Coal Handling Details in Essar

FORMAT NO: EESD (H).PRA.DM.025.F01 Page ‐ 1 -

ESSAR POWER (JHARKHAND) LIMITED 2X600 MW TORI THERMAL POWER PLANT

INTERNAL COAL HANDLING SYSTEM

TECHNICAL SPECIFICATION FOR

IDLERS (ICHS)

ESSAR ENGINEERING SERVICES DIVISION. HAZIRA

TSP NO: 3003-H000-A00032-0016-1615-0002–R00 JUN-2011

ESSAR POWER (JHARKHAND)

LIMITED

2 X 600 MW TORI THERMAL POWER PLANT


TECHNICAL SPECIFICATION FOR IDLERS (ICHS) TSP NO -

3003-H000-A00032-0016-1615-0002-R00

AEGIS LIMITED ESSAR ENGINEERING SERVICES DIVISION

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TS for Idlers (ICHS)

DETAILS OF REVISION:

DATE DETAILS OF REVISION REVISION NO.

03.05.2011 INITIAL ISSUE P00

01.06.2011 ISSUE R00


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CONTENTS

CHAPTER NO.

DESCRIPTION PAGE NO.

1 GENERAL INFORMATION 4

2 TECHNICAL SPECIFICATION 5

3 SCOPE OF WORK 07

4 INSPECTION & TESTING 08

5 HSE REQUIREMNT 08

6 DELIVERY 09

7 PAINTING 10

8 WORKMANSHIP & PERFORMANCE GUARANTEE 12

9 DOCUMENTS TO BE SUPPLIED 13

ANNEXURE

I SITE CONDITIONS 14

II FORMAT FOR DEVIATION FROM TENDER DOCUMENT 16

III QUESTIONNAIRE TO BE FILLED IN AND SUBMITTED

WITH OFFER 17

IV (A) TECHNICAL DATA SHEET

(B) APPLICATION DATA SHEET 18

V OVERALL SUPPLY & IMPLEMENTATION SHEDULE 20

VI QUALITY ASSURANCE PLAN 21

VII TECHNICAL SPECIFICATION DRAWINGS ( 7 SHEETS )


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Chapter 01 01. GENERAL INFORMATION

ESSAR POWER JHARKHAND LTD. (EPJL) propose to install a 3 x 600 MW

(present units of 2 x 600 MW and future units of 1 x 600MW) coal fired pit head

based thermal power station near Chandwa Tehsil, Latehar district, Tori,

Jharkhand. The coal for this project would be received from Chakla and Ashok

karkata coal fields belonging to Essar’s captive coal mines in Eastern coal field

basin. Coal handling system would be installed to meet the coal requirements for

the proposed two (2) units receiving feed from the proposed mines.

This technical specification is intended to enable the Tenderer to submit a detailed offer for supply of Idlers for Internal Coal Handling Facility at Tori, Jharkand.

The site climatic conditions are given in Annexure I.


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Chapter 02

02. TECHNICAL SPECIFICATION

a) Scope of work of the Tenderer consists of Manufacture, Inspection, testing,

assembly painting and dispatch of all the idlers as per technical specification

drawings as per annexure VI enclosed in this technical specification.

b) All idler roll shall be manufactured from ERW tubes conforming to latest edition of IS-

9295, 1983 (re-affirmed 1990) or from seamless tubes conforming to IS-3601, 1984

(Re-affirmed 1990) / BS 6323, 1990 unless specifically mentioned. The minimum

shell thickness shall be as per attached drawings.

c) Each roll for all idlers shall be equipped with anti-friction seize resistant ball bearings

or as mentioned in the drawings and shall have minimum double labyrinth type seals

for keeping the lubricant in and dirt out. The bearings and the sealing devices shall

be mounted in an internal structure that will ensure alignment, proper spacing, and

good support and minimize the size of lubricant chamber. The bearing housings shall

be pressed steel and both the bearing housings shall be welded to the rolls

simultaneously. All idler bearings shall be seize resistant or as mentioned in the

drawings, double side sealed, lubricated for life and deep groove type bearing should

be used. Minimum life of all life lubricated idler bearings shall be 80000 working

hours. The external and internal labyrinth seals for all type of rollers can also be

Zamak and rain cap Nylon 6 & dust cover CRCA/IS513 shall be provided for all type

of rollers

d) The idler unit shall be extra heavy duty, suitable for continuous operation at high

capacities. The troughing idlers having rolls of equal length, the rolls as well as the

roll components shall be interchangeable.


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e) For the impact type units, the rolls shall be made of rubber treads, rings or discs

mounted on a steel tube and securely held in place. The rubber shall be of Natural

rubber with Shore hardness of 55 to 65 on Scale A.

f) Material of construction of shaft should be EN-8/C-40 solid bright bar.

g) Friction factor shall be below 0.015

h) T.I.R (Radial) should not exceed 1 mm.

i) Axial float of shaft within assembled rollers shall not exceed 0.5mm.

Following test shall be conducted at random on the assembled idlers.

Visual checking for manufacturing quality

Radial run out test

Water ingress test

Dust ingress test

Friction factor test

Axial float test.


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Chapter 03 03. SCOPE OF WORK, BATTERY LIMITS & EXCLUSIONS

a) The scope of work of the Tenderer shall consist of design, Engineering, manufacture,

inspection, assembly, shop testing, painting at manufacturers shop, packing, loading and transportation supply F.O.R Essar Power (Jharkhand) Limited site in completely assembled condition.

b) The scope of work shall stand supplement by such details as are given in specification or purchase order or contract or general specifications

c) The Tenderer shall submit a dimensional scaled drawing showing all the details, in AutoCAD format and design report immediately on placement of order. The manufacturing shall be taken up only as per client’s approved drawings.

d) Erection instructions / manual, Spare parts manuals all other drawings & documents as required by the purchaser / his consultant.


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Chapter 04 04. INSPECTION AND TESTING

Inspection & testing of equipment shall be carried out by Client or an authorized agent of Client at the works of supplier during manufacturing and on final product to ensure conformity of the same with the acceptable criteria of technical specification, approved drawings, authenticated manufacturing drawings and relevant national / international standards.

Chapter 05

05. HSE REQUIREMNT

Not Applicable


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Chapter 06

06. DELIVERY

a) The delivery of all equipment covered under this specification shall be FOR M/s. Essar Power (Jharkhand) Limited site stores at Tori and as per the address and delivery schedule to suit commissioning of plant within 6 months from the date of placement of order.

b) Unless requested by Purchaser, supplier shall dispatch equipment with all its attachments, parts, components, spares, documents etc as a single lot with logical identification of packing.

c) All equipment shall be packed properly for prevention of damage during transit and deterioration during storage.

d) Goods shall be dispatched only on written clearance from Client.

e) All equipment should be provided with date of manufacturing, Batch no, QC clearance Identification code as QA/QC plan.


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Chapter 07

07. PAINTING

The following specification shall be applicable for all equipment covered under this document. This specification covers the facilities and quality requirement for surface preparation and painting.

The term "painting" referred herein covers rust preventive, preventive and decorative coating along with surface protection.

I. Surfaces made of aluminum, brass; bronze, stainless steel, cast iron and other corrosion resistant alloys are not required to be painted unless specified except for aesthetic purposes or for identification band. All machined mating surfaces shall be properly cleaned, greased and protected before dispatch.

II. All surfaces will be sand blasted before applying primer. General compatibility between primer and finishing paints shall be certified by the paint manufacturer supplying the paints.

III. Areas which become inaccessible after assembly shall be painted before assembly (after painting clearance has been given by the inspecting authority) after requisite surface cleaning as specified.

IV. The machine finished surfaces shall be coated with white lead and covered before shipment or before being put out into the open air.

V. The Color code to be followed for the final coat shall be intimated to the successful Tenderer.

VI. The complete paint system for any item includes the following activities

i) Proper surface preparation

ii) Application of primer coats

iii) Application of intermediate coats

iv) Application of finished coats

VII. Surfaces which cannot be painted but require protection shall be given a coat of rust inhibitive grease according to standards. The general guideline followed for painting is follows:


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GENERAL SPECIFICATION FOR SURFACE TREATMENT AND PAINTING

Sl.No Description

Surface Preparation

Painting scheme Total

DFT

At shop At shop

1 Steel structure and Mechanical equipment (temp. not over 80 deg C) Both static and rotary equipment for indoor or outdoor duty

SP

-Sa

2 1/

2

2 coats of two pack air drying, Epoxy polyamide resin based red oxide - zinc phosphate (Epoxy content (% wt.) - 15 to 18, Temperature resistance - up to 120 deg C dry heat, DFT/Coat-30 microns (min)) and One coat of a two pack air drying high build epoxy resin based paint with MIO(Temperature resistance - up to 180 deg C dry heat, DFT / coat - 100 microns)

2 coats of a two pack air drying epoxy polyamide enamel suitably pigmented.(Air drying time - 2 to 3 hours (touch dry - 7 days (full cure)),DFT / coat - 40 microns(min), Temperature resistance - up to 130 deg C dry heat)

240

2 Equipment with hot indoor or outdoor duty surface (temp. unto 200 deg C)

SP

-Sa

2 1/

2

2 coats of a two pack air drying Epoxy polyamide with zinc dust of at least 92% zinc dust on the dry film.{Epoxy content (% wt) - 8 to 10, Air drying time - 10 minutes (touch dry), - 2 hours (hard dry), DFT / coat - 40 microns (min), Temperature resistance - up to 120 deg C dry heat}

2 coats of a single pack synthetic rubber based aluminum paint. {Air drying time - 2 hours (touch dry) DFT / coat - 25 microns, 24 hours (hard dry), Temperature resistance - up to 200 deg C dry heat, color - smooth aluminum}

180

3 Equipment with hot surfaces (temp. up to 400 deg C)

SP

-Sa

2 1/

2

2 coats of a two pack heavy duty zinc dust rich silicate primer{(ethyl zinc silicate, ezs , based), Total solid (3 wt) - 84 +/- 2, Density- 3.07 +/- 0.005, Air drying time - 16 hours, DFT / coat - 60 microns, Temperature resistance - up to 450 deg C dry heat}

2 coats of a single pack heat resistant silicon resin based paint with leafing aluminium, Air drying time - 3 to 4 hours (touch dry), 24 hours (hard dry), DFT / coat - 20 microns (min),Temperature resistance - up to 400 deg C dry heat, Colour - smooth aluminium

180


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Chapter 08

08. WORKMANSHIP AND PERFORMANCE GUARANTEE

a) The material used and the fabrication carried out shall be new and best of its kind

available and shall conform to relevant latest Indian and international standards.

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

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

c) The supplier shall warrantee for satisfactory performance of the facilities for a period of

30 months from the date of receipt at site by the purchaser or 18 months from the date

of commissioning whichever is earlier.

d) The Tenderer shall prepare and submit draft performance test procedure for approval.


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Chapter 09 09. DOCUMENTS TO BE SUPPLIED BY THE TENDERER WITH OFFER WHICH IS

APPLICABLE

The following information/documents are to be submitted by the Tenderer along with the offer:

a. Dimensional drawing of Idler rollers & frames showing dimensional and

component details including rotating and total weight.

b. Specifications, materials of construction of parts/ component along with standards and chemical composition.

c. The deviation list filled in and submitted by the Tenderer as per Annexure-II.

d. The questionnaire filled in and submitted by the Tenderer as per Annexure-III.

e. Overall schedule as per Annexure-V.

f. Exclusions list if any.

g. The following documents to be submitted along with the tendered offer :- i. List of clients for whom such materials/equipment supplied.

ii. Client Performance certificate.

iii. Capacity of their plant and current assignment.

iv. Approval for list of Inspection Agency.

h. The following documents to be sent in 3 copies and in soft copies, one month before the supply

i. All Test reports for the tests conducted. ii. Joint Inspection report and dispatch clearance from Client’s

Representative. iii. Approved Dimensional and cross section drawing with all the details in

AutoCAD format.


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ANNEXURE-I SITE CONDITIONS 1.0

Location of the plant

At Village- Angaraha Tehsil Chandwa, District : Latehar, State: Jharkhand.

1.1 Nearest Railway Station & Distance Tori Railway Station is about 5 km.

1.2 Nearest Airport Ranchi Airport at a distance of about 70 km from site.

2.0 Latitude and Longitude Latitude : 230 43’ 0” N Longitude : 840 47’ 0” E

3.0 Elevation above mean sea level About 530-550 m

4.0 Climatic conditions 4.1 Temperatures : Annual basis Mean Maximum Temperature 48°C Mean Minimum Temperature 11°C Wet bulb temperature 28°C 4.2 Relative humidity 35.2% 4.3 Annual average rainfall Annual average rainfall is about 1215

mm (most of which occurs during the monsoon season from June to October)

4.4 Basic Wind Speed (Vz) as per IS 875

(Part-III) 39m/sec.

4.5 Seismic Zone Zone - IV 4.6 Present use of land

Non-Agriculture/Waste land

4.7 Topographical features of the site

Generally undulated

4.8 Source of Water Amanat River (Around 40 km from site)

5.0 Auxiliary power supply:

Auxiliary electrical equipment to be supplied against this specification shall be

suitable for operation on the following system :


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a) For motors rated above 1500 kW

11000V, 3 phase, 3 wire, 50Hz medium earthed AC

b) For motors rated ≥ 200 KW & ≤ 1500 kW

3300V, 3 phase, 3 wire, 50Hz medium earthed AC

c) For motors rated below 200 kW 415V AC, 3-phase, 4-wire, 50 Hz effectively earthed

d) DC motor starters, DC solenoids, DC alarm, control and protections of Breakers

220V DC, 2 wire, unearthed DC

e) AC control & protective devices 230V, 1 phase, 50Hz, 2 wire AC supply. The single-phase 110V AC supply shall be derived by CONTRACTOR BY PROVIDING 415V / 110V control transformers of adequate rating with MCCB / MCB on both the primary and secondary sides

f) Uninterrupted power supply 230V, 1 phase, 50Hz, 2 wire AC supply

g) Lighting fixtures and space heaters

240V, 1 phase, 2 wire, 50Hz

h) The above voltages may vary as follows : All devices shall be suitable for continuous operation over the entire range of

voltage and frequency indicated below without any change in their performance.

AC supply Voltage variation ± 10% Frequency variation ± 5% Combined voltage & frequency variation

10% DC Supply .1 Voltage variation +10%

-15% 6.0 All the electrical equipment shall be designed for 50οC reference ambient

temperature.


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Annexure II FORMAT FOR DEVIATIONS FROM TENDER DOCUMENT

Sl. No.

Clause No. Tenderer’s Deviations Reason for Deviations

The Tenderer hereby certifies that the above mentioned are the only deviations from the tender documents.

Signature : Name : Designation :

Company seal :


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Annexure III QUESTIONNAIRE TO BE FILLED IN AND SUBMITTED BY THE TENDERER

01. Tenderer's name and address.

02. Quotation number and date.

03. Total estimated transporting weight of items offered by Tenderer in tabular form.

04. Special transport requirement.

05. Special storage requirement.

06. Available manufacturing facility.

07. Available spare capacity.


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Annexure – IV (A) TECHNICAL DATA SHEET

TOTAL = 7200

Sr.No.

Idler Type.

Belt width. (mm)

ACTUAL

QTY

SPARE QTY

Total QTY.

(No of sets)

Tender Drawing No.

1. 35° Carrying

Idlers

1800 3860 340 4200 3003-B000-A00032-0016-1618-0001

2. 10° Transition

Idlers

1800 50 10 60 3003-B000-A00032-0016-1618-0002

3. 20° Transition

Idlers

1800 50 10 60 3003-B000-A00032-0016-1618-0003

4. S.A Carrying

Idlers

1800 290 30 320 3003-B000-A00032-0016-1618-0004

5. Impact Idlers 1800 210 40 250 3003-B000-A00032-0016-1618-0005

6. Garland Type Return Idlers

1800 2050 200 2250 3003-B000-A00032-0016-1618-0006

7.

Flat Roll Type Return

Idlers

1800 50 10 60 3003-B000-A00032-0016-1618-0007


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(B) APPLICATION DATA SHEET

BELT WIDTH: - 1800 MM

1) CONV. CAPACITY:-

a) DESIGN:- 2750 tph b) RATED :- 2500 tph

2) BELT SPEED:- 3.2m/s

3) IDLER SPACING:- a) CARRYING:- 1.5m b) RETURN:- 3m

4) BELT WEIGHT :- 60 kg/m (max)

5) BELT TENSION:-

a) MAXIMUM RUNNING TENSION:- 193 kN b) MAXIMUM ACCELERATION TENSION:- 280 kN


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Annexure – V

OVERALL SUPPLY SCHEDULE

S.NO DESCRIPTION OF EQUIPMENT QTY. INSPECTION CALL

PERIOD (IN WEEKS) DELIVERY PERIOD (IN

WEEKS)


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Annexure VI

QUALITY ASSURANCE PLAN (QAP)

a) QAP shall be prepared and furnished by supplier for all components.

b) Inspection and test requirements shall be decided with due consideration of factors like

safety, duty cycle, operating conditions, equipment life, environment conditions, place of

installation and statutory regulations, as applicable for a particular equipment.

c) QAP shall clearly indicate the followings through use of codes in the appropriate

columns:

I. Range of inspection & tests to be carried out by manufacturer and cross checked

during manufacturing of equipment from raw materials to finishing stage.

II. Suggestive check /hold points for CLIENT inspection and witnessing of tests during

manufacturing and final product inspection.

III Details of test certificates, internal inspection reports and calibration certificates to

be furnished by supplier / manufacturer to CLIENT.

IV. Inspection documents to be furnished by supplier / manufacturers to CLIENT for

reference during inspection along with acceptable norms as per codes / regulations.

Test Certificates and Documents

For each of the items being manufactured, following test certificates and documents in

requisite copies including original shall be submitted to inspection agency. All test

certificates must be endorsed by the manufactures and contractor with linkage to project,

purchase order and acceptance criteria.

I. Details of stage wise inspection

II. Manufacturer’s bought out material test certificates

III. Surface preparation and painting certificates


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Annexure VII

LIST OF ENCLOSED DRAWINGS FOR TENDERER.

S.NO TENDERER DRAWING NO.

1 3003-B000-A00032-0016-1618-0001 2 3003-B000-A00032-0016-1618-0002 3 3003-B000-A00032-0016-1618-0003 4 3003-B000-A00032-0016-1618-0004 5 3003-B000-A00032-0016-1618-0005 6 3003-B000-A00032-0016-1618-0006 7 3003-B000-A00032-0016-1618-0007