TENDER DOCUMENT

NIT No.: DLI/C&E/WI-665/291

FOR

Tender for Design, Engineering, Supply, installation,

testing & commissioning of MOBILE TRIPPERS AND
ASSOCIATED WORKS for the project of
Augmentation of Raw Material Handling Receipt and
Handling facilities with new OHP Part B (Package-
061) of Bhilai Steel Plant, (SAIL).

VOLUME 2B

TECHNICAL SPECIFICATION

ENGINEERING PROJECTS (INDIA) LIMITED

(A GOVT. OF INDIA ENTERPRISE)
Core-3, Scope Complex, 7,
Lodhi Road, New Delhi-110003
TEL NO: 011-24361666 FAX NO. 011- 24363426
 VOLUME - 2B

CONTENTS

Sl. No. DESCRIPTION

1. General, Documents/Information to be furnished alongwith offer

2. Scope of Supply

3. Technical Specifications Mobile Tripper

4. Spares

5. Technical data sheet (to be filled by the vendor)

Page1of10
 GENERAL

The following Technical Specification shall be read in conjunction with General Technical
Specification (GTS) of Bhilai Steel Plant, SAIL and General Specification. If there are
any provisions in this Technical Specification, which are at variance with the provisions
of General Technical Specification (GTS) of Bhilai Steel Plant, SAIL and General
Specification, the provisions in this Technical Specification shall take precedence.

1.0 DOCUMENTS / INFORMATION TO BE FURNISHED ALONGWITH OFFER.

(i) Clear Scope of supply.

(ii) List of Commissioning spares and start-up spares with unit rates.

(iii) List with unit rates of special tools and tackles, if any required.

(iv) Price Schedule for supply & erection work as per the format enclosed.

(v) List of recommended spare parts for 3 (Three) years trouble free
operation and maintenance alongwith unit rates as per the format
enclosed in price schedule.

(vi) Technical data sheets duly filled by the vendor (blank data sheets enclosed).

(vii) Catalogues/ Leaflets and O&M Manuals.

(viii) Reference list of your Customers for the similar supply of items.

(ix) Un-priced Copy. (Furnish un-priced copy of Price Schedule alongwith

the Technical Bid.)

Page2of10

2.0 SCOPE OF SUPPLY

The scope of the supply includes Design, engineering, manufacture, shop fabrication.
assembly, testing and inspection at manufacturers works, packing, dispatch,
transportation, delivery to site, receipt, required fabrication at site, installation, testing &
commissioning completion of facilities, performance guarantee testing, final painting at
site and handing over to Bhilai Steel Plant, SAIL/EPI of MOBILE TRIPPERS AND
ASSOCIATED WORKS as per specifications and scope defined in tender documents
complete with all accessories and drive, which are not mentioned specifically but are
required for the efficient and trouble free operation of the equipment/system.

a) Following items are also included in bidders scope.

(i) Complete Mobile trippers including all the mechanical, electrical & Instrumentation
items as per the details given in the specifications.
(ii) Consumables like first fill of lubricating oils etc. for the initial operation of the
equipment till handing over.
(iii) Commissioning spares and start-up spare parts.
(iv) Special tools & tackles, if any required.
(v) Recommended spare parts for (3) three years trouble free O&M.
(vi) Painting of complete equipment (including final painting before handing over to the
Employer).
(vii) Installation, testing & commissioning at site.
(viii) All drawings / documents along with operation and maintenance manuals as per
requirement mentioned elsewhere in the tender document.
(ix) Getting approval of design/drawings and any other design calculation related to the
equipment from BSP/MECON.
(x) 3 Ph, 415V, +10% & -15%, 50 Hz +4% & -6%, power supply shall be provided at
Diverter gate terminal at one point through power cable.
(xi) Carrying out any modifications/ deletions /additions / alteration in design /
drawings/ documents as required by client & Clients consultant and EPI for proper
execution of works at site till completion and handing over of the project to the
client.
(xii) Trailing / Flexible Cables as required for trippers shall be in bidders scope

Exclusions:
(i) Civil works including grouting.

Page3of10
b) Tenderer to note the following:

(i) Makes of gear box shall be Elecon/ NAW/ Flender/ Premium energy transmission/
Shanthi gears.
(ii) BSP approved preferred make list shall be followed for Hydraulics & Pneumatics.
(iii) All HT and LT AC / DC motors, actuators, brakes etc. as per technological and
process requirement.
(iv) Generally Squirrel Cage Induction Motor with DOL starter / VFD / Soft Starter will
be provided. Use of Slip ring motor in general will be avoided. Suitable Rotor
contactor panels and SS-grid Resistance Boxes will be provided for slip ring motors
if inevitable
(v) Soft starter will be provided for LT motors of rating more than 75kW.
(vi) All LT motors for conveyors will be S6 duty and will have class F insulation with
temperature rise limited to class B. Inverter duty motors (used for VFD
application) will have class H insulation with temperature rise limited to class F.
(vii) Equipment selection and dating will generally be based on ambient temperature of
+ 50 Deg.C. For specific areas and shops, the ambient temperature conditions
indicated above will be taken into consideration and equipment suitably derated
wherever necessary.
(viii) The equipment should be suitable for smooth, efficient and trouble free service in
the tropical humid climate prevailing at plant site and under the ambient
temperature conditions indicated elsewhere.
(ix) Roller bearings will be provided at DE end for motor of rating 30KW and above
(x) Other Technical Data:
Main Conveyor Z5-C1/C2/C3 Capacity : 1500 TPH (Rated) &
1800 TPH (Design)
Belt width of main conveyor Z5 : 1400 mm
Belt speed of main conveyor Z5 : 1.6 M/Sec
Material to be handled by the conveyor :
- Size of Raw Material

i) Lump Iron Ore : -40 mm

ii) Iron ore fines : -8 mm
iii) Lime Stone (BF/SP grade) : -60mm
iv) Dolomite (BF/SP grade) : -60 mm
v) Quartzite : -50 mm
vi) Lime Stone (SMS grade) : -25 mm
vii) Dolomite (SMS grade) : -25 mm
viii) Pellets : -18 mm
ix) Manganese Ore : -25 mm
x) Coke Breeze : -25 mm

Bulk density of raw material shall be considered as 2.2 t/m3 for power calculation/load
data of structures and 1.6 t/m3 for volumetric capacity calculation of conveyor

Page4of10
3.0 TECHNICAL SPECIFICATIONS OF MOBILE TRIPPERS

3.1 The tripper shall be designed as per IS: 14386-1996.

3.2 Travel drive of trippers shall be individual wheel drive, independent of the main
conveyor drive and shall be through electric motor, helical gear box etc. Chain
drive shall not be used. Tripper shall be provided with D.C. electro-magnetic brake
for stopping the same at desired location. Travel speed of trippers shall not exceed
0.2 m/sec.

3.3 The traveling tripper shall consist of belt scrapper with adjustable rubber strip,
rubber lagged head and bend pulleys complete with shaft bearings, chutes, stops
and limit switches, brakes etc. The tripper shall have two-way discharge chute
which shall be capable of discharging material into the bunker openings.

3.4 Traveling trippers shall be of adequate length with proper slope of conveyor idlers
to match with the flow properties of material being handled. The maximum
inclination of the conveyor belt on the tripper shall not be morethan 12.

3.5 Vertical and horizontal guide rollers shall be provided to control sway and uplift of
the belt in unloaded condition. The tripper shall run on standard flat bottom Indian
Rails at least of 60 lb/yd. Wheels shall be double flanged with parallel tread
running on anti-friction bearings and shall have min hardness of 350 BHN. Material
of wheel shall be forced steel / cast steel

3.6 Traveling trippers shall be equipped with manually operated rail clamps and rail
cleaners and jacking pads.

3.7 Diverter gates on two way or three way chutes shall be electrically operated.

3.8 Power supply to the tripper shall be given through motorized cable reeling drum
with trailing cables, cable trays for resting the trailing cables and end limit switches
for protection against over travel of the tripper. The cable reeling drum and trailing
cable of each tripper shall be suitable for the entire length of the bunker bay. The
cables shall have copper conductors, proper insulating material and braided
armoring in accordance with IS: 691.

3.9 Position indicators shall be provided as per requirement of control logic. Operating
push buttons for local control and emergency stop shall be within easy reach of the
operator on the main conveyor walk way.

3.10 All stipulation regarding belt pulley, belt scraper, idlers, safety guards, wind guard,
access for maintenance etc. specified for belt conveyors, diverter gates and
discharge chutes shall be applicable for the traveling tripper.

3.11 The rating of tripper travel motor shall be adequate to move the tripper smoothly
either in forward or opposite direction to belt direction under fully loaded
conditions. Coefficient of friction shall be taken as maximum 0.15.

3.12 Minimum two drive axles shall be provided for tripper travel. Arrangement shall be
provided at the starting point of the tripper to avoid folding of belt.

3.13 Provision shall be kept for automatic tripping of bunker bay conveyor in event of
traveling tripper getting dragged (.i.e. travel speed in excess of rated speed).

Page5of10
3.14 The supporting structures for the rails with necessary end stops shall also be
supplied under this specification. Suitable belt hold down guide pulley shall be
provided over the concave curve of belt over tripper.

3.15 The bunker sealing arrangement shall keep the bunkers sealed and prevent dust
emission into tripper room.

3.16 Separate openings shall be provided on the bunker floor of each bunker to
measure level of material in the bunker. Hinged door/ flaps shall be provided on
these openings.

3.17 Suitable gratings are to be provided in between bunkers in the tripper travel zone.
Opening size shall be decided during the detail engineering stage.

3.18 Suitable dust cover shall be provided over tripper head pulley. Serrated rubber
seal shall be provided at open side to prevent dust nuisance. Suitable dust tight
access doors shall be provided. Counter weighted type belt cleaner shall be
provided below the tripper head pulley to cleaning the carrying side of the belt.

3.19 Suitable access platform of Chequered plate with ladders, hand railings and
walkways on both sides shall be provided for access / maintenance of equipment
on tripper. Also crossover platform shall be provided with tripper so that operator
can cross the belt through the same.

3.20 Continuous deck plates shall be provided below carrying idlers on the trippers.

Page6of10
4.0 SPARES

(A) Commissioning Spares and Insurance Spares

Supply of commissioning spares and insurance spares as required shall be in
scope of supply of the Bidder alongwith the equipment. The list of
commissioning spares and the insurance spares as per the format as given in
SBD shall be furnished alongwith the tender. It shall cover requirements of
erection, cold tests, startup and initial operation of the plant till integrated
testing & successful commissioning and commencement of commercial
production up to a period of six months. Any leftover commissioning spares
shall be the property of the Purchaser. Any commissioning spares required
over and above the list given by the Bidder shall have to be provided by the
Bidder free of cost up to the successful commissioning & commencement of
commercial production of the plant and equipment. The Bidder shall supply
adequate insurance spares to ensure smooth operation and maintenance of
the plant.

(B) Consumables
The Bidder shall supply all consumables such as initial fill of lubricants, oils,
grease, chemicals, refractories, resins etc. as required to complete the plant
till commissioning and shall have a shelf life of minimum one year. The scope
of consumables shall include electrodes, shims, packings, bolts, nuts, gaskets,
rivets, washers etc. The Bidder shall fulfill the requirement given in SBD.

The Bidder shall also furnish Indian equivalent of oils, lubricants, refractories
and other consumables along with necessary specifications, drawings,
catalogues etc. to enable the Purchaser to procure them from indigenous
sources.

The Bidder shall indicate the annual requirement of all such consumables.

(C) Operating, Maintenance and Two Years Spares:

(1) The Bidder shall ensure the interchangeability of the parts wherever
possible. The Bidder shall furnish an itemized list of interchangeable spares
as given in SBD.

(2) The list of spares as necessary and recommended by the respective

manufacturer for two years of reliable and trouble free operation and
maintenance of all equipment under this package shall be in the scope of the
Bidder. The same shall be quoted separately. In the event of order the
successful Bidder shall furnish complete specification of the same.

Page7of10
 (3) Spares list giving complete list of the replaceable parts, fully illustrated, shall
be supplied. The list shall include the following information.

Item designation
Reference drawings
Quantity installed
Quantity recommended for two years normal operation including the
insurance spares
Weight of each spare part
Supplier or sub-suppliers catalogue number
Recommended minimum stock
Expected replacement time
Installation instruction in detail shall be supplied both for original
installation and future, for replacement of major electrical equipment,
circuit wiring diagram shall be provided.

(D) Special Erection / Maintenance Tools and Tackles:

(1) The Bidder shall supply a complete and unused wet of all the special tools
and tackles including required number of tool boxes as required for erection,
maintenance, overhaul or complete replacement of the equipment and
components required for the plant. The Bidder shall submit a list of such
special erection and maintenance tools and tackles.

(2) All the tools shall be supplied in separate containers clearly marked with the
name of the equipment for which they are intended.

(3) The Successful Bidder shall indicate list of construction machineries, handling
equipment and other facilities including tower crane or equivalent for
erection at high elevation required for the execution of work based on their
previous experience, considering site conditions and other considerations of
work and furnish resource deployment plan. The successful Bidder shall
mobilize these equipment at site for the execution of work and this is an
important requirement of the project. The availability of required facilities
shall be ensured for completeness of the project in time.

(4) For any fabrication / control assembly (necessary for erection) work to be
done in the plant premises the plan shall be indicated by the Bidder. The
necessary equipment such as plate bending machines, special purpose
welding machines, fixtures, tools & tackles and other equipment required for
fabrication shall be arranged by the successful Bidder.

(5) The successful Bidder shall carry out the testing of welded joints by
radiographic and ultrasonic methods. They must have only qualified /
certified welders with them for completing all the welding jobs.

(6) All the measuring instruments shall be calibrated having reference to NPL
(National Physics Laboratory).

Page8of10
 (7) All tools and tackles, apparatus, special instruments required for erection,
testing, commissioning and establishment of the Performance Guarantee
Test, measurements required for establishing the pollution control norms
and such other instruments, as required, shall be arranged by the successful
Bidder. After commissioning, the successful Bidder shall handover all the
special tools & tackles to the Purchaser as per the requirement given in SBD.

(8) The successful Bidder shall supply all required consumables, initial fill, oil,
lubricants, construction and erection materials including but not limited to
shims, packing plates, joining compounds, kerosene, solvents, sealing
compounds, tapes, connectors, brazing and soldering materials, welding and
brazing gases and rods, electrodes and wires, erection bolts, nuts, rivets,
piano wire, packing sheet and packing compounds, temporary supports,
spacer templates, jute and cotton waste cloth, sand and emery paper etc.
for the commissioning of the plant.

(9) For load testing of handling equipment, loads shall have to be arranged by
the successful Bidder. Electrical/ operation tests, as per standard practice,
shall also be arranged and completed by them.

(10) All materials, equipment, tools, tackles etc. brought at site by the successful
Bidder within the plant area shall not be removed without the written
permission of the Purchaser. Similarly, all enabling works built/erected
and/or acquired by them within the plant premises shall not be dismantled
and removed without the written permission of the Purchaser.

(E) Information/ Data on Spares and Consumables

The list of Spares & consumables shall be furnished by the successful Bidder
as required in SBD. However, the successful Bidder shall furnish various
information regarding spares, consumables, tools & tackles etc. as per the
schedules indicated in chapter 12 of this Technical Specification.

Page9of10
5.0 TECHNICAL DATA SHEET (To be filled by the vendor)

1. Name and address of the Tenderer

2. Previous experience of the
Tenderer
3. List of similar equipment supplied
4. Tripper Details
5. Sealing belt details
6. List of drgs./ literatures enclosed
withthe offer
7. Drive details
8. Motors
a) KW rating
b) RPM
c) Type
d) Bearing
e) Make
f) Expected life (hrs)
9. Gear Boxes
a) Make
b) Type
c) Reduction ratio

d) Torque rating (kg-m)

e) Overall efficiency
f) Wt. of gear box (Kg)
10. Couplings
a) Make & Type of high speed
couplings
b) Make & Type of low speed
couplings
c) Weight (Kg)
11. Belt Cleaners
a) Type
b) Weight (Kg)
12. Any other information

Page10of10