TS-Compressed Air System

BRAMHANI INDUSTRIES LTD.
,
JAMMALAMADUGU, KADAPA DISTRICT.
MECON LIMITED
2.5 MT CAPACITY INTEGRATED STEEL PLANT BAR MILL AND WIRE ROD MILL CHAPTER NO. 05.14
05.14 COMPRESSED AIR FACILITIES

05.14.01 Intent of Specification
This specification is intended to cover the supply and installation of 3 nos. of 75 Nm 3/min (approx.) centrifugal air compressors and auxiliary equipment in the rolling mill area. The compressors are intended to supply oil free compressed air required to various units of Bar mill and Wire rod mill. The air compressors and auxiliaries are to be designed, engi neered and installed in accordance with this technical specification. 05.14.02 Instr uctions to Tenderer 05.14.02.01 Scope of work
The scope of work covers design, engineering, manufac ture, procurement, shipping, testing, shop painting, transportation including transit insurance, unloading at site, storage at site, erection, testing and commissioning of the complete Compressor System along with all related mechanical items, motors & other electrical items, piping, instruments, cables and other accessories, its auxiliary facilities and final painting, on turnkey basis as per the appl icable standards & suitable to the si te conditions.
The tenderer shall include in his scope all equipment, material, all accessories and auxiliaries, measuring and control equipment, all necessary interconnecting pipes and pipe fittings, wiring in conduits for instrument sensors upto terminal box mounted on equipment and upto the control panel, electrics, earthing, which are not specially mentioned but are required to complete the equipment offered in every respect for satisfactory operation
01
Stage wise inspection of the equipment during manufac turing/procurement as per approved QAP/Documents/dr awings and performance test of the equipment before
MEC/S/Q6L2/01/PJ/T06-001, Rev. 0 2008, MECON Limited. All rights reserved.
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BRAMHANI INDUSTRIES LTD.,

MECON LIMITED
dispatch will be conducted by the contractor in the presence of owner/consultant at the manufactur ers work are also included in scope of wor k.
02
The location of compressors in the mill area should be furnished by tender er and it s hould be located in the area near by maximum load center .
03
The tenderer s hall comply with the equi pment parameters as specified in datasheets .
04
Scope of work also includes supply of spares for 2 years for normal operation & mai ntenance.
05.14.02.02 Material and Workmanship:
The mater ials used for manufac turing of items shall be new and best of i ts kind and shal l comply with relevant Indian / international standards . All materials used for fabrication / assembly shall ascertain for the quality of material as per relevant standard with all documentar y support, testi ng and inspection, wherev er required.
Qualified and certified welders shall be employed for carrying out the fabrication work. Welder qualification as well as welding procedure qualification shall be carried out as per applicable standards / codes in presence of O wner / Co nsultant as requi red.
The workmanship covering welding, casting, fabrication / manufac ture, assembly, etc. shall be of best quality as per relevant standards .
The material of construction of all items shall be as indicated in the datasheet/appr oved drawings. Deviation, if any, from agreed material of construction shall be only with prior approval of Owner / Cons ultant.
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01 Foundation Bolts, Lifting Lugs
The scope includes supply of foundation bolts, nuts, washers, base plates for the equipment. Any special fixing / installation arrangement, if required shall have to be spelt out and shal l also be included in scope. Equipment to be supplied shall have suitable lifting lugs, eyebolts, etc, to facilitate erection & maintenance. Inspection
02
Inspection will be carried out as per procedure laid down and details stipulated elsewhere in this specification. For all items, QAP as per enclosed format shall be submitted for approval to Owner / Consultant. Inspection shall be done based on approved QAP. Apart from such inspection by Owner/Consultant, the Contractor shall comply with all other inspection requirements of the applicable/specified codes or by statuary authorities having jurisdiction over the installation. Name Plate
03
E ach equipment will be fitted with an SS nameplate containing approved detai ls. Cleaning, Protection and Painting
04
Internal/external surfaces of equipment must be free from oil, grease, dirt, protective coatings (on materials as received from factory) and other foreign matter. Descaling, pickling and passivation shall be done for all stainless steel parts. Cleaning solution should be chloride free (especially for stainless steels). Painting shall be done as per enclosed painting specification. Spares
05
All spares are to be supplied as indicated in the specification and B OQ will be as per Price Schedule.
MEC/S/Q6L2/01/PJ/T06-001, Rev. 0 2008, MECON Limited. All rights reserved. PAGE No. 05.14 - 3 of 32

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06 Consumables
All consumables are to be supplied in line with stipulations indicated in the specification. Special To ols and Tackles
07
Special tools and tack les, if any, shall be supplied in line with specification. 05.14.03 BATT ERY LIMITS AND SITE CONDITIONS
05.14.03.01 BATTERY LIMITS a) Suction of air compressor at suction filter. b) Delivery of air pipelines - upto the us er points of the mills. c) Cooling water s upply and return from cooling tower to equipment & back to cooling tower. d) Anti-surge valve at 1 m abov e the building roof. e) E lectrics : from the mai n electrical panel upto the equipment. 05.14.03.02 Design Conditions
1) Approx. +225 m above MS L 2) Ambient temper ature 3) Relative humidity : 46 0 C : 100% ( max.)
4) P ower supply frequency : 47.5 Hz For capacity calculations in Nm 3/Hr. both 460 C and 100% RH s hall be considered oc curring simultaneously.
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Codes And Standards 05.14.04.01 System
Metric system of units shall be followed in design and manufacture of all equipment as well as drawing /document. Name plate of equipment as well as operating /
maintenance instructions shall be in English language 05.14.04.02 Applicable Cod es and Standards
The material used and the equipment supplied shall be new and the best of their respective kinds and shall comply with the latest revision of relevant Indian Standards specification /relevant International Standards . The equipment shall also comply with the statutory requirements of Government of India, Govt. of Andhra Pradesh, and the latest revision of Indian Electricity rules. Where the equipment is not according to Indian Standard, the regulations to which the equipment conforms shall be submitted along with the tender. 05.14.05 Techn ical Specificatio n
The following air compressors are envisaged for Bar mill and Wire rod mills. Broad technical parameters are given below.
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05.14.05.01 TECHNICAL PARAMETERS SL. NO. 1. PARAMETER No. of air compressors
3
DESCRIPTION 3 nos.(2W+1S) 75 Nm /min. (dry moisture free) with
2.
Capacity
zero negative tolerance. The v olume is net output measur ed at the after c ooler outlet
3. 4.
Type of air compressor Delivery pressure at the out l et of after cooler Delivery temperature at the out let of after cooler Lubricated/non lubricated Cooling Design power s upply frequenc y No. of stages Cooling water inlet temperature Surge margi n at 50 Hz . 75 Nm 3/min, 8.0 Kg/c m2 (g) Surge margi n at 47.5 Hz. 75 Nm 3/min, 8.0 Kg/c m2 (g) Operation at 47.5 Hz . 75 Nm 3/min, 8.0 Kg/c m2 (g) Turndown at 47.5 Hz., 8.0 Kg/cm 2 (g)
Centrifugal 8.00 Kg/Cm 2 (g) 100 C above inlet cooling water temp. Non lubricated Water cooled 47.5Hz 3 Approx. 32 0 C 25%
5. 6. 7. 8. 9. 10. 11.
12.
Not less than 10%
13.
Stable
14.
25 % minimum
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05.14.05.02 General Requirement of Air Compressors
01
The air compressor shall be a 3 stage, integral gear design air compressor and shall be designed generally as per API 672. The compressors shall be axial/ radial, mixed flow design. The compressors shall have high efficiency over the required wide range of operation and shall be suitable for continuous operation under the specified conditions and shall meet the most severe and fluctuating process requirements without operating anti-surge valve. A liberal factor of safety shall be allowed as regards to duty and mechanical design of air compressor, so that machine shall be capable of delivering the specific process air requirement at duty conditions indicated in the specification. The critical speed of the air compressor shall be sufficiently away from the normal working range.
02
The air compressor shall be of integral gear design, with suitable split casing for the integral gear. The machine shall be of heavy duty construction, with cast-in short air passages to reduce internal pressure drop and noi se.
03
The machine parts shall be designed to balance the machine loads due to fluid flow by suitably engineering the components to r educe, the axial thrust by canceling.
04
The inter cooler and after cooler shall be designed in such a way that, the tubes bundles can easily be accessible for cleaning. The location of the inter cooler shall be such that water carry over to the next stage shall be minimum (preferably least or zero). The inter coolers and after c oolers shall be external type.
05
The impeller blades shall be optionally designed in radial /mixed configuration to give optimum size for the impellers. The diffuser and impeller combination shall be designed to give best efficiency over wide range of capacity of the impeller. The size of the impellers shall be chosen to deliver flows in excess of 100 % with only a slight reduction in pressure. The design shall have low operating stress levels giving high mechanical
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integrity. The material of blades and diffusers shall be selected in such a way that the affect of erosion and cor rosion on the l ife of the machi ne is negligible.
06
Separate and horizontally split air and oil seals shall be provided to keep the air totally oil free.
07
An acoustic enclosure for gear box & compressor shall be provided to limit the noise level at 85 dBA at 1 meter fr om the compressor.
08
The capacity of the ai r compressor shall be controlled with the inlet guide vane c ontrol. Anti Surge Control Device An anti-surge control device shall be provided to protect the compressor against mechanical damage for process disturbance. The device shall automati cally open a blow-off valve, when the load fluctuates below the surge line. Blow off valve (or surge control valve) shall be actuated automatically by electric-pneumatic actuators. The anti surge pipe shall be provided with silencer & shall be terminated 1 meter above the building roof with suitable supports & cowl. The anti-surge control loop shall be
09
controlled from local panel. The impeller combination shall be such that the volume turn down and efficiency of the compressor shall be optimum for the size of the air compressor specified. Turn down
10
The compressors will be used for supply of process air. The air demand on the air compressors vary very widely. The compressors having high turn down will be advantage for operation. Suction Air filter
11
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Heavy duty dry type air filter shall be supplied. Pressure drop across the filter at full load should not exceed the limit normally allowed for the type of filter offered. Filters supplied shall have sufficient reserve capacity and it shall be indicated in the tender. Silencer
12
Adequate provision of appropriate type of silencers shall be supplied for suction and discharge sides. The expected noise level from the compressor with silencer and also without silencer shall be indicated. T he compressor casing including suction pipeline be acoustic insulated in addition to thermal insulation so as to contain the noise level in the limits 85 dBA at 1 meter from the compressor. The sound level from the antisurge valve silencer shall also be less than 85 dba at 1 meter fr om the silencer. Cooling system
13
The compressors shall be provided with inter and after coolers for the air and lubricating oil cooler. The cooler shall be high efficiency type. These shall be water cooled. Inter coolers and after c oolers shall be provided with moisture separator. i) Inter coolers : Water cooled inter coolers shall be provided as per the compressor manufactur es standard. ii) After coolers: Water cooled inter coolers shall be provided as per the c ompressor manufactures standard.
The cooling water requirements for 3 compressors (2W+1S), shall be included while designing the cooling tower for the mill. Tenderer shall offer 4 cooling water pumps each shall have capacity of cooling water required for one compressor working at full load. Out of 4, 3 pumps will be working for 3 compressors & one will be standby. The pumps shall be provided in the common circulating cooling water pump house of the mill. The tenderer shall include the interconnecting waterlines to cater for 3 compressors working. Scope of suppliers shall also include the suction & delivery

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isolating valves. Each pump shall have one non-return valve, suction strainer & pressure gauge on del ivery side. Lubrication & Governing oil system
14
A self contained oil system for lubrication of motor & Compressor and reduction gear bearings shall be provided. The system shall comprise of a main shaft driven oil pump & A.C motor driven auxiliary oil pump of full capacity. A D.C motor driven emergenc y oil to supply only bearing lubrication and flushing oil when main and auxiliary pumps are out of operation (if required) shall be provided. An automatic interlocking system shall be provided to operate the various oil pumps in a sequential manner as desired for the protection of the compressor. An oil tank of adequate capacity (5 meters retention time) with duplex filter including changeov er and all other necessary fittings and motor driven vent blower shall be provided. Adequate ar rangement s hall be made for proper filtration and cleaning of the oil as it circulates through the system. The straining elements shall be replaceable when the machine is under operation. Not less than 2 oil coolers of adequate size shall be provided. Each cooler shall be capable of meeting 115 %
maximum requirement of the machi ne, thus pr oviding one of the cool er as standby.
Lubricating oil line from oil filter to the machine shall be of SS 304 material. Oil filter body also shall be of SS 304 Bearings
15
The bearings of the motor, reduction gear and compressor shall be lined with white metal and arranged for forced lubrication. A combined journal and thrust bearing shall be provided with adequate cooling. The bearing type selected shall be such that vibrations are minimum. Impel lers shall be provided with segmented ti lting pad beari ngs. Piping, Valves and Fittings
16
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Supply of air compressor and auxiliaries shall include all interconnecting compressed air, cooling water, Antisurge and drain piping complete with valves, fittings, supports as required for the system within the terminating points defined elsewhere in the specification and general ly as indicated below: a) Suction air pipeline from suction filter to inlet of compressor (Stainless steel material), and air discharge pipeline including discharge silencer, Non return valve, shut off valve pipe, pipe fittings and supports. Expansion joints shall be provided on both inlet and outlet pipelines.
b) Drains, vents and other miscellaneous pipelines for all the units of the system.
c) Exhaust pipelines from all equipment. The pipelines shall be complete with blow off valves, silencers, etc. The exhaust line leading to atmosphere shall be suitably
terminated and l eft such as not to caus e any damage to bui lding structures.
d) Oil pipeline interconnecting various sub systems with necessary valves and pipe fittings shall be provided to c omplete lubricating system. Non-return valve
17
Each compressor after the after cooler shall be provided with a non-return valve of plate type. The valve body shall be of cas t steel and the nominal diameter shall be 150 mm . Shut off valve
18
Each compressor shall be provided with a shut off valve after the non-return valve. The body of valve shall be of cast steel and hav ing a nomi nal diameter of 150 mm. The v alve shall be a butter fly with soft seating and S S 304 disc. 19 Air Receiver
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The Air receiver of capacity 15 m3 volume to be provided and arranged properly. The inter connecting piping should be as per the s cheme. Filters
20
E ach compressed air system shall be provided with the following filters
1. Materi al of construction a) B ody : Carbon steel : 75 Nm 3/min. : 8.00 Kg/c m2 : 5 microns
b) F iltering element : S intered stainless steel 2. Capaci ty 3. Pressure 4. Size Electrics
21
All motors and other electrical equipment necessary for operation and control of the air compressor, shall be provided. Chapter 05.07 of the specification shall be referred for the detai ls. . Instrumentation
22
1. All controls and instrumentation necessary for operation and control of the air compressor, shall be provided. Chapter 05.07 of the specification shall be referred for the detai ls. The following are minimum instruments & controls required for each compressor, over & above any other instruments & controls required shall also be included. A. MEASURING INSTRUMENTS.
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1. Indication & integration of air flow through the compressor, with Pressure & temperatur e correction in NM/min 2. 3. a) Indication & control of air pressure at the c ompressor discharge. Instruments on the oi l cooler- on common line Oil side - Inlet temperature - Outlet temper ature - Inlet pressure - Outlet pressure b) Cooling water Side - Outlet water pr. - Inlet water temp. - Outlet water temp. 4. Indication of air temperatur e - Local gauge at the i nlet of compressor - Local gauge at eac h inter stage - Local gauge on delivery side of the compressor 5. Indication of air pressure - Local gauge at the i nlet of compressor - Local gauge at eac h inter stage of compres sors - Indication of differential pressure gauge on s uction filter - Indicating of each bear ing temperatur e local panel 6. Vibration measuring system one set of X, Y probes on each impeller, axial vibration on each probe 7. 8. Two displacement probes on s haft. Inlet guide vane - % openi ng for indication on local panel Local gauge Local gauge Local gauge - Inlet water pr . Local gauge Local gauge Local gauge Local gauge Local gauge
B. ALARM AND TRIPS
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1. Thrust bearing temperature High Very high 2. Vibration High Very high 3. Axial displacement of impeller High Very high 4. Differential pressure across the suction High filter 5. 6. Temperatur e of lube oil Position of blow off valve High Open - Alarm - Alarm - Alarm - Trip - Alarm - Trip - Alarm - Trip - Alarm
7.
Lubricating oil supply pressure
Low Very low
- Alarm - Trip - Alarm - Trip - Alarm - Trip - Alarm
8.
Oil tank level
Low Very low
9.
Impeller Bearing temperature
High Very high
10. Suction air temperature
High
C.
INTER LOCKS
1. Compressor cannot be s tarted unless the oil level in the oil tank is above the minimum level and so water fl ow is present.
2. Compressor cannot be started unless the lubricating oil pressure is within the limits. All the bearing temperatur e alarms and trip level signals to be taken to DCS installed by the owner. All analog signals and digital signals shall be wired to the local JB in compressor room for connecting to DCS . A mod bus c onnection shall also be provided 05.14.05.03 D esiccant Type Air Dryer
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a) b) c) d) e) f) g) h) i) j) k) l) m) No. of desi ccant air dryer Type Capacity Cycle time Pressure before the air dryer Temperatur e before the ai r dryer Source of air Air pressure drop ac ross the air dryer Automatic/Manual Pre filter After filter Dew point after the dryer Desiccant : 3 nos. (2W+1S) : Split flow no loss : 75 Nm 3/min.. : 8+8 hours drying cycle : 8 kg/cm2 maximum : 43 deg. C max imum : From the outl et of air compressor : Not more than 0.2 k g/cm2 : Automatic : 25 microns sintered stainless steel : 25 microns after filter Sintered SS : (-) 40 deg. C atmospher ic dew point : Silica gel/activated alumina
E ach air dryer shall be compl ete with the fol lowing:
i)
Base frame mounti ng all the components of the dry er
ii)
Twin desiccant towers:- The towers shall be designed as per ASME Section VIII Div-1. Materials of construction shall be as per IS :2062 Gr. II.
iii)
Instrumentation Air pressure gauge before and after the dr yer A ir temperature gauge before and after the dry er and heater
iv)
Dew poi nt apparatus
v)
Timer - Mechanical
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vi) Silencers on each ex haust air lines
vii) 05.14.06
By pass valve (ball valve) on dryer
Inspectio n and Testing Inspection an d Testing at Manufacturers Premises GENERAL
06.01
06.01.01
06.01.01.01
The owner/ consultant shall be allowed to use all the inspection/testing facilities available with the manufacturers for the purpose of inspection/testing and tenderer shall offer all necessary facilities for the same free of cos t. INSPECTION
06.01.02
06.01.02.01
The owner or his representative will be entitled to inspect the manufac turer's and his contractors facilities as well as review non-proprietary drawings and calculations, quality plans, fabrication schedules, materials, workmanship and equipment any time during the design and fabrication period. The inspections may not disturb the normal work proceedings, unless an item being fabricated does not c omply with the spec ifications.
06.01.02.02
The i nspection at manufac turer's works shall be carried out by the owner/ cons ultant in order to ensure follow up and i mplementati on of the approved Q C and QA .
06.01.02.03
Inspection shall be carried based on approved drawings and specifications and as per relevant standards .
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06.01.02.04 A copy of the order on the sub-contractors, comprising of all the detailed specification and the qualities of the materials, bill of materials shall be sent to the owner/ c onsultant sufficiently prior to the start of inspection.
06.01.02.05
The manufactur e shall control his production by sample tests in his laboratory to make sure that the materials are in accordance with the data given in the specification of the order. The results of such tests done at the place of
manufactur e shall be made avai lable to the owner.
06.01.02.06
The tenderer shall inspect the material before offering to the owner/ consultant for inspection and satisfy himself with regard to the quality and quantity and issue an internal inspection certificate along with manufactur er's test certificate duly signed by competent authority to the owner for the review. Inspection shall be done at the place of manufacturer's premises as well as on arrival at the site unless otherwise mentioned.
06.01.02.07
The tenderer shall intimate for inspection along with his internal inspection certificate at atleast three weeks prior to start of inspection. While sending the information, the tenderer shall ensure that reasonable quantity is offered for inspection.
06.01.02.08
During the inspection, the owner/ consultant in the presence of manufac turer shall draw samples for testing of various properties. The supplier shall render all the help during drawing samples, checking for physical appearance, size tolerance and testing at their laboratory. The testing shall be conducted as per relevant IS and / or mutual ly agreeabl e standards .
06.01.02.09
The final acceptance certificate will be issued by the owner/ consultant within a week after compl etion of inspection and testing.
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06.01.02.10 In case of any dispute, the samples shall be sent to a national laboratory for necessary testing at the ful l expenses of the manufac ture/ tenderer .
06.01.02.11
The owner/ consultant shall have the full right to accept or reject the materials, if during inspection and testing, the materials are found not conforming to specification.
06.01.02.12
Inspection by the owner/ consultant or his representati ves shall not relieve the successful tender of his liability for rectifying any defects, which may subsequently appear or be detected during or after erection. After rectification, the testing of the plant and equipment/ pipe joints etc. shall be repeated to the satisfaction of the ow ner.
06.01.02.13
All the items of work and supply as covered under this specification shall be subject to inspection by owner/ consultant. Primer paint shall not be applied before inspection. Testing
06.01.03
06.01.03.01
All the necessary testing shall be carried out at the manufactur er's premises in the presence of the owners/consultant and the test results shall be signed by both the manufactur e and the owner / consultant.
06.01.03.02
Manufactur er shall provide all the test tools, material and tes t parts. If any part is found defecti ve the same shall be replaced by the manufactur er at his own cost.
06.01.03.03
Suitable test rigs as per relevant international approved codes and standards shall be installed at the test premises to carry the following tests
Tes ts for air compressors Capacity test.


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Specific power consumption test. Speed test. Overall efficiency Functioning of cons tant pressure controls Functioning of Anti-surge contr ol system Any offer test relevant to air compressor to be carried out mutually decided by owner/consultant and the manufac turer s premises
Tests for air dryer.
a) Dew point test b) Functional test
Tests for valves
a) Body test b) Seat test SITE TESTING
06.02
The following tests shall be carried out at s ite
06.02.01
Hydrostatic test for all pipelines, etc.
06.02.02
Supplier shall perform dew point test at the site along with the centr ifugal compressors at full load
06.02.03 05.14.07
Run test of compres sors and its accessories PREPARATION, PACKING & FORWARDING
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07.01 GENERAL
07.01.01
The successful tender on receipt of acceptance certificate shall ensure the dispatch of the accepted materi al only.
07.01.02
The supplier shall in no case dispatch the materials from his works unless it has been inspected, tested and acc epted by the owner / consultant.
07.01.03.
Mater ial shall be dispatched only after receipt of dispatch clearance from the owner. PREPARATION
07.02
07.02.01
All openings in the equipment shall be sealed to prevent entry of foreign matter during shipment. Couplings shall be provided with pipe lugs or tight metal caps to protect the threads and flanges shall be provided with wooden covers bolted in place to protect the fl ange face.
07.02.02
All unprotected parts liable to rust shall be given a protective coating. All moving parts shall triple coated with a rust preventive heavy lubricant and then wrapped in plastic suitable for prolonged peri ods of outside storage.
07.02.03
All items shall be provided with adequate lifting lugs to facilitate unloading and handling before and during erection and shall be properly braced and supported during handling and shi pment.
07.02.04
All items are to be permanentl y marked with the respective equipment, part and order numbers.
07.02.05
All components shall be aligned and mating parts marked before disassembly for shipment.
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07.02.06 All machined surfaces shall be protected against corrosion and physical damage during shipping. PACKING & FORWARDING
07.03
07.03.01
All equipment shall be suitably packed to prevent any damage or deterioration during transit.
07.03.02
Packing must also be suitable for inland transport, railway or truck, and strong enough for several reloading and long term storage under the climatic conditions specified under "S ite Conditions .
07.03.03
Packing must be suitably for crane, fork lift or hand loading operations.
07.03.04
All connections/protrusions shall be suitably protected. Flanges, if any, shall be provided with suitable wooden disc protection fastened to equipment as bolts. Threaded connec tions shall be closed with plugs.
07.03.05
Fragile components shall be specially protected dur ing handl ing and s torage.
07.03.06
All items are to be per manently marked with the res pective equipment, par t and order number s.
07.04
ERECTION AND CO MMISSIONING
07.04.01
General
a)
The erection of all plant and equipment shall be carried out according to the latest engineering practices and according to the working drawings, specifications, instructions etc. duly approved by the owner/ consultant. The tenderer shall carry out the works in the presence and/ or as per the
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instructions of site engineers /supervisory personnel deputed by the Owner. The erection shall be carried out by highly skilled workmen.
b)
The Tenderer shall take care of positioning, leveling and plumbing of all pipelines and equipment as well as supporting structures within the required accuracy and tolerance limits. It shall be a contractual obligation that the pipes are not thrown out of alignment or lifted off curing commissioning and subs equent operati on.
c)
There may be more than one contractor working in the area at the same time. As such the work has to be carried out in proper co-ordination and consultation with the Owner and all other parties concerned with the work. The Tenderer shall take due notice of the working conditions, practices and agreements prevalent in the area of the plant site and s atisfy himself before quoting.
d)
The Tenderer shall be responsible for paying strict attention to statutory regulations for prevention of accidents and to other safety rules. The
regulations for prevention of accidents shall be displayed at appropriate places and should be distinctly visible to all personnel working in the area.
e)
The Tenderer shall submit with the tender, a list of similar works executed by him, indicating the column of erec tion work in each of them.
f)
The Tenderer shall supply all required consumables, construction and erection materials, petrol, diesel, oil, kerosene, solvents, sealing
compounds , tapes, brazing and soldering materials, welding sets, pipe bending matches, cable clamping tools, gauges, erection bolts, nuts and packing sheets/ compounds, temporar y supports, wooden blocks, spacers, templates, jute and cotton wastes, sand and emery paper etc. as required for satisfactory completion of erecti on work.

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g)
The Tenderer shall make his own arrangement for handling the equipment and pipelines at the s tores and tr ansporting it to the site of installation.
h)
In addition to the above, the Tenderer shall follow all the relevant erection clauses/ conditions stated under various chapters of this specification.
07.04.02
Equipment (Compressors, Air dryers, etc)
a)
The equipment shall be erected on prepared foundation and leveled with shims and wedges wi th the help of precision levels and other instruments.
b)
The drive and coupling shall then be coupled and aligned. The method of alignment and tol erance for alignment s hall be maintained as specified in the manufactur er's instruction manual .
c)
During manual rotation, it shall be ensured that the shaft assembly moves freely and no noi se develops from beari ngs.
d)
Before coupling the motor to the equipment it shall be ensured that the direction of rotation of the motor corresponds to that of the equipment indicated by the manuf acturer /supplier.
07.04.03
Valves
B efore erection of valves, it shall be ensured that
a)
All grit and foreign matter are removed from the inside of the valves before connecting the pipes.
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b) All the faces are thoroughly cleaned and coated with a thin layer of mineral grease.
c)
Valves shall normally be installed with the spindle vertical except on vertical pipes where the spindle shall be horizontal.
The v alves shall be tightly closed when bei ng installed, to prevent any foreign matter fr om getting on between the work ing parts of valves. 07.04.04 Piping
Laying and joining of pipelines
a)
Compressed air pipes shall not be connected by screwed joints. They shall be butt welded by electric arc welding.
b)
Pipes shall be laid to lines and levels as shown in the approved drawings. Laying and joining of welded pipes shall be as per IS :5822-1994. For making welded joints, the welding shall be performed by the manual shielded metallic arc process. All welding including the proposed procedure and the qualification of welders and welding operations shall be done according to power piping code ANSI B 31.1 and ASME Section IX or approved equivalent. Pipes for butt welded run shall be supplied with ends levelled by machining or grinding. The ends of the pi pe -to-pipe, pipeto-fitting and fitting-to-fitting joints shall be aligned as accurately as is practical within the existing commercial tolerance on pipe diameters, wall thickness and out- of -roundness. Alignment shall provide the most favourable conditions for weld deposition of the root bead. Welds shall be full penetrati on, continuous without defects .
PAGE No. 05.14 - 24 of 32

MECON LIMITED
c) As a rule, butt welding shall be carried out without interruption until the entire joint is welded. In any case, however, welding of butt joints must not be interrupted ti ll atleast 50% to 60% of wel ding thickness is completed.
d)
If there is an unscheduled interruption in such work, it is necessary to ensure slow and uni form cooling of metal by covering it with asbestos or by other means to eliminate the possibility of sharp zonal cooling of metal. Before starting the welding again, it is necessary to heat the butt upto the required temperature and maintain this temperature till the butt welding is completed.
e)
Besides systematic inter-operational control, the quality of welded joints shall be controlled by visual inspection and mechanical tests in conformity with the prov isions of applicable standard c odes.
f)
The Contractor shall supply/fabricate and install pipes and fittings in strict compliance with the detailed engineering drawings. Deviations if
considered neces sary to suit site conditions could however, be permitted in consultation with and wi th prior approval of the O wner/ Cons ultant.
g)
All openings in the piping shall be kept effectively closed until assembled in the system to avoi d foreign matter enteri ng into the sy stem.
h)
All piping shall follow the general arrangement drawings, shall be cut accurately to measurements established for the work by the Contractor and shall be installed without springing.
i)
All piping shall be installed with adequate clearance for lighting, bracing, doors, windows and other openi ngs.
PAGE No. 05.14 - 25 of 32

MECON LIMITED
j) Piping shall be arranged in the straightest possible runs with minimum amount of fittings. Flanges of the pipelines, fittings, etc., must be so mounted that top bolt holes are symmetrical about the vertical axis of the flange.
k)
Joints should be as far as possible located at one third span from supports and must be av oided in the middle of the span.
l)
Openings provided in the walls for pipelines must be closed with bricks or mortar with 10 to 20 mm clearance between the brick work and pipe. The clear space must be stuffed wi th felt or asbestos.
m)
The Contractor shall supply/fabricate and install pipe supports and all that is necessary to completely support all the piping and piping components including but not limited to beam clamps, pipe clamps, fabricated structural supports, guides and anchors, brackets, saddles, U-bolts, etc. Only
approved type of anc hor fasteners shall be used for RCC ceiling and walls. Also supporting members required in addition to building structure shall be furnished and installed. Concrete pedestals for supporting the pipes as well as valves are also included in the Contrac tors scope of work .
n)
Screwed joint (wherever applicable)
Pipe sealant shall be used to makeup screwed joints and shall be applied to male threads only. Threaded parts shall be wiped clean of oil or grease using appropriate solvent if necessary and allowing proper time for drying before applying the sealant. Pipe shall be free from fins and burs. Pipe ends shall be reamed or filled out to size of bore and all chips shall be removed.
Mati ng surfaces shall be coated wi th white lead. All the joints shall be

MECON LIMITED
ensur ed for water tightness.
o)
Flanged joint
Flanged joint shall be used for connections to vessels, equipment, fl anged valves, and road crossings and also on suitable straight lengths of pi pelines of strategic points to facilitate erection and s ubsequent mai ntenance work. 05.14.08 PERFORMANCE GUARANTEE
1. The performance of the individual equipment of the system shall be guaranteed by the contractor as per the requi rements of i ndividual equipment specification.
2. For compressors & air dryers, power consumption at the motor/ dry er terminal shall be guaranteed. The addi tional power consumption for each compressor / dryer shall be penalized at the rate of Rs . 3,00,000/- per extra kW, drawn fr om the mai ns.
3. Input Power to Motor of Compres sor indicated is guaranteed v alue without any positive tolerance.
4. Party shall carryout the test for establishing guaranteed input power to motor at the works during inspection, prior to dispatch. All test facilities & measuring instruments of required accuracy shall be provided at the works, with no extra cost to owner.
5. The guaranteed motor input power shall be indicated as per enclosed format along with the price bid and blanked format shaft power shall be submitted along with the techni cal bid. 05.14.09 LIST OF APPROVED MAKES
PAGE No. 05.14 - 27 of 32

MECON LIMITED
1.
Centrifugal Air compressors
Atlas Copco, Ingersoll Rand, Chi cago Pneumatics, Elgi Equipment, CICB Siemens, Industrial systems & equipment BHEL, Bharat pumps & compressors ltd., Industrial systems & equipment, Cooper turbo compressors, Buffalo, USA
2.
Air dryers Refrigeration type
Del Air Gem equi pment Lloyds Steel Industries Sanpar Air dryers
3.
Air receivers
Gem equipment L&T Lloyds Steel Industries Artson Engineering Ltd., Patel Air Temp (Indi a) Cethar Vessels Eagle Engineers
4.
Intercoolers / After coolers.
BHPV Excel Engineering & Design organization. Reliance Heat Trans fer Pvt. Ltd., Kaveri Engineering As per manufacturer s standard
PAGE No. 05.14 - 28 of 32

MECON LIMITED
5. Seamless Pipes TATA Jindal Lloyds Metals & Engineers BHEL Steel Tube Company Maharastra Seam less Ltd., The Indian Seam l ess Metal Tubes Company Ltd., 6. Centrifugal Pumps Best and Cr ompton KSB Pumps Mather & Platt Beacon Weir Ltd., Kirloskar Brothers 7. Ball Valves Audco India Ltd. KSB Pumps Virgo Engineers. Micro finish 8. Non Return V alves Audco India Ltd. KSB Pumps Paharpur 9. Cooling Towers Thermopack Gem 10. Fine Filter Ultra Filters Dominic Hunter 11 Motors SIEMENS / Bharat Biglee / ABB / Kirloskar / Alstom / Crompton Gr eaves 12 Switchgear & Control gear : SFU, SIEMENS / L & T / GEPC / CGL/ ABB ACB, MCCB, Load break switches, Fuses, Contractors, Overload Relays with SPP,
PAGE No. 05.14 - 29 of 32

MECON LIMITED
13 Control voltage Transformer Southern Electric / KAPPA / Automatic Electric / Kalpa 14 Control Circuit Breakers SIEMENS / MDS / STD / GEPC / Havell / Indo Kopp / North West Switchgear / S & S Power Swtich gear 15 16 17 18 19 Meters : Ammeter, V oltmeter Push buttons CTs/PTs Control/Selector switches AE / IMP / MECO Vaishno / Siemens / L & T / BCH / GEPC Pragati/Kappa/Precise/AE Kaycee / Salzer
LT Power Cables & LT Control Asian / CCI / Finolex / Fort Gloster / KEI Cables. Transmitters SMART type (Pressure, flow, level and DP) /Nicco / Polycab / Universal Yokogawa B lue star Ltd Tata Honey Well Ltd Rosemount (India) Pvt Ltd Flow Measur ements (Orifice plate) Engineering Specialties Pvt. Ltd. Micro Precisions Instrumentation Ltd Hydro pneumati c Baliga
20 21
22 23
Pressure Switches Local pressure gauges / temperature gauge
Switzer / Indfos s / Varmatrafag H Guru / Waree instruments / WI / General instruments
24
Level Measurement
SB Electro Mechanical Nivo Controls / Placka instruments Sigma / Chemtr ols / KROHNEMARSHALL
PAGE No. 05.14 - 30 of 32

MECON LIMITED
25 Temperature Measur ement General instruments Pyro Electric Toshbro Pvt Ltd Instrumentation Ltd 26 27 Solenoid valves Control Valves ASCO / Rotex / Schrader Duncan Ltd Samson / A RCA / FOURESS Instrumentation Ltd Fisher xomox MIL Control s Ltd. 28 Control Panel Megatech, Chemi n control, Instrumentation Ltd 29 Digital Indicators / Controllers / Recorders. 30 31. 32. 33. 34. 35. 36. Programmabl e logic controller Micro processor based meters Indicating meters LT MCCs & PDB ACBs MCCBs MPCBs Yokogawa B luestar / Leetr otek Systems / MASIBUS / SIEMENS / ABB SIEMENS/ABB/Allen Bradely/GE/Fanuc Enercon/Swift/Neptune/A BB/Siemens AE/IMP/MECO/Rishabh Schneider/L & T / Siemens Schneider/Siemens/L & T Merlin Gerin/L & T/Siemens/ABB Siemens / Telemechanique / Sprecher and Schuh 37. 38. Contactors, O / L relays with SPP SFU, Load break switches, Fuses, , Telemecanique/L & T / Siemens SIEMENS / L & T / GEPC / Schnieder/ ABB 39. Control voltage Transformer Southern E lectric / KAPPA / Automatic Electric / Kalpa / Pragathi Electrics 40. 41. MCB / ELCB Motor protec tion relays MDS/Hager/Siemens L & T (MM-30) / Schneider
PAGE No. 05.14 - 31 of 32

MECON LIMITED
(SEPAM)/Multilin (239) 42. Variable Frequency Drives Cables ABB / Siemens / L & T/ Schneider / Allen Bradley NICCO/Polycab)/Fort Gloster/Universal/RPG control)/Delton (control) 44. 45. 46. Push buttons Indicating lamps (LED type) Industrial Plugs & Sockets Local push button station Vaishno / Siemens / L & T / BCH / GEPC Siemens / Raas Contr ols / L&T Best & Crompton/S chneider Electrics/ Bharatia Industries BLEP/Flexpro/Flameproof Equipment/Pushtron 48. GRP cable Trays ERCON/General composites/Densons (LT power &
43.
47.
PAGE No. 05.14 - 32 of 32

JAMMALAMADUGU, KADAPA DISTRICT
MECON LIMITED
2.5 MT CAPACITY INTEGRATED STEEL PLANT CHAPTER NO.05.15 BAR MILL & WIRE ROD MILL SECTION I
SECTION I : CONTENTS & GENERAL SCOPE 1.00
The Technical specification for civil works is covered under the following chapters :
SECTION
DESCRIPTION
NO.OF PAGES
SECTION - I SECTION - II SECTION IIII SECTION IV SECTION - V SECTION VI SECTION VII
CONTENTS & GENERAL SCOPE ACHITECTURAL AND DESIGN REQUIREMENTS TECHINICAL SPECIFICATIONS DIMENSIONAL TOLERANCES METHOD OF MEASUREMENT SAFETY REQUIREMENTS FOR CONSTRUCTI ON WORKS LIST OF RECOMMEND ED MAKES & MANUFACTURERS
1-5 6-29 30- 211 212-218 219 220-224
225-228
2.00.00
GENERAL SCOPE OF WORK
2.01.00
The work to be performed under this specification consists of providing all labour, materials (For owner supplied materials refer clause 2.11.00), construction equipment, tools and plant, batching plant, scaffolding, supplies, transportation, all incidental items not shown or specified, but reasonably implied or necessary for successful completion of the work including Contractors supervision and in strict accordance with the
MEC/S/Q6L2/01/P J/T06-001, Rev. 0 2008, MECON Limited. All rights reserved.
PAGE No.05.15 - 1 of 1

MECON LIMITED
drawings and specifications.
2.02.00
The nature of work shall generally involve earthwork in excavation including hard rock/ soft rock, dewatering, shoring and strutting, backfilling around completed structures and plinth filling, disposal of surplus excavated materials, piling if required, formwork, placement of reinforcement, inserts, steel gratings, checkered plates, anchor bolts, concreting, brick work, architectural finishes etc., construction of RCC foundations, structures, trenches, laying of GI/ PVC conduits and other ancillary items.
2.03.00
The layout and levels of all structures, etc. shall be made by the Contractor at his own cost from the general grid of the plot and bench mark given by the Consultant. He shall provide all instrument, materials and men to the Consultants for checking the layout and levels. However, the Contractor shall be fully responsible for correctness of layout and levels
2.04.00
The contractor will be required to set up site laboratory at his own cost and maintain all the equipment in proper condition with all calibration and certificates of the equipment. The site laboratory will be manned by independent qualified engineer. The cost of setting up site laboratory and performance of all the tests shall be borne by the Contractor. In case any specific test such as testing of reinforcement, testing of specific materials requiring specialist equipment and conditions, shall be done in approved laboratories. The cost of such tests and the arrangements for witnessing such tests shall be borne by the Contractor.
PAGE No.05.15 - 2 of 2

MECON LIMITED
2.05.00
The contractor shall be required to make all arrangements for storage of materials like cement, steel, and other construction materials. In case the materials are issued by the owner, the cost of transportation, weighment, loading & unloading shall be to contractors account.
2.06.00
The scope of work also includes clearance of site of any vegetation, bushes, scrap, debris, etc. before starting the work and recording spot levels at the site of work as well as storage areas. The cost of such clearance shall be included in the quoted rates. The Contractor shall also clear the construction site of all debris and construction materials before handing over.
2.07.00
The construction site is in arid area, water table is expected to be very low. However, the Contractor shall adopt dewatering methods as approved by Consultant. The period for which the de-watering should be in effect shall be as directed by the Consultant.
2.08.00
For underground structures like cable cellars, hydraulic room, tunnels, scale pit requiring open excavation with dewatering, completely dry working conditions during excavation, shuttering, placement of
reinforcement, concreting, water proofing of structures, backfilling and any other operation shall be maintained by suitable dewatering method as approved by Consultant.
2.09.00
All costs towards construction of temporary roads, covered and open storages, site office, fencing watch & ward/ security, receiving, transportation, loading & unloading of owner supplied materials shall be
PAGE No.05.15 - 3 of 3

MECON LIMITED
deemed to have been included in the quoted rates.
2.10.00
Cost towards inspection, testing of materials, workmanship, etc is deemed to have been included in the quoted rates unless specified otherwise in the specifications and schedule of items.
2.11.00
Client intends to supply cement, reinforcement steel, steel for light structural and embedded conduits. The general requirement of these materials, size-wise shall be brought to the notice of the client well in advance so that work does not get hampered due to lack of availability of materials.
3.00.00
DRAWINGS
3.01.00
The work shall be executed in accordance with the specification and the drawings `issued for construction. Drawings will be issued by the turnkey supplier of the plant facilities in stages in close coordination with the availability of data and sequence of construction. Drawings for such facilities which are outside the scope of the turnkey supplier will be furnished by the consultant. Only latest revisions of the drawings shall be followed. All old revisions shall be clearly marked `SUPERCEEDED and kept separately or destroyed as directed by Consultant.
4.00.00 4.01.00
SITE RECORDS All works shall be recorded in appropriate proformas to be firmed up by the contractor in consultation with the Consultant. Where ever required
PAGE No.05.15 - 4 of 4

MECON LIMITED
reference to drawings and clauses of specification shall be recorded in the correspondence.
4.02.00
Records of cement and steel receipts, issue, and consumption shall be scrutinized from time to time by consultants and Owner. Statement of cement and steel receipts, statement of theoretical consumption and reconciliation accompany every bill. Records of spot levels jointly recorded before the start of the work shall form the basis of all measurements.
5.00.00
APPROVAL AND TESTS
5.01.00
A high standard of quality is required for all materials and workmanship in construction work. They shall be best of the kind obtainable indigenously in each case and shall be procured from manufacturers of repute in order to ensure uniformity of quality and timely supply.
5.02.00
All materials shall be subjected to inspection and testing. The Contractor shall submit samples for testing as may be required by the Consultant. Sampling and testing shall be carried out in accordance with relevant IS Standards.
5.03.00
Where ever IS codes are referred, they shall be latest edition/ publication as on date irrespective of the date of finalisation of the work.
6.00.00
REJECTION OF MATERIALS
PAGE No.05.15 - 5 of 5

MECON LIMITED
6.01.00
Any material brought to site which, in the opinion of the Consultant is damaged, contaminated, deteriorated or does not comply with the requirement of this specification shall be rejected.
6.02.00
If the routine tests or random site tests show that any of the materials, brought to site, do not comply in any way with the requirements of this specification or of IS codes as applicable, then that material shall be rejected.
6.03.00
The Contractor at his own cost shall remove from site any and all such rejected material within the time specified by the Consultant. SITE MOBILISATION
7.00.00
7.01.00
Tenderers shall clearly indicate their present job commitments and their proposed deployment for the present work. Tenderers shall also indicate the capacity of their construction equipment and their availability in respect of the following:
a) b) c) d) e) f) g) h)
Batching plant Weigh batchers Concrete pumps Tuffets Transit mixers Shuttering material Barbending equipment Vibrators
PAGE No.05.15 - 6 of 6

MECON LIMITED
i)
Pumps and curing methods
7.02.01
Tenderers shall also indicate their proposed deployment of site personnel and their responsibilities.
7.03.00
Tenderers shall indicate their internal quality assurance plan
PAGE No.05.15 - 7 of 7

MECON LIMITED
2.5 MT CAPACITY INTEGRATED STEEL PLANT CHAPTER NO.05.15 BAR MILL & WIRE ROD MILL SECTION II
SECTION II : ARCHITECTURAL AND DESIGN PARAMETERS 1.0 1.1 GENERAL This part of the specification defines the Architectural requirements and design parameters for analysis and design of the civil buildings, civil Structures and facilities. 2.0 2.1 ARCHITECTURAL DESIGN REQUIREMENTS Architectural design shall be in accordance with the following referenced publications: a) National Building code of India, b) State Government Factories Act. c) Local Municipality or any other authoritys Bye-laws as applicable. 2.2 2.2.1 Spatial requirements: Spatial requirements inside a building shall be based on the activities to be performed in the building, equipment layout, etc. 2.2.2 The objective of spatial arrangement is to satisfy functional requirements and physical comfort and safety regulations as well as aesthetics which has significant role in creating a favourable working and living conditions. 2.2.3 However the following are the limiting sizes, dimensions for various purposes, which are to be adhered to:
PAGE No. 05.15 11 of 1

TS-Compressed Air System

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BRAMHANI INDUSTRIES LTD.

05.14 COMPRESSED AIR FACILITIES

MEC/S/Q6L2/01/PJ/T06-001, Rev. 0 2008, MECON Limited. All rights reserved.

PAGE No. 05.14 - 1 of 32

BRAMHANI INDUSTRIES LTD.,

05.14.02.02 Material and Workmanship:

MEC/S/Q6L2/01/PJ/T06-001, Rev. 0 2008, MECON Limited. All rights reserved.

PAGE No. 05.14 - 2 of 32

BRAMHANI INDUSTRIES LTD.,

BRAMHANI INDUSTRIES LTD.,

MEC/S/Q6L2/01/PJ/T06-001, Rev. 0 2008, MECON Limited. All rights reserved.

PAGE No. 05.14 - 4 of 32

BRAMHANI INDUSTRIES LTD.,

MEC/S/Q6L2/01/PJ/T06-001, Rev. 0 2008, MECON Limited. All rights reserved.

PAGE No. 05.14 - 5 of 32

BRAMHANI INDUSTRIES LTD.,

DESCRIPTION 3 nos.(2W+1S) 75 Nm /min. (dry moisture free) with

Not less than 10%

MEC/S/Q6L2/01/PJ/T06-001, Rev. 0 2008, MECON Limited. All rights reserved.

PAGE No. 05.14 - 6 of 32

BRAMHANI INDUSTRIES LTD.,

MEC/S/Q6L2/01/PJ/T06-001, Rev. 0 2008, MECON Limited. All rights reserved.

PAGE No. 05.14 - 7 of 32

BRAMHANI INDUSTRIES LTD.,

MEC/S/Q6L2/01/PJ/T06-001, Rev. 0 2008, MECON Limited. All rights reserved.

PAGE No. 05.14 - 8 of 32

BRAMHANI INDUSTRIES LTD.,

BRAMHANI INDUSTRIES LTD.,

MEC/S/Q6L2/01/PJ/T06-001, Rev. 0 2008, MECON Limited. All rights reserved.

PAGE No. 05.14 - 10 of 32

BRAMHANI INDUSTRIES LTD.,

MEC/S/Q6L2/01/PJ/T06-001, Rev. 0 2008, MECON Limited. All rights reserved.

PAGE No. 05.14 - 11 of 32

BRAMHANI INDUSTRIES LTD.,

1. Materi al of construction a) B ody : Carbon steel : 75 Nm 3/min. : 8.00 Kg/c m2 : 5 microns

b) F iltering element : S intered stainless steel 2. Capaci ty 3. Pressure 4. Size Electrics

MEC/S/Q6L2/01/PJ/T06-001, Rev. 0 2008, MECON Limited. All rights reserved.

PAGE No. 05.14 - 12 of 32

BRAMHANI INDUSTRIES LTD.,

B. ALARM AND TRIPS

MEC/S/Q6L2/01/PJ/T06-001, Rev. 0 2008, MECON Limited. All rights reserved.

PAGE No. 05.14 - 13 of 32

BRAMHANI INDUSTRIES LTD.,

Lubricating oil supply pressure

Low Very low

- Alarm - Trip - Alarm - Trip - Alarm - Trip - Alarm

Oil tank level

Low Very low

Impeller Bearing temperature

High Very high

10. Suction air temperature

MEC/S/Q6L2/01/PJ/T06-001, Rev. 0 2008, MECON Limited. All rights reserved.

PAGE No. 05.14 - 14 of 32

BRAMHANI INDUSTRIES LTD.,

Base frame mounti ng all the components of the dry er

Dew poi nt apparatus

MEC/S/Q6L2/01/PJ/T06-001, Rev. 0 2008, MECON Limited. All rights reserved.

PAGE No. 05.14 - 15 of 32

BRAMHANI INDUSTRIES LTD.,

By pass valve (ball valve) on dryer

Inspectio n and Testing Inspection an d Testing at Manufacturers Premises GENERAL

MEC/S/Q6L2/01/PJ/T06-001, Rev. 0 2008, MECON Limited. All rights reserved.

PAGE No. 05.14 - 16 of 32