.
3.3
GREASE PUMPS
1) Grease pumps shall have sufficient delivery pres
sure to compensate for
pressure loss in the piping and be operated stably.
High pressure system with
400 bar pump pressure shall be used.
2) Electric driven type grease pumps shall be autom
atically operated with a
timer.
Grease pumps shall, in principle, be stopped automa
tically with an alarm
under the following conditions:
Delay of system operating time from the pre-set val
ue.
No grease in reservoir.
Overloaded operation of pump motor.
3) Unless otherwise specified, one standby pump sha
ll be provided for each
system.
4) The pumps shall have built-in check valve and re
lief valve to protect the
pump components from over pressure.
3.4
FILTERS
1) Filters used in grease lubrication system shall
be line mounted type. The
filter element shall be so located that dismantling
the filter is not necessary
for cleaning the element. The filter element shall
be stainless steel or
phosphor bronze. Filters shall also be mounted to f
ilter grease fed to the
reservoir.
3.5
PIPING
1) All main line, branch live and feed lines shall
be seamless carbon steel pipes
conforming to DIN 2391. Fittings will be forged ste
el with phosphate plating
ferrule type as per DIN 2353.
2) Piping shall be so designed as to facilitate con
firmation of the operation of
the distribution valve.
3) The distribution valve shall, in principle, be i
nstalled on the supporting bed.
4) A flange, sleeve, or union shall be used as pipe
joints.
However, for pipes with a diameter of more than 25
mm, a flange or sleeve
shall be used.
5) Flexible hoses shall be connected so that excess
ive load may not occur on the
connection part.
6) Proper supporting means shall be provided for lo
ng hoses.
7) Hoses which are used in a corrosive environment
or in an environment where
the outer surfaces of hoses can easily be damaged s
hall be protected by some
RSP ANNEXURE 3.5.7.5-1 CET/05/RN/3170/TS/IR/02/R=1
UPGRADATION OF BF-1 PAGE 11 OF 12
appropriate means such as stainless wire braid, etc
. according to the working
conditions.
8) Hoses fittings shall be stamped with normal work
ing pressure at a place
where it is easy to be read.
3.6
ACCESSORIES
1) On centralised grease lubrication systems, spool
and plunger type dose
feeders suitable for 400 bar pressure shall be used
.
2) End pressure regulator and electromagnetic rever
sing valve suitable for 400
bar pressure shall be provided in the grease system
to ensure pressure
attainment in the circuit during the cycle and to r
everse grease flow. The end
pressure regulator shall be mounted at the end of t
he grease supply line after
the last grease feeder.
3) Pressure gauges shall not be directly mounted on
the grease lines. A suitable
grease oil separator shall be used. One side of the
separator shall be charged
with oil and connected to the pressure gauge and th
e other side to the grease
supply line.
4.0
OIL CELLARS
1) The following shall be taken into consideration
when an oil cellar is provided
for the lubrication systems:
a) Entrance stairs shall be provided at least at tw
o places.
b) Suitable fire fighting facility shall be provide
d.
c) An electric / manual hoist shall be installed fo
r maintenance.
d) One centrifuge of adequate capacity shall be pro
vided for centralised
oil lubrication system.
e) One sump pump of adequate capacity shall be prov
ided in the oil cellar.
2) A ventilator of not less than 15 m3/min capacity
per 100 m3 of cellar
capacity shall be provided.
5.0
PICKLING AND FLUSHING
5.1
PICKLING
1) Pickling shall, in principle, be done after fina
l welding.
2) De-greasing and water washing should be done pri
or to pickling, if
necessary.
3) Water washing and neutralization shall be made i
mmediately after pickling.
4) Proper anti-corrosive treatment shall be given t
o pipes which will require
being left for long periods of time after pickling.
5.2
FLUSHING
1) The entire system shall be flushed.
2) Draining of flushing oil shall be performed imme
diately after the completion
of flushing. Attention should be paid so that oil i
s not left in the lower part of
the piping.
RSP ANNEXURE 3.5.7.5-1 CET/05/RN/3170/TS/IR/02/R=1
UPGRADATION OF BF-1 PAGE 12 OF 12
In order to return oil completely to the reservoir,
nitrogen gas or air can be
used.
3) Flushing shall, in principle, be performed twice
using the same kind of fluid
as working oil (low viscosity fluid for the first f
lushing and the same
viscosity as working fluid for the second).
6.0
INSPECTION AND TESTING
Inspection and testing shall be as specified in TS.
However, following are to be
necessarily take care of:
1) After completion of flushing, grease shall be fe
d into the piping system and
pressure increased up to 1.5 times the working pres
sure to check grease
leakage in each section.
RSP
SCHEDULE 2.4.5.6-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 1 OF 3
SCHEDULE- 2.4.5.6 - 1
TECHNICAL FEED BACK DATA SHEET
(To be filled up by the Bidder)
1. BELT CONVEYORS
Item
SC 1A-2
SC 2A-2 OC 2A-1 OC 1A-1 SFC 1A-6 SFC 2A-6
Capacity
(tph)

Length (c/c
mm)

Belt speed
(m/s)

Motor
Details

Gear Box
Details

High Speed
Coupling
Details

Low Speed
Coupling
Details

Pulley
Details

Idler Details

Safety
Switch
Details

External
Scraper
Details

Internal
Scraper
Details

RSP
SCHEDULE 2.4.5.6-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 2 OF 3
2. VIBRATING FEEDER
Parameters Sinter
Feeder
Coke Feeder
Ore Feeder Additive
Feeder
Type
Manufacturer
Numbers
Guaranteed capacity
Size (mm x mm)
Type of drive
Type of vibrator
Mounting
Inclination of deck
Frequency and stroke/
amplitude of vibration

Feed rate adjustable
Type and construction of deck
Material of the deck
Liners provided
Material of springs
Power requirement at
guaranteed load, at motor input
terminal kW

Motor nameplate rating, kW
Details of VVVF
3. VIBRATING SCREEN
Parameters Sinter Screen Coke Screen
Type
Manufacturer
Numbers
Guaranteed feed rate capacity
Size (mm x mm)
Type of drive
Type of vibrator
Mounting
Inclination of deck
RSP
SCHEDULE 2.4.5.6-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 3 OF 3
Parameters Sinter Screen Coke Screen
Frequency and stroke/ amplitude of
vibration

Feed rate adjustable
Type and construction of deck
Material of the deck
Size of aperture
Type of aperture
Liners provided
Material of springs
Power requirement at guaranteed load,
at motor input terminal kW

Motor nameplate rating, kW and rpm
Details of soft starter
4. ELECTRIC HOIST
Description
Detail Parameter
Nos. offered
Lifting capacity
Height of lift
Class of duty
Hoist
Speed in m/min with safe working load
kW & rpm of motor
Travel
Speed in m/min
kW and rpm of motor
Type of power supply arrangement
Head room of the hoist with hook in the top
most position
Recommended size of I-beam
Name of the manufacturer
Provision of pendant push button control
Signature of the Bidder
Seal of Company
Name
Designation
RSP
SCHEDULE 2.5.9.1-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 1 OF 2
Schedule 2.5.9.1-1
TECHNICAL PARTICULARS FOR PUMP
(The Bidder has to fill-up this schedule for each t
ype of pump set separately and submit
along with his offer)
Sl.
No.
DESCRIPTION OFFERED
1.
Type
2.
Service (Working Medium)
3.
Quantity (No.)
4.
Capacity (m
/h)
5.
Minimum submergence/NPSH
(m)
6.
Column length (For Vertical Turbine
Pumps only)
7.
Suction Head (m)
8.
Discharge Head (m)
9.
Ends :
Conforming standard of flanges
Size of Delivery ends
10.
Motor Speed (rpm)
11.
Pump Speed (rpm)
12.
Weight of pump set (kg.)
Pump
Motor
Base Frame
13.
Impeller Type & Size
14.
Working Temperature (
C)
15.
Ambient Temperature Considered (
C)
16.
Accessories
Companion Flanges, Bolts, Nuts &
Gaskets
Foundation Bolts, Nuts & washers
Suction strainer
RSP
SCHEDULE 2.5.9.1-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 2 OF 2
Sl.
No.
DESCRIPTION OFFERED
17.
Material of Construction
Casing/Bowl assembly
Impeller
Shaft
Shaft sleeve
Companion flanges
Bolts, nuts for flanges
Coupling
Foundation Bolts & Nuts
18.
Bearings
Type
Qty
Make
19.
Duty
20.
Pump Efficiency at Specified Condition
21.
Shaft Sealing
22.
Shut Off Head
23.
Shaft Power Required
24.
Dynamic load (with direction) of pump
25.
Pumps rotating parts are both
Statically & Dynamically Balanced
Yes/No
26.
Make
Pump
Motor
Coupling
Bearings
27.
Guarantee
28.
Delivery period
29.
Test Pressures & Duration
30.
Conforming Standard / Code for tests
to be conducted:
31.
Painting shall be as per Specification Yes/ No.
Signature of the Bidder
Seal of Company
Name
Designation
RSP
SCHEDULE 2.5.9.1-2 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 1 OF 1
Schedule 2.5.9.1-2
TECHNICAL PARTICULARS FOR DIESEL ENGINE
(The Bidder shall submit the following information
in his offer for Diesel Engine)
Sl.
No.
DESCRIPTION OFFERED
1.
Type
2.
Make
3.
Quantity (No.)
4.
Service
5.
No. of cylinder
6.
Bore/Stroke
7.
Rated RPM
8.
Output BHP at rated RPM
9.
Safety devices
10.
Starting devices (Volt)
11.
Speed control
12.
Cooling System
13.
Speed control system governor as per BS:5514
14.
Exhaust
15.
Fuel supply system
16.
Fuel tank capacity
17.
Coupling
18.
Mounting
19.
Engine de-rating factor
20.
Engine Efficiency at Specified Condition
21.
Accessories
22.
Dynamic load (with direction)
23.
Testing & Duration
24.
Conforming Standard/ Code for tests to be
conducted:
Signature of the Bidder
Seal of Company
Name
Designation
RSP
SCHEDULE 2.5.9.1-3 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 1 OF 3
Schedule 2.5.9.1-3
TECHNICAL PARTICULARS OF COOLING TOWER
(The Bidder shall submit the following information
in his offer for Cooling Tower)
Sl. No.
Particulars Offered by Bidder
1.0 General

Name of the manufacturer

Type of tower

Number of cells

Capacity per cells

Tower overall dimensions, m
(Length x Width x He
ight to fan
deck)

Dimension of each cell,m (Length
x Width)

Fill height

Design wet bulb temperature,
C

Approach,
C

Cooling range at rated flow,
C

Evaporation loss at rated condition
/h/cell

Type of fill, splash or film
2.0 Fan

Type

No. of fans/cell

Fan diameter, m

No. of blades per fan

Blade tip clearance, mm

Capacity, m
/min

Speed, rpm

Fan stack height, m

Type (standard/ velocity recovery)

Stack exit air velocity, m/sec
RSP
SCHEDULE 2.5.9.1-3 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 2 OF 3
Sl. No.
Particulars Offered by Bidder

Fan pressure, mmWc
Louvres
Eliminator
Velocity head
Total head
Velocity recovery, if any
Net head

Fan efficiency, %

Brake power, kW

Power at fan shaft, kW

Motor size, kW

Material of construction
Blades
Hub
Fan shaft
3.0 Reducing Gear Unit

Make

Reduction ratio

Rated output, kW

Service factor at rated output

Details of bearings

Efficiency
4.0 Hot water Distribution System

Type

Elevation, inlet above curb, m
5.0 Cold Water Basin

Basin dimension, m

Basin curb elevation, m

Normal water level, m

Maximum water level, m

Basin invert level, m

Effective capacity, m

6.0 Material Of Construction
RSP
SCHEDULE 2.5.9.1-3 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 3 OF 3

Structural member

Casing

Louvers

Inner and outer casings

Fan stack

Distribution header

Fills

Fill support & grid

Grid supporting structure

Gear box
Gear
Shaft
Enclosure

Drive shaft
7.0 Material Handling services

Type

Capacity

Material of construction
8.0
Noise level dBA (measurement as
specified)
9.0 Sluice Gate Details
10.0 Valve Details
11.0 Cooling Tower Testing & duration
12.0 Testing code/ standard
Signature of the Bidder
Seal of Company
Name
Designation
RSP
SCHEDULE 2.5.9.1-4 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 1 OF 2
Schedule 2.5.9.1-4
TECHNICAL PARTICULARS OF HEAT EXCHANGER
(The Bidder shall submit the following in his offer
for Heat Exchanger)
1) Type
2) Make
3) Quantity
4) Type of flow
5) Fluid Flow rate:
a)
Primary side
b)
Secondary side
6) Fluid inlet temp.:
a)
Primary side
b)
Secondary side
7) Fluid outlet temp.
a)
Primary side
b)
Secondary side
8) Max. Pressure drop (mWC)
a)
Primary side
b)
Secondary side
9) Heat load (kcal/h)
10)
Fouling Factor (%)
11)
Overall Heat Transfer
Coefficient in clean condition
(Kcal/m
.h.
C)
12)
Total heat transfer area reqd.
with fouling (m
)
13)
Total heat transfer area
provided (m
)
14)
Max. operating pressure
a)
Primary side
b)
Secondary side
15)
Test Pressure & duration
a)
Primary side
b)
Secondary side
16)
Design temperature
17)
Design pressure
18)
H.E. Plate thickness
19)
No. of plates
20)
Heat transfer area/plate(m
)
21)
Type of gasket
22)
Material of construction
a)
Heat exchanger plate
RSP
SCHEDULE 2.5.9.1-4 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 2 OF 2
b)
Pressure plate
c)
Frame
d)
Nozzles
e)
Sealing
material/Gasket
f)
Upper & Lower
carrying bar
g)
Drain valve
23)
Overall dimension
24)
Empty weight
25)
Operating weight
26)
Design code
27)
Testing & duration
28)
Testing code/ standard
Signature of the Bidder
Seal of Company
Name
Designation
RSP
SCHEDULE 2.5.9.1-5 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 1 OF 2
Schedule 2.5.9.1-5
TECHNICAL PARTICULARS OF SOFT WATER PLANT AND
ACCESSORES
(The Bidder shall submit the following information
in his offer for DM water plant)
Sl. No.
Particulars Parameters
01
General:
Manufacturer
Model number
Number of units
Number of stream
Capacity of each unit (m
/h)
02
Guaranteed Performance
Rate of flow (m
/h) / unit
Maximum flow (m
/h) / unit
Output between two regenerators
Pressure loss through plant
Regeneration requirement
Regeneration time
03
Technical data for vessel
Quantity
Make
Dimension
Design pressure
Design code
Material of construction
Lining & Thickness
Thickness of shell & dished end
Fill material
Type
Size
Quantity
Life
04 Technical date for dilution tanks
Quantity
RSP
SCHEDULE 2.5.9.1-5 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 2 OF 2
Sl. No.
Particulars Parameters
Make
Dimension & thickness
Effective capacity
Design pressure
Material of construction
Lining & thickness
Agitator
Type
Make
MOC
Rpm
05 DM water storage tank
Quantity
Capacity
Make
IS standard
Material of construction
Accessories
06 Miscellaneous
Painting details
Weight of each unit
Life of the plant
07 Testing & duration
08 Testing code/ standard
09 Guarantee
10 Delivery period
11 Painting shall be as per
Specification
Yes/No
Signature of the Bidder
Seal of Company
Name
Designation
RSP
SCHEDULE 2.5.9.1-6 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 1 OF 1
Schedule 2.5.9.1-6
TECHNICAL PARTICULARS OF VALVES
(The Bidder shall submit the following information
in his offer for all Type of Valves
separately)
RATING
:
Service
:
CODES
:
Valve :
Face to Face
Dimensions :
Flange Drilling :
TYPE OF VALVE:
Type :
Ends :
TESTING
:
Hydrostatic test & duration:
Body & Back Seat:
Seat :
Testing Code :
MATERIAL OF CONSTRUCTION
:
Body & Disc :
Stem :
Trim :
Packing :
Hand Wheel :
Bolts & Nuts :
Companion Flanges
ACCESSORIES
:
Company Name & Seal
Signature of the Bidder
Name
Designation...
Signature of the Bidder
Seal of Company
Name
Designation
RSP
SCHEDULE 2.5.9.1-7 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 1 OF 1
Schedule 2.5.9.1-7
TECHNICAL PARTICULARS OF DUPLEX WATER FILTER
(The Bidder shall submit the following in his offer
for Duplex Water Filter)
Sl.N
Particulars Parameters
1)
Make & Model :
2)
No. of units :
3)
No. of chambers/ baskets :
4)
Type of body :
5)
Material of body :
6)
Material of spindle :
7)
Material of basket cage :
8)
Material of filter element :
9)
Material of valve disc
10)
Degree of Filtration :
11)
Flow, Normal m
/hr :
12)
Flow, Maximum m
/hr :
13)
Working Pressure kg/cm
:
14)
Hydrostatic test pressure kg/cm
:
15)
Design Temp.
C :
16)
Pressure drop under normal flow
condition
:
17)
Pressure drop under maximum
flow condition
:
18)
Inlet & Outlet nozzle size
19)
Suitable for installation in
Horizontal/ Vertical pipeline.
:
20)
Overall dimensions of filter unit :
21)
Weight of filter
22)
Drawing showing the G.A. &
cross sections.
:
Signature of the Bidder
Seal of Company
Name
Designation

RSP SCHEDULE 2.5.9.1-8 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF BF-1 PAGE 1 OF 1
Schedule 2.5.9.1-8
TECHNICAL PARTICULARS OF FIRE EXTINGUISHERS
(The Bidder shall submit the following information
in his offer for all Type of fire
extinguishers)
Sl.
No.
Unit / Area
with size
Type of fire extinguishers
CO
Type
(4.5 Kg.)
DCP
Type
(10 Kg)
Foam
Type
(9 litr.)
Water
(Gas Pr)
(9 litr)
1.

2.

3.

4.

5.

Note: The type of portable fire extinguishers envis
aged for various units
shall conform to IS:15683-2006.
Signature of the Bidder
Seal of Company
Name
Designation

RSP SCHEDULE 2.5.9.1-9 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF BF-1 PAGE 1 OF 3
Schedule 2.5.9.1-9
TECHNICAL PARTICULARS OF CA FAN
This schedule is to be filled in separately for CA
fan for Stoves and CDI systems
(without these filled in sheets offers are liable t
o be rejected): -
1. General
1.1 Manufacturer :
1.2 Model number :
1.3 Application :
1.4 Type of fans :
1.5 Number of fans :
1.6 Suction Temperature :
1.7 Suction Pressure :
(after taking into consideration total pressure dro
p upto fan inlet)
1.8 Relative Humidity :
2. Guaranteed performance
2.1 Rated capacity, Nm
/hr.& FAD (Specify also tolerance limit)
2.2 Fan total pressure at rated capacity, mmWC :
2.3 Range of operation of the fan
Parameter Flow rate
(Nm
/h)
FAD
(m
/h)
Del. Pressure
(mm WC)
Power
(kW)
Maximum
Normal
Minimum
2.4 Delivery temperature
C :
2.5 Fan performance curve, efficiency & power cons
umption curve furnished:
Yes/No
2.6 Fan rated speed, RPM
2.7 Shaft critical speed R.P.M. :
2.8 Guaranteed fan efficiency at rated capacity an
d other duty points(specify
also tolerance limit) :
2.9 Expected Noise Level db at a distance of 1.0 m
:
2.10 Expected vibration limit as per ISO-1940/VDI20
56 :
2.11 Permissible vibration level (frequency/amplitu
de) :

RSP SCHEDULE 2.5.9.1-9 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF BF-1 PAGE 2 OF 3
3. Design & Construction features
3.1 Type of fan casing :End suction/ Radially spli
t/ Axially split/ Barrel
3.2 Impeller life :
3.3 Type of blade
3.4 Blade angle at exit & entry :
3.5 Tip speed :
3.6 Inlet velocity at full load :
3.7 Outlet velocity at full load :
3.8 Moment of inertia of the complete rotating sys
tem including fan, motor,
coupling, etc. (GD2- Kg sq.m) :
3.9 Type & size of coupling between fan & motor :
3.10 Name of the supplier of coupling :
3.11 Direction of Rotation :
3.12 Bearing
3.12.1 Type & Material :
3.12.2 Location & No. :
3.12.3 Type of lubrication :
3.12.4 Type & average consumption of Lubricant :
3.12.5 Design life (Hrs.) :
3.13 Shaft Sealing Arrangement:
3.13.1 Type :
3.13.2 Sealing liquid :
3.14 Utility requirement with flow rate and pressu
re. :
4. Material of Construction (Indicate applicable
code/standard)
4.1 Casing with thickness
4.2 Casing liner
4.3 Diffuser
4.4 Impeller
4.7 Shaft
4.10 Base plate
4.14 Stuffing box
4.19 Coupling
5. Connections and others Dimensional details

RSP SCHEDULE 2.5.9.1-9 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF BF-1 PAGE 3 OF 3
5.1 Fan shaft diameter (mm) :
5.2 Impeller diameter (mm) :
5.3 Flexible joints (cross section, length & materi
al) :
5.4 Suction side dia x length :
5.5 Suction side material :
5.6 Delivery side dia x length :
5.7 Delivery side material :
5.8 Throw angle at discharge
6. Drive Data :
6.1 Drive unit at ambient condition, kW
6.2 Rated speed, RPM :
6.3 Whether drive unit power rating takes care of t
he 10% stipulations
Yes/No.
7. Inspection and Testing
7.1 Material Test :
Yes/No
7.2 Hydrostatic test pressure and duration of test,
minutes. & std.
7.3 Performance test on fan at : Full speed/reduced
speed
7.4 Dynamic balance test :
8. Weight and Loading Data
8.1 Weight of the fan and drive
assembly for foundation design,:kgf
8.2 Weight of the fan assembly, kgf.:
8.3 Weight of the motor only, kgf :
8.4 Weight of Impeller with shaft kgf:
8.5 Weight of the heaviest piece to be handled, kgf
9. Safety devices for
9.1 Pressure
9.2 Temperature
9.3 Vibration
10. Control device
10.1 Type
10.2 Type of actuator

RSP SCHEDULE 2.5.9.1-10 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF BF-1 PAGE 1 OF 1
Schedule 2.5.9.1-10
TECHNICAL PARTICULARS OF BAG FILTER
Sl. No. Description Parameters to be submitted by t
he
Bidder
1.
Type
2.
Capacity M

3.
Design Code
4.
Design / working pressure (kg/cm2)
5.
Material of Construction
6.
Service Media
7.
Standard followed (Manufacture)
8.
Test Code followed
9.
Air to Cloth ratio
10.
Type of Bag Material / Dia of Bags /
length
11.
Detail of accessories
12.
No. of Pulse valve / type
13.
Compressed air requirement
14.
Pressure of Compressed air

15.
Quality of compressed air requirement
16.
Over all size
17.
Weight of Tank
18.
Hopper capacity Hopper capacity
19.
Material thickness of Hopper

RSP SCHEDULE 2.5.9.1-11 CET/05/RN/3170/TS/IR/01/R=
1
UPGRADATION OF B.F 1 PAGE 1 OF 1
Schedule 2.5.9.1-11
TECHNICAL PARTICULARS FOR HOT GAS GENERATOR
Sl. No. Description Parameters to be submitted by t
he Bidder
1.
Type
2.
Overall Size
3.
Design Code

4.
Design flue generation capacity &
temperature
C
5.
Design pressure kg/cm2 (g)
6.
Working temperature 0C
7.
Working Pressure kg/cm2 (g)
8.
Details of combustion system
9.
CA Fan Detail
10.
Material of Construction
11.
Standard followed (Manufacture)
12.
Test Code followed
13.
Efficiency
14.
Detail of accessories
15.
Actuator detail

16.
Weight of unit

RSP SCHEDULE 2.11-1 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE -1 OF 1
CHEDULE
-2.11-1
DECLARATION
OF
SITE
VISIT
(T
O BE FILLED UP BY THE
IDDER
)
I, hereby, declare that I have visited the site at
Blast Furnace-1, Rourkela Steel Plant, to
understand the site conditions and acquainted mysel
f with the extent of total works involved
for proposed package.
Signature of the Bidder
Seal of Company
Name
Designation
RSP SCHEDULE 2.11-2 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 1 OF 1
Schedule 2.11-2
REQUIREMENT
OF
CONSTRUCTION
WATER
POWER
(T
O BE FILLED UP BY THE BIDDER
)

.
ESCRIPTION
Q
UANTITY
01 Power requirement
Maximum Load
Average Daily Load
02 Water
Avg. Daily Consumption
Peak Daily Consumption
Signature of the Bidder
Seal of Company
Name
Designation
RSP
Schedule 2.11-3 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 Page -1 of 1
CHEDULE
-2.11-3
LIST OF EXCLUSIONS
(T
O BE FILLED UP BY THE
IDDER
)
Sl. No. Reference clause of TS Details of exclusion
s Reasons
















Signature of the Bidder
Seal of Company
Name
Designation
RSP SCHEDULE 2.11-4 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE -1 OF 1
CHEDULE
-2.11-4
LIST
OF
DEVIATIONS
(T
O BE FILLED UP BY THE
IDDER
)
Sl. no.
Reference clause of TS
Details of deviations Reasons
















Signature of the Bidder
Seal of Company
Name
Designation
RSP SCHEDULE 2.11-5 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE 1 OF 1
Schedule 2.11-5
LIST OF SIMILAR JOBS EXECUTED
(T
O BE FILLED UP BY THE
IDDER
)

.
OB
ESCRIPTIO
AME OF
MPLOYER
ALUE OF
ORKS
(R
UPEES
)
RDER
EFERENC
PECIFICATIO
N OF
ORK
TY
. C
ONTRACT
XECUTION
ERIOD












Signature of the Bidder
Seal of Company
Name
Designation
RSP
Schedule 2.11-6 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 Page -1 of 1
CHEDULE
-2.11-6
LIST
OF
RECOMMENDED
SPARES
FOR
TWO
YEARS
OPERATION
(T
O BE FILLED UP BY THE BIDDER
)
Sl.No.
Equipment Description
of spares
Quantity
Installed
No.
Recommended
Remarks















Signature of the Bidder
Seal of Company
Name
Designation
RSP SCHEDULE 2.11-7 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE -1 OF 1
CHEDULE
-2.11-7
LIST
OF
SPECIAL
TOOLS
TACKLES
(T
O BE FILLED UP BY THE BIDDER
)
Sl.No.
Tools / Tackles Description /
Specification
Application Quantity
















Signature of the Bidder
Seal of Company
Name
Designation
RSP SCHEDULE 2.11-8 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE -1 OF 1
Schedule-2.11-8
LIST OF ERECTION AND
COMMISIONING
SPARES
(T
O BE FILLED UP BY THE BIDDER
)
Sl. No.
Description of item Quantity














Signature of the Bidder
Seal of Company
Name
Designation
RSP SCHEDULE 2.11-9 CET/05/RN/3170/TS/IR/01/R=1
UPGRADATION OF B.F 1 PAGE -1 OF 1
Schedule 2.11-9
IMPLEMENTATION
SCHEDULE
(T
O BE FILLED UP BY THE BIDDER
)
Signature of the Bidder
Seal of Company
Name
Designation
RSP SCHEDULE 3.5.7.3-1 CET/05/RN/3170/TS/IR/02/R=1
UPGRADATION OF BF-1 PAGE 1 OF 2
Schedule 3.5.7.3-1
Data Sheet for Injection Pressure Vessel and Inject
ion System
Sl. No. Description Parameters / Data to be
Furnished by the Tenderer
No. of injection vessels
2.
Size

i)
Volume in m
ii)
Diameter
iii)
Type of Construction
iv)
Nos.
v)
Height
vi)
Degree of cone
vii
Material of vessel
3.
Required pressure of injection
System
Kg/cm
4.
Design Pressure
Kg
/hr
5.
Qty. of N
gas required
Nm
/hr
6.
Pressure of Nitrogen gas
gas reservoir required
Size of gas reservoir required
9.
Compress air gas reservoir required
(if any)

10.
Size of compressed air. reservoir
11.
Injection rate
i)
Minimum
ii
Maximum
Kg/hr.
12.
Size of injection line between
pressure vessel & coal distributor
NB
13.
Injection per tuyere
i)
Minimum
ii)
Maximum
Kg/hr.
14
Grain size distribution
15.
Moisture in the fines
16.
Details of control of flow through
injection vessel
% max
17.
Type, size and specifications of the
hydraulic system and valves used in
injection vessel
18.
Details of instruments and electrics
used in the injection vessel
19.
Testing and Inspection procedure of
injection vessel and associated
equipment
RSP SCHEDULE 3.5.7.3-1 CET/05/RN/3170/TS/IR/02/R=1
UPGRADATION OF BF-1 PAGE 2 OF 2
Sl. No. Description Parameters / Data to be
Furnished by the Tenderer
20.
Standards applicable for various
equipment
21.
Details of screen / vibrating screen
before injection vessel
22.
Details of fine coal silo, type, size,
capacity, No. of outlets from silo etc.
23.
Sieve size of screen Microns / mesh
24.
Type, make capacity, material of
screen
25.
Dimensions of screen
26.
Technical & operating write up on
injection vessels, screens, N
reservoir, valves & hydraulic system
etc.
27.
Details of hydraulic system
indicating type of power pack,
complete specifications & quantities
of pump, direction control valves,
hydraulic cylinders,, flow control
valves, non return valves, hydraulic
hoses, type of oil to be used etc.
28.
Details of weighing system in the
injection vessel
29.
Details of other equipment associated
in injection vessel
RSP SCHEDULE 3.5.7.3-2 CET/05/RN/3170/TS/IR/02/R=1
UPGRADATION OF BF-1 PAGE 1 OF 1
Schedule 3.5.7.3-2
DATA SHEET FOR COAL DISTRIBUTOR
1.
Type and specification of coal distributor
2.
Size of inlet injection line
3.
Size of outlet injection line
4.
Control of flow of injected coal
5.
Specification of control valves
6.
Flow of coal in the inlet line:
Maximum
Minimum
7.
Injection coal through one tuyere
Maximum
Minimum
8.
Details of operation of distributor
9.
Details of instruments & electrics
10.
Details of injection lances (material,
Diameter, length, angle to tuyere etc.)
RSP SCHEDULE 3.5.7.2-1 CET/05/RN/3170/TS/IR/02/R=1
UPGRADATION OF BF-1 PAGE 1 OF 1
Schedule 3.5.7.2-1
DATA SHEET FOR GRINDING MILL
Sl.
No.
Description Parameters / Data to be
furnished by the Tenderer
1.
Type
2.
No. of mill
3.
Output size of fine coal
4.
Capacity of the mill
5.
Type and No. of grinding rollers
6.
Material of rollers
7.
Hardness of rollers
8.
Type of sealing & its details
9.
Type of cooling & its details
10.
Lubrication system and its details
11.
Lubricant used
12.
Bearing and its details
13.
Grinding index
14.
KW Rating
15.
No. of motors & its details
16.
Drying media and its details
17.
Transportation & its details
18.
All technological & technical parameters of
grinding mill
19.
Total weight of assembly
RSP SCHEDULE 3.5.7.1-1 CET/05/RN/3170/TS/IR/02/R=1
UPGRADATION OF BF-1 PAGE 1 OF 2
Schedule 3.5.7.1-1
DATA SHEET FOR CONVEYOR SYSTEM
Sl.
No.
Description Parameters / Data to be
furnished by the Tenderer
1.
Conveyor No. :
2.
Carrying capacity (T/hr.) :
3.
Centre to center horizontal distance (m) :
4.
Lift (m) :
5.
Belt/chain width (mm) :
6.
Belt/chain speed (m/s) :
7.
Type of fabric/chain used :
8.
Motors

Kw rating
RPM
:
9.
Gear boxes
Make
Type
Reduction ratio
Torque rating
:
10.
Couplings
Make & type of high speed couplings
Make & type of low speed couplings
:
11.
Type of Take-up :
12.
Belt /chain speed switches :
13.
Hooter alarm type & make :
14.
Brake, No. & its location, Brake Drum dia :
15.
Torque rating (kg-m) :
16.
Idlers
Type & Make
:
RSP SCHEDULE 3.5.7.1-1 CET/05/RN/3170/TS/IR/02/R=1
UPGRADATION OF BF-1 PAGE 2 OF 2
Sl.
No.
Description Parameters / Data to be
furnished by the Tenderer
Roll diameter (mm)
Roll thickness (mm)
Tube specification (ERW/ Seamless)
17.
Bearings
Make & Type
Expected Life
:
18.
Pulleys
Diamtere
Face width
Thickness of rubber lagging (mm) & shore
Hardness (for drive pulley)
Groove pattern of rubber lagging
:
19.
Plummer Block
Orientation of mounting (horizontal /
vertical)
Bearing Size
Make & Type
:
20.
Lubrication arrangement
:
21.
No of short post & its size :
22.
Details of deck plate :
23.
Weight of frame in running meter length :

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