CEMENT PLANT NEW 450 TPD
B. SERVICES 1. Project Engineering (Basic Know how, detailed Engineering Services for Civil, Mechanical, Utilities and offsite Facilities.) US$ 192,000 2. Price for Supervision of Erection & Commissioning US$ 130,000 The following Deputation charges for our experts for commissioning activities would be on per diem basis : a) Manager/Engineer US$ 250/day b) Supervisor/Technician US$ 150/day
To and fro air fare/air ticket pre-paid shall be provided for all staff deputed for erection/commissioning from time to time. Free boarding & lodging, site transport, medical & insurance shall be provided to all the staff deputed for supervision of Erection & Commissioning.
ERECTION PERIOD
Envisaged Erection period for this 450 TPD Cement Project is 5 to 6 months in normal working conditions.
MODE OF PAYMENT :
Payment will be through an irrevocable, transferable, divisible documentary letter of credit without recourse to the opener for 100% of the contract value in our favour confirmed by First Class International Bank. Letter of Credit should allow part Despatches/Shipment.
TERMS OF PAYMENT
a) Supply Portion 20% advance through above mentioned letter of credit . 80% on prorata against each shipment.
b) Services
1. Engineering Drawing & Design charges will be payable in three equal installments as follows :- Ist Installment : Within One month from the date of LC against process flow sheet G.A.Drawings & Sectional Layout.
-IInd Installment : Within Three months against supply of load data and Civil Drawing.
-IIIrd Installment : Within Four months against Equipment Drawing, Erection Drawing and other remaining technical data & documentation.
2. Payment for supervision of erection and commissioning shall be made in two equal installments : -Ist Installment : At the time of mobilization. -IInd Installment : Two months from the date of mobilization.
DELIVERY/ SHIPMENT:
In 8-10 months from the date of receiving confirmed L/C /receipt of advance payment and other clear techno commercial terms.
ANNEXURE - II TECHNICAL SPECIFICATION FOR 450 TPD ROTARY KILN
CEMENT PLANT (OIL FIRED)
A. LIME STONE CRUSHING SECTION: 1.1 Uncrushed Limestone Hopper (client scope) Quantity One Capacity 50 Tones Size 3.5 x 3.5 x 4.5 M Approx. Lump size 400mm Bottom opening 1000 x 1500 mm Construction RCC
Bottom pin gate and discharge chute are in our scope of supply. Lining and bottom grouting frame are in client scope.
1.2 Reciprocating Feeder: Quantity One Capacity 60 TPH Size 1000 * 2500 mm Lump Size 300 mm Drive 7.5 HP 1440 RPM The unit is complete with discharge chute.
1.3 Jaw Crusher: Quantity One Capacity 60 TPH Crusher Size 900 x 500 mm Feed Size 400 mm Product size 75 mm Motor 60HP , 1440 RPM
1.4 Belt Conveyor: Quantity One Capacity 65 TPH Belt Width 600 mm Length 20 Meter(approx.) Type of conveyor Troughed Drive 7.5HP, 1440 RPM
1.5 Hammer Mill: Quantity One Capacity 60 TPH Feed size 75 mm Product size 80% Minus 15 mm Impactor size 1000 mm dia * 1000 wide Drive 75 HP, 1440 RPM
1.6 Belt Conveyor feeding to stockpile: Quantity One Type Trough Type Capacity 65 TPH Belt Size 600 mm Conveying Length 55 M (approx) Drive 15 HP
The unit is complete with discharge chute
1.7 Dust Collector for Hammer Mill : Quantity One set Type Reverse pulse jet type Capacity 8500 M3/hr Fan motor 15 HP,1440 RPM Air to cloth ratio 1.8 Accessories Fan with motor, R.A.L.
1.8 Circular/Rectangular Stockpile for lime stone: Quantity One Type Flat Bottom Circular Size 30M dia. OR 30x20M No. of opening at bottom 3 Size of opening 1000 X 1000mm Capacity 3000 Tons
1.9 Ground Hopper for Stockpile Quantity Three Size 1000x1000MM Construction M.S.
1.10 Pin Gate: Quantity Three Nos. Size 600 X 600 mm Type Pin type Construction M.S.
1.11 Vibratory Feeder: Quantity Three Nos. Type Electromagnetic Vibratory feeder Capacity 50 TPH
1.12 Belt Conveyor below Stockpile With Fixed Scrapper Quantity One Capacity 50 TPH Belt width 600 mm Length 75M Motor 25 HP, 1440 RPM
1.13 Dust Collector for Tunnel Ventilation: Quantity Type Capacity Accessories
1.14 Dust Collector for Hopper: Quantity Capacity Type Accessories
1.15 Compressor: Quantity Type Capacity
1.16 Hopper for Raw Material: Quantity
Construction
One Reverse pulse jet type 7800 M3/hr Exhaust fan with motor, RAL
One 7000 M3/hr Reverse pulse jet type Exhaust fan with motor and RAL.
One Double stage reciprocating To suit the dust collectors
(Client Scope)
One No. for Lime Stone One No. for Additive One No. for Clay RCC
B. ADDITIVE & CLAY STORAGE AND HANDLING SECTION: 2.1 Dump Hopper for Additive: (Client’s scope) Quantity Two Construction RCC/M.S
2.2 Pin Gate for additive: Quantity Tw0 Size 600 X 600 mm Type Pin type Construction M.S.
2.3 TABLE FEEDER Quantity Two Size 900mm dia Drive 3.7KW 1440 rpm with, AC
Frequency drive
C. RAW MATERIAL STORAGE, PROPORTION AND GRINDING SECTION: 3.1 Slide Gates: Quantity 3 Nos. Type Rack & Pinion type Size 450 x 450 mm
3.2 Weigh Feeders: Quantity 3 Nos.(1 No. for Lime & 1 No. for
Additive & 1 for clay) Type Electronic, load cell type weigh feeder Size 800 X 1500 mm for Limestone
600X 1500 mm for Additives and clay HP of Motor 2.0 HP for Limestone
1.0 HP for Additives and clay 3.3 Belt conveyor: Quantity One Type Troughed belt conveyor Capacity 45 TPH Belt Width 600 mm Convey Length 50 Meter (approx) Motor 10.0 HP 1440 RPM
3.4 Raw Mill: Quantity One unit Size 2.8 x 7.50mt long+2.0m Drg Chamber Capacity 40 TPH Feed Size Minus 15MM Shell thickness 30 mm Flange thickness 60 mm Liner thickness 35 mm Drive motor 800 HP, 1000 RPM TEFC slip-ring Gearbox 2 stage helical Grinding Media 45 Tones. Feed Size minus 15 mm Product size 17% residue on 90 microns Maximum moisture 0.5% in lime stone, 3% in additives and
6% in clay. Material of construction: Shell IS-2062 Gr.2 Headers Cast steel IS-1030 Gr. I Girth Gear Cast steel IS-2708 Gr. III Liners Manganese steel IS-276 Gr. I Grinding Media Balls of Forged steel
3.5 FLAPPER VALVE : Quantity One Type Double flapper valve gravity operated 3.6. AIR SLIDE AFTER MILL : Quantity One Length 5m Capacity 80 TPH Motor for fan 5.0 H.P.2900 rpm TEFC Squirrel cage
3.7 BUCKET ELEVATOR : Quantity One Capacity 80TPH Conveying height 18 M Motor 25,H.P. TEFC Squirrel cage
3.8 AIR SLIDE FEEDING TO CLASSIFIER : Quantity One Size 315 mm Capacity 80 TPH Fan motor 5.0 H.P., 2900 RPM, TEFC Squirrel cage Capacity 10 m3 at 600 mm WG
3.9 HIGH EFFICIENCY CLASSIFIER : Quantity One Size 1650 mm dia Motor AC Frequency drive Motor HP 50 H.p, TEFC Squirrel cage
3.10. CYCLONE : Quantity One (Twin type) Size 2200 mm dia Thickness 6mm Accessories Rotary Air Lock
3.11. DUST COLLECTOR FOR AIR CLASSIFIER : Quantity One Type Reverse pulse jet Capacity 11000 m3/hr Air to cloth ratio 1.4
3.11.1 EXHAUST FAN FOR DUST COLLECTOR : Quantity One Type Centrifugal Capacity 12000 m3/hr Pressure 250 mm WG Motor 25 H.P. 1440 RPM, TEFC Squirrel cage
3.12 CIRCULATING AIR FAN : Quantity One Capacity 72000 M3/hr Pressure 550 mm WG Motor 250H.P. 1440 RPM, TEFC Slipring cage
2.13 AIR SLIDE FOR COARSE RETURN : Quantity One Size 450mmx10m Construction M.S. Fan (2 nos.) 10 M3/min. At 600 mm WG Motor for fan 5.0 H.P. 2900 RPM, TEFC Squirrel cage
3.14 AIR SLIDE FOR FINES : Quantity One Capacity 40 TPH Length 4 m Fan 10 m3/min. At 600 mm WG
3.15. Air Lift Quantity One Size 1000 mm dia Capacity 45 TPH Blower 2500 M3/hr at 4000mm WG Motor HP 60 HP, 1440 RPM
3.14 AIR SLIDE ABOVE SILO : Quantity One Capacity 45 TPH Length 4 m Fan 10 m3/min. At 600 mm WG
3.12 Compressor: Quantity One Type Double stage reciprocating Capacity To suit the dust collector
3.13 Dust Collector Common for Raw mill & kiln section: Type Reverse PULSE Jet
Capacity 1650 M3/Min.
Dust loading 60 gms/M3
Pressure drop 250 mm WG
Fan for Dust collector 1850 M3/Min at 250 mm WG with 200 HP 1440 rpm Motor
3.15 EXHAUST STACK: (CLIENT SCOPE) Quantity One Size 3000/2800 mm Height 55 M 3.16 SCREW CONVEYOR BELOW BAG HOUSE : Quantity One Capacity 5 TPH Size 200 mm x 10 m long Motor 5.0 H.P. at 40 RPM
D. BLENDING AND STORAGE SECTION: 4.1 PARALLEL DISTRIBUTOR Quantity One Construction M.S
4.1.1 DISTRIBUTION AIR SLIDES Quantity Six Size 200mm
4.1.2 High Level Indicator Quantity One Type Capacitance Type
4.2 CONTROLLED FLOW STORAGE SILO: (CLIENT’S SCOPE) Quantity 1 No. Capacity 3000 Tons Size 14.0M * 24M height(total height 32M) Construction RCC
The silo's grouting frames are in client scope . However Aeration box Pipeline and Valves, Aeration cloth, Slide gate, Level indicator, Manhole, Pressure equalizing valves are in scope of supplier.
4.2.1 Manual Cut-off Gate: Size 300mm Quantity Six
4.2.2 Pneumatic Cut-off Gate: Size 300mm Quantity Six
4.2.3 Flow Control Gate: Size 300mm Quantity Six
4.2.4 Air Slide For Silo Discharge Size 300mm Quantity Six
4.2.5 Fan for Air Slide Quantity One Capacity 15M3/Min Motor 5H.P. x 2900 RPM
4.3 ROOTS BLOWER : Quantity 1 No. Capacity 400 M3/hr Pressure 6000mm WG Motor 15HP, 1440RPM
The unit is complete with standard accessories like Discharge
silencer, V-belts, Pulleys, Belt guard, suction filter, Pressure
relief valve etc.
4.4 Collecting Hopper: Number of Inlet Six Number of Outlet One 4.5 Screw Sampler: Quantity One 4.6 Air Slide System : Quantity Capacity Size 1 No. 35 TPH To suit Motor at Fan 5 HP, 2900 RPM
4.7 Dust collection for Blending silo: Quantity 1 No. Type Reverse pulse jet type Capacity 9200 M3/hr Fan 9200 M3/hr at 250 mm WG Motor for fan 20 HP,1440 RPM The unit is complete with standard accessories like compressor, Bags exhaust fan etc.
4.8 Compressor: Quantity One Type Double stage reciprocating Capacity To suit the dust collector
E. OIL STORAGE AND FIRING SECTION: 5.1 Burner for Kiln Firing: Quantity 1 No. Capacity 2 m3/h
5.2 Air Receiver: Quantity 1 No.
5.3 Pump Unit: Quantity 1 No. Capacity 2 m3/min
5.4 Service Tank: Quantity 1 No. Capacity 0.99 m3 Accessories fittings & valves
5.5 Lighting up Unit: Quantity 1 No.
5.6 Oil Storage & Handling Unit upto Service Tank: Quantity 1 Set
The unit will be complete with pumps, piping with fittings.
5.6 Fan : Quantity 1 No. Capacity 100 m3/min @ 700 mmWG Motor 18.5 KW The unit will be complete with coupling & inlet vane control with actuator.
F. KILN FEED SECTION: 6.1 BUCKET ELEVATOR: Quantity One Type Gravity discharge chain type Capacity 35 TPH Height 15 mtr. Motor for Roots Blower 20H.P, 1440 RPM
6.2 AERATED FEED BIN WITH LOAD CELL : Quantity One Capacity 15 m3 No. of outlet One Accessories Aeration pads Bin in Client scope Accessories in Cpw Scope
6.3 BIN AERATION BLOWER : Quantity One Capacity 3 m3/min Pressure 3000 mm WG Motor 5H.P. 6.4 SOLID FLOW METER : Quantity One+One standby Accessories Pneumatic slide gate & flow control gate Capacity 10-60 TPH
6.5 DUST COLLECTOR : Quantity One Capacity 4500 M3/hr Type Reverse pulse jet type Accessories Exhaust fan and RAL
6.6 Air Lift: Quantity One size 1000 mm dia. Capacity 35 TPH Height 25 M Motor for Roots Blower 50 HP, 1440 RPM
6.6 Screw Sampler: Quantity One Drive 0.25 HP geared motor
G. PRE HEATER AND KILN SECTION: 7.1 FAN: Quantity 1 No. Capacity 1360 cubic meter/min at 640 mmWG/320Deg centigrade Drive Motor 190 KW AC frequency drive Accessories Inlet Multi Louver Damper with
Actuator
7.2 PREHEATER : Quantity Single Capacity 450 TPD-rated Type 5 stage suspension preheater Size of cyclone Dia.3.8/3.5/3.2/3/2x2.5M (stages counted from bottom) Riser Duct Dia.2/2/2/1.6/1.2 (Dimension of units
on inside shell of cyclone/ duct) Kiln Riser Duct 1.8x2.6 Calciner Not required The unit will be complete with centre tube, material chute, sluice flap, metallic expansion joint, dividing gate and other accessories for each cyclone.
7.3 KILN INLET HOOD: Quantity 1 No. Pneumatic kiln seal Included Number of air cylinders 8 No. x 4” size 7.4 COMPRESSOR WITH AIR RECEIVER : Quantity 1 No. Capacity To suit 7.5 CENTRALISED LUBRICATOR FOR SEAL: Quantity One set 7.6 EXHAST GAS DUCTING: Quantity 1 No. Size Dia.1.3M x length 60M (approx.) 7.7 AUXILARY STACK WITH HOISTING DAMPER: Quantity One set Drive 0.75KW 7.8 SHOCK BLASTER: Quantity 1 Set. Capacity 100 Liters each No. of Blasters 8 No. Sequence controller Included Compressor Included
7.9 EXHAUST GAS ANALYSER: (CLIENT'S SCOPE) Quantity 1 No. 7.10 PASSANGER LIFT: (CLIENT'S SCOPE) Quantity 1 No. Capacity 1 Ton 7.11 ROTARY KILN : Quantity 1 No. Size 3.0 Meter dia x 45M long Capacity 450 TPD No. of supports Three Slope 3.5% Max. Kiln max. speed 2.5 RPM Drive 90 KW,1000 RPM AC variable speed drive Shell thickness 25mm in burning zone & 20/22mm in other Places Shell thickness at gear 32 mm Shell thickness at tyre 36 mm Shell Material IS-2062 Gr. 2 or Equivalent Tyre I / II / III 3720 OD,3180 ID, 340mm Wide Roller I / II / III 1000 dia X 400 wide Supporting Bearing I / II / III 300mm dia Girth Gear Module 20, 236 No. of teeth
Face Width 300 mm Pinion Module 20, 21 No. Of teeth The Rotary kiln will be complete with supporting tyres, Rollers, Thrust roller, Roller shafts, Bearing housing, Girth gear and Pinion, Pinion shaft and Bearings. Kiln inlet and outlet seal, and discharge hood.
7.12 Kiln Multi channel Coal Burner Length 6.5M 7.13 BARRING DEVICE: Quantity 1 No. Drive 11 KW, 1480RPM The unit will be complete with gear unit coupling and thruster. 7.14 THRUSTER DEVICE : Quantity 1 No. Type Thrust roller with mechanical screw adjustment
7.15 GIRTH GEAR LUBRICATION: Quantity 1 No. Grease Sump with idler pinion (Aluminum / cast iron )
7.16 AXIAL FAN WITH DRIVE FOR COOLING SHELL & TYRE : Quantity 5 Nos. Motor 2.2KW 7.17 KILN DISCHARGE HOOD:
Quantity 1 No. Complete fabricated hood mounted on wheel assembly & inlet graphited block seal, inspection door & burner mounting frame peep holes.
7.18 NOSE RING COOLING FAN: Quantity 1 No. Capacity 4500cubic meter per hour Pressure 300mmWG Drive motor 5.5 KW, 1440RPM
7.19 CLINKER COOLER: Quantity 1 No. Cooler Size designation 629-H (Single Horizontal Grate, 6 Plate widex29 Rows length) Capacity 450 TPD-rated Grate area 16 Sq mtr
The unit will be complete with grate plate, instruments and other hardware etc.
7.20 MECHANICAL DRIVE FOR GRATE 1: Quantity 1 No. Grate Drive Rating 11 kW, 1500 rpm VSAC Motor with Chain Drive Grate Speed Range 4-14 SPM
The unit will be complete with gear unit with fly wheel and input coupling.
7.21 DUST SLUICE: Quantity 6 Nos. Type motorized double flap valve Motor 0.75 at 15 rpm 7.22 DRAG CHAIN CONVEYOR : Quantity 1 No. Size 250 x 10M Long Motor 3.7kW, 8rpm geared motor chain drive 2.1:1
7.23 CENTRALISED LUBRICATOR SYSTEM: Quantity One set 7.24 Clinker Breaker : Quantity 1 No. Capacity 30 TPH Type Impactor Motor 22 KW, 1460 RPM Drive V Belt Drive 7.25to
7.29 Cooling fan : 7.25 FAN(V1): Quantity 1 No. Air volume flow 11500 at 40 deg.C
Pressure 500mmwg Motor 30 KW, 1440 RPM
The unit will be complete with coupling and inlet vane control
with actuator.
7.26 FAN (V2): Quantity 1 No. Air volume flow 12700 at 40 deg.C Pressure 400mmwg Motor 30 KW, 1440 RPM
The unit will be complete with coupling and inlet vane control with actuator.
7.27 FAN (V3): Quantity 1 No. Air volume flow 14400 at 40 deg.C Pressure 350 mmwg Motor 22.5 KW, 1440 RPM The unit will be complete with coupling and inlet vane control with actuator.
7.28 FAN(V4): Quantity 1 No. Air volume flow 13800 at 40 deg.C Pressure 250mmwg Motor 18.50 KW, 1440 RPM The unit will be complete with coupling and inlet vane control with actuator.
7.29 FAN(V5): Quantity 1 No. Air volume flow 10700 at 40 deg.C Pressure 200 Motor 15 KW, 1440 RPM The unit will be complete with coupling and inlet vane control with actuator.
7.30 MULTICLONE FOR COOLER EXHAST: Quantity 1 No. Capacity 1150AM3/min at 250 deg.C. Dust loading before cooler 0.3 to 0.5 gms/m3 Construction detail Fabricated housing with 75 Nos. C.I. multclone cells with whirl insert and detachable cone, vent pipes for each cell.
7.31 ROTARY AIR LOCK Quantity 2Nos. Capacity 3TPH each
Size Dia.200mm Speed 725 RPM Drive 1.5KW, Geared Motor
7.32 COOLER EXHAST FAN FOR ESP: Quantity 1 No. Capacity 1265AM3/min at 250 deg.C. The unit will be complete with coupling and inlet vane control with actuator. 7.33 STACK : (CLIENT’S SCOPE) Quantity 1 No. Size Dia.1800MMx25M high Construction RCC/MS Exhaust Fan 1740M3/min at 250 deg.C. 150 mm WG static Draft Motor Rating 65 kW.1000 rpm
7.34 SCREW CONVEYOR : Quantity 1 No. Capacity 4 TPH Size Dia.200mm Length 10 Meter Drive 2.2KW Geared motor 7.35 Deep Pan conveyor Capacity 30TPH Size 400 Wx400 bucket pitch Speed 0.30 M/Sec Conveyor Layout 6 M Horizontal 16 M Inclined at 40°C
10.3 M Lift Chain for conveyor Double strand flat link chain with traveling Rollers. Pitch-200 mm Roller pitch-800 mm Breaking strength-30 Tons
Drive capacity 3.7 shaft power,
Tripple stage Helical Gear box for ratio 125:1, anti run back device Motor 5.5KW,
H. CEMENT MILL SECTION: 8.1 Slide Gates: Quantity Three Nos. Type Rack and Pinion Size 450 x 450 mm
8.2 Weigh Feeder: Quantity One No. for clinker One No. each for Gypsum & additive
8.3 Belt Conveyor: Quantity One Type Trough type Belt width 500 mm Conveyor length 45 Meter. Motor 12.5 HP,1440 RPM
8.4 Cement Mill: Quantity One Size 2.6M dia x 9.0 M. Feed size Close circuit, 2 compartment Product size 3200 blains Capacity 20 TPH Drive motor 800 HP,960 RPM
Construction Details:
Shell IS-2062 Gr. 2A Headers Cast steel IS-1030 Gr.I Gears Cast steel IS-2708 Gr.III Bearings Bush Cast steel IS-1030 Gr.I Bush lining White metal Liners Manganese steel IS-276 Gr.I Grinding Media Hyper steel IS-6079 Gr.I
8.5 Air Slide: Quantity One
Capacity 60 TPH
Width 315 mm
Length 4 M
Fan 15 M3/Min at 500 mm WG with 5 HP
motor
8.6 Bucket Elevator: Quantity One Type Centrifugal discharge
Capacity 60 TPH Lifting height 18 M (approx.) Motor 20 HP,1440 RPM
8.7 Air Slide feeding to Air Classifier: Quantity One Size 315mmX4.0M Capacity 60 TPH Fan 15 M3/Min at 630 mm WG
8.8 High Efficiency Air Classifier: Quantity One Size 1500 mm Capacity 20 TPH Motor 40 HP with AC frequency drive
8.9 Cyclone: Quantity One Type Twin cyclone Size 1400 mm Accessories Rotary Van Feeder
8.10 Circulating Fan: Quantity One Capacity 36000 M3/hr Pressure 550 mm WG Motor 150 HP,1440 RPM
8.11 Air Slide for Coarse Return: Quantity One Size 315M X 8M Fan 10M3/min at 500 mm WG
8.12 Air Slide for product: Quantity One Size 200mm X 5M Capacity 25 TPH Fan 10M3/min at 500 mm WG
8.13 Air Lift for Product: Quantity One Capacity 25 TPH Root Blowers 1600 M3/hr at 4000 mm WG Motor 40 HP,1440 RPM
8.14 Dust Collector for Mill ventilation: Quantity One Type Reversible pulse jet type Capacity 10000 M3/hr Fan 11000 M3/hr at 250 mm WG Compressor As per suppliers recommendation
8.15 Compressor: Quantity One Type Double stage reciprocating
Capacity To suit the dust collector
8.16 Dust Collector for Classifier: Quantity One Type Reversible pulse jet type Capacity 10000 M3/hr Fan 11000 M3/hr at 250 mm WG
I CEMENT STORAGE & PACKING SECTION:
9.1 Cement Silo: Quantity 1 No. Capacity 1000 T Size 10 M dia x 15 M height (Effective) The grouting frames are in client scope. However aeration system is in our scope of supply.
9.2 Dust Collector for Cement Silo: Quantity One Type Reverse pulse jet type Accessories Fan with motor and RAL Capacity 7000M3/hr
9.3 Compressor: Quantity One Type Double stage reciprocating Capacity To suit
9.4 Slide Gate: Type Screw type Quantity 1 No. Size 450 x 450 mm
9.5 Extraction Blower: Quantity One Capacity 450 M3/hr. Pressure 2000 mm WG Motor 7.5 HP,1440 RPM Type Roots blower
9.6 Packing Machine: Quantity 1 No. Capacity 45 TPH No. of spout 3 stationary type, mechanical packers.
9.7 Dust Collector: (Client’s scope)OPTIONAL ITEM Quantity 1 No. Type Reverse pulse jet type, bag house model Capacity 6000 M3/Hr
The unit is complete with Exhaust fan, compressor, chimney etc.
9.8 Spillage Hopper : Type Square Construction M.S. fabricated Size 1.5 x 1.5 M. Quantity One
9.9 Spillage Screw Conveyor : Quantity One Capacity 5 TPH Type Trough type Size 250 mm dia x 6 M. long Motor 3 HP,1440 RPM
9.10 Truck Loading Belt Conveyor with Spiral chute: Quantity 1 No. Length 10 M Width 800 mm Motor 5HP, 1440 RPM
*********
ANNEXURE-III
EXCLUSIONS
1. All civil works, building, supporting, structures, stairs platforms. 2. All R.C.C Tanks, Hoppers, Silos. 3. All foundation and grouting parts. 4. Grouting materials. 5. Service water facility, air lighting and other utilities. 6. Bore-well station. 7. Liaison with electricity department and obtaining power sanction. 8. Lighting , communication system, Fire Alarm system. 9. Obtaining approval from electrical inspectorate. 10. Captive power generation and distribution system. 11. Emergency lighting. 12. Granite jelly and barbed wire fencing from sub-station. 13. Preparation and filling up of cable laying trenches. 14. First filling of oil. 15. Water pump, Tanks & pipeline. 16. Laboratory & workshop Equipment. 17. Final Painting . 18. Civil and Structural design & drawing. 19. Weigh Bridge 20. Passenger lift for kiln. 21. Refractory. 22. Any other item not specified in the specification.
SPECIFICATIONS FOR ELECTRICALS FOR
1. 11 KV SWITCH YARD : The Switch Yard will have two transformers having following specifications:
TRANSFORMER NO. 1 :
Capacity 2000 KVA Quantity 1 No. Voltage 11 KV/ 6600 V Frequency 50 HZ +/-3% System Neutral Solidly Grounded Variation in supply Voltage + 10%
TRANSFORMER NO. 2 :
Capacity 3000KVA Quantity 1 No. Voltage 11 KV/ 420 V Frequency 50 HZ +/-3% System Neutral Solidly Grounded Variation in supply Voltage + 10%
The incoming HT supply terminal to be provided by the purchaser upto the Double Pole structure installed near transformers.
2. 11 KV LIGHTING ARRESTOR AND EARTHING : This will be station class with heavy duty lighting arrestors, insulators and effective earthing and lighting protection system comprising of earth wire/ flats, earthing pit, air terminal rod will be installed in the plant area. The substation will be within 30 meters from the Cement Mill .
Quantity 3 Nos.(for each transformer)
3. 11 KV CURRENT TRANSFORMER :
The current transformer will be primarily wound, oil cooled type current transformer for protection and motoring with required accuracy and burden.
Quantity 3 Nos.(for each Transformer)
4. 11 KV VACUUM CIRCUIT BREAKER : The 11 KV Vacuum Circuit Breaker will be provided having suitable breaking capacity at 11 KV.
Quantity 3 Nos.(One No. for 2000KVA Transformer, One No. for 3000KVA Transformer & One common for both the Transformer)
5. H.T.CABLE : 1.1 KV class XLPE insulated aluminum conductor power cable will be installed between OCB & transformer. 6a. 11 KV/6600 V, 2000 KVA POWER TRANSFORMER :
This 11 KV/6600 V, 2000 KVA power transformer will be equipped with off load tap changer and with standard accessories as per Indian Standard. The details of the same are given below :
TECHNICAL PARTICULARS FOR HT TRANSFORMERS :
1. Type Outdoor Double Wounded Core Type 2. Normal Continuous Rating(KVA) 2000 KVA 3. Winding Material Copper 4. Frequency 50 HZ 5. Number of Phases Three 6. No Load Voltage Ratio 11000/6600 V 7. Connection a. High Voltage Delta b. Low Voltage Star 8. Vector Group Dyn 11 9. Tapping on HV side for + 7.5% in steps of 2.5% by off giving voltage variation of circuit. HV by off circuit 10. Magnetizing current in terms 2 of full load current (approx.%) 11. Temperature rise of oil by 38°/48° C over an ambient of 42°C thermometer/ windings by resistance method, over File:/450 TPD ROTARY KILN cement plant 22.6.09
specified ambient temp. of °C at principal tap
12. No load loss at rated voltage and frequency 13. Full Load loss at rated current at 75°C 14. Impedance at rated current and frequency at 75°C
As per I.S. tolerance As per I.S. tolerance As per I.S. tolerance
ACCESSORIES FOR TRANSFORMER Each Transformer will be provided with following accessories :
1 Oil conservator with plain oil gauge, filling hole and drain plug. 1 Silica-gel Dehydrating breather. 1 Off-Circuit externally operated tapping switch with position indicator, handle & locking device. 1 Double Diaphragm explosion vent. 4 Bidirectional flat rollers. 3 Thermometer pockets. 1 Drain valve with plug. 1 Filter valve with plug. 2 Lifting Lugs. 1 Marshalling Box. 2 Earthing Terminals 1 Rating & Diaphragm Plates. 1 Air release plug. 1 6" O.T.1 with M.R.P., R.S.D and Alarm & Trip contacts. 1 6" W.T.1 with M.R.P., R.S.D and Alarm & Trip contacts. 1 Buchholz relay with T & A contacts. 1 6" M.O.G. with L.L.A. contacts. 2 Shut off valves.
TERMINAL ARRANGEMENT HV : 3 Bare porcelain bushing.
LV : Quad furcating air insulated cable box suitable to receive. 6b. 11 KV/420 V, 3000KVA POWER TRANSFORMER :
This power transformer is also equipped with off load changer and with standard accessories as per Indian Standard. The details of the same are given below :
TECHNICAL PARTICULARS FOR LT TRANSFORMERS :
1. Type 2. Normal Continuous Rating(KVA) 3. Winding Material 4. Frequency 5. Number of Phases File:/450 TPD ROTARY KILN cement plant 22.6.09
Outdoor Double Wounded Core Type
3000 KVA Copper 50 HZ Three
6. No Load Voltage Ratio 11000/420 V 7. Connection a. High Voltage Delta b. Low Voltage Star 8. Vector Group Dyn 11 9. Tapping on HV side for + 7.5% in steps of 2.5% by off giving voltage variation of circuit. HV by off circuit 10. Magnetizing current in terms 2 of full load current (approx.%)
11. Temperature rise of oil by 38°/48°C over an ambient of 42°C thermometer/ windings by resistance method, over specified ambient temp. of °C at principal tap 12. No load loss at rated Subject to I.S tolerance voltage and frequency 13. Full Load loss at rated Subject to I.S tolerance current at 75°C 14. Impedance at rated current Subject to I.S tolerance and frequency at 75°C ACCESSORIES FOR TRANSFORMER
Each Transformer will be provided with following accessories :
1 Oil conservator with plain oil gauge, filling hole and drain plug.
1 Silica-gel Dehydrating breather.
1 Off-Circuit externally operated tapping switch with position indicator, handle & locking device.
1 Double Diaphragm explosion vent.
4 Bidirectional flat rollers.
3 Thermometer pockets.
1 Drain valve with plug.
1 Filter valve with plug.
2 Lifting Lugs.
1 Marshalling Box.
2 Earthing Terminals
1 Rating & Diaphragm Plates.
1 Air release plug.
1 6" O.T.1 with M.R.P., R.S.D and Alarm & Trip contacts.
1 6" W.T.1 with M.R.P., R.S.D and Alarm & Trip contacts.
1 Buchholz relay with T & A contacts.
1 6" M.O.G. with L.L.A. contacts.
2 Shut off valves.
TERMINAL ARRANGEMENT
HV : 3 Bare porcelain bushing.
LV : Quad furcating air insulated cable box suitable to receive. 7. L.T.PANEL : There will be two L.T panels. The first L.T panel will be suitable for 6600 Volts and second will be suitable for 420 Volts and shall be 3 phase with neutral supply of 50 HZ. the L.T Panel will be cubical. the detail of enclosure wiring and other specifications will be as per following general specifications: Quantity Two Nos.
L.T.PANEL NO. I: This L.T. Panel No. I will have provision only for outgoing feeder for 900 HP(2 Nos.) Ball Mill Motor and Capacitor.
L.T. PANEL NO.II: This L.T. Panel No. II will have provision for the following outgoing feeders : a. Lime stone Crushing & storage Section b. Additive storage & transport section c. Raw mill feeding section d. Raw mill section e. Blending & storage section f. Kiln feed section g. Preheater & Kiln section h. Raw coal crushing section i. Oil storage and firing section j. Cement mill and packing section. j. Plant Lighting(75 KW) k. Workshop and Water supply(25 KW) l. Capacitors(To suit the motor) m Laboratory(30 KW) n. Spare The LT Panels will also be provided with one number ammeter, voltmeter, selector switch and PF meter. All out going feeders shall be provided with one ammeter, one selector switch and one indicating light. Main Bus Bar : These shall be EC grade aluminum for 1400 amperes.
CONSTRUCTIONAL DETAIL OF L.T.PANEL :
a. Material of Enclosure: 14 B.G. thick cold rolled steel b. Compartmentalization: The entire cubical is fully compartmentalized. Separate chamber being provided for each feeder as well as for vertical & horizontal bus bar together with vertical cable allays and bottom chamber.
c. Dust & Vermin Proofing : Heavy duty rubber gasket will be fitted on all open-able cover to make the panel dust & vermin proof.
d. Cable Gland Plates : Removable plates are provided on the cable alleys bottom for easy drilling & fixing of cable glands during installation. e. Back Opening : Rear door of suitable dimensions and suitable reinforced are provided in each panel f. Base Plate : Channel legs or as a complete channel frame with holes for grouting of bolts are fixed to the panel.
g. Panel Knobs : The front doors are provided with quick opening cam type knob. Key operated heavy duty twist lockers are provided for rear door. h. Hardwares : All Nuts, Bolts, Washers etc. are high quality galvanized. 8.CONSTRUCTIONAL DETAILS OF MCC :
a. Material of Enclosure: 14 B.G. thick cold rolled steel b. Compartmentalization: The entire cubical is fully compartmentalized. Separate chamber being
provided for each feeder as well as for vertical & horizontal bus bar together with vertical cable allays and bottom chamber.
c. Dust & Vermin Proofing : Heavy duty rubber gasket will be fitted on all open-able cover to make the panel dust & vermin proof.
d. Cable Gland Plates : Removable plates are provided on the cable alleys bottom for easy drilling & fixing of cable glands during installation. e. Back Opening : Rear door of suitable dimensions and suitable reinforced are provided in each panel f. Base Plate : Channel legs or as a complete channel frame with holes for grouting of bolts are fixed to the panel. g. Panel Knobs : The front doors are provided with quick opening cam type knob. Key operated heavy duty twist lockers are provided for rear door. h. Hardware : All Nuts,Bolts, Washers etc. are high quality galvanized. 9. CONTROL SUPPLY : 110 AC through neutral double wound 440 -415-400/120-110 volt control transformer of suitable rating.
10. LIQUID ROTAR STARTER : Quantity 2 Nos.
Liquid Rotor Starter for slip-ring motors of ball mills will be provided.
TECHNICAL PARTICULARS FOR LIQUID ROTOR RESISTANCE
Starter will be floor mounting free standing type and of dust & vermin proof construction. It will be provided with M.S. fixed & moving electrodes system,
M.S Electrolyte Tank, Mechanism Box, Cable Box Mechanical shorting mechanism to short circuit the resistance. When motor attains full speed, and interlocking arrangements with starter so that main motor cannot be started unless resistance is in fully-in position, having : Motor 800 HP for raw mill & 900 KW for Cement mill Motor 1000 RPM Voltage 6600 V Frequency 50 Hz
The Starter should have following accessories : Sr. Description
1. Contactors 2. Ammeter flush mounted. 3. Ammeter selector switch. 4. Voltmeter flush mounted. 5. Voltmeter selector switch. 6. Current Transformer. 7. HRC fuse with fuse fitting for voltmeter. 8. Earth Faulty Relay. 9. Current Transformer Protection Class Ratio 600/5 A. 10. Indicating Lamps. 11. Terminal Block. 12. Liquid Rotor Resistance. 13. Motor Driven System. 14. Interlocking arrangement. 11. L.T.CABLE : 1.1 KV class PVC insulated aluminum conductor power cable will be installed between MCC & motors. All control cables will be of copper of conductor. 12. CAPACITOR : Capacitor for Motors will be installed in panel which will be switched ON/OFF automatically in both LT Panel.
13. EARTHING : GI wire will be provided for motor up-to 40 HP and GI strip will be provided for higher rating motor. Suitable each pits will also be provided near MCC Panel.
14. CABLE TRENCHES AND CABLE TRAYS : The cables will be laid in RCC cable trenches in the ground. For cable above ground M.S fabricated cable trays will be provided.
15. REMOTE OFF SWITCHES : Remote off switches will be provided for all motors, height more than 6 M and far away from MCC room.
EXCLUSIONS FOR ELECTRICALS ITEMS FROM SCOPE OF CPW
1. Captive power generation and distribution system 2. Electric power line up to double pole structure near transformer. 3. Barbeded wire fencing for sub station. 4. Digging and civil construction of earth pits. 5. Cable trenches and cable trays. 6. Plant lighting. 7. Fire protection equipment. 8. Rubber sheeting for flooring. 9. Follow-up and approval from electricity board. 10. Emergency lighting.