ANNEXURE A

QUANTITY
01) Manufacture, inspection, testing and supply of duly cast, heat treated machined top
Grinding ring of NI- HARD-IV composition similar to IS-4771,type IB and as per 03 Nos
Drawing No.HWB/M/807,Rev 03,dated 29.10.2008.

Weight (approx): 5580 kgs (machined weight @ 5.2 M tons)
Quter dia (OD) 2819 mm
Total thickness 229 mm

02) Manufacture, inspection, testing and supply of duly cast, heat-treated machined
Bottom grinding ring of NI-HARD-IV composition similar to IS-4771,Type IB and as 03 Nos
Per drawing no: HWB/M/808 ,Rev 03,dated 29.10.2008.

Weight ( approx) : 5400 Kgs (machined weight @ 5.15 M tons)
Outer dia (OD) : 2819mm
Total thickness : 229 mm

%Chemical composition for Ni-Hard-IV material similar to IS- 4771,Type IB for the above
Top and bottom grinding rings, (besides Iron) will be as follow :

C Si Ni Mo Mn Cr S P
Min% 2.8 1.5 5.15 - 0.4 8.0
Max% 3.3 2.0 6.5 0.5 0.6 10.0 0.1 0.3

Hard ness of above rings will be 575-620BHN and uniform

03) Manufacture, inspection, testing and supply of un machined hollow grinding.
Balls of Cr-Ni-108 Material for 8.5 E-10 P.F mill as per drawing no.HWB/M/823,Rev 01 03Sets
Set consists of 10 no standard ball of size 654 mm OD x 90 mm thick and one number
Fill in ball of size 585 mm OD x 55 mm thick. %Chemical composition of above
hollow grinding balls of Chrome Nickel- 108 material will be as follows

C Si Mn S P Cr Ni Mo
0.65-0.85% 03-06% 0.8-1% 0.05% MAX 0.05% MAX 1.5-2.3% 0.6-1% 0.35-0.45%

Hard ness of the balls should be 380-425 BHN
The above composition is an indicative range. The chemical composition should be balanced for
highest strength and toughness. The composition should be adjusted so as to avoid Graphite precipitation in
the casting. In order to lower Austenite in the heat-treated casting it is essential to use such type of Induction
furnace where temperature controls are with in (+10, -10) degree centigrade of the set point at any given time
and the capacity should allow preferably for single pouring only ( Terms and condition of the enquiry are attached )

The casting process should have proper drag, cope & vent holes given to proper depth at suitable
distances. Good moulding sand ( Preferably Zircon Sand) should be used having proper Refractoriness,
Chemical resistivity, strength with proper binder, permeability, surface finish, Flowability & collapsibility.

For the above casting 98% pure SiO 2 is recommended as per IS:1987
The patterns should be designed to take care of shrinkage, Machining, Draft-Tolerances.


TERMS AND CONDITIONS OF THE INDENT

1. The original equipment :8.5E-10 - Ball and race Type coal Mill was supplied by M/s ABL,
Kolkata. So interchangeability with original equipment is to be furnishing along with the supply.

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2. Heat treatment of grinding rings and balls shall be done properly so as to achieve the required durability
and the hard ness as mentioned above. Heat treatment temperature cycle to be followed for
NI-HARD-IV Rings and Cr-Ni-108 Ball castings must be submitted for the reference & approval.
3. There should be no defects like blowholes, cold shuts,inclusions on the contact surface of the bottom
and top Grinding rings.
4. Un machined ball track race should be free from burrs ridges and unevenness.
5. Surface cracks on the surface of the grinding rings, balls are not acceptable.
6. Grinding balls should be Un machined, no welding repair is allowed on the ball surface.
7. Variation in the center line depth of ball tracks measured by depth gauge from a straight edge placed
on the shoulders should not be more than 2mm
8. Hollow grinding balls shall be manufactured meeting the dimensional tolerances as given below:
Ovality of the balls should be less than 3mm in three perpendicular directions. Each ball to be
tested in three perpendicular directions at 6 points.
The grinding balls of 654mm diameter and fill in ball of 585 mm diameter shall have tolerance of
+2.0 mm on outside diameter (+2.0/- 0.0)
The rated weight tolerance of one set of balls (10 Nos) shall be within of +2%. The weight of
each ball should also be punched on wall surface.
The internal diameter and external surface for the grinding balls must be concentric with in 3.0
mm. The thickness of the ball at various points shall be checked by ultrasonic back wall echo
method as per ASTM-A-609 quality level-3.
9. The cored holes in th grinding balls need not be plugged. Core hole size should not
exceed as mentioned in the drawing.
10. Rings and balls shall be supplied in fully heat treated condition. Recorded cycle charts of the heat
treatment certified by competent authority shall be provided in support of the heat treatment cycle
followed.
11. Finished casting of the grinding rings and balls shall be free from blowholes, dents and fettled to give
smooth finish. It is recommended that castings be heat treated slowly up to 200 250 degrees
centigrade and held for 4 hours at that temperature prior to fettling to reduce the possibility of
cracking in the region of feeding head.
12. Grinding rings shall not have any warpage over the diameter. No welding repairs are allowed on the
rings.
13. The microstructure of the rings shall show discontinuous distribution of hard carbide in martensitic
matrix.
14. The casting should be sound and should able to take shock loads because of entrapped foreign
materials in coal if any.
15. TEST COUPON:
One block of the same material thickness and cross section shall be cast and heat treated along with
the casting for each heat charge and sectioned to check the hardness over cross section with accurate
hardness tester. Depth of hardness on test block sample shall also be checked.
16. Inspection and testing shall be carried out as per the requirement of annexure-B
17. Necessary marking, from where practically and legibly visible shall be available on each ring set and
balls set, which can be traced to the melt & batch of heat treatment.
18. Where tolerances have been specified in the drawings, they are to be strictly followed.
19. The contractor shall be responsible for and perform inspection test required in accordance with the
specification mentioned above. The purchasers engineers inspectors will witness quality
surveillance test in respect the work performed by the contractor. The contractor shall allow
reasonable facility and free access to his works/factory and records to the purchasers engineers
inspectors for carrying out inspection/testing. The contractors shall give at least two weeks advance
intimation to Dy General Manager (U), HWP(M) for arranging inspection. All the items covered by
this indent shall be delivered from the contractor work only after final inspection /test is carried out
by the purchasers engineer/inspector.

20. SUBMISSION OF DRAWINGS:

The contractor shall prepare and submit the fabrication drawings to Deputy General Manager
(Utilities), HWP(M) for his approval within a period of one month from the date of receipt of the
purchase order, However an advance copy for necessary corrections of these drawings may kindly
be sent along with the quotations.
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21. GUARANTEE: Performance Guarantee 80% through 75 mesh and max 1% through 50 mesh, for min
8,000 hrs / Set with Prorata refund . The above clause is applicable for deciding the life of the rings and balls
as a set, after carrying all necessary corrections in the operation and mechanical local settings on the each and
every individual mill.
A ) For top and bottom grinding rings.
Top and bottom rings should be guaranteed for its quality workmanship and performance for a period of
8000 running hours. If any of the rings fail due to bad workmanship of defective material before 4000
running hours, free replacement should be effected for the failed item only. If failure occurs between
4001 and 8000 running hours, pro-rate refund should be affected on the ex-works value of the failed item.
The purchaser will return failed item only after receipt of replacement/ settlement of failed items.

B) For grinding balls:

The standard grinding balls shall be guaranteed for its quality, workmanship and performance for a period
of 8000 running hours. If the standard ball fails due to defective material or bad workmanship before
4000 running hours or up to 588 mm of dia free replacement should be affected for the failed item.
If the standard ball fails between 4001 and 8000 running hours, pro-rata refund shall be affected on the
ex-works value of the failed item.The purchaser will return failed item only after receipt of
replacement/settlement of failed items.
The life of rings set shall be considered as completed when the ball track wear reaches 75mm top ring or
6 3.5mm on bottom ring whichever is earlier with prevailing coal quality at HWP(Manuguru)
The life of rings set shall be considered as completed hen the ball track wear reaches 75mm top ring or
63.5mm on bottom ring whichever is earlier with prevailing coal quality at HWP(Manuguru).

22. All quotation may be submitted in duplicate copies of previous 5 years order executed to be enclosed.
Parties should have executed minimum order of Rs. 50 lakhs at a time of similar type of jobs.

23. Quality control assurance plan from supplier/Manufacture Preferably having ISO 9001/9002 having
CAD/CAM facility to be enclosed for carrying out various checks at different levels. Quality control
during production shall be as per IS:397, which enables the purchaser to judge its acceptability.

24. Supplier may be asked to supply heat treatment cycle for our review/approval before the start
manufacturing.

25. Grinding ring ( item 01 and item 02) and grinding balls ( item no.3) will be procured as set. Hence the
Firms may quote for grinding rings (items 1 &2) and grinding balls (item 3) as a set.
Note:
a) Suppliers are requested to sign each and every page of this enquiry with remarks clearly indicating
Accepted or Not accepted . Alternative acceptance essentially may or may not be considered.

b) Material should be supplied essentially For Total 03 Sets,(1st set to be supplied within 02 months
f from placement of order, followed by staggered supply 01 set, after every 45days .)i.e Total supply within
(4-1/2 to 05) months from the date of placement of the order.

c ) Suppliers are requested to give details of break up of prices for grinding rings and balls with total cost
of grinding ring and ball per set including all taxes for HWP(Manuguru) door delivery ( Format attached)

d ) THE LIFE OF GRINDING RINGS & BALLS OF 8000 RUNNING HRS OF TROUBLE FREE
OPERATION IS ESSENTIAL (.) VENDOR IF SO DESIRE CAN VISIT OUR SITE TOO ASSESS THE
WORKING CONDITION OF 8.5 E-10 COAL MILL/COAL QUALITY, WHICH WE ARE USING.

e e) Even after the supply has been made the supplier must visit site with instrument and measure the hardness
jointly after every Three months and decide on the wear pattern/wear rate. If the wear rate is more free
Replacement or prorate refund shall be made as per the guarantee clause Sl.No. 19.0.


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ANNEXURE B

Sl
No
Type of test Extent of test Method/procedure Acceptance criteria
01 Chemical
analysis
For each heat
charge
02 Micro
structure
study
For each heat
charge
Thro recognized
laboratory and or
manufacturers
laboratory as per the
relevant code
requirement 98
100% pearlite
Chemical analysis and microstructure
study for finished product shall be
carried out for sample taken out from
each heat charge. Sample shall be
identified by purchaser engineer.
Original copy of mill test certificate
incorporating above test report shall be
furnished
03 Visual
inspection
100% components ASTM A 802
(standard practice for
steel castings, surface
acceptance standards,
visual examination
Casting surface shall be free from
burrs, ridges unevenness, expansion
and fusion discontinuities, external
chills, parting lines, inserts and
nonmetallic inclusions. Cracks and hot
tears are not permitted. Gas porosity
and metal removal marls shall be
within limit of level II of ASTM A
802.
04 Dimensional
measurement
100% components As per manufacturers
practice
1. Rings as per drawing No:
HWB/M/807 & 808,Rev 03
2. Ball as per drawing No.
HWB/M/823,Rev 02
And as per Sl.No.8 of the terms and
conditions of the indent.
05 Hardness test 100% components As per IS : 1500
manufacturers practice
Average surface hardness for the
top/bottom grinding rings and hollow
grinding balls shall be with in specified
limits.
24 readings for each ring and ball shall
be taken at equidistant points to work
out average figures.
Hardness measurement across the cross
section of the test coupon for each heat
lot shall be also measured and same
should be uniform and with in limit
specified for the respective material
specification.
06 Ultrasonic
test
100% surface area
of all the rings and
balls
As per ASTM A-
609/IS-9565-1980
IS:3664
As per ASTM A 609/IS-9565-1980
Level-III
(Standard practice for casting, carbon,
low alloy and martensitics stainless
steel, ultrasonic examination thereof)
07 Magnetic
particle test
100% surface area
for balls and
pockets and ball
race area for top &
bottom grinding
rings
As per ASTM E-1444
(standard practice for
magnetic particle
examination & E 709
(guide for magnetic
particle examination)
as per IS : 3703
1. All indications of crack like in
nature are to be rejected
irrespective of their size and
location.
2. Indications those are visually
determined to be laps, seams or
other similar plains are acceptable.
3. All linear indications shall be
investigated further.

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08 D.P Test 100% surface area
of all the rings and
balls
As per ASTM E-165 /
IS : 3658 & IS:12889
ISO:3452/3453
1. Total defects on the contact
surface at the bottom and top rings
will be less than 2.5% of the total
contact area.
2. The ball track will be un-
machined. The burrs, ridges &
unevenness will be removed by
hand grinding. Total defect on this
area shall not exceed 2.5% of the
total area.
3. Grinding balls shall be un-
machined. Total defect shall not
exceed 2.5% of the total area.
4. No single defect on above
examined area shall be more than
6mm x 6mm x 3mm deep.
5. No surface crack anywhere on the
surface of grinding rings and balls
shall be acceptable.




Note: 1. All above test will be carried out in presence of purchase engineer/inspector.
2. six sets of test and inspection report duly typed and in bounded conditions shall be furnished.
3. Casting and development time 5 7 months

































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ANNEXURE C


DETAIL BREAK UP PRICE OF GRINDING RING AND BALL OF 8.5 E 10 COAL MILL

Sl.
No.
Description Price
1 Top grinding ring
2 Bottom grinding ring
3 Grinding ball set
4 Packing and forwarding charges per set
5 Fright charges upto Manuguru
6 Insurance charges
7 Total cost of one set (i.e Item No.1.2 & 3) excluding charges
8 Excise duty
9 Sales tax
10 Other taxes
11 Total cost per set on door delivery basis HWP (Manuguru)
























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COAL MILL SPARES


ANNEXURE DETAILS TO INDENT NO: HWB/RB/003 DT: 06/04/2009

Sl.
No.
Annexure Description
01 Annexure-A Details, terms & conditions of the indent (page Nos 1 to 4)
02 Annexure-B Inspection and testing procedures for finished casting (page
No.5 to 6)
03 Annexure-C Details break up price for grinding ring and ball (Page No.7)
04 Annexure-D Drawings of
a) Top grinding ring (Drawing. No.HWB/M/807
revision No.03)
b) Bottom grinding ring (Drawing. No.HWB/M/808
revision 03)
c) Hollow grinding ball and filler grinding ball
(Drawing No.HWB/M/823,Rev02)






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