Coal Handling Details in Essar

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-A00032-0016-1615-0002R00
JUN-2011
FORMATNO:EESD(H).PRA.DM.025.F01 Page 1 -
2 X 600 MW TORI THERMAL POWER PLANT INTERNAL COAL HANDLING SYSTEM TECHNICAL SPECIFICATION FOR IDLERS (ICHS) TSP NO 3003-H000-A00032-0016-1615-0002-R00
AEGIS LIMITED ESSAR ENGINEERING SERVICES DIVISION
DETAILS OF REVISION: DATE 03.05.2011 01.06.2011 DETAILS OF REVISION INITIAL ISSUE ISSUE REVISION NO. P00 R00
TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)
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CONTENTS
CHAPTER NO. 1 2 3 4 5 6 7 8 9 ANNEXURE I II SITE CONDITIONS FORMAT FOR DEVIATION FROM TENDER DOCUMENT QUESTIONNAIRE TO BE FILLED IN AND SUBMITTED III WITH OFFER (A) IV V VI VII (B) TECHNICAL DATA SHEET APPLICATION DATA SHEET 18 20 21 17 14 16 DESCRIPTION GENERAL INFORMATION TECHNICAL SPECIFICATION SCOPE OF WORK INSPECTION & TESTING HSE REQUIREMNT DELIVERY PAINTING WORKMANSHIP & PERFORMANCE GUARANTEE DOCUMENTS TO BE SUPPLIED PAGE NO. 4 5 07 08 08 09 10 12 13
OVERALL SUPPLY & IMPLEMENTATION SHEDULE QUALITY ASSURANCE PLAN 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 Essars 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 IS9295, 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 clients 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. 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. 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. The machine finished surfaces shall be coated with white lead and covered before shipment or before being put out into the open air. The Color code to be followed for the final coat shall be intimated to the successful Tenderer. The complete paint system for any item includes the following activities i) ii) iii) iv) VII. Proper surface preparation Application of primer coats Application of intermediate coats Application of finished coats
II.
III.
IV. V. VI.
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

Surf ace Pre para tion Painting scheme At shop 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 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 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} At shop 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) Tot al DF T 240
Sl. No 1
Description Steel structure and Mechanical equipment (temp. not over 80 deg C) Both static and rotary equipment for indoor or outdoor duty Equipment with hot indoor or outdoor duty surface (temp. unto 200 deg C)
SP-Sa 2 1/2
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} 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
SP-Sa 2 1/2
SP-Sa 2 1/2
Equipment with hot surfaces (temp. up to 400 deg C)
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 Representative. report and dispatch clearance from Clients
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. Tori Railway Station is about 5 km. Ranchi Airport at a distance of about 70 km from site. Latitude : 230 43 0 N Longitude : 840 47 0 E About 530-550 m
1.1 1.2 2.0 3.0 4.0 4.1
Nearest Railway Station & Distance Nearest Airport Latitude and Longitude Elevation above mean sea level Climatic conditions Temperatures : Annual basis Mean Maximum Temperature Mean Minimum Temperature Wet bulb temperature Relative humidity Annual average rainfall
48C 11C 28C 35.2% Annual average rainfall is about 1215 mm (most of which occurs during the monsoon season from June to October) 39m/sec. Zone - IV Non-Agriculture/Waste land Generally undulated Amanat River (Around 40 km from site)
4.2 4.3
4.4 4.5 4.6 4.7 4.8 5.0
Basic Wind Speed (Vz) as per IS 875 (Part-III) Seismic Zone Present use of land Topographical features of the site Source of Water 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 b) For motors rated 200 KW & 1500 kW c) For motors rated below 200 kW d) DC motor starters, DC solenoids, DC alarm, control and protections of Breakers e) AC control & protective devices
11000V, 3 phase, 3 wire, 50Hz medium earthed AC 3300V, 3 phase, 3 wire, 50Hz medium earthed AC 415V AC, 3-phase, 4-wire, 50 Hz effectively earthed 220V DC, 2 wire, unearthed DC
f) Uninterrupted power supply g) Lighting fixtures and space heaters
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 230V, 1 phase, 50Hz, 2 wire AC supply 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. Voltage variation 10% Frequency variation 5% Combined voltage & frequency variation 10% DC Supply .1 Voltage variation +10% -15% All the electrical equipment shall be designed for 50C reference ambient temperature. AC supply
6.0
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Annexure II FORMAT FOR DEVIATIONS FROM TENDER DOCUMENT
Sl. No.
Clause No.
Tenderers 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. 02. 03. 04. 05. 06. 07. Tenderer's name and address. Quotation number and date. Total estimated transporting weight of items offered by Tenderer in tabular form. Special transport requirement. Special storage requirement. Available manufacturing facility. Available spare capacity.
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Annexure IV
(A) TECHNICAL DATA SHEET
Sr. No.
Idler Type. 35 Carrying Idlers 10 Transition Idlers 20 Transition Idlers S.A Carrying Idlers Impact Idlers Garland Type Return Idlers Flat Roll Type Return Idlers
Belt width. (mm) 1800 1800 1800 1800 1800 1800
ACTUAL QTY
SPARE QTY
Total QTY. (No of sets) 4200 60 60 320 250 2250
Tender Drawing No.
1. 2. 3. 4. 5. 6.
3860 50 50 290 210 2050
340 10 10 30 40 200
3003-B000-A00032-0016-1618-0001 3003-B000-A00032-0016-1618-0002 3003-B000-A00032-0016-1618-0003 3003-B000-A00032-0016-1618-0004 3003-B000-A00032-0016-1618-0005 3003-B000-A00032-0016-1618-0006
7.
1800
50
10
60
3003-B000-A00032-0016-1618-0007
TOTAL
7200
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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. II. III Range of inspection & tests to be carried out by manufacturer and cross checked during manufacturing of equipment from raw materials to finishing stage. Suggestive check /hold points for CLIENT inspection and witnessing of tests during manufacturing and final product inspection. 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. Manufacturers 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 1 2 3 4 5 6 7 TENDERER DRAWING NO. 3003-B000-A00032-0016-1618-0001 3003-B000-A00032-0016-1618-0002 3003-B000-A00032-0016-1618-0003 3003-B000-A00032-0016-1618-0004 3003-B000-A00032-0016-1618-0005 3003-B000-A00032-0016-1618-0006 3003-B000-A00032-0016-1618-0007
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Coal Handling Details in Essar

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ESSAR POWER (JHARKHAND) LIMITED

2X600 MW TORI THERMAL POWER PLANT INTERNAL COAL HANDLING SYSTEM

TECHNICAL SPECIFICATION FOR IDLERS (ICHS)

ESSAR ENGINEERING SERVICES DIVISION.

TSP NO: 3003-H000-A00032-0016-1615-0002R00

ESSAR POWER (JHARKHAND) LIMITED

TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)

ESSAR POWER (JHARKHAND) LIMITED

TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)

ESSAR POWER (JHARKHAND) LIMITED

TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)

ESSAR POWER (JHARKHAND) LIMITED

Chapter 02 02. TECHNICAL SPECIFICATION

TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)

ESSAR POWER (JHARKHAND) LIMITED

TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)

ESSAR POWER (JHARKHAND) LIMITED

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

TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)

ESSAR POWER (JHARKHAND) LIMITED

Chapter 04 04. INSPECTION AND TESTING

Chapter 05 05. HSE REQUIREMNT Not Applicable

TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)

ESSAR POWER (JHARKHAND) LIMITED

Chapter 06 06. DELIVERY

TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)

ESSAR POWER (JHARKHAND) LIMITED

Chapter 07 07. PAINTING

TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)

ESSAR POWER (JHARKHAND) LIMITED

GENERAL SPECIFICATION FOR SURFACE TREATMENT AND PAINTING

TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)

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

ESSAR POWER (JHARKHAND) LIMITED

Chapter 08 08. WORKMANSHIP AND PERFORMANCE GUARANTEE

TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)

ESSAR POWER (JHARKHAND) LIMITED

i. All Test reports for the tests conducted. ii. Joint

TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)

ESSAR POWER (JHARKHAND) LIMITED

ANNEXURE-I SITE CONDITIONS

1.1 1.2 2.0 3.0 4.0 4.1

4.4 4.5 4.6 4.7 4.8 5.0

TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)

ESSAR POWER (JHARKHAND) LIMITED

f) Uninterrupted power supply g) Lighting fixtures and space heaters

TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)

ESSAR POWER (JHARKHAND) LIMITED

Annexure II FORMAT FOR DEVIATIONS FROM TENDER DOCUMENT

Reason for Deviations

Signature Name Designation Company seal

TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)

ESSAR POWER (JHARKHAND) LIMITED

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

TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)

ESSAR POWER (JHARKHAND) LIMITED

Belt width. (mm) 1800 1800 1800 1800 1800 1800

Total QTY. (No of sets) 4200 60 60 320 250 2250

Tender Drawing No.

3860 50 50 290 210 2050

3003-B000-A00032-0016-1618-0001 3003-B000-A00032-0016-1618-0002 3003-B000-A00032-0016-1618-0003 3003-B000-A00032-0016-1618-0004 3003-B000-A00032-0016-1618-0005 3003-B000-A00032-0016-1618-0006

TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)

ESSAR POWER (JHARKHAND) LIMITED

TSP No.: 3003-H000-A00032-0016-1615-0002-R00 TS for Idlers (ICHS)