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PART IV
DESIGN CRITERIA

1. BASIC REQUIREMENTS
1.1 GENERAL
All equipment to be supplied shall be new, of robust design & construction and
shall correspond to state of the art of cement manufacturing technology.
Throughout, such equipment shall be selected which operate at optimum speed to
minimise wear and tear, have a high degree of availability in operation and require
less maintenance.
The design criteria employed throughout shall be based on heavy-duty industrial
application, handling abrasive and very abrasive materials in dusty environments.
The system shall be suitable for continuous operation at uniform maximum load
without adverse effect on the life or maintenance of the equipment under prevailing
conditions.
All equipment and material shall be of a standard equal or better than specified
herein or as laid down in the latest relevant international standards.
The equipment and materials shall be suited to the local climatic conditions
especially the high relative humidity and dusty environment prevailing and under
upset conditions in a cement plant.

1.2 PLANT CLASSIFICATION (MECHANICAL AND ELECTRICAL

EQUIPMENT)
1.2.1 General
For proper identification of all equipment, the Bidder is required to adopt the plant
classification system as defined herein.
The plant classification is done by means of an "Asset Code" which is described in
full detail in Vol. B Annex. IV-1.

1.2.2 Structure of Asset Code

The Asset Code is composed of a six-digit alphanumeric code, which can be
supplemented according to the area of application by additional specific codes.

1.2.3 Mechanical and Electrical Equipment

First six alphanumeric digits of Asset Code define a physical unit (e.g. a crusher)
and shall be used for identifying all mechanical equipments.
Out of six digits, first three indicate "Group-Number" defining the function and the
place (location) of a unit (equipment) within the production process. Next three
digits give "Asset-Number" defining the unit, i.e. stating the kind of production
equipment or machine and their sequence number.

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Example
4 9 1 BC 1

Sequential numbering of equipment (digit 6)

Unit code (digit 4,5)

Sequential numbering of production line (digit 3)

Group (digit 2)

Department (digit 1)

with the following meaning:

Digit 1 : Department "4" Clinker manufacture
Digit 2 : Group "9" Clinker transport and storage
Digit 3 : Production line "1" Production line 1
Digit 4, 5: Unit code "BC" Belt Conveyor
Digit 6 : Sequential number "1" Belt Conveyor number 1

1.3 EQUIPMENT STANDARDIZATION, MATERIALS AND STANDARDS

1.3.1 Equipment Standardisation
Identical equipment and components shall be used wherever practical to permit
interchangeability of parts, minimise spare parts inventory, and simplify
maintenance.

1.3.2 Cross Reference List

The Bidder shall furnish a cross-reference list with complete identification of
identical equipment, components and parts.
This is in particular applicable but not limited to:
Feeders
Screw, pneumatic, etc.
Bucket elevators
Air slides
Gates, valves, dampers
Bag Filters

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Fans
Blowers
Gear boxes
Couplings
V-Belt drives
Lubrication systems.
Expansion Joints.
Dampers
Screw Conveyors
Chain Conveyor
Pan Conveyor
Lubrication Pumps

1.3.2.1 Materials and Applicable Standards

In general, the equipment/ component shall conform to the latest edition of
relevant International Standards.
National standards of the country of the Purchaser if any shall have priority over
the above standards for application regarding construction, erection, safety and
environmental aspects.
The metric system (SI-units exclusively) will have to be applied for design (all
specifications, drawings and manuals) and for manufacturing of all machinery and
equipment.
The equipment shall also conform to the latest Electricity Rules and Statutory
Requirements of the country as regards safety, earthing and other essential
provisions specified therein for installation and operation of Electrical plants. The
Bidder shall provide all necessary data/documentation/information for obtaining the
approvals from the statutory authorities.
Purchaser shall provide all necessary assistance in case any approval is required
from the concerned authorities of Bhutan.
All materials shall be of the highest quality of their respective kinds and suitable for
their application. The Bidder shall supply material and workmanship in accordance
with the best and most modern practice.
The chemical composition, tensile strength, elastic limit, compressive strength,
flexural strength, elongation etc. of the various materials employed, shall under no
circumstances be inferior in quality to the minimum requirements of the relevant
specification.
All components shall be new and shall be manufactured from identified sound
material, completely free from all imperfections such as cracks, flaws and
inclusions.
No material shall be accepted in a condition known to be faulty even under
guarantee of replacement in case of failure.
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Where reference is made to codes of practice and/or standards the latest
amendments thereof shall be deemed to be incorporated.
In cases, where the offer deviates from the generally accepted codes and
standards, the Bidder shall indicate clearly in his offer the standards proposed to
be adopted by him along with details there of and reasons for deviations.

1.4 MAINTENANCE AND SAFETY ASPECTS

1.4.1 WalkWays, Stairs and Platforms
All items of machines and equipment requiring periodic inspection, lubrication,
cleaning, adjustment, monitoring, repair or replacement, or which are designed for
manual operation shall be easily accessible without obstruction either by virtue of
their location or by means of stairs, galleries or platforms.

1.4.2 Supporting Structures, Maintenance Platforms, Safety Accesses

The Supplier shall indicate all maintenance platforms, stairs and safety accesses
for the equipment in their scope. The proper and safe access to his equipment for
the purpose of inspection and maintenance of the plant as well as emergency exit
ways has to be indicated, as recommended by them.
For safety purposes hand-railings and kick plates shall be provided around all
open platforms, stairways and walkWays and landings. Bidder shall
recommend/specify such specific needs required for their equipment.

1.4.3 Cranes/Hoists/Chain Pulley blocks

To enable easy and safe maintenance and/or replacement, repair service, the
Bidder shall provide sufficient Cranes, electric hoists, monorail trolleys or Chain
Pulley blocks.

1.4.4 Safety
All equipment to be offered shall be provided with adequate safety devices
according to international standards as well as the national standards of the
country of the Purchaser.
Safety guards will be used at all possible points of physical contact with moving
machinery, i.e. V-belt guards, coupling guards, chain casing etc.
Guards must also be provided around explosion vents and flap valves.

1.5 QUALITY AND OPERATIONAL ASPECTS

1.5.1 Site Assembly

The goods which are delivered at the site in semi-finished form due to size
restrictions for shipping and transport, i.e. all prefabricated parts shall be properly
prepared for the site assembly with appropriate matched holes/marks preferably
with dowel pin and with temporary bracings/spiders and gadgets.
All matching parts will be alphabetically punched and marked with paint for proper
assembly at site.

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3.3.1 Welding
All welding materials as required for the on-site assembly by welding of any portion
of the goods which are delivered to the site in a semi finished form or requiring
special electrodes including but not limited to e.g. cyclones, foundation frames,
safety and access platforms, (Connected with the equipment) shall be indicated in
the drawings clearly. Welding instructions shall be included as required.
Any specific criteria required for the welding at site must be enclosed with the
packing list.

1.5.3 Painting
All steel and cast surfaces of machinery, equipment and its supporting steel
structures shall have a proper surface preparation and painted thereafter.
In case where there is no seaworthy packing involved, the painting must give a
protection against corrosion during sea transport.
All surfaces of equipment subjected to high temperatures should be applied with
heat resistance paints. Supplier shall submit a list of such equipment for
Purchasers/Consultants approval.
Before undertaking the painting work the painting scheme shall be proposed by
the Supplier for Purchaser/consultants approval. Following shall be considered
during preparation of Painting scheme.
All machinery/equipment shall be supplied with finished painting as applicable.
All surfaces shall be dry abrasive blast cleaned as per latest standard.
Grease & Oil shall be removed by solvent cleaning.
All exposed sharp edges shall be grounded.
All inside and outside surfaces unless lined with refractory, ceramic, etc. shall
be painted with one coat of Red-oxide Zinc Chromate primer of thickness 25-
30 micron, as per IS: 2074.
All outside surfaces shall be painted with two coat of Alkyd based synthetic
enamel of thickness 25 micron/coat as per IS:2932. Shade of finish paint shall
be as per IS: 5.
For equipments subjected to temperature more than 100 OC shall be applied
with two coat of Heat resistant Aluminium paint as finish painting. No primer
shall be applied.
Suitable colour coding shall be considered.

1.5.4 Name Plates

The following metal plates of corrosion resistant material (min. 1.6 mm thickness)
shall be fitted to the machines and the equipment as follows:
Manufacturers label with the usual technical data, e.g. capacity, power, rpm,
duty, type/quantity of lubricants to be used and year of manufacturing.
Plate of reasonable size having the equipment number good readable/
engraved according to the final coding as per plant classification.
Instruction plates, as far as necessary for safe operation, in English.
Arrow showing the direction of rotation and/or flow.
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1.5.5 Special Tools/Tackles
Special tools required for the operation or maintenance of any piece of equipment
shall be supplied with the equipment.

1.5.6 Bolts, Screw Threads, Holding-Down Bolts and Base Plates

All bolts and nuts shall have metric threads only.
All bolts, nuts, washers and securing devices for the proper assembly of the
equipment shall be included. This means also all foundation bolts and fastening
devices required for the attachment of the equipment to the steel structure or
concrete works or foundations, as well as sliding rails for V-belt drives to be
mounted on base plates e.g. fan drives.
Further, all base plates, frames, anchoring, fastening, pack plate, shimming
material etc. necessary for proper installation shall be included.

1.5.7 Protection during Transport / Storage at site.

All the exposed parts will be provided with anti-rust coating and the machine
internals will be covered with protective coating or suitable lubricant.

1.5.8 Wear Parts and Wear Protection

All equipment exposed to wear, fans, grates, chutes, etc. shall be executed from
high wear resistant materials and/or provided with wear protection liners.

1.5.9 Vibration Prevention

Drive trains of the main machinery (main fans and blowers) should be analysed for
critical speeds, and any coincidence with operation speeds should be avoided.
The anti-vibration pads and blocks shall be provided for all fans. The process fans
placed on ground should not be provided with antivibration pads, however the
process fans placed on platforms shall only be provided with anti-vibration pads.

1.6 ENVIRONMENTAL ASPECTS

1.6.1 Dust Emission

1.6.1.1 Fugitive Dust Bag filters
To operate a dust-free plant all dedusting points of the equipment shall be skilfully
designed with adequate size of Bag Filters, with provisions for adjustment and fine
tuning. These dedusting points should cover:
Hoppers, bins
Exhaust gases
Dust producing machinery.

Provision for manual dust sampling points shall be kept for major stacks. Bag filter
shall be designed to achieve stack emission level of <30 mg/Nm 3
1.6.1.2 Process Bag Filter/Electrostatic Precipitators (ESP)
For the purpose of dedusting, the electrostatic precipitators shall be designed to
achieve emission of less than 30 mg/Nm 3. The Bag house shall be designed to

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achieve less than 30 mg/Nm3 dry at the full rated output of the equipment with N-1
chambers of the dust control equipment working, where N is the total number of
installed chambers.
In a bag house chambers should be compartmentalised so that a section at a time
can be taken out of service for maintenance.

1.6.1.3 Dust Emission Monitoring

All major stacks shall have continuous monitoring of total suspended particulate
emission.

1.6.1.4 Conveyor for Handling Dust

Conveying equipment handling the dust collected by the dedusting equipment shall
be designed to carry 33% more than the full load under maximum stable operation.

1.6.2 Noise Emission

The fundamental principles for the noise emission levels shall be as per ISO 3744,
3746, 4871, 6081 and National Environment Commission (NEC), Bhutan Norms -
2007. Further for determination of noise level ISO 11201 to 11204 shall apply.
As an indication the following shall be considered:
Max. value allowed in the workplace is 75 dB(A) as per NEC, Norms.
At the work places max. level is 85 Db(A) at a distance of 1.0 m from source.
At the closest point of the nearest living area outside the building max. level is
50 Db(A) night and 60 Db(A) day (06:00-21:00 h).
The fans to be provided with the silencers.
Wherever these standards are not met, proper equipment redesign / accoustic
hoods shall be provided.

1.7 SUB-SUPPLIERS
A recommended list of sub-suppliers is enclosed as Vol. B Annex. IV-2.
Suppliers to follow this list while preparing the Tender. In case of any deviations,
same shall be highlighted. The Purchaser reserves the right to accept/reject such
deviations.

2. REQUIREMENTS FOR MECHANICAL EQUIPMENT

2.1 GEAR AND SPEED REDUCERS

The design, manufacture and testing of the gear boxes shall be as per the latest
applicable standards:

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(a) Type of Gear : Planetary/ Bevel helical
(b) Rating : Rating of gear box shall be selected considering
service factor on the original motor rating.
(c) Recommended : 1.5 for gearbox < 37 KW
service factor on installed 2.0 for gearbox > 37 KW & < 132 KW
motor 2.5 for gearbox > 132 KW

(d) Duty : To be designed for continuous operation, 24

hrs/day, 7 days/week operation
(e) Reduction Ratio : Gear reducer ratio shall be so selected to obtain
direct coupling to driven machine. However, in
exceptional cases, chain/belt drive at the gear
outlet end shall be accepted to facilitate drive
mounting arrangements. Prior approval of
Consultant/Purchaser shall be required in such
cases.
(f) Starting duty : Two consecutive starts under cold conditions
and at full load.
Four starts per hour against full load under hot
conditions
Six starts per hour only for trial run during
commissioning and occasional abnormal
operating conditions.
(g) Bearing : Antifriction
All roller bearings contained in plant items which
normally operate on two or three shifts per day
are to be sized for a theoretical lifetime as
follows:
For main drive gearboxes (e.g raw mill, kiln
& cement Mill): 1,00,000 hrs.
For medium size gearboxes (e.g. bucket
elevator fans): 50,000 hrs.
For small gearboxes: 30000 hrs.

(h) Hold back : Integral hold back at input shaft, wherever

required.
(I) Lubrication : Splash or forced lubrication
All the hose connection should be supplied
in the required length to suit the site location
and no fabrication of hoses and fitting of the
end connection shall be carried out at site.
Gearbox lubrication system shall have built
in oil filtration pump with 8 micron filter. Only
for forced lubrication gear box.

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Field instrumentation shall include display of
temperature and pressure at all individual
locations within the gearbox and for its
accessories like oil cooler and tanks etc.
apart from all the safety instruments.
Oil cooler shall be sized to cool the water up
to 32-33 deg. C
Lubrication system shall include all safeties
and shall most modern. Gearbox lubrication
monitoring system design and specifications
shall purchasers guidelines. Also gearbox
with lubrication system shall be, tested (no
load trial) at manufacturers works in
pressure of purchaser, before despatch.
(j) Temperature Monitoring : For gear oil and bearing temperature monitoring
& Vibration Monitoring through 3 wire RTDs
wherever required.
Vibration monitoring equipment shall be
included, as required.
(k) Input & Output coupling : For Equipments below 37 15 kW drive tyre
couplings (unless otherwise specified in
technical specification) may be provided at the
input and output side. Above this Fluid coupling
at inlet and geared coupling at output shall be
provided.
(l) Spares : Spares like input shaft with the matching gear,
seals and high speed bearings are to be
included with the gearbox.
(m) Guarantee : Mill main gearboxes shall be guaranteed for a
period of 10 3 years from the date
commissioning or 4 years from the last supply
whichever is earlier..

2.1 BLOWERS

General (Air slides etc. )
a) Type : High Efficiency centrifugal
b) Duty : To be designed for continuos, 24 hrs/day, 7
days/week operation.
c) Speed of blower : Below 1500 3000 rpm, direct driven
d) Design capacity : 25% higher on volume and 15% on pressure
than the rated requirement.
e) Bearings : Antifriction
f) Damper : Manual
g) Air Filter : Inlet air filter shall be mounted on the blower
h) Casing : Mild steel

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i) Impeller : Cast steel/ Cast aluminium, mounted directly on
the motor shaft
j) Base frame : Combined base for blower and motor

Low Pressure Compressed Air (Silo Aeration etc.)
a) Type : Root blowers upto 1 bar and reciprocating
horizontal screw compressor above 1 bar
b) Duty : To be designed for continuous, 24 hrs/day, 7
days/week operation.
c) Speed of blower : 1500 3000 rpm (indigenous) and 3000rpm for
(imported).
d) Speed of compressor : 1500 rpm
e) Design Capacity : 25% higher on rated volume and 15% higher on
rated pressure
f) Impeller : Preferably mounted on a separate shaft on
antifriction bearings and coupled to the drive
motor.
g) Bearings : Antifriction
h) Damper : Control damper (flap/louvre type) shall be
provided.
i) Air Filter/ Silencer : Inlet air filter shall be mounted on the blower.

Flexible connection to the ducting/pipeline for isolation of vibration

Safety valve setting should correspond to 1.5 times operating pressure

Piping system with throttle valve

Anti vibration pads

Single stage, air cooled blowers/non-lubricated type compressors to be
provided along with corresponding standby duty equipment.

Motor suitable for cold start at damper full open condition

Compressor to be complete with safety valves, air receiver, air dryer

Compressor/Blower to be complete with necessary set of valves

Equipment shall be provided with 1 working + 1 standby (100% standby), 2
working +1 standby (50 % standby) or 3 working +1 standby (33 % standby)

2.3 BUCKET ELEVATORS

Belt or Chain type self supporting bucket elevators shall be supplied depending on
the respective application and design requirements.
All bucket elevators shall fulfil the following requirements:

2.3.1 Type of Elevators

Continuous discharge type are preferred, however centrifugal discharge are
also acceptable.

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Chain type and Belt type both are acceptable, belt type elevators shall be
considered for continuous flow homogenising silo, kiln feeding etc.

The factor of safety for chain/belt shall be minimum 1110

The elevator tail drum should be supplied with rack and pinion tensioning
arrangement with counter weight.

2.3.2 Drive

Bevel helical speed reducer coupled directly to head shaft

Fluid coupling for heavy duty starting behaviour at input side

Gear box output shaft should be hollow, shaft mounted, shrink disk type

Drive supported at elevator steel casing with torque arms and combined base
frame

Hold-back device at input shaft

Inching/Barring drive for maintenance, if bucket elevator height is more than
25 meter.

Auxiliary drive shall be sized for speed not more than 10% of the normal
speed.

2.3.3 Casing

Casing with inspection opening 1.5 m high having hinged doors

Casing to be braced every 8-10 meters and at the head-platform

Boot section with loading chute and cleaning door

Boot and Drive casings shall be provided with dust proof sealing.

2.3.4 Chain Type Bucket Elevator

High wear resistant, central chains make preferably or double calibrated round
link with carrier bolts.

Heavy duty sprockets with wear resistant fully interchangeable tooth segments
fixed with fit bolts.

Surface hardness of 50-55 HRC to a depth of 5mm is required on chain &
sprockets.

Joining U-type shackles are not acceptable

2.3.5 Belt Type Bucket Elevator

Rubber belt, heat resistance up to 150120C continious & 150C for short
duration with steel cord is envisaged with elongation not more than 1.5 - 2 %.

2.3.6 Design

Design Parameters

Type of material Filling degree Max. Speed m/s

1) 2) 3)

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Raw Meal, Cement and Clinker < 75 % 1.3 1.6 1.8

1) Chain type, double chain

2) Chain type, central chain
3) Belt type

The factor of safety of the chain selected shall be minimum 11 10 over
working tension.

Mono-rail hoist for maintenance shall be provided

Suitable vent hood to be provided in top boot

2.4. AIR SLIDES

All air slides shall fulfil the following requirements:

2.4.1 Air Slide Design

Enclosed type and well sealed

Sight glasses and Inspection openings at upper channel

Suitably protected polyester fabric

Cloth covered by metal screen at material feed points, and at location where
air slides change direction; also (fully covered) for the airslides handling
coarse material

Height to width ratio of 1.5:1 (Shall be as per HWI standards)

Slope as per following table:

Type of Material Slope angle >

Raw meal Coarse 10
Raw meal Fine 8
Cement grit 12
Cement fine 8
Filter dust 8

Air to cloth ratio : 2 (m3/min)/m2

Air Volume : 2.5 (m3/min)/m2
Air Pressure
Air slide width < 500 mm : 250 500630 mmWG
Air slide width > 500 mm : 500- 1,250630 mmWG
Air intake : Every 6 m of air slide length
Dedusting air quantity 150 % of the fan air quantity
Air connection shall be provided for each chamber separately

2.4.2 Discharge Gates

Motorised with limit switches
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2.5 SCREW CONVEYORS
All screw conveyors shall fulfil the following requirements:

2.5.1 Drive

Geared motor shall be provided with minimum gearbox rating of 1.6 of motor
power

Motor rating to be based on 100 % trough filled condition

2.5.2 Screw

Filling degree max. 30% for size selection

Max. circumferential speed 0.75 m/s

Length should be max. 6 m (hanger bearings are not acceptable)

Reverse flight screws shall be provided at both discharge ends to keep areas
free of dust

Bearings shall be anti-friction type provided with effective seal

Inspection covers to be provided with safety measures (locks)

Maximum Minimum clearance between casing and screw shall be 1.5mm

Pipe diameter selection shall be such that maximum deflection shall be limited
to 6 mm

Hard facing of flights shall be done with minimum depth of 3 mm on carrying
side only

Continuous duty 24 hrs/day and 7 days/week operation

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2.6 BAG HOUSES AND BAG FILTERS
All Bag house and Bag Filters shall fulfil the following requirements.

2.6.1 Bag House for Raw mill/ Kiln Dedusting

Bag house shall be designed for maximum pressure drop of 20 mbar.

Bag house shall be complete with reverse air for cleaning of bags.

Air to cloth ratio shall be 0.58 cum/min/sqm (gross). One extra chamber shall
be provided for the maintenance.

Filter bags of material fibre glass(woven) with sillicon-graphite-teflon coating

Weight of cloth bags shall be 480 to 550 gm/cum

Permeability of filter cloth shall be 720 to 1040 1440 cum/sqm

Bag size shall be 250-300305 mm diameter with length of 6 to 10.5 m

Bags should be suitable for the kiln gases (240 deg. C continuous operation
and 260 deg. C for short duration).

Bags life shall be 36 to 48 months

2.6.1.1 PULSEJET BAG HOUSE FOR RAW MILL/ KILN DEDUSTING

Bag house
Bag house shall be designed for direct operation (when raw mill is not in operation) and
compound operation (when kiln and raw mill both are in operation)

For the purpose of dedusting, the bag house shall be designed to achieve less than 30
mg/ Nm3 dry at the full rated output of the equipment with N-1 chambers of the dust
control equipment working, where N is the total number of installed chambers.

The bag house should be design with the provision of online maintenance in the
particular chamber. So that one section at a time can be taken out of service for
maintenance.

Dust Emission Monitoring

Stack shall have continuous monitoring of suspended particulate emission.

Bag house shall be controlled directly from plant DCs.

Bag House for Raw mill/ Kiln Dedusting

Bag house shall be designed for maximum pressure drop of 20mbar.

Air to cloth ratio shall be 1.0 cum/min/sqm with N-1 chamber

Fiber Glass Bags (needle felted) with PTFE membrane bags

Galvanised bag cage of 4 mm wire, welded construction.

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Rotary airlock with geared motors

Bags should be suitable for the kiln gases.

Minimum bag life shall be 48 to 6024 + 24 months on pro-rata basis

Air dilution through damper to bring down the P.H exhaust gas temperature
from 320 0C to 240 0C during direct operation.

Zero speed switches for material conveying equipment.

Bag house with auxiliary equipments complete in all respects excluding

trough/pyramid type bottom hoppers, ducts, supporting structures, for which
suitable fabrication drawing shall be supplied by the supplier, based on those
fabrication drawings, DCPA shall fabricate the same at site.

Other Electrical Specification

Design criteria of Electrical Equipment

All electrical and control systems and components, sub-control systems (under
Suppliers scope) and devices for individual machines shall be standardised and to be
approved by the Consultant. The Supplier shall provide all the necessary drawings,
schematics and other information of the offered electrical equipment.
All electrical equipment and documentation shall be in conformity with this specification.
Numbering of equipment and devices shall be as specified in this document or conveyed
by the Consultant during the execution.

Basic Design Criteria of Field Control Elements (Sensors)

Field control elements included in the Supplier' supply shall conform to the following
general design criteria:

a. Dust proof conforming to NEMA 12/IP65

b. Water proof conforming to NEMA 4/IP65

c. Wiping action on contacts (self-cleaning), encapsulated contacts are

preferred

d. Housing preferably made of metal. Covers to be fitted easily, screws to

be secured. Electronic equipment to be suitably protected against radio
interference, as required.

e. Resistant against vibration (contact pressure)

f. All potential free contacts shall be wired upto terminal block

g. Current rating:

Contacts (2 NO + 2 NC) : 5 amp at 220 V AC (min.)

:
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0.5 amp at 24 V DC (min.)

Electronic :

short circuit proof

protected from inductive voltage spikes
maximum inverse voltage &over voltage
protection
Analogue :
4-20 mA, galvanically isolated (against
earth and power supply)
Local Analog digital display indication
h. Mounting : By screws, mounting holes to be
sealed, adequate mechanical protection to
be
Included. The installation shall be done
by the Supplier.

i. Connections :
Sensor type field elements to be
supplied with min 10 mtrs long
extension cable.
All others: Lug type connection
A documentation giving details of all special electrical devices included in the
Supplier scope of supply (wiring diagrams, maintenance manual, special operating
instructions, etc.) shall be provided.

All types of elements will be subject for approval by the Purchaser/Consultant.

2.6.2 Bag Filters

Automatic cleaning by Reverse flow compressed air jet injection during
operation (jet-pulse system)

The air to cloth ratio for different material for bagfilters is given below:

Material Limestone Raw meal Clinker Gypsum Cement Fly ash

A/C ratio in 1.2 1.2 1.2 1.5 1.5 1.5
m3/min/m2

The needle felt filter cloth shall be made from high quality polyester fibres for
standard applications and, from polyacrynitrile/ mixed felt with Teflon coating
fibres for high temperature applications, i.e. cement mill/separator exhausts
and the like. The specific weight of the cloth shall be above 500 gm/m 2. For
standardisation of bag filters (160127/200 160 mm) all filters shall be
matched in such a way that only one size and type filter bags is used. Length
of the bag should not exceed 3000 mm.For nuisance bag filters 3.66m (max.),
for coal mill bag filter 5.0 m (max.), for cement mill bag filter 8.0 m (max.), for
RABH 10.85 (max.).

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The bagfilter casing shall be suitably designed to withstand a negative
pressure equivalent to the bagfilter fan design pressure. Tube sheet shall be
designed for stiffness to prevent damage or leakage by distortion due to
differential pressure across the tube sheet.

Bagfilter shall be supplied in fully assembled condition. No loose pieces shall
generally be supplied for assembly at site. External structural stiffening should
be designed to discourage the retention of dust accumulation.

Each Bag Filter comprises of :
Casing assembly (3.15 mm MS construction) complete with air manifold,
nozzle pipes.
Pyramid/ trough type hopper of min. 6 mm thickness to be provided.
Valley angle of hopper should not be less than 70 deg.
40 NB solenoid operated pulse cleaning valve (ASCO make). 25/40/75
soleniod of suitable size (from 25NB- 75 NB) operated pulse cleaning
valve (ASCO/ Equivalent make).
Bag cage of rust proof material and anodised. Cage construction 4 mm
rod with horizontal rings of 5 mm rod diameter at 175 mm spacing.
Electronic Pulse Controller (220 V AC) with IP 54 degree of protection. It
shall be suitable for operation from remote/local and have the interface
with the Plant Control System
Wear resistant double pendulum flap valve with a distance piece between
two flaps, for air sealing.
Pressure regulator with Dial gauge indicator
Manual valve in compressed air line header & Filter and moisture trap
Ready for start, Remote/Local mode, Feed back, DP high high.
Geared Motor for the above rotary airlock.
Steel support structure, maintenance platform & handrails, ladder (For
support structure and ladder a clearance of 1000 mm between rotary
airlock outlet and floor level to be considered).
Filter regulating unit.
Pressure switch with 1 NO + 1 NC contact
Foundation bolt.
Matching flanges at inlet and outlet.
Junction box for connection of solenoid valves.
Control cable between valve and junction box.
DP switch with low, high and high-high contact along with copper tubing
with a manometer.
Set of hopper heating with thermostat (but without local panel) for 1/3rd
bottom portion of hopper. For smaller filter heating pads shall be used.

Norms for Dedusting

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The norms for dedusting for various pick up point are given in the
following table:

MACHINE UNIT SIZE TOTAL A B C

( MM ) (m3/h) (m3/h) (m3/h) (m3/h)
BELT CONVEYORS 650 4250 2000 1250 1000

A 800 5250 2500 1750 1000

A
1000 6500 3000 2250 1250

B 1200 7750 3500 2750 1500

C
A 1400 8750 4000 3250 1500
B
C 1600 10000 4500 3750 1750
A
1800 11000 5000 4250 1750

2000 12250 5500 4750 2000

APRON CONVEYORS A B C
(m3/h) (m3/h) (m3/h)

800 6500 3500 2000 1000

1000 7500 4000 2500 1000

1200 8750 4500 3000 1250

1400 9750 5000 3500 1250

1600 10000 5500 4000 1500

A PAN CONVEYORS A B C
(m3/h) (m3/h) (m3/h)

800 9000 9000

1000 3000 10000 10000

B C 1200 3500 11000 11000

1400 4000 12000 12000

BUCKET ELEVATORS Chain m3/h Belt m3/h

A A B A B

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400 1250 1000 2000 1000

500 1500 1000 2250 1000

630 2000 1250 2500 1250

B 800 2500 1250 3000 1250

1000 3000 1500 3500 1500

1250 3500 1500 4500 1500

1600 4000 1500 6000 1500

MACHINE UNIT SIZE TOTAL VOL. DETAILS/REMARKS

( MM) (m3/h)

TROUGH CHAIN AND 200 500

SCREW CONVEYORS 250 500
315 500 /10 m Length
400 750
500 750
630 1000
800 1000
1000 1250

AIR SLIDES 150% of Air Blower

capacity
CLASSIFYING-SCREEN 50 Per tph ( Open )
VIBRATORY SCREEN 450 /m2 ( Closed )
SWING SCREEN 600 /m2 ( Closed )
VIBRATING FEEDER 600 900
800 1500
1000 2400
1200 3600

AIR LIFT 60 per tph or 150% of

expanded compressed
air volume

FULLER PUMP 50

PRESSURE VESSEL 40

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FLUIDSTAT ( BUHLER ) 30

BIN BIG 1000 Mechanical

SMALL 500 Feeding

ROLLER CRUSHER 0-50 tph 36 per tph

50-100 tph 60 per tph

MACHINE UNIT SIZE TOTAL VOL. DETAILS/REMARKS

(MM) (m3/h)

JAW CRUSHER 0-100 tph 60 per tph

100-400 45 per tph
tph
400-700 30 per tph
tph

IMPACT CRUSHER 0-100 tph 90 per tph

100-300 60 per tph
tph
> 300 tph 40 per tph

GYRATORY CRUSHER 0-100 tph 60 per tph

( CONE CRUSHER ) 100-400 45 per tph
tph
400-700 30 per tph
tph

CEMENT MILL V = Di2 X K [ M3/H ]

K = 2500-3000
(V= Volume; Di=Diameter;
M3/H= Flow)

PACKING MACHINE 8000 8-Spouts Rotary Packer

6000 6-Spouts Rotary Packer
300 Feed Point

2500 Per Spout In-Line Packer

Collecting Funnel
1500 Screen size 1x2.5m
2000 Takeaway Belt Conveyor
2500 Bag Cleaning Unit
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MACHINE UNIT SIZE TOTAL VOL. DETAILS/REMARKS

( MM) (m3/h)

LOADING MOBILE 5000 Air slide 400 mm

5000 Screw 630/800
1500 Hopper Mobile
4000 Double Articulated

LOADING HEAD Loading Rate:

900 Cement = 300 m3/h
1500 Cement = 600 m3/h
12000 Clinker 300 m3/h

TANKER VEHICLES Loading Rate :

540-660 Road = 60 tph at 2.5
Bar

660 Rail = 60 tph at 2.5 Bar

WEIGH FEEDER 2500

2.6.2 Filter Support

Standard supporting structures

Connected platforms and ladders

2.6.3 Filter Fan

The fans shall be statically and dynamically balanced before shipment from
the manufacturers works. The vibration intensity of the fans shall be checked
during the commissioning of the plant. Measuring method, vibration velocity
limits and other test conditions shall be agreed upon and included in the final
contract as a part of the guarantee.

Fans working in an abrasive atmosphere shall have their impeller blades hard
surfaced either by welding or spraying.

All fans shall be located on the clean air side of the dust collectors and
suitable for 24-hours operation

Fan blades shall be of the backward curved high efficiency (above 80%) type

Fans shall be designed for 115 percent of dust collector calculated capacity
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Speed of the fan shall be limited to 1500 rpm and circumferential speed of
impeller shall not exceed 150 m/s.

Drive motor shall be directly coupled with fan and shall be suitable for
operating at damper fully open with cold air.

Motorised inlet dampers to be provided for all process bag filters.

Anti-vibration pads.

Each fan consists of :
Fan assembly complete
Manually operated butterfly/louver damper at inlet for fans having motor
rating less than 37 kW. Motorised actuator operated butterfly/louver
damper (on/off type) for fan having motor rating equal to or above 37 kW.
Non-metallic expansion joints at inlet and outlet
Vibration isolator for fan.

2.6.3.1 Airlocks

Rotary type for all materials with geared motors.

Wear resistant Double pendulum type for clinker

2.6.3.2 Vent Ducts

Material of duct shall be weldable quality structural steel IS: 2062.

Upward and downward sloping for dust laden gas.

Vent velocity in ducts shall be 15-18 m/s except for clinker, which shall be 12-
16 m/s.

Angle of inclinations for Vents Ducts shall be minimum 50 o.

Duct velocity between bagfilter and fan should not exceed 15 m/s.

Duct velocity between fan to atmosphere should not exceed 10 m/s.

Minimum duct size shall be 100 NB.

Line diagram indicating vent volume, vent velocity and duct diameter shall be
submitted prior to duct fabrication drawings for consultant approval.

2.7 ELECTROSTATIC PRECIPITATORS (ESP)

All ESPs shall be designed to handle the required amount of gases with
necessary safety margins.

Migration velocity of gas in the range of 0.6 to 1.0 m/s with 400 mm plate
spacing is recommended.

Aspect ratio of 1.0 to 1.8 is recommended.

ESP shall be designed to achieve the required results in term of efficiency and
emission level.

Depending upon the inlet gas flow conditions the gas distribution screens shall
be suitably designed.

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Collecting plate and Discharge electrodes shall be made up of cold rolled
steel plates (stainless steel wherever applicable), system shall be provided
with suitable rapping device. Electrodes shall be suspended from top and
guided from bottom depending upon the length of electrodes

The rapping device shall be controlled through timing relay, which can be
varied from seconds to hours to achieve optimum setting.

The ESP casing shall be suitably designed to withstand a negative pressure
equivalent to the ESP fan design pressure. Casing shall be designed for
stiffness to prevent damage or leakage by distortion due to differential
pressure across the ESP.

Pyramid type hopper shall be provided. Valley angle of hopper should not be
less than 60o. Hoppers shall be equipped with hopper level controls, hopper
heating to avoid caking, baffle plates to avoid underflow of the electrodes.

Access doors to hoppers and to each compartment of housing, all sealed for
air tightness shall be provided. All access doors are to be quick release
opening design (clamp type)

Transformer sets shall be placed on the roof top for easy maintenance with
suitable capacity monorail hoist.

Suitably ESP discharge arrangement comprising of enmasse conveyor, screw
conveyor, rotary air lock shall be provided.

Auxiliary motor control centre shall be suitable for interfacing with Plant
Control System. The interfacing scheme shall be identical as for main plant
and shall be informed to successful Bidder.

The scope of ESP is as under:
Casing and hopper MS construction with inspection doors, 5 mm thick
Roller/ axial bearings
Insulator housing to be placed on roof
Gas distribution screens with inlet and outlet transition pieces
Rapping arrangement for ESP collecting and emitting electrodes,
preferably, should be with Magnetic Impulse Gravity Impact (MIGI) rapping
mechanism.
Emitting system with suspension arrangement including spiral type emitting
electrode. As per manufacturers design.
Collecting system with suspension arrangement
Mild Steel Cold Rolled (MS CR) collecting electrodes
Inspection doors
Transformer rectifiers. The TR sets are suitable for connecting to two
adjacent fields through a bus coupler in case one of the TR set fails.
Control panels for rectifiers , complete with thyristor control
Bust duct connection or TR set and emitting system
Microprocessor based TR controller with inbuilt rapper controller and energy
saving feature shall be provided 4-20 mA galvanically isolated signal for
current, voltage and kilo watt signal for remote monitoring

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Remote terminal unit
High level switch for ESP hoppers
Auxiliary control panel of non-drawout type with auxiliary contacts for PLC
interfacing which shall have feeders for following :
- Insulator heaters
- Rapping geared motors
Inlet funnel made (5 mm MS)
Outlet funnel (5 mm MS)
Outer roof
Key interlock system
HT change over switch & motorised field earthing switch
Thermostatically controlled electric heating element or support insulator
housing
Electric heating elements for rapping geared motor
Stairways and handrails from bearing support level to roof of ESP
Support Insulators
Shaft Insulators
Manual bus ducts
Motorised HT isolator switches
Mechanical safety interlocks
Rotary airlocks complete with motor.
Earthing arrangement upto bearing support level of ESP
Hopper heater complete with 1.5 mm thick heating jackets
Mechanical expansion joints at ESP inlet/outlet
Grouting plates below the slide bearings
Matching flanges for all gas inlet, outlet and dust discharge points of ESP
Local push button stations for all feeders included in control panel
Opacity meters
Junction box
TR sets maintenance arrangement

2.8 PROCESS FANS (COOLER FANS, PREHEATER/ PRECALCINER FAN, COOLER

EP FAN, ETC.)
a) Type : High efficiency Centrifugal (Efficiency shall not
be less than 85%)> 85% efficiency will be
provided in possible cases for clean gases fans
or maximum possible efficiency but not less
than 80% will be obtained from fan vendors.

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Cooling air fans and primary air will be excluded
from the above category.
b) Duty : To be designed for continuous 24 hrs/day, 7
days/week operation.
c) Speed : Below 1000 rpm for large/critical fans (above
132 kW) and fans handling dusty gases; below
1500 rpm for others.
d) Rated Capacity : Rated capacity shall be at least 25% capacity
higher on volume and 15% on pressure than
that required for the process after considering
system leakages etc.15% margin on volume
with corresponding required safety margin on
pressure will be considered. 25% margin will be
considered as minimum requirement for
pressure for process fans. For mill fans HWI to
follow their design requirement which shall be
minimum 10% on volume after considering air
leakage and corresponding requirement on
pressure.
The Bidder shall submit the characteristic
curves for all large/critical fans for Purchasers/
Consultants perusal along with the offer.
e) Impeller : Fans handling dusty gases shall have radial
tipped backward curved blades.
Liners shall be provided for abrasive dust
handling.
Clean air fans shall have high efficiency
backward curve.
Removal of impeller assembly should be
possible without shifting the drive motor.
(f) Design Critical Speed : 1.25 times (Min.) the maximum speed of the
fans.
(g) Casing : Horizontal split casing.
(h) Coupling : Tyre coupling for small Fans.
Tyre/geared for large fans (above 75 kW).
(i) Bearing : Bearing oil temperature shall not exceed 80C.
For all fans above 75 kW or handling high
temperature gases shall be provided with oil
lubricated bearings.
Bearings may be provided with suitable heat
dissipaters or water/air cooling to maintain
lubricant temperature within the limit. All fans
must have RTD for bearings.
Life of bearings for fan with a capacity of >
100,000 m3/hr shall be 50,000 operating hours.

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Life of bearing for fan with a capacity of <
100,000 m3/hr shall be 75,000 operating hours.
(j) Compensators : Non-Metallic type Flexible connection to the
ducting for isolation of vibrations shall be
provided at Inlet & Outlet.
(k) Inlet damper : Multivane louvre type dampers shall be provided
for the fans handling dusty gases. For clean air
fans, inlet guide vane dampers may be
provided. For small fans below 22 kW, butterfly
type dampers with actuators may be provided.
Motorised dampers, wherever required, shall be
operated by a servo-motor equipped with 1000
Ohms potentiometer, complete with 4-20 mA
galvanically isolated signal transmitter, end
position limit switches and torque switches. Inlet
cone adjustment from outside should be
possible. Dampers shall have antifriction needle
bearings. Bearing should be mounted outside
the frame with proper dust sealing.
No inlet damper shall be provided for fans with
variable speed drive.
(l) Anti vibration pads : All process fans are to be provided with anti
vibration pads.The process fans placed on
ground should not be provided with anti
vibration pads, however the process fans
placed on platforms shall only be provided with
anti-vibration pads.
(m) Vibration levels : For fans absorbing less than 300 kW power
velocity (max.): 1.1 mm/sec
For fans absorbing more than 300 kW power
velocity (max.): 2.8 mm/sec
(n) Instruments : With large fans, (Preheater fan and cooler vent
fan) local instruments such as bearing
temperature sensors (PT 100) 3 wire type, and
vibration sensors are to be provided.
Transmitters with 4-20 mA galvanically isolated
analog outputs to be included for vibration
sensors.

2.9 AIRLOCKS

Capacity should be designed for 125% of material handling and for continuous
duty.

Rotary type for all type of materials.

The clearance between casing and blades shall be designed to prevent
flushing through it. For flushy materials spring plates shall be provided with the
rotor blades for sealing.

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Feeders working against positive pressure shall be suitable to operate against
the pressure indicated. In such case, suitable venting arrangement shall also
be provided.

Geared motor driven airlocks

Torque limiter shall be provided wherever required

2.10 SAMPLERS

All automatic sampling stations should be combined with a sample receiving
pot and electrical control to obtain random or composite samples at variable
time intervals.

Samplers should be installed in the appropriate locations to ensure that
representative samples are taken (raw meal, clinker, cement etc.).

Additional manual sample collecting points shall be provided next to each
sampler.

Geared motor driven screw samplers shall be preferred.

2.11 GATES AND VALVES

All gates and valves depending upon requirement shall be designed as follows:

Shut-off gates manually operated, with chain if applicable

Shut off gates motorised

Shut-off gates pneumatically operated (self cleaning)

Proportioning gates linear type pneumatically operated

Combined shut-off gates and proportioning gates

Double flap valves pneumatic, motorised or counter-weight type

Designed for continuous 24 hrs/day, 7 days/week operation.

2.12 LUBRICATION PIPE WORK

2.12.1 Grease system

All pipe work for grease system shall be of seamless/welded steel
construction.

Wherever there are chances of breakage of a pipeline, flexible metallic or non
metallic type hoses shall be provided.

All hoses shall be complete with permanently attached end fittings.

Rubber hoses shall have a minimum of two wire braided construction.

All lubricant lines on each piece of equipment shall be brought to a common
header station.

Galvanised pipes shall not be used for lubricant service. High pressure
release valve with alarm, must be provided in case of blockage of grease
pumps.

2.12.2 Recirculation Oil System

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All feed and return pipe work of recirculating oil systems shall have exposed
connections on housing and easily accessible for replacement.

Piping should never enter from the bottom.

Galvanised pipes shall not be used for this purpose.

Required strainers, coolers, etc. are to be provided wherever necessary.

2.12.3 Hydraulic Pipe work

All hydraulic systems shall be designed and installed for maximum working
pressure, not less than 30% above the normal working pressure.

Systems shall be designed for the hydraulic fluid to be used and all
components shall be compatible with specified fluid.

Hoses shall be provided wherever there is vibration and it shall be of minimum
two wire braided construction suitable for working pressure with permanently
attached crimped end fittings.

2.13 PAN CONVEYOR

All Pan Conveyors shall fulfil the following requirements:

2.13.1 Drive

Drive motor, hollow shaft mounted type helical gear speed reducer with shrink
disk and common base frame for motor gearbox

150100% of full load start must be ensured

Hold-back stop for inclined arrangement

2.13.2 Chain and Rollers

Heavy-duty chain construction

Outboard rollers

Head & Tail sprockets to be replaceable segmented type

Factor for safety shall be minimum 1110

2.13.3 Overlapping Aprons

Highly resistant against shocks, heat expansion, deformations and high
abrasive

Maximum filling degree shall be 75 % ( As per manufacturer standard)

Maximum speed shall be 0.3 m/s

2.13.4 Lubrication

Centralised lubrication where applicable

2.13.5 Skirt Plates

Skirt plates with adjustable sealing rubber pads

2.13.6 Angle of Inclination

Upto 28 without Baffle Plates

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Upto 40 with baffle plates.

2.14 APRON FEEDERS

All apron feeders shall fulfil the following requirements:

2.14.1 Drive

Helical gear speed reducer coupled directly to head shaft

Fluid coupling or soft start for heavy duty starting behaviour

Full load start must be ensured

Hold back device for inclined arrangement

2.14.2 Chain, Rollers and Sprockets

Heavy-duty chain construction

Factor of safety for breaking load of chain selected shall not be less than 11.

Heavy duty sprockets with wear resistant fully interchangeable tooth segments
and fit bolts for fastening.

Surface hardness of 50-55 HRC to a depth of 5 mm is required on chain,
sprockets and guide rollers.

2.14.3 Aprons

Highly resistant against shocks, heat expansion, deformations and wear.

Shall be interchangeable and designed for smooth turning profile over
sprocket.

Shall be made up of welded plate construction and bolted to chain.

2.14.4 Lubrication

Centralised lubrication where applicable

2.14.5 Skirt Plates

Skirt plates with adjustable sealing rubber pads

2.14.6 Tensioning Device

Screw type tensioning device is recommended with sufficient tensioning distance.

2.14.7 Spillage Conveyor

Type : Chain and Scrapper type

Chain, Roller & Sprocket : Simplex chain (mild duty)
Lubrication : Centralised type

2.15 BELT CONVEYORS

The belt conveyors shall fulfil the following requirements:

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2.15.1 Speed
To be considered as indicated below:

Material handling belt conveyors : 1.01.5 m/s

Conveyors with magnetic separator/detector : To suit response time

Packed cement bags : 1.01.5 m/s

2.15.2 Troughing Angle

Carrying side : 3 Rollers with 45 deg. troughing angle except for

Packing Plant Conveyors which shall be with flat
idlers.
For non magnetic idlers, the centre idler frame shall
be with 15 degree troughing angle and idler frames
on either side shall have 45o troughing angle.
Return side : Flat idlers

2.15.3 Drive

Drive shall be provided at head end as far as possible

Bevel Helical gear box shall be provided

Full load start must be ensured

Combined base frame with suitable fasteners shall be provided for housing
motor and gearbox.

2.15.4 Pulley

Type : All pulleys to be adequately sized and statically

balanced
Pulleys shall be of welded construction
The pulleys shall conform to IS 8531
Material of
Construction
Shell The material of construction will be as per IS 2062 plates
Hub Forged Steel as per IS - 2004/MS rounds as per IS
2062
Shaft EN 8/C 45 alloy steel.
Bearings : Double row spherical roller bearings with adaptor
sleeve. Grease lubrication through nipples labyrinth seal
for sealing.
The bearing life shall be minimum 40,000 hrs.
Shaft : Shaft diameter for the pulleys of same and similar size
shall be standardised for the purpose to have minimum
spares
Hub Hubs shall be keyed to the shaft for all the pulleys.

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Connection
Dimensions Width of the pulleys to be generally 200 mm more than
belt width and generally as per IS 8531
Lagging Rubber lagging shall be done for Head, Tail and Snub
Pulleys.
Pulleys shall be lagged in double herring-bone design
with natural rubber (12 mm thick natural rubber). The
depth of the groove shall be 6 mm.
For reversible conveyors diamond lagging shall be
provided on head and tail pulleys.
The Shore Hardness of the lagging rubber shall be 60
65A.
Crowning Tail and drive pulleys shall be suitably crowned

Shell Diameter of Pulley (in mm)

Belt Width in mm 650 800 1000 1200 2000

Head 400 500 630 800 1000

Tail 315 400 500 630 800

Take up 315 400 500 630 800

Bend 315 315 400 500 630

Snub 315 315 400 500 630

NOTE Minimum belt width shall be 800 mm, however for conveyors
carrying packed cement bags the belt width shall be 650 mm

2.15.5 Idlers

Material : MS ERW rollers and MS bars for shafts.

Sealing : Double labyrinth seal on external side and contact nylon
seal on inner side. On the outer side of the roller face, an
additional water proof neoprene rubber contact lip seal shall
be provided.
Bearings : Antifriction ball bearings/seize resistant bearings & life long
and lubricated.
Lubrication
Bearing housing shall be CRCA sheet of 3.15 mm thickness
of EDD quality.
Carrying : Mounted on thrust bearings for swivel arrangement with
and Return necessary stoppers.
Trainers
Transition : One set each before tail and head end. Each set consisting

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Idlers of minimum 2 no. 20 degree troughing idler.

Shell Diameter of Idlers

Belt Width in 650 800 1000 1200 2000
mm
Carrying 114.3 139.7 139.7 139.7 152.4
Transition 114.3 139.7 139.7 139.7 152.4
Return 89.0 114.3 114.3 114.3 139.7
Impact Tube dia. + NA 88.9+38 88.9+38 88.9+38 114.3+38
Rubber thickness

Max. Spacing Intervals for Idlers (in mm)

Belt Width in mm 650 800 1000 1200 2000
NA 1,000 1,000 1,000 1,000
Carrying idlers
(troughed conveyor)
300 NA NA NA NA
Carrying idlers (flat
conveyor)
15,000 15,000 15,000 15,000 15,000
Carrying
(Minimum one number per conveyor)
trainers (troughed &
flat conveyor)
3,000 3,000 3,000 3,000 3,000
Return idlers
30,000 30,000 30,000 30,000 30,000
Return
(Minimum one number per conveyor)
Trainer
Impact idlers shall be provided to cover complete feed area of the belt. The maximum
spacing for Impact Idlers shall be 300 mm Impact Idlers shall be so placed that on
installation the gap between the idler faces is maximum 100mm.
Impact idlers are not required for cement bag conveyors.
Conveying idlers for reclaim conveyor shall have a spacing of 750 mm

2.15.6 Short Supports and Stringers

For belt conveyors with open type of gallery no short supports and stringers
shall be considered.

Gallery design shall be such that the stringers are integral part of the gallery
itself. Idlers supports shall be directly mounted on the gallery structural
member.

However, the conveyors which do not require a open gallery or have a partially
open gallery shall have short supports and stringers.

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Short supports (wherever applicable) shall be considered at 3,000 mm
spacing.

Stringer/short supports shall be MS channel/angle, rolled section (not re-
rolled).

2.15.7 Skirt Board

Skirt board shall be provided at all feed points for troughed belt conveyors.

Track mounted skirt board sealing system to be provided to have continuous
dust tight seal and to allow wear adjustment of segments in small increments
or easy replacement of worn out segments.

Skirt boards shall be provided for minimum 5 m length at each feed point.
However, when two or more feed points are there on a conveyor, continuous
skirt arrangement may be required.

The skirt board top cover shall be maintained at 450 mm from belt top at all
locations.

2.15.8 Chutes and Liners

Feed and discharge chutes shall be made out of 8 mm thick MS plate with 10
mm wear resistant liners (Tiscral/Sail Hard).

Feed and discharge chute shall be provided from conveyor to conveyor.

2.15.9 Discharge Hood

Properly designed discharge hood for effective dedusting and dust tight
flexible rubber access door shall be provided.

Suitable liners shall be provided

The height of discharge hood shall be 1500 mm from belt top. Required vent
connection hood with flange shall be included.

Belt conveyors if any which are discharging at 90 deg. shall be provided with
deflector in discharge hood.

2.15.10 Take-up Device

Screw/Vertical Gravity/Horizontal Gravity take ups shall be provided.

Gravity take-up assembly shall be located close to the ground level for ease of
maintenance.

Take-up tower for HGT shall be Suppliers scope.

For VGT, the take-up tower shall be in-built in one of supporting trestles of the
belt conveyors. Conveyors upto 50 m length shall be provided with screw type
take up.

2.15.11 Deck Plate/Seal plate

Deck plate shall be 2 mm MS Sheet.

Deck plate shall be provided for 5 m length at all loading and discharge points
of the conveyor.

No deck plate is considered for cement bag conveyors.

2 mm thick seal plate to be provided below conveyor belt at the road crossings
as well as other conveyor crossings.
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2.15.12` Local Covering

Belt conveyors suitable for installation in the open shall, however, be provided
with a local covering so that the belting (conveying and return) can be
protected from rain.

Hood shall be provided for covering belt and shall be of 24 SWG galvanised
corrugated sheet with inspection door every 10 m intervals.

Hood shall be fixed with the help of bolts on the gallery member.

2.15.13 Belt Scrapers

Belt conveyors are to be provided with belt scrapers as follows:
V type internal at tail end
Primary & secondary scrapers (Hosche design or equivalent) at head end

The location of these scrapers should be such that inspection/adjustment/
replacement of these scrapers are possible while the conveyor is running.

2.15.14 Couplings

Tyre type couplings are to be provided on the input side for conveyors with
drive motor up to 37 15 kW.

Fluid coupling shall be provided on the input side on all conveyors with drive
motors above 37 15 kW.

On output side geared couplings shall be used.On output side flexible
coupling shall be used. If the motor is above 37Kw rating, geared coupling
shall be used.

Service factor of 1.25 on motor rating or 1.5 on shaft power which ever is
higher shall be considered for the couplings.

2.15.15 Safety Devices

3. Pull Cord Switch : At 30 m interval on both sides (2 No. min)

should be provided. The pull cord switch shall
be complete with wire-rope, supports,
fasteners etc.
4. Zero Speed Switch : At tail pulley (1 No.)
5.
6. Belt Sway Switch : At 50 M interval on both sides(2 No. min)

2.15.16 General Belt Design

Design capacity shall be 25% extra than rated.

Trough angle shall not be less than 30

Wrap angle at head pulley shall be minimum 210 degree.

Knee bracing shall be provided at every fourth short support wherever
applicable.

The number of plies for fabric rubber belts shall never be less than 3.

Belt sag between two idlers shall not exceed 2%.
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Radius of curvature for concave curve shall be minimum 200 150 m.

Min. distance between centre of tail end pulley and start of skirt
arrangement 1.2 m

Travel for gravity take up shall be 2.5 to 3 % of conveyor length.

Travel for screw take up shall be 2 % of conveyor length.

Belt conveyor maximum allowable slopes are as follows :

Material Max. Slope

Crushed Limestone 15 O
Iron Ore 15 O
Coal 15 16 O
Clinker 12 O

2.15.17 Belting

Belt quality shall be standardized for each belt width with the highest required
belt rating.

Nylon/Nylon belting shall be provided.

The rating of the belt should be such that the maximum tension induced in the
belt should not exceed 80% of the maximum recommended belt tension.

The rating and duty conditions shall be decided on the maximum tension
anticipated in the belt, max. belt width for adequate load support, min. belt
width for adequate troughing.

The safety factor shall be 10.

Cover grade shall be N17 for cement bag conveyors. Belt grade shall be M 24
for other conveyors.

Heat resistant belting shall be provided for clinker conveyors and wherever the
material temperature(normal or maximum) exceeds 80 deg. C

2.18 EN-MASSE CONVEYOR

All en-masse conveyors shall fulfil the following requirements:

2.18.1 Drive

Maximum speed for chain shall be 0.30 m/s

Direct driven with geared motor shall be used.

Rating to be based on 100% conveyor plates height fully filled condition

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2.18.2 Casing

Wear resistant liners to be fixed at suitable spacing on bottom and side

Sufficient inspection openings are to be provided

Provided with adequate sealing arrangements.

Filling degree shall be limited to 40%

2.18.3 Chain & Sprockets

Driving and driven sprockets shall be wear resistant, running on anti-friction
bearings and with adequate sealing arrangement.

High wear resistant, heavy duty chain links shall be provided

Self locking chain links shall be preferred

Heavy-duty chain construction

Heavy duty sprockets with fully interchangeable tooth segments

Surface hardness of 50-55 HRC to a depth of 5 mm is required on chain &
sprockets.

Chain factor of safety shall be 11

2.19 HOT AIR GENERATOR

The Hot air generation system required to meet the drying heat requirements in
raw mill as described in technical concept of plant, shall have following features:

Direct vertical down fired, which shall be suitable for pulverised coal/diesel oil

Capacity to be designed considering worst condition.

Shall use fresh air as dilution air with suitable capacity fan.

Fuel transport to Hot air generator shall be by pneumatic pumps for solid fuel.

Fuel Oil operated burner, using compressed air for atomisation shall be used
for initial start-up.

Shall be provided with suitable explosion flaps, refractories, and supports.

Suitable dampers motorised/manual shall be provided to suit system
requirement.

2.20 UTILITY SYSTEM

The system shall comprise of compressed air, water, fuel oil system suitably
designed as per requirements and conforming to respective International
standards.

2.20.1 High Pressure Compressed AIr

Compressed air system shall be installed to meet the compressed air
requirement of all the equipments.

System shall consists of pipeline and accessories starting from equipment to
the main header provided at one point for each package

Compressors shall be provided with the concept of 1 working + 1 standby (for
capacity upto 1000 cum/hr compressed air requirement) or 2 working + 1
standby (for compressed air requirement greater than 1000 cum/hr)
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Air Compressor shall be reciprocatingscrew type, balanced , opposed, non
lubricated, heavy duty , air cooled compressor including following
accessories :
Dry type suction air filter cum silencer
Exchangers with air through tubes, removable type bundle complete with
safety valve and automatic drain trap
2 step (0-100) electro-pneumatic capacity control
Dual Control system giving flexibility for operating the compressor on base
duty (Load/Unload operation) or standby duty (With auto On/Off operation)
Volume bottle after exchanger for reducing pulsation to a level of 5%
Cooling water piping for cylinder jacket and heat exchangers cooling
complete with inlet and outlet isolation valves and flexible hoses for
vibration isolation
Flexible hoses for cooling water inlet/outlet and drain piping
Drive sheeve and motor rails
Air dryer for drying the compressed air to a dew point of 3 deg. C
Automatic Starter cum PLC based Control Panel complete with :
- Power ON indicating lamp
- Main and delta contactors and star contactors
- Single phase preventor
- Start/Stop Push Buttons
Display Unit having LCD windows for input status of PLC unit such as
- Compressor Duty i.e. Base or Standby
- Capacity Control Status i.e. 0% or 100%
- Fault Indication
- Running hours
MMI keys for
- Test/Accept/Reset Push Buttons
- Selector Switch for Base/Stand by duty selection
- Selector switch for Auto/Manual load/Unload
Interlocking Safety for:
- Low oil pressure
- Low cooling water pressure
- High discharge air temperature
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- Motor Overload (Thermal)
- Single phase power supply
Instruments shall be :
- Vacuum indicator for suction filter
- Lube oil Pressure gauge
- Inter stage Pressure gauge
- Discharge air pressure gauge at terminal point
- Discharge air temperature indicator cum controller after compressor
- Discharge air temperature indicator cum controller at inlet to air dryer
Air Piping shall comprise of interconnecting air piping upto isolation valves
and non-return valve at the terminal point. By pass arrangement with
isolation valve to isolate the air dryer
Water Piping shall comprise of interconnecting piping within the
Compressed Air system. Drain piping from all drain points leading to a
common drain header
Cabling and Tubing shall be :
Instruments tubing from measuring point to gauge panel
Unloader piping from suction valves to unloader
Power cabling between starter and motor laid out through cable trays
with fixing clamps
Control cabling between the various instruments and starter cum control
panel duly terminated and properly laid through ducts/cable trays with
fixing clamps
Power Supply shall be separate for air dryer and Compressors
Connectivity to be provided for PLC
System to be suitable for Interface with Plant Control system

2.20.2 Compressors Accessories

Local air receivers after main header shall be sized for One sixth of
compressed air demand in cum/min.

Air Receiver for Local Areas: Minimum 0.2 cum nominal volume, vertical air
receiver suitable for working pressure of 10 kg/sqcm, conforming to IS 2825/
ASME Sec VIII complete with welded supporting stand, inspection opening
with cover, IN/OUT flanged connections with companion flanges, 1 no. safety
valve, Pressure gauge, drain valve and foundation bolts including 1 no. non
return valve and 2 nos. isolation valves.

2.20.3 Pipeline and Pipe Fittings

All pipe joints shall be air tight and ferrule type fittings shall be used.

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In case of ERW (Electric Resistance Welded) pipes and welded pipe fittings,
weld joints shall be air tight.

All pipelines shall be sized for air velocity of 6-8 m/s.

All pipelines shall be designed for water velocity of 2-3 m/s

Water pipeline network shall be designed in close loop and shall have
minimum bends and connections.

Suitable numbers of water traps shall be installed in compressed air pipeline.

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2.20.4 Piping Material Specifications
Line Numbering System
XX- XX- XXX- XXX
Line Serial No.
Pipe Class
Pipe Size (NB)
Medium (Refer Legend)
Legend for Medium
CA- Compressed Air
DW- Domestic Water
CWS- Cooling Water Supply
CWR- Cooling Water Return
PW- Process Water
DO- Diesel Oil
CLASS- F10
PIPE CLASS : F10
MATERIAL : C.S
ANSI CLASS : 150#
MEDIUM : CWS, CWR, PW, CA, DO
CORROSION ALLOWANCE : 1.5 mm
PRESSURE TEMP. LIMITS :

TEMP Deg C -29 50 100 150

PRESS. BAR 19.6 19.2 17.7 15.8

PIPE : MATERIAL: API 5L Gr. B

15 NB to 40 NB welded with plain ends, dimension stds. as per API 5L
50 NB to 300 NB welded with bevelled ends, dimension stds. as per API 5L.

MATERIAL : API 5L Gr. B & Pipe thks, as per the following table.

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PIPE SIZE 15 20 25 40 50 65 80 100 125 150 200 250 300

(NB)

OD mm 21.3 26.7 33.4 48.3 60.3 73 88.9 114.3 141.3 168.3 219.1 273 323.9

Thk. mm 3.73 3.91 4.55 5.08 3.91 5.16 5.49 6.02 6.55 7.11 6.35 6.35 6.35

Sch. No. 80 80 80 80 40 40 40 40 40 40 20 20 20

FITTINGS:
All fittings 15 NB to 40 NB socket welded 3000 #, Dimensional Stds. as per ANSI B
16.11; Material ASTM A 105.
All fittings 50 NB to 300 NB butt welded, Elbow Rad. -R=1.5D, Dimensional stds.
as per ANSI B 16.9; Material ASTM A 234 Gr. WPB
Caps & Plugs screwed 3000# Dimensional stds. as per ANSI B 16.11; Material
ASTM A 105.

FLANGES
15 NB to 40 NB socket welded RF (Serrated finish) 150#; Dimensional stds. as per
ANSI B 16.5; Material ASTM A 105.
50 NB to 300 NB SO RF 150 (Serrated finish) 150#; Dimensional stds. as per ANSI
16.5; Material ASTM A 105.
15 NB to 300 NB Blind flanges RF (Serrated finish) 150#; Dimensional stds. as per
ANSI B 16.5; Material ASTM A 105.

GASKETS
15 NB to 300 NB flat ring 150 #; 2 mm thk.; Dimensional std. as per ANSI 16.21 :
Material : As per IS2712

BOLTING
Stud bolts ASTM A 193 Gr. B7 threaded full length with 2 ASTM A 194 Gr. 2H nuts;
as per ANSI B 16.5

VALVES
Gate, globe, ball and check valves (piston lift type) from 15 NB to 40 NB socked
welded ends 800#; Material : Body ASTM A105 ; Trim : 13% Gr.
Gate, Globe, ball & check valves (Swing check type) from 50 NB to 300 NB
flanged ends RF 150# (serrated finish); Material: Body ASTM A 216 Gr. WCB; Trim
13% Cr.
Butterfly valves from 80 NB to 300 NB wafer type 150#; Body material ASTM A 216
Gr. WCB; Trim 13% Gr.

STRAINER

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15 to 300 NB size Y-type Strainer; Body material ASTM A 216 WCB, Internals SS-
304, Flanged ends-150# serrated finish.

CLASS F12
PIPE CLASS : F12
MATERIAL : C.S Galvanised
ANSI CLASS : 150#
MEDIUM : DW
CORROSION ALLOWANCE : 1.5 mm
PRESSURE TEMP. LIMITS :

TEMP Deg C 38 50 90

PRESS. BAR 19.6 19.2 18

PIPE : MATERIAL: IS 1239-Heavy Galvanised

15 NB to 80 NB ERW with screwed ends, dimension stds. as per IS 1239
MATERIAL : IS 1239 Heavy Galvanised Pipe thks, as per the following table.

PIPE SIZE (NB) 15 20 25 40 50 65 80

OD mm 21.3 26.7 33.4 48.3 60.3 73 88.9

Thk. mm 3.25 3.25 4.05 4.05 4.5 4.5 4.85

Sch. No. IS 1239 Heavy

FITTINGS:
All fittings 15 NB to 80 NB Screwed ends 3000#, Dimensional Stds. as per ANSI B
16.11; Material ASTM A 197 Galvanised
Caps 15 NB -80NB screwed 3000# Dimensional stds. as per ANSI B 16.11;
Material ASTM A 105. Galvanised

FLANGES
15 NB to 80 NB Screwed RF (Serrated finish) 150#; Dimensional stds. as per ANSI
B 16.5; Material ASTM A 105.Galvanised
15 NB to 80 NB Blind flanges RF (Serrated finish) 150#; Dimensional stds. as per
ANSI B 16.5; Material ASTM A 105.Galvanised

UNIONS
15 NB to 50 NB Screwed RF (Serrated finish) 3000#; Dimensional stds. as per
ANSI B 16.11; Material ASTM A 105.Galvanised

COUPLINGS
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80 NB Screwed RF (Serrated finish) 3000#; Dimensional stds. as per ANSI B
16.11; Material ASTM A 105.Galvanised

GASKETS
15 NB to 300 NB flat ring 150 #; 2 mm thk.; Dimensional std. as per ANSI 16.21 :
Material : as per IS 2712 Gr W/3

BOLTING
Stud bolts IS 1364 Cl 4 (Galvanised) threaded full length with 2 Nuts; as per ANSI
B 16.5

VALVES
Globe and check valves,* from 15 NB to 80 NB Screwed ends 800#; body material
ASTM B62, Trim Brass
Butterfly valves above 80 NB wafer type 150#; Body material ASTM A 216 Gr.
WCB; Trim Brass.
- Up to 40 NB Piston Lift
- Above 40 NB Swing Check

STRAINERS
Y- type strainers: Galvanised body material according to ASTM A 216 WCB:
Internals as per SS-304, flanged ends 150 #, serrated finish.

2.21 EXPANSION JOINTS

Expansion Joints shall be provided in the ducts which are used in the transfer
of high temperature gases for thermal expansion or isolation of vibrations.

Metallic expansion joints are preferred for handling high temperature gases or
at the locations not easily accessible.

Expansion Joints shall be manufactured to ensure protection against dust
abrasion and/or dust deposition.

The design of the expansion joints should confirm to EJMA code required.

Non metallic expansion joints may also be offered as per system requirement.

2.22 PROCESS DAMPERS

Dampers shall be suitably designed based on the process requirement. The design
of dampers shall be one of the followings and shall be motorised or pneumatic
based on the application.

Multivane louvre type dampers shall be provided for the fans handling dusty
gases. For clean air fans, inlet guide vane dampers may be provided.

For small fans below 22 kW, butterfly type dampers with actuators may be
provided. Inlet cone adjustment from outside should be possible.

Shutoff dampers for isolation purpose.

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Cooling air dampers for gas dilution and exhaust dampers for venting of
gases.

Dampers to have antifriction bearings. Bearing should be mounted outside the
frame with proper dust sealing.

Suitable seal air/cooling air fan shall be provide wherever required.

Wherever variable speed drive is used for fan, inlet damper is not required.

2.23 FIRE EXTINGUISHERS

Following type of local fire extinguishers are envisaged for the plant
7. Soda Acid
Foam
Carbon Dioxide
Halon 1211

2.24 CHUTES
All transfer chute/connections shall be designed considering following aspects:

The minimum valley angle shall correspond to the material characteristic.

All chutes, covered skirt-boards and hoods shall be provided with suitable
hood connection terminating at a duct flange.

Chute connection shall be of flanged and bolted construction. At least one
flange between two fixed locations shall be shipped loose to facilitate ease of
field erection.

Chute support connection shall either be bolted or welded in design, but shall
designed to facilitate ease of field erection and assembly of parts.

All chutes handling abrasive, sticky material shall be provided with suitable
liners.

All chutes handling clinker shall be provided with stone boxes and lining.

Chute shall be constructed of 6mm thick plate minimum.

Bolted liners shall be provided wherever required

A hinged inspection door shall be provided wherever necessary.

2.25 INERT GAS SYSTEM

The inertisation system required for flooding inert gases to suppress fire in case of
emergency and to prevent explosion in Coal mill, Mill Bag Filters, Fine coal bins
and related ducts must have following features:

CO2 based

CO2 cylinders to be mounted on load cells with standby system.

Total 3 set of cylinders will be required (2 in system one in transit for refilling)

Temperature Sensors must be provided.

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2.26 MAGNETIC SEPERATOR, PERMANENT MAGNET AND METAL DETECTOR

Permanent Magnet and Magnetic separator shall be designed to detect/
separate and lift the ferrous parts.

Non Magnetic idlers to be used for the conveying system under the magnetic
separator.

Magnetic separator shall be suitable for separating magnetic particles of 15
kg. (max.) and M20 *100 size bolt (min.)

Magnetic separator shall be microprocessor based complete with sensitivity
adjustment search spool optical and acoustics warning device for locating
metallic pieces

2.27 GOODS AND PASSENGERS ELEVATORS

Passenger elevator shall confirm to followings:

Type shall be of industrial type for Preheater lift and decorative type for
Central Control Room lift.excluded

All floors and major maintenance platforms of buildings where elevators are
provided shall be made accessible by an appropriate number of stops.

Elevator shall be equipped with electro-mechanical drive system located on
top of elevator shaft.

The elevator car and hoisting door shall be with collapsible gate

Emergency openings shall be considered as per requirement

Suitable dust protection arrangement to be provided for Preheater lift

The elevator car shall fulfil the following specifications:

PREHEATER LIFT
Car Capacity Capacity 2 t
Speed (drive) 0.5 to 0.7 m/s

2.28 OVERHEAD CRANES, ELECTRIC HOISTS AND TROLLEY

Overhead cranes, electric hoists and trolleys for maintenance shall be capable
to carry the heaviest piece of equipment to be moved in the respective
production area plus a margin of 20% as safe working load.

The capacity shall not be less than 2 t.

Cranes are to be test loaded in accordance with the appropriate national or
international standard regulation.

Beams with trolley shall be installed over heavy equipments such as bearings,
motors, pumps, gearboxes, bucket elevators, fans, VRMs, Cement mills, etc.
wherever necessary for maintenance or replacement.

Lifting hooks shall be provided wherever necessary.

2.29 WEIGH FEEDER: BELT/APRON

Shall be designed for flow control range of 10:1

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Shall be designed for weighing accuracy of + 0.5% set design rate.

Hermetically sealed temperature compensated load cell.

Shall be totally enclosed with supporting frame, bottom frame, frame cover,
rear cover with cover plate, vibro hopper with flap switches, etc.

Apron weigh feeder shall comprise of
High wear resistant, two strand chain
Steel pans bolted to pans
Rails supporting and return rollers for supporting and guiding pan assembly.
Take-up sprocket assembly including shaft, antifriction bearings and
housings.
Take-up arrangement.
Discharge hood with chute
Main frame and hood assembly.
Safety guards for rotating parts.
Load cell and weighing arrangements.

Belt Weigh Feeder shall be completely assembled equipment with DC AC
motor, insulation class-F, IP-55 protection, gear box and test weights.

Electrical shall be housed in Control cubicle, completely wired, tested, of
protection class IP-54 with basic dimensions 600 x 650 x 2105 mm (w x d x h)
housing the following:
Microprocessor based measuring and control unit
Digital main display (8 position) for operational parameters, feed rate set
point.
Digital support display (8 position) for parameter inputs, totaliser counts and
special information.
Automatic tare programme and status information for interlocking signals.

Single phase full wave full controlled thyristor drive for speed control of
DC motor.

Necessary switch gears comprising of isolating switch, fuses, overload

relay and power contractor.

local control comprising of the following :-

Selector switch for local/remote.

Stop push button for stopping of weigh feeder under any mode of
operation.

Start push button for starting of weigh feeder in emergency mode.

Potentiometer for rate setter in emergency mode.

2.30 VIBRATING SCREEN

Vibrating screen must have the following features:

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Single/double/ triple Deck as per requirements.

The screen decks should be made of perforated sheet metal. /segmental type
for easy removable/replaceable type

Optimum utilisation of the screening area by a deck arrangement which is
adapted to suit the grain size concerned, namely longitudinal, transverse,
inserted and laid linings.

Quick changing of the screen mats and of specially developed removable
frames, to allow lengthwise tensioning using simple screw connections.

Dust seals should be provided.

Drive arrangement must consist of eccentric weight motor and V Belt drive.

2.31 REFRACTORY NOT IN HWI SCOPE (ONLY ENGINNERING BY HWI)

The refractory/castables shall conform to the following:

S LINING BRICK RAW RUL CCS AFTER OPEN THERMAL CHANGE OF LENGTH BY
MATERIAL HEATING POROSITY SHOCK THERMAL EFFECT % AT
No BASIS TO 110 C RESISTANCE

ta 0 C N/ sqmm % Cycles 800oC 1200oC

A BRICKS
1 Kiln Bauxite >1500 >70 18-20 >= 30 ~0.5 ~0.8
2 Kiln Fire Chamotte > 1400 > 40 =< 19 > 20 ~0.5 ~0.7
Hood
(KFH)
3 Kiln, Chamotte > 1350 > 30 =< 20 > 15 ~0.5 ~0.7
Cooler
4 Preheater Chamotte > 1350 > 35 =< 22 > 15 ~0.5 ~0.7
(PH),
Cooler
5 Tertiary Air Chamotte > 1250 > 65 =< 14 > 15 ~0.5 ~0.7
Duct (TAD)
6 Hot Air -- > 1300 15-25 62-66 - - ~0.5
Generator
(HAG)
7 HAG -- > 1500 >40 23 - ~0.8 at 1500 deg C

SNo LINING BRICK BULK THERMAL CONDUCTIVITY W/m * K REMARKS

DENSITY at

kg/cum 400 o C 700 o C 1100 o C

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A BRICKS (contd.)
1 Kiln 2800 1.9 1.9 1.8 Al2O3 ~ 75 %

2 Kiln Fire ~ 2300 1.3 1.4 1.5 Al2O3 ~ 40%,

Hood
(KFH)
3 Kiln, ~ 2200 1.3 1.4 1.5 Al2O3 35-40%
Cooler
4 Preheater ~ 2100 1.2 1.3 1.4 Al2O3 30-35%
(PH),
Cooler
5 Tertiary Air ~2200 1.2 1.3 1.4 Al2O3 25-30% Acid proof
Duct (TAD)

6 Hot Air ~1000 0.24 at 600 deg C Al2O3 35%

Generator
(HAG)
7 HAG ~2400 - - - Al2O3 60%

SN REFEACTORY RAW MAXIMUM CCS at 110 / 400 PERMANENT CHANGE OF LENGTH BULK DENSITY
MATERIALS MATERIAL SERVICE / 600/ 1200 deg LINEAR BY THERMAL
BASIS TEMP. C SHRINKAGE IN EFFECT
% AFTER
HEATING

ta 0 C N/ sqmm to o C/hours % at 800 o C kg/cum

B CASTABLES
1 Kiln Extremely ~ 1800 > 80 /100/ -0.3,1200; .5, 800 ; . ~ 3000
wear 100 /100 -0.5,1500 8, 1200
resistant
castable

2 Kiln, Wear ~ 1400 > 40 / 40 / -0.1,500; .5, 800 ; . ~ 2100

Cooler resistant 30 / 25 -0.3,1000 8, 1200
castable

3 TAD, Wear ~ 1250 > 20 / 20 / -0.1,500; .4, 800 ; . ~ 2000

PH/PC resistant 20 /15 -0.3,1000 6, 1200
castable

SNo LINING BRICK BULK THERMAL CONDUCTIVITY W/m * K REMARKS

DENSITY at

kg/cum 400 o C 700 o C 1100 o C

4 PC/HAG Extremely ~ 1500 > 80 / 80/ -0.2,1000; .4, 800 ; . ~ 2300

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wear 80 80 -0.5,1500 6, 1200

resistant
castable
5 PH/Riser Special ~ 1150 > 45 / 20 / -0.2,600; .3, 800 ~ 2000
Pipes Castable 15 -0.3,1100
6 PC/HAG Insulating ~ 1300 > 12 / 11 / 8 -0.4,1000 .4, 800 ; . ~ 1300
Castable /12 5, 1200
7 Kiln Fire Extremely ~ 1600 > 50 / 70 / 0,500; .4, 800 ; . ~2500
Hood wear 70 / 80 -0.3,1000 6, 1200
(KFH) resistant
castable
8 Kiln Fire Insulating ~1600 > 18 / 16 / -0.1,800; .5, 800 ; . ~1600
Hood Special 14 20 2.0,1400 8, 1200
(KFH) Castable
9 Kiln Fire Extremely ~1650 > 35 / 40 / -0.2,800; .4, 800 ; . ~ 2700
Hood wear 50 / 80 -0.0,1400 6, 1200
(KFH) resistant
castable
C BLOCK INSULATION
1 PH/Riser Calcium >= 1000 >= 1.6 =< 1; 0.55 ~ 250
Pipes/ sillicate 1050/12
Cooler/
TAD

SN REFEACTORY RAW THERMAL CONDUCTIVITY ( W/m K) REMARKS

MATERIALS MATERIAL
BASIS

400 o C 800 o C 1200 o C

B CASTABLES
1 Kiln Extremely 2.0 1.9 2.2 Al2O3 > 90% LCC
wear
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resistant
castable
2 Kiln, Wear 1,1 1.2 1.4 Al2O3 ~ 45%
Cooler resistant
castable
3 TAD, Wear 0.7 0.7 0.8 Al2O3 ~ 35%
PH/PC resistant
castable
4 PC/HAG Extremely 1.3 1.4 1.5 Al2O3 ~ 50% LCC
wear
resistant
castable
5 PH/Riser Special 0.7 0.7 - Al2O3 ~ 22%
Pipes Castable
6 PC/HAG Insulating 0.4 0.4 0.4 Al2O3 ~ 35%
Castable
7 KFH Extremely 1.7 1.7 1.7 Al2O3 ~ 60% LCC
wear
resistant
castable
8 KFH Insulating 0.4 0.5 0.5 Al2O3 ~ 40%
Special
Castable
9 KFH Extremely 1.8 1.9 2.0 Al2O3 ~ 80% LCC
wear
resistant
castable
C BLOCK INSULATION
1 PH/Riser Calcium 0.07 0.09 0.10
Pipes/ sillicate
Cooler/
TAD

SN REFEACTORY RAW MAXIMUM CCS at PERMANENT CHANGE OF BULK THERMAL

MATERIALS MATERIAL SERVICE 110 / 400 / LINEAR LENGTH BY DENSITY CONDUCTIVITY (
BASIS TEMP. 600/ 1200 SHRINKAGE THERMAL W/m K)
deg C IN % AFTER EFFECT
HEATING

ta 0 C N/ sqmm to o C/hours % at 800 o C kg/cum 400 o C

D MISCELLANEOUS
1 PH/Riser Ceramic >= 1250 - =< - 96 - 128 -
Pipes/ Fibre Mat 1.75;1000/
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Cooler/ 24
TAD/ HAG

SN REFEACTORY THERMAL CONDUCTIVITY ( W/m K) REMARKS

MATERIALS

400 o C 800 o C 1200 o C

D MISCELLANEOUS
1 PH/Riser Pipes/ 0.1 0.15 0.22
Cooler/ TAD/ HAG

E ANCHORS
1 PH/PC/Cooler/ TAD 2321 SS/ 304 SS

2 Cooler 304 SS Cast

NOTE:
REFRACTORY MATERIAL SHALL BE SUPPLIED WITH 5% RESERVE MATERIAL. 100%
RESERVE IS TO BE CONSIDERED FOR TRANSITION ZONE AND BURNING ZONE.

3.0 MATERIAL CHARECTERSTICS

Following characteristics shall be the basis of main machinery selection and
design:

3.1 Crushed Limestone

Type of Material : Crushed ROM Limestone

Abrasiveness : Abrasive

Angle of Repose : 36 Degree

Contamination : Nil
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Bulk Density : For Equipment Sizing: 1.36 t/m3
For Power : 1.52 t/m3

Particle Size : Normal : 95% < 75mm
Maximum : 100 mm

Moisture Content : Average : 8%
Maximum : 12%

Temperature : Atmospheric

3.2 Iron Ore

Type of Material : Lumpy average flowing

Abrasiveness : Very abrasive

Angle of Repose : 30O

Contamination : Nil

Bulk Density : For Equipment Sizing: 2.0 t/m3
For Power : 2.4 t/m3

Particle Size : 95% < 75mm

Moisture Content : Average : 5%
Maximum : 8%

3.3 Phylite

Type of Material : Fractured/Friable

Abrasiveness : Less abrasive

Angle of Repose : 30O

Contamination : Nil

Bulk Density : For Equipment Sizing: 1.28 t/m3
For Power : 1.6 t/m3

Particle Size : 95% < 75mm

Moisture Content : Average : 12%
Maximum : 15%

3.4 Raw Meal

Type of Material : Dry and Ground Raw material

Abrasiveness : Abrasive

Angle of Repose : 15 Degree

Contamination : Nil

Bulk Density : For Equipment Sizing: 0.72 t/m3
For Power : 1. 2 t/m3

Particle Size : 15% retained on 90 microns Sieve
and 2% retained on 212 micron Sieve

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Moisture Content : Maximum : Less than 1%

Temperature : 100 Degree C

3.5 Clinker

Type of Material : Hot Dry Clinker

Abrasiveness : Highly Abrasive

Hardness/Grindability : To be checked by Bidder

Angle of Repose : 33 Degree

Contamination : Nil

Bulk Density : For Equipment Sizing: 1.2 t/m3
For Power : 1. 4 t/m3

Particle Size : 95% below 25 mm and maximum 40 mm

Moisture Content : Negligible

Temperature : 120 Degree C

3.6 Uncrushed Gypsum

Type of Material : Wet Sticky Gypsum

Abrasiveness : Negligible

Angle of Repose : 40 Degree

Contamination : Nil

Bulk Density : For Equipment Sizing: 1.28 t/m3
For Power : 1. 44 t/m3

Particle Size : 40 mm maximum

Moisture Content : Maximum : 15%

3.7 Uncrushed Coal

Type of Material : Uncrushed ROM Coal

Abrasiveness : Highly Abrasive

Angle of Repose : 40 Degree

Contamination : Nil

Bulk Density : For Equipment Sizing: 0.72 t/m3
For Power : 0.96 t/m3

Particle Size : Maximum : 500 mm

Moisture Content : Average : 10%
Maximum : 15%

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3.8 Crushed Coal

Type of Material : Crushed ROM Coal

Abrasiveness : Highly Abrasive

Angle of Repose : 38 Degree

Contamination : Nil

Bulk Density : For Equipment Sizing: 0.72 t/m3
For Power : 0.96 t/m3

Particle Size : 90% > 75mm and maximum 90mm.

Moisture Content : Average : 9%
Maximum : 14%

3.9 Dry & Ground Coal

Type of Material : Dry & Ground Coal and Lignite

Abrasiveness : Highly Abrasive

Angle of Repose : 20-40 Degree

Contamination : Nil

Bulk Density : For Equipment Sizing: 0.72 t/m3
For Power : 0.96 t/m3

Particle Size : 15% retained on 90 micron sieve

Moisture Content : Maximum 1% for coal

Temperature : 80 Degree C Maximum

3.10 Cement

Type of Material : Ordinary Portland Cement (OPC)
Portland Pozzolona Cement (PPC) &
Portland Slag Cement (PSC)

Abrasiveness : Abrasive

Angle of Repose : 10 Degree

Contamination : Nil

Bulk Density : For Equipment Sizing: 0.90 t/m3

For Power : 1.44 t/m3

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Particle Size : 3,400 cm2/gm Blaine for OPC
3,600 cm2/gm Blaine for PPC and PSC

Moisture : Dry

Temperature : 100 Degree C Maximum

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4. REQUIREMENTS FOR ELECTRICAL NOT IN HWI SCOPE (ONLY
MOTORS ARE IN HWI SCOPE)
4.1 INTRODUCTION
The requirements of Electrical installations are discussed in the following
paragraphs. The specification of electrical equipment and scope sheets given
shall be read in conjunction with the details given in section Vol. B Part V.
The Scope Sheets are to be filled by the Bidders and to be enclosed with the
Tender.
All electrical and control systems and components, sub-control systems (under
Suppliers scope) and devices for individual machines shall be standardised and
to be approved by the Purchaser/Consultant. The Supplier shall provide all the
necessary drawings, schematics and other information of the offered electrical
equipment.
All electrical equipment and documentation shall be in conformity with this
specification. Numbering of equipment and devices shall be as specified in this
document or conveyed by the Purchaser/Consultant during the execution.
The Purchaser/Consultant reserves the right to request detailed information on
all electrical equipment included in the mechanical equipment supply. In addition
he may specify the preferred make, type and Supplier of electrical equipment.

4.2 SITE CONDITIONS

All electrical and control equipment shall be suitable for the local climatic
conditions specified in Vol. B, Part II. Note in particular that the equipment will be
subject to dusty atmosphere (cement, clinker, coal, etc.)

4.3 APPLICABLE STANDARDS

The design and construction of the equipment and all its components and
accessories shall conform to the practices outlined in the latest editions and
supplements of the following standards:
Indian Standards
Indian electricity rules
Relevant code of practices as per prevailing rules in Bhutan
IEC, IEE, NEMA, DIN

The standards shall be applied in the order of priorities as listed above.

4.4 FREQUENCY AND VOLTAGE LEVELS

The frequency of the power supply for the whole plant and its infrastructure
shall be 50 Hz.
The different voltage levels are:
Incoming power : 132 KV
MV-distribution : 6.6 KV
Medium voltage motors : 6.6 KV
(Hereafter termed as HT motors), (above P 200 kW)

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Low voltage motors : 415 V/3 phase
(P 200 KW and below)
Frequency : 50 Hz
Lighting : 230 V/1 ph+N+E
Welding socket outlet : 415V / 3 ph+N+E
Solenoid voltage : 220 V AC for solenoid controlle from
Purchasers MCC/plant control
AC control (MCC's) : 220 V/1 ph+N+E
AC control (Control & sensing : 220 V/1 ph+N+E
devices)
DC Control (for 2 wire : 24V DC
transmitter)
Analogue signals : 4-20 mA (2-wire)

All electrical equipment shall be designed, selected to guarantee full

performance during following fluctuations in the supply system
Voltage variation : + 10% for MV and + 6% for 415 V
Frequency variation : +3%, -5%
Combined voltage and : +10% for MV and
Frequency variation +6% for 415 V
All electrical equipments shall be designed for 45 degree
centigrade ambient temperature.

4.5 ASSISTANCE
The successful Supplier shall extend necessary assistance to the Purchaser and
render the necessary coordination work with the supplier of control,
instrumentation and process automation system.

4.6 TESTING OF ELECTRICAL EQUIPMENT

Type test certificates shall be submitted to the Purchaser as stipulated in the
relevant standards. Type tests shall be carried out as per relevant standards in
the presence of Purchasers representatives for the equipment.
Routine tests as per relevant standards shall be carried out on all equipment in
the presence of Purchasers/Inspector representatives and test certificates shall
be submitted. No equipment shall be despatched unless the test certificates are
accepted by the Purchaser.
The supplier shall offer the equipment for the following Inspections/tests. The
supplier shall be responsible for providing instruments of correct accuracy that
may be required for carrying out these tests. All tests shall be carried out as per
relevant Indian Standard Specifications or other International Standard
Specifications.

4.6.1 DC MOTORS

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a) Visual Inspection
For general assembly, provision of specified terminal arrangement,
accessories like space heaters, grease nipples, earth terminals etc.
Proper name plate details and other instruction plates.
b) Routine Tests
Measurement of resistance
Measurement of insulation resistance
High voltage test
Test to determine the direction of rotation
c) Type Tests
Temperature rise test
Efficiency test
Measurement of load characteristics
Specified overload test
Starting torque test
Commutation test

Routine and type tests on DC motors shall be as per IS-4722. 2613. Type test
shall be conducted on one motor of each rating.

4.6.2 THYRISTOR CONVERTER

a) Visual Inspection
For layout of components, bus bar mounting, dimensions, electrical
clearances as per approved drawings.
General workmanship, finish, identification labels, routing and termination
of control and power cables/jumpers etc.
Verification of test certificates for Boughtout components.
b) Routine Tests
Functional, scheme and interlock check as per approved drawings.
High voltage test
Insulation resistance test
Calibration of instruments.
c) Type Test
Speed holding test under guaranteed voltage, frequency and load
variations
Guaranteed efficiency of thyristor converter
Temperature rise in cubicle & Heat sinks
Guaranteed ripple content

4.6.2.1 Field Mounted Control Units

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a) Visual Inspection
For layout of components, general workmanship, finish, identification
labels, termination arrangement of cable/wires.
For checking up of dimensions & electrical clearances.
Verification of test certificates for bought- out components.
b) Routine Tests
High voltage test
Insulation resistance test.

4.6.3 INVERTER PANELS

a) Visual Inspection
For layout of components, bus bar mounting, dimensions, electrical
clearances and bill of materials as per approved drawings.
General workmanship, finish, identification labels, routing and termination
of control and power cables/jumpers etc.
Verification of test certificates for boughtout components.
b) Routine Tests
Functional, scheme and interlock check as per approved drawings.
High voltage test
Insulation resistance test
Calibration of instruments
Operational test (without motor)
Full load & overload test
c) Type Tests
Speed holding test under guaranteed voltage, frequency and load
variations.
Heat run test at full load
Guaranteed efficiency and ripple content
The test shall be conducted on one drive system of each rating.
4.6.3.1 Field Mounted Control Units
a) Visual Inspection
For layout of components, general workmanship, finish, identification
labels, termination arrangement of cable/wires.
For checking up of dimensions and electrical clearances.
Verification of test certificates for bought-out components.
b) Routine Tests
High voltage test
Insulation resistance test
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4.6.4 MOTOR CONTROL CENTRES
a) Visual Inspection
For layout of components, bus bar mounting compartmentalisation etc. as
per approved drawings.
For checking of dimensions, electrical clearances, phase marking,
tightness of joints etc.
General workmanship, finish identification labels, routing and termination
of control and power wires/cable etc.
Verification of test certificates for bought-out components .
b) Routine Test
Functional and scheme check as per approved drawings.
High voltage power frequency withstand test.
Insulation resistance test
Heat run test of main circuits on sample panel.

3.6.4.1 Field Mounted Push Button Stations

a) Visual Inspection
For layout of components, dimensions, clearances, termination
arrangement and cable space as per approved drgs.
General workmanship finish, identification labels, routing and termination
of wires/cables.
b) Routine Tests
Functional and scheme check as per approved drawings.
Insulation resistance test
Power frequency, high voltage test at 2.5 KV for one minute.

4.7 CONTROL DEVICES

4.7.1 GENERAL REQUIREMENTS
Sensing elements, field devices and instrument items and Transmitters which
are required and included as part of the mechanical equipment by the
Supplier, have to be clearly defined. This definition shall include specifications
of equipment, quantity, and make. Instruments required for the machinery safety
along with transmitters shall be included as part of main package.

4.7.2 BASIC DESIGN CRITERIA OF FIELD CONTROL ELEMENTS (SENSORS)

Field control elements included in the Supplier' supply shall conform to the
following general design criteria:
a) Dust proof conforming to NEMA 12/IP65
b) Water proof conforming to NEMA 4/IP65

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c) Wiping action on contacts (self cleaning), encapsulated contacts are
preferred
d) Explosion proof where required
e) Housing preferably made of metal. Covers should to be fitted easily,
screws to be secured. Electronic equipment to be suitably protected against
radio interference, as required.
f) Resistant against vibration (contact pressure)
g) Suitable for ambient temperature of - 0 degree to + 45 deg. C
h) All potential free contacts shall be wired up to terminal block
i) Current rating:
Contacts (2 NO + 2 NC) :
5 amp at 230 V AC (min.)
: 0.5 amp at 48 V DC (min.)
Electronic
short circuit proof
protected from inductive voltage spikes
maximum inverse voltage & over voltage
protection
Digital :
To be Communicated on
Profibus/modbus
4-20 mA, galvanically isolated (against
earth and power supply)
Local digital display indication
j) Mounting : By screws, mounting holes to be sealed,
adequate mechanical protection to be
included. The installation shall be done
by the Supplier.
k) Connections :
Sensor type field elements to be
supplied with min 10 m long extension
cable.
All others : Lug type connection

A documentation giving details of all special electrical devices included in the

Supplier' scope of supply (wiring diagrams, maintenance manual, special
operating instructions, etc.) shall be provided.
All types of elements will be subject for approval by the Purchaser/Consultant.

4.7.3 DESCRIPTION OF INDIVIDUAL CONTROL DEVICES AND EQUIPMENT

4.7.3.1 Motion Detectors

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It shall be a standardised proximity head fitted wherever possible to the final
driven element of the machine.
The Supplier shall provide a hole in the centre of the final driven shaft of the
machine.
The motion detector, controller as well as operating metal protrusion shall form a
part of Suppliers Scope of Supply.

4.7.3.2 Proximity Switches/Limit Switches

It shall be standardised proximity head type limit switches. The Supplier shall
provide special mountings as may be required for an application.
Application of this type of switch will be to chute gates, belt take-up, tripper
positioning, valve position, clutch position, brake position, damper, gates and
similar applications.
Limit switches (2 NO + 2 NC) for diverter gates, actuator controlled valves, shut
off valves etc. are part of the Suppliers scope of supply.

4.7.3.3 Level Detectors/Indicators

Types of level detectors vary for individual applications. The Supplier shall
provide specification, mounting device and typical drawing of preferred level
detectors only. Level detectors for Bucket Elevator Boot, silos, hoppers, process
bag filter hoppers, FK pump hopper, cooler spillage hopper, coal and kiln feed
bins shall form a part of Suppliers Scope of Supply. Ultrasonic level sensors
shall be supplied for continuous level monitoring for hoppers and silos.

4.7.3.4 Pressure, Flow and Temperature Switches/Sensors for Machine Protection

Shall be supplied and installed by the Supplier to suit the individual application.
Locally mounted, continuous monitoring devices with an isolated output 4 - 20
mA, 2-wire technique, external load up to 600 Ohm are preferred. For
applications which require one set point only, switches with liquid (mercury type)
or pressure operated contact systems can be applied. All transmitters shall be
provided with locally mounted indicator.
Switches to be adjustable over full range and calibration scale visible with the
case closed shall be ensured. The type of switch or sensor shall be subject to
approval by the Purchaser/Consultant.
Flow element wherever required (Venturi, Orifice) shall be included in the scope.

4.7.3.5 Temperature Detectors

Temperature detectors where specified or necessary for protection and
monitoring of large bearings, gearboxes resistance temperature detectors type
PT100 3 wire including junction boxes. The scope shall include the sensor & local
mounted transmitter (with output signal 4-20 mA galvanically isolated).
Thermocouple and transmitters for cooler grate and cooler spillage hopper shall
be included in the scope of supply.

4.7.3.6 Vibration Detectors

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Big fans, gear boxes, Mill and any other critical equipment shall be provided with
vibration sensors for X-Y-Z Co-ordinates. The scope of supply of the Supplier
includes the sensor and the locally mounted transmitter (with output signal 4-20
mA galvanically isolated).

4.7.3.7 Load Cells

The Supplier shall supply the load cells of hermetically scaled design with field
mounted electronic unit with local indication and circuitry giving 4-20 mA isolated
output for remote display. The load cells shall also be supplied with brackets and
expansion assemblies for other vessel. Copper straps shall be supplied along
with to bridge-over each load cell to protect them from stray welding current.
Special cable required between the load cell junction box and field mounted
electronic unit shall be included by the Supplier in addition to special cables
required between load cells and junction boxes. The load cell system shall be
subject to approval by the Purchaser/Consultant.

4.7.3.8 Process Instrumentation

Unless otherwise specified, the Supplier shall provide mounting arrangements
(brackets, holes, flanges, etc.) for process control and monitoring sensors
specified for temperature, pressure, flow, position, etc. Location, size and type of
arrangements to be subject to Purchaser/Consultant's approval.

4.7.3.9 Valves/Dampers/Gates and Actuators

On/off valves shall be included in the supply. Best quality equipment shall be
provided. Valves shall be standardised and be subject to approval of the
Purchaser/Consultant.
End limit and torque limit switches for valves shall be supplied by the Bidder with
2 NO + 2 NC Contacts.

4.7.3.10 Control Valves and Actuators

Solutions with variable speed drives (for pumps, critical large fans, etc.) are
preferred to solutions with constant speed drive and control actuators. Where
this is not possible, control valves and actuators and corresponding mechanical
linkages shall be included by the Supplier. Actuators and valves shall be
standardised as much as possible. Motors shall be preferable of the 3-phase
squirrel-cage type. The feedback element shall be 4 - 20 mA, galvanically
isolated. Where required the feedback element shall be directly connected to the
shaft. Actuator internal limit and torque switches shall generally be included. The
pot shall be 1 K ohm & transmitter shall be mounted in the actuator.
Actuator travel time and flow characteristic shall be adjusted to the specific
application.

4.8 DRIVES
4.8.1 GENERAL REQUIREMENTS
The Supplier shall supply requisite ratings, speed, torque characteristics &
special features for all HV motors and control gears liquid rotor starters and
capacitor bank, DC motors, AC motors and special motors which form an integral
part of the mechanical equipment. Special motors viz. Geared Motor, Drum

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Motor, Flange Mounted Motor, Integral Motor with Machinery shall be included in
the scope of supplier.
The Supplier shall also supply holding down bolts, couplings, pulleys, slide rails,
mounting blocks, foundation frames and any other accessory items required for
all motors. The base frame & sole plate integral or separate irrespective of scope
of supply of motor shall be included in the Scope of the Supply of the supplier.
The Supplier shall be responsible for sizing of all motors and application
engineering and shall provide full information as requested in the Tender
documents for main equipment in the time specified to allow the Purchaser to
arrange purchase and delivery of the required control equipment such as motor
control centers, thyristor converters, variable frequency drives, sub control
system etc. The information shall also contain technical data of variable speed
drives, torque characteristics of special drives, torsional analysis of the complete
rotating part for AC variable speed slip energy recovery systems, details of shaft
extensions and bearings etc.

4.8.2 MOTOR SPECIFICATION

The Supplier shall supply motors based on the below mentioned specification
mentioned below:
4.8.2.1 General
Motors of the IEC rating above 200 kW shall be high voltage slip ring induction
motors.
Motors below IEC 200 kW shall be squirrel cage induction motors.
All motors are to be equipped with oversize terminal boxes to provide ample
space for convenient connection, arranged on right-hand side when looking at
the driving end of the motor.

4.8.2.2 Low Voltage Motors

01 Type of motor : Squirrel cage/slip ring (High- Efficiency)
02 Class of insulation : Class 'F'. Temperature rise limited to
Class 'B' at site ambient (45 degree
centigrade). For motors below Kiln
ambient shall be 60 degree centigrade.
03 Deration for variable speed : Low voltage AC motors operating in
application conjunction with variable
frequency converters are to be derated
suitably depending upon the extent of
speed range required and the level of
harmonics generated.
04 Starting torque : 200% FLT with IS tolerance
05 Pull out torque : 250% FLT with IS tolerance
06 Acceleration : Starting time of the motor with the drives
equipment coupled does not exceed
80% of its hot withstand time. For high
inertia fan loads, motor shall be selected
for a prolonged acceleration having
longer hot withstand time.
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07 Performance : Conforming to IS:325
08 Duty : To be designed for continuous 24
hrs/day, 7 days/week operation.
09 Type of enclosure : IP-55. Motors located outdoors shall
have detachable rain shed/ cover.
10 Cooling : IC 0141/IC 0151 as per IS 6362 effective
for bidirectional rotation. For variable
speed applications a forced draft cooling
fan mounted separately for effective
cooling at all speeds is preferred.
11 Bearings : Anti-friction ball/roller type. Bearings
shall be housed in dust tight bearing
shields and shall be provided with
easily accessible greasing nipples with
valve to eject excess grease.
12 Installation : Indoor/Outdoor
13 Frame size : Refer Vol. B, Annex IV-3
14 Mounting : Horizontal foot mounted/as per
machinery requirement.
15 Terminal box : Shall be suitable for terminating oversize
aluminium conductors. The exact cable
size shall be furnished to the successful
Supplier after receiving the motor
ratings.
16 Method of starting : a) Direct on-line for squirrel cage
motors.
b) Liquid rotor starter/Grid resistance
starter for slip ring induction motors
17 Maximum starting : a) Not more than 600% FLC with DOL
current starter for squirrel cage motor
b) Not more than 250% FLC for slip
ring induction motors.
18 Starting duty : a) Two consecutive starts under
cold conditions and full load.
b) Four starts per hour against full
load under hot conditions.
One hot restart must to be
permitted.
c) Six starts per hour only for trial
runs during commissioning/
occasional abnormal operating
conditions.
19 System fault level : 35 MVA at 415 volts
20 Stator coil : Shall be vacuum impregnated. The
completely wound stator shall be
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preheated dipping in synthetic varnish
and oven cured. Double treatment shall
be given by repeated dipping and curing
cycle to ensure high resistance to
moisture, vibration, injurious deposits as
well as any chemical contamination.
Six terminals of the stator winding shall
be brought out to the terminal
box.
21 Rotors : a) For smaller size of squirrel motors,
rotor shall be of die cast
construction whereas for larger
size, it should be brazed or
welded to the end rings so as to
withstand locked rotor condition.
b) Where high starting torque is
required, the motor shall be of
double cage construction.
c) The rotor shall be dynamically
balanced.
d) The stator & rotor slot shall be skewed
in relation to each other for quiet
running and good acceleration during
starting.
22 Slip rings : The motor frame design shall be such
that brush gear and slip ring are easily
accessible for inspection and
maintenance through inspection cover
plates provided on the motor body.
23 Accessories : a) 2 nos. grounding terminals on body
and one no. on stator terminal box.
b) Lifting eye bolt.
c) Space heaters, suitable for 240 V
AC supply shall be provided for
motors of rating above 90 kW.
d) Name plate including motor description
and equipment code number as
advised by the Purchaser.
24 Painting : Corrosion resistant paint to be used.
25 Brake mounting : The brake shall be mounted (where
applicable) on the non-drive end and
coupling shall not be used as brake
drum. The electromagnetic brakes shall
be of self aligning, quick acting, disc
type, suitable for floor mounting and
operated from rectified DC supply.
26 Type of coupling : Flexible/V-belt drive.
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4.8.2.3 DC Motors
DC motor shall be complete with pulse tacho generator.
01 Type of Motor : Separately excited
a) Shunt wound upto 100 kW
b) Shunt compensated above 100 kW
02 Nature of speed : Constant torque throughout the control
speed range
03 Method of speed : By armature voltage variation
Control
04 Armature voltage : 440 V DC max. from Thyristor
Converter
05 Excitation : Separately excited at 220 V DC from diode
bridge rectifier
06 Class of insulation for DC : Class F
motor and AC cooling fan
motor
07 Type of enclosure : a) Totally enclosed CACA with heat
exchanger above 55 kW

b) Totally enclosed surface cooled for

motors rated up to 5 kW

08 Degree of protection : IP 55

09 Mounting : Horizontal foot mounted/ vertical

mounting
10 Starting duty : a) Four starts per hour against full load hot
condition, one hot restart without use to be
permitted
b) Six starts per hour for trial run,
commissioning and abnormal
operating conditions
11 Operating duty : Continuous
12 Shaft extension : a)Drive end-standard
b)Non-drive end suitable for mounting tacho
generator for speed indication and feed
back
13 Temperature rise : Limited to class B over site ambient
temperature
14 Bearing : Ball and roller
15 Rating : Continuous 24 hours/day 7 days per week
and service hours per year
16 Bearing and winding : a) 3 wire RTD one in main pole
and one in interpole winding for
motors rated 200 kW and above
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b) 2 nos. RTDs for bearing in motors rated
100 kW and above.
17 Starting torque : 200% FLT
18 Speed variation : 1:10 at constant torque by armature voltage
control
19 Duty : a) 100% continuous
b) 200% load for 60 sec, 6 times per hour.
20 Anti-condensation : Suitably rated heaters should be provided
for motors 75 kW and above.
Heater shall be suitable for 240 V AC
single phase.
21 Type of Yoke : Laminated
22 Design : a) As per IS
b)Since the motor will be fed from thyristor
converter, it should be designed to cater
for extra heating due to presence of
ripple content and offer no
commutation problem. Deration shall be
considered in line with thyristor converter
design.
c)The atmosphere is full of abrasive dust.
The motor winding and enclosure must be
suitably designed.
d)Motor winding should be specially
treated for tropical conditions
23 Terminal boxes : The motor shall have separate cable
terminal boxes for power cables, RTDs and
space heaters. The power cable box shall
be sized to accept Al. Conductor armoured
cables. The terminal boxes shall accept
multicore cables. Cable sizes shall be
furnished to successful bidder.
24 Painting : Light grey shade
25 Foundation bolts : To be included with necessary hardware for
each DC motor to fix motor to the base
frame
26 Rating plate : Motor rating plate shall have the following
information as per BS 5000
a) Reference standard
b) Type of motor
c) Manufacturers name
d) Manufacturers serial number
e) Frame size
f) Class of insulation

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g) Enclosure class
h) Duty
i) Rated output in kW
j) Rated armature current in amp
k) Speed
l) Excitation voltage
m) Excitation current
n) Mounting
o) Ambient temp
p) Bearings DE/NDE
q) Year of manufacture

4.8.2.4 Thyristor Converter

1 Panel Design
The thyristor converter should be housed in floor mounting, free standing,
cold rolled sheet steel cubicle suitable for indoor use with IP-54 protection.
The thickness of sheet steel would be 2 mm except for all the covers which
will be 1.6 mm. The base channel would be 3.25 mm thick. The panel shall
be totally enclosed dust and vermin proof.

2 Application
Each thyristor converter would be connected to respective DC motor and
would control motor speed by varying its armature voltage.
Acceleration/Deceleration time shall be adjustable.

3 AC Input supply
415 V +6%, 3 ph. for 3 ph. thyristor converters and 415 V +10%, bridge
phase to phase for 1 phase, converters, 50 Hz + 3% combined voltage and
frequency 6%

4 Bus Bar Material : Copper

5 Overload Duty : Same as given under DC motors.

6 Field supply
The field circuit shall be complete with incoming isolator or circuit
breaker, air cooled auto transformer fed from same source as the main
converter, contactor, resistor, field loss relay etc. Field supply unit shall be
un- controlled and shall have in built field failure protection. The output
current and voltage ratings shall be to suit the motor full field conditions. A
suitable double wound step down transformer before the rectifier circuit will
be included.

7 Momentary

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The converter shall be designed Voltage Dips to withstand momentary dips
of about 30% in supply voltage without damage to the thyristors or blowing
of fuses.

8 DC Output : 440 V DC

9 Switching Duty :
a) Normal : 4 starts per hour
b) Trial run & Commissioning : 6 starts per hour

10 Details of Modules
a) Power Modules
This will consist of isolator, HRC fuses, contactor, current transformer,
thyristor bridge etc.

b) Plug-in Type/surface mounted control modules

This shall consist of following units:
Power supply unit
Speed amplifier - PI action
Current amplifier - PI action
Firing circuits with pulse amplifier
Motorised reference potentiometer

c) Standard features of power pack

This shall consists of the following units :
Power Supply unit
PI type speed controller
Adjustable ramp generator
Current amplifier PI action
EMF control
Firing circuits
Function block programmable
Digital reference unit with remote control
Adjustable torque limitation
Fully digital electronic regulator
Auto tuning for armature and field control

11 Cooling System
The thyristor converters of rating 30 kW and above will be designed for
continuous operation in specified ambient condition with forced cooling. The
panel shall be able to deliver the rated load of the motor in fan failed

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condition. The thyristor converters of rating below 30 kW shall have natural
cooling.

12 Operational Features to be provided

Soft start with adjustable time acceleration.
Automatic changeover from tacho feedback to armature voltage
feedback in case of loss of tacho-generator signal.
Cooling fans of motor and panel shall be switched on first, when start
command is given. These fans shall continue for about 15 minutes and
then stop in case of stop command.
PC based commissioning and maintenance tool
Additional meters (e.g. tph, speed/position) shall be provided on field
control box for sub-control system e.g. solid flow feeder panels etc.
Additional lamps e.g. pneumatic gate open/close shall be provided on sub-
control system panel e.g. solid flow feeders

13 Salient features of Digital regulators

Programme sequencing monitoring
All parameters shall be stored in the event of power failure
Display for fault messages
Self optimisaiton
On line change in parameters shall be possible
Self tuning for ease of commissioning and optimisation
Network interface with higher level automation system

14 Protection
Following protection shall be provided for the converters:
Surge protection, short circuit, instantaneous over current, fan failure (for
thyristor panel and DC motor), Loss of feedback, Thermal overload, current
feedback and adjustable current limit, solid state phase sequence-cum-single
phasing preventer, sensitive earth-fault protection, control and regulated
power supply failure, heat sink temperature high, AC under voltage.

15 Indicating Lamps to be Mounted in Front of Panel.

Thyristor ON-OFF, failure of motor force ventilation unit, failure of panel
ventilation unit, semiconductor fuse failure, field failure, over current,
overload, phase failure, loss of feedback from tacho, control supply failure,
incorrect phase sequence, earth leakage, converter ready, motor running,
regulator fault, R,Y,B phase.

16 Controls to be Provided on the Front Panel

Start-stop push button, lockable local-remote-panel mode selector switch,
ON-OFF isolator with door interlocks, lockable inch/run selector switch, speed
raise-lower switch (spring return type), Lamp test.

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17 Indicating Meters of 96 x 96 mm Flush Mounted on Front of the Panel
AC Ammeter with selector switch, AC Voltmeter with selector switch, DC
voltmeter, reference indicator, DC ammeter, (with shunt mounted inside the
panel), speed indicator, field voltmeter, DC Ammeter for field current
Testmeter for immediate self diagnosis of electronic cards, speed indicator.

18 Extra Auxiliary Relays and Contacts for Interlocking

The interfacing scheme with plant control system shall be provided by the
Purchaser/consultant
The necessary auxiliary relays for sequencing, alarm and indication
circuits as required would be provided.
One potential free contact common for all the faults shall be wired upto
terminal board for remote common fault indication.
Control schematic diagram shall be suitable for interfacing with
programmable controller.
Panel shall be suitable for accepting external isolated 4-20 mA signal for
speed set point
Panel shall make available 4-20 mA isolated DC signals for armature
current and speed for remote indication in control room.
Switchgears for control of motor cooling fan (wherever required) shall be
part of thyristor converter.
Field mounted control unit comprising of start/stop,
increase/decrease/inch. Push buttons and indicating meters for speed
and current shall be provided by the Supplier.
The drive shall provide serial interface with plant control system.
Necessary hardware e.g. gates, cables etc. if required shall be included in
the scope. The supplier shall furnish the interface protocol details to C&I
supplier during detailed engineering.

19 Desired Performance
a) Speed Holding Accuracy
The thyristor converter offered should be capable to hold the speed
accuracy better than + 0.5 % of base speed under:
Specified supply voltage and frequency variation
100% load variation and
+5 deg. C temperature variation per minute all
occurring simultaneously.
b) Converter Efficiency
The efficiency of converter of rated voltage and load will be > 99%.
c) Ripple Content at Rated Current and Speed
4% approximately.

4.8.2.5 Hydraulic Drives

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Hydraulic drives shall preferably be of the hydrostatic type. Hydraulic motors in
conjunction with squirrel cage motors shall be used for air separators and other
variable speed drives of similar power ratings, unless electrical variable speed
drives are to be used for special reasons.
All necessary devices as cooler, fans, field devices for temperature, level and
pressure control shall be included and shall conform with the enclosed detailed
specification sheets for field devices and instrumentation. Provisions shall be
made for remote indication of pressure (torque) and speed of hydraulic motor.
Make of drive systems shall be the same throughout the plant and actuators for
speed control shall be of the same type as used for other devices as flaps, etc.
for reasons for standardisation. Hydraulic drives shall be of the compact type,
factory assembled as far as possible on a rigid frame, arranged for easy handling
and installation. All necessary pipes and accessories shall be included.
Drive motor for pumps, etc. shall be totally enclosed fan-cooled for the protection
type IP:55.
4.8.2.6 MV Motors
The design, manufacture and testing of 6.6 kV Slip ring Induction Motors, Rotor
starters/regulators and Power Factor Improving Capacitor Bank shall be carried
out as per the latest applicable Indian Standards/International Standards, Indian
Electricity Rules and Code of Practices. However, for ready reference, some of
the Standards are listed below :
Wherever the Indian Standards do not exist the equipment/components shall be
designed, assembled and tested in accordance with the latest editions of the
Standards of the International Standard Institutions, Institution of Electrical &
Electronic engineers, USA (IEEE), National Elect. Manufacture Association, USA
(NEMA) and International Electro-Technical Commission (IEC).
IS:4722 : Specification for rotating electrical machines
IS:325 : Specifications for 3 phase induction motors
IS:1231 : Dimensions of 3 phase foot mounted induction motors
IS:2834 : Shunt capacitors for power system
IS:4029 : Guide for testing 3 phase induction motors
IS:4691 : Degree of protection provided by enclosures for rotating electrical
machinery
IS:6362 : Designation of methods of cooling for rotating electrical
machines
IEC:43 : Recommendations for rotating electrical machines - rating and
performance
IEC:72 : Dimensions and output ratings for rotating electrical machines
IS:1271 : Thermal evaluation and classification of electrical insulation
IS:12075: Mechanical vibration of rotating electrical machines with shaft
heights 56mm & higher measurement evaluation & limits
IS:2848 : Platinum type resistance temperature detector
IS:6098 : Noise Measurement

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IS:2253 : Designation for types of construction and mounting arrangement
of rotating electrical machines
IS:4728 : Terminal marking and direction of rotation for rotating electrical
machinery
IS:8789 : Values of performance characteristics for three phase induction
motors
IS:4889 : Method of determination of efficiency of rotating electrical
machines
IS:2071 : Method of high voltage testing
IS:7816 : Guide for testing the insulation resistance of rotating machine
IS:12065: Permissible limits of noise level for rotating electrical machines
IS:12802: Temperature rise measurement of rotating electrical machines
IS:12824: Type of duty and classes of rating assigned
IS:8223 : Dimensions and output ratings for foot-mounted rotating electrical
machines with frame numbers 335 to 1000

Wherever the stipulation in this specification are in conflict with any of the above
standards, the requirement under this specification shall be binding.

The motors shall conform to following :

01 Rated voltage and : 6.6 kV, 50 c/s
Frequency
02 Allowable variation : Voltage + 10%
in voltage and Frequency + 5%
frequency
03 Combined voltage & : 10%
frequency variation
04 a) System fault level : 360 MVA
b) System of earthing: Non-effectively earthed
05 Enclosure : TETV/CACA/CACW/TEFC
06 Protection : IP-54
07 Method of cooling : IC 0151 or IC 0161
08 Overload : 100% overload for 60 seconds, 4 times per
hour
09 Class of Insulation : F
10 Temperature rise : As per IS:12802, but limited to Class
B

11 Motor Winding : The stator and rotor winding

assemblies shall be vacuum pressure
impregnated before final assembly.

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12 Chemical Treatment : Motor windings shall be treated for
tropical and abrasive dust operating
conditions.
13 Duty : S1-Continuous, 24 hrs/day, 7 days/
week, 8000 hrs/year.
14 Starting Torque : 200% of rated torque without any
negative tolerance
15 Pull out Torque : 250% of rated torque without any
negative tolerance
16 Slip Rings
a) Type of brush gear :Continuous with constant pressure
brush
springs
b) Isolation from the : To be provided
main motor internals
c) Separate air cool- : To be provided
ing/ventilation for
slipring compartment
d) Type of sliprings : External type, continuous rated 3
nos.
of stainless steel / centrifugal cast of
Bronze/Cupro Nickel
17 Mounting : IMB3-Horizontal foot mounted
18 Direction of rotation : Bidirectional
19 Drive arrangement : Direct with flexible coupling for all
and type of coupling motors

20 Shaft extension : Drive end-Standard with threaded

centered hole for all motors. Non-
drive
end To be provided for variable
speed
motors for mounting Tacho generator.
21 Starting Duty
a) Two consecutive starts from cold condition against full
load.
b) Four starts per hour against full load under hot condition
with two consecutive starts and other two equally
spread in one hour for occasional duty.
c) Six starts per hour only for trial run during
commissioning and occasional abnormal operating
conditions.
22 Accessories

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Each motor should be complete with the following accessories
:

i) Bed plates and Foundation bolts/nuts

Fabricated plates, sole plates, foundation bolts, nuts and

holding down bolts for fixing the motor to the base frame
shall be provided.

ii) Tacho mounting supports

To be included for variable speed motors.

iii) Terminal Boxes

a) One -Phase segregated stator terminal box suitable for XLPE
cables. The box shall be inclined to the vertical to
avoid fouling with common base frame. Pressure
release vent shall be provided in the terminal box to
prevent explosion in case of fault.
b) One - Rotor terminal box suitable for
PVC/XLPE cables.
c) One - Neutral terminal box for stator point
with shorting links and ample space for mounting of
CT, if required.
d) One - Terminal box for resistance
temperature detector (RTD) for winding and
bearings.
e) One - Terminal box for space heater
f) Suitable brass compression type cable glands and crimping type
cable lugs of tinned copper for all the LV terminations.
iv) Earthing
Two earthing terminals should be provided on each motor
and one additional earthing terminal on stator terminal
box.
v) Bearings
Only Ball and Roller Bearings shall be considered.
Bearings shall be insulated from earth for motors with
shaft voltage above 200 mV and all variable speed motors.
Catch plates to collect excess grease shall be provided for
each bearing.
vi) Stator Winding Protection
12 nos. embedded 3 wire RTDs at possible hot spots on
the stator winding with leads coming out to the terminal
box.
vii) Bearing Protection
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1 no. 3 wire RTD per bearing shall be provided.
viii) Stator Core Protection
Suitable nos. of RTDs to be located at bottom of stator
slots with leads brought to the terminal box.

ix) Anti-condensation Heaters

Required nos, of space heaters suitable for operation at
240 V AC should be provided.
x) Drain Holes
Drain holes with threaded plugs shall be provided on the
motor frame to allow drainage of any condensed water
from the enclosure.
xi) Rating Plate
Motor rating plate shall have the following information :
a) Reference Standard
b) Type of motor
c) Manufacturers name
d) Manufacturers serial number
e) Frame size
f) Duty
g) Insulation class for stator and rotor
h) Enclosure class
i) Frequency
j) No. of phases
k) Rated output in kW
l) Rated voltage and winding connections
m) Rated current
n) Speed
o) Rotor voltage and winding connection
p) Rotor current
q) Ambient temp.
r) Year of manufacture
s) Bearings DE, NDE
23 Painting
Corrosion resistant paint to be used and final finish shall be as
per Shade No. 631 of IS:5.
24 Torsional Analysis
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Torsional Analysis for the complete rotating parts including the
motor drives equipment and coupling to be done by the motor
supplier for variable speed application .
25 Motors with Slip Power Recovery System (SPRS)

i) Motors operated with SPRS to achieve specified speed variation shall be

complete with AEI, UK make tacho generators type BD 2510/equivalent
Hubner make with flexible coupling on NDE side of the motor. The
tachogenerator shall be insulated from earth.
ii) Motor with SPRS shall have capacitor bank rated for 7.59 KV (6.6K V +
15%) to meet system requirement recommended by SPRS supplier.
iii) Motor frame shall be adequately selected so that the additional heating
due to the harmonic current/reduced cooling at lower speeds, while
working in association with SPRS is suitably taken care of for satisfactory
and trouble free operation of the motors.
iv) Supplier shall clearly specify how much deration they could except on
specified kW rating of the motor due to operation of SPRS.
v) For SPRS drives earthing brush on the shaft shall be provided.

Liquid Rotor Starter/Grid Resistance type Starter-cum-Speed

Regulator
Liquid Rotor Starters shall be provided for 6.6 KV slip ring motors
having fixed running speed, while Grid Resistance type Starters-cum-
controllers shall be provided for variable speed 6.6 KV slip ring
motors operating in conjunction with Slip Power Recovery Systems.
Hence the LRS/GRR for different groups shall be designed taking into
consideration maximum rotor current (RA) & maximum rotor voltage
(RV) of that particular group i.e. the LRS/GRR of a particular group
shall be suitable for all the motors of that group.

Liquid Rotor Starter

The vapromatic type static electrode rotor controller shall be
provided on the principle of different resistivity between liquid
electrolyte at different temperature and its vapour. To further reduce
the resistance a metallic resistance connected in parallel with the
liquid resistance shall be introduced in the circuit with the help of a
timer and contactor when the motor reaches near-about 80% speed.
The final shorting contactor shall be introduced in the circuit when
motor reaches about 95% speed to shunt the metallic and liquid
resistance. The power circuit of the starter shall be suitable for
respective rotor voltages.
The welded sheet steel tank shall be provided with special epoxy
coating and phase insulated barriers for limiting cross current and
electrode to electrode current. The three adjustable electrodes shall
be mounted on porcelain bushings suitable for respective high rotor
voltages. The metallic resistance, timers, contactors and operating

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control shall be mounted in a separate enclosure having IP55 degree
of protection. A thermostat shall be provided for giving annunciation
and trip in case of excessive number of starts, indefinite prolonged
start and locked rotor conditions.
The rotor controller shall be suitable for termination of 6.6 KV (UE)
grade, XLPE insulated, armoured, Aluminium cables. The controller
shall give maintenance free, very smooth stepless starting of the
motor without any large starting and shorting current kicks. The
rotor controllers shall have provision for adjustment of electrodes to
achieve higher starting torque, if required. The final paint shade shall
be as per shade 631 of IS:5. The rotor controller shall be complete
with the mounting base frame. Following signals potential free
contacts shall be provided for stator panel and plant DCS :
a) 2 nos. - Rotor controller healthy (ready to start)
b) 2 nos. - Resistance maximum
c) 2 nos. - Resistance minimum
d) 2 nos. - Tripping
e) 2 nos. - Alarm
f) 2 nos. - Level OK
g) 2 nos. - Temperature high

Grid Resistance Type Starters-cum-Speed Regulators

Control Panel for Rotor Starter-cum-Speed Regulator shall be housed
in 2 mm thick CRCA sheet steel enclosure, indoor type, floor mounted
with enclosure class IP55. The panel shall house auxiliary
contactors, timers, selector switches, indication lamps etc.
Indicating lamps shall be provided for each speed step.
The GRR for motors operating with SPRS shall have necessary rotor
power circuit changeover contactors (for GRR and SPRS mode of
operations). The voltage and current rating of the contactors used
shall be suitable for the voltage and frequency levels in the rotor
circuit. The operation of these contactors shall be controlled through
SPRS panel for which necessary interfacing facility shall be provided.
The final logic shall be furnished to the successful bidder during
detailed engineering.
The grid resistance shall be housed in a dust proof sheet metal
enclosure with wire mesh at the top. The housing shall be force
cooled and cooling blower shall be provided for the same. The
cooling blowers shall be on separate foundation and connection to
the GRR panel shall be through the duct and flexible joints to avoid
transmission of vibrations.
All the power and control terminals in the Rotor panel shall be
brought up to a terminal box suitable for termination of cables.
Similarly, the grid resistance box shall be wired to a separate
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terminal box. The cabling between the rotor control panel and the
resistance box shall be arranged by the purchaser.
The resistance grid shall be punched stainless steel/silicon graded
cast iron grid elements with high thermal reserve capacity and shall
be suitable for temperature rise limited to 302 deg. C over an
ambient of 48 deg. C. The resistance shall be mounted in fiber-
glass/mica insulated MS rods. The insulation between the elements
shall be pure ruby mica. The resistance units shall be configured to
facilitate maintenance/replacement of damaged units. The grid
elements shall be of TALSON/PEFCO/PEW make.
The voltage and current rating of the contactors used in the rotor
circuit for step-wise switching ON/OFF the resistors shall be suitable
for the voltage and frequency levels in the rotor circuits. The
contactors shall be selected for rated rotor current and shall be of
the same rating.
A solid state logic switch for local/remote operation shall be
provided. A manual logic shall also be incorporated for local
operation in the event of failure of above mechanism. For a smooth
changeover from SPRS mode to regular mode and vice-versa
microprocessor based auto speed tracking by the regulator shall be
built-in for motors with SPRS.
Suitable timers shall be provided in the rotor panel to achieve the
time delay between the operation of various contactors irrespective
of the command for increasing/decreasing the speed.
The rotor regulator control panels and resistor boxes shall be suitable
for starting and control of motor speed between 60% to 100% in
steps of 2%. There shall be 20 steps available for precise speed
control as well as to avoid large current kicks. The equipment shall
be suitable for 4 starts per hour of the motors with two consecutive
starts from hot condition and a starting time of 30 minutes (max.).
The regulator shall be designed for 200% starting torque.
The control voltage shall be 220 V AC for which suitable 415/200 V
control transformers shall be provided in the rotor panel.
Necessary PLC interface shall be provided for remote
increase/decrease of speed.

Power Factor Improving Capacitor

ONE for each motor of suitable size, metallised/All polypropylene,
delta connected power factor improving capacitor for individual
motor to achieve an operating full load power factor of 0.975 lag. The
capacitor bank should be mounted in cubicle with IP:54 protection.
It should be complete with incoming line HRC fuses, unit protection
fuses, discharge resistance in all phases and cable box for indoor
use with brass compression glands/lugs/termination kit etc.
Unbalance protection by means of residual voltage transformer and a
trip contact may be provided, wherever considered necessary. The

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normal voltage rating shall be 7.26 KV, when used with the motors
except for SPRS for which it shall be 7.59 KV. Also, the capacitor
KVAR will be limited to 90% of no load KVAR of motor.
The capacitors shall be capable to cope up with the amount of higher
harmonics existing at the respective voltage level. If necessary,
series air core reactors shall be provided.

4.9. CONTROL DESKS AND POSTS

4.9.1 Control Desk
1) The desk shall comprise sturdy framework with hinged sloping top panel and
bolted side, front and rear covers, fabricated from heavy gauge sheet steel of
thickness not less than 2 mm and made completely dust-tight with neoprene
gasketing. The bottom of the desk shall have removable cover plate to
facilitate drilling of holes for cable entry as required during the installation.
2) The desk shall be factory assembled, painted and fully wired with 1.5 sq.mm
PVC insulated copper cables as required. All outgoing connections shall be
brought out to terminal blocks which shall be accessible by opening the front
cover. The terminal block shall be complete with terminal studs, links, nuts,
spring washers, label carrier, etc. All terminals shall be provided with ferrules
having engraved numbers. All devices on the desk shall be provided with
abbreviated inscription plates fixed in a readily visible position. The
designations shall correspond to those shown in the respective drawings.
3) Provision to earth the panel and door at two points shall be made available.
4) Door interlocked limiting shall be provided to facilitate working inside the plant.

4.9.2 Control Post

The control stations/posts offered shall be of sheet steel dust-proof design
suitable for wall or pedestal mounting. The control devices shall be located on
the front hinged door. Bottom plate shall be removable type to facilitate drilling of
holes for cable entry as required at site. The wiring arrangement, termination,
labelling etc. shall be identical to those specified for the control desk.

4.9.3 Field Mounted Control Unit

1) Housing
a) Construction : Fabricated out of 14 SWG CRCA steel sheet
b) Enclosure protection : Totally enclosed, dust & vermin proof,
neoprene gasketed, IP54
c) Mounting : Suitable for pedestal/wall mounting
d) Installation : Outdoor
e) Paint finish : As per shade no. 631 of IS-5
2) Controls & Indication
a) Increase and decrease push buttons
b) Stop push button - mushroom headed, lockable in pressed condition
c) Start push button
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d) Inch pushbutton
e) Speed/frequency indicator
3) Other Features
a) The components in the control box shall be complete with wiring,
interconnections and multiway terminals. A total of 20 nos. terminals shall
be provided.
b) The front cover of the control box shall be hinged type
c) The control box shall have undrilled, removable gland plate at the bottom
d) External inscription plates and internal identification tags shall be
provided.
e) The box shall have two nos. external terminals for earthing.
f) Terminals shall be stud type
g) Brass compression type cable glands and crimping type lugs shall be
provided for all incoming and outgoing cables.

A documentation giving details of all special electrical devices included in the

Supplier' scope of supply (wiring diagrams, maintenance manual, special
operating instructions, etc.) shall be provided. All types of elements will be
subject for approval by the Purchaser/Consultant.

4.10. LOW VOLTAGE MOTOR CONTROL CENTRES(MCCS)/AUXILIARY CONTROL

PANELS
01 The MCCs shall be totally enclosed self supporting, floor mounted, dust and
vermin proof in IP - 54 enclosure and rated for fault level of 35 MVA at 415 V.
MCCs shall be suitable for extension on both sides.
02 The MCC cubicles shall be of robust design, pressed sheet steel construction
with minimum thickness of steel not less than 2 mm. The cubicles shall be
provided with neoprene gaskets at joints/front doors.
03 The MCC cubicle shall be multi-tier draw out type and of compartmentalised
construction. Fixed type MCC shall be provided for mobile equipment. The
feeders shall be separated from each other with a metallic separator. Direct
on - line (DOL) reversible starters shall be provided for all motors.
04 Each outgoing motor circuit to be mounted on the fixed unit shall have its
own load break isolator, contactor, starter, short circuit and overload
protection devices and other accessories such as auxiliary relays for
sequential control, indicating lamps, push buttons control switches, ammeter
with or without current transformer, etc. as required.
For fan type loads, heavy duty DOL feeders having overload relays operating
in conjunction with saturable core CTs shall be provided.
5 The control voltage shall be 220 V AC through 2 nos. control transformers,
each100% rated (one of them standby unit) of 415 +10% / 220 V of suitable
VA rating. Manual changeover switch for selecting any one of the control
transformers shall also be provided. Protective fuses shall be provided on
both primary and secondary circuits of the transformers.

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06 The busbars in the MCCs shall be of copper/aluminium. All bus joints shall be
bolted with spring washers to prevent loosening. Clamps shall not be used.
Surfaces at bolted plug in connections shall be plated with tin, silver or
cadmium. All bus bars shall be sleeved with PVC for full operating voltage.
The power and control equipment in the MCCs shall be carried out with
standard PVC copper conductor cable. The control cable will be 1.5 mm sq.
stranded flexible copper conductor. All cables will be terminated with crimping
type sockets/lugs and provided with interlocked ferrules with engraved
numbers.
07 The busbar arrangement and clearances in MCCs shall conform to IS : 375.
The busbars shall be supported on moulded incombustible insulators to
withstand short circuit current of 50 KA for one second.
The maximum temp. in MCCs for busbars shall not exceed 85 degree C
during operation when measured by thermometer.
08 Upto 630 A rating, each MCC shall have a full capacity load-break incoming
isolator operable externally to the control cubicle. The isolator shall be
capable of withstanding the through-fault short circuit current. Above 630A,
fully rated ACBs having built in overload, short circuit and earth fault releases
shall be provided for the incomer conforming to the requirements given in the
Indian Standards.
The isolators shall have AC 23 duty and shall be selected from standard
ratings i.e. 25, 63, 100, 200, 400 and 630 Amps. Maximum rating of isolators
shall be 630 A.
09 The rating of the contactors for reversible feeders and the MCCs mounted on
the mobile equipment shall be of AC-4 duty and for the balance applications
it shall be AC-3 duty.
The contactors shall be chosen from the standard sizes i.e. 32, 63, 100, 160,
250,400 and 600 Amps.
10 The minimum operating height shall be 400mm and maximum shall be 2000
mm. Indicating instruments shall also be located not higher than 2000 mm.
11 The overload protection for the motors shall be triple pole thermal overload
relays of hand rest type and the range shall be 60-100% of the motor to be
controlled. The thermal over-load relays shall be ambient temperature
compensated. The overload relay resetting device shall be brought out on
the panel front.
12 1 No. screw type ON indication lamp in RED colour and rated for 220 AC
shall be provided for each feeder.
13 Each motor feeder shall be provided with single phasing preventer. Motors of
rating above 2.2 kW shall have direct operated ammeter. Motors of rating
above 11 kW shall have CT operated ammeter, CTs with 1 amp. secondary
current.
14 Each feeder shall have HRC fuses of suitable rating.
15 A copper earth busbar shall be provided at the bottom of the cubicle and
shall run for entire length of MCC. The minimum size of this copper earth bus
bar shall be 35 x 6 mm.
16 The power and control terminals shall be brought at the bottom of the cubicle
and they shall be suitably segregated from each other.

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Study type terminal blocks shall be used. 20% spare terminals shall be
provided.
17 The MCCs shall conform to IS : 8623 for factory built assemblies and IS :
4237 for general requirement of switchgear.
18 MCC shall have three distinct positions i.e. service, test and dislocated
positions with pad locking arrangement
19 Control supply shall be available at the terminals in all three positions
20 Test Push Button with wiring shall be positioned on each MCC module for
testing of control circuitry with isolation in OFF position
21 All relays shall be microprocessor based

4.11. VARIABLE FREQUENCY CONTROLLER (VFC)

1 Application
Each VFC shall be connected to respective AC Squirrel Cage Induction
motor and shall control speed by varying stator voltage and frequency.
2 Operating Principle of VFC
Voltage/current source with thyristors/transistors/GTOs with PWM technique
3 Panel design
The variable frequency controller shall be housed in floor mounting, free
rolled sheet steel cubicle IP-54 protection. The thickness of sheet steel would
be 2 mm except for all the covers which will be 1.6 mm. The base channel
would be 3.15 mm thick. The panel shall be totally enclosed dust and vermin
proof.
4 AC input supply
a) 415V, 3 cycles, 50Hz, 35 MVA
b) Duty : Continuous
05 Installation : Indoor
6 AC output
Voltage wave form approx. sinusoidal to provide stepless speed variation to
squirrel cage motors rated for operation on 415 V, 3 phase, 50 Hz power
system.
6 Speed range
Speed range shall be 1:10. Torque for above drives shall be speed
dependent. VFCs shall be designed accordingly.
09 Desired performance :
a) Switching
Normal - 4 starts per hour
Trial run and commissioning - 6 starts per hour
b) Overload
150% overload for 15 secs., 4 times per hour.

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c) Speed holding
The variable frequency accuracy controller offered shall be capable to
hold the speed accuracy better than + 0.5% of base speed with
voltage feed back (The motors shall note provided with any tacho-
generator) under following conditions :
Under specified voltage and frequency variation
+ 100% load variation
Up to + 5 Deg. C temperature variation per minute.
d) Frequency stability
VFC shall be capable to hold frequency stable within + 0.1 %
e) Acceleration/ deceleration time
Upto 60 secs. independently adjustable
f) Voltage dips
The VFC shall be designed to withstand momentary dips of about 30
percent in supply voltage for 3 cycles without damage to thyristors or
blowing of fuses.
g) VFC efficiency
The efficiency of VFC at rated voltage and load shall be better than 98%.
h) Ripple content at rated current and conduction speed
4% approximately at 120 Deg.
i) Safety factor
The ratio of peak inverse voltage to rms voltage shall be more than 2.5.
10 Deration for motor
The bidder shall confirm his selection requirement
11 Details of modules
a) Power modules
This shall consist of isolator, HRC fuses, contactor,
thermal overload devices, current transformer, semi conductor devices.
b) Plug-in type /surface mounted module(PCB)
This shall consist of the following units
Power supply unit -
Speed amplifier - PI action
Current amplifier - PI action
Digital reference unit with remote control

12 Cooling system
The variable frequency controller shall be designed for continuous operation
at site ambient condition with force cooling.

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The necessary controls for panel fan motors shall be provided in panel. The
number of fans should be selected to provide 100% redundancy. Without
cooling fans, VFC shall be suitable for operation at full load without any
overloads.
Forced air cooling shall be with low noise ventilation fan at the top of the
cubicle which shall suck air through the thyristor modules. The arrangement
shall preferably be such that ventilation air passes only through thyristor heat
sinks in a separate duct so as to prevent dust deposition and consequent
tracking.
A thermal switch or a vane switch for exit air temperature monitoring or air
flow monitoring shall also be incorporated.

13 Control supply
220 V, AC from 415/220 V double wound step down control transformer
mounted in panel. The transformer shall be suitably rated for providing
interfacing power requirement with DCS.

14 Operational features
a) Soft start with adjustable to be provided time acceleration
b) VFC shall be equipped with by-pass facilities so that the motor may be
operated as a fixed speed motor if required.
c) Lockable 3-way selector switch for remote/panel/CCP mode selection.
d) The controller shall have internal fault detection and include protection
features as specified. The fault detection system shall shut down the
inverter firing circuit and output a fault signal. The display shall identify the
abnormal condition which shut down the drive system.
e) Auto manual selector switch for set point. In auto position, it should accept
4-20 mA DC external signal and in manual position the control shall be
from the digital reference of the panel.
f) Suitable control circuit for interfacing with centralised programmable
controller as detailed under para - 19
g) Analogue channels for remote indication of speed and current.
h) Analogue circuitry for close loop control (4-20 mA signal from plant PLC).
i) Digital operator shall be supplied with each panel
j) Profibus connectivity for control and para meterization

15 Protection
Following protections shall be provided for the VFCs : -
a) Surge protection
b) Short circuit
c) Instantaneous over-current
d) Fan failure VFC panel
e) Stall protection
f) Fuse failure
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g) Thermal overload
h) Phase sequence protection
i) Solid state single phasing preventer for 3 phase bridges only.
j) AC under voltage protection
k) Earth fault protection
l) Control and regulated power supply failure protection
m) Panel temperature high protection
n) Any other VFC protection as required for the particular application. The
devices provided shall be clearly stated in the offer.

16 Control for forced ventilation

a) Starter for panel force ventilation unit
b) Cooling fans of panel shall be switched on first, when start command is
given. These fans shall continue for about 15 minutes and then stop in the
case of stop command.
c) Vane switch along with associated wiring shall be provided in the panel.

17 Indication & fault Monitoring

a) Status Indication Lamps
Motor running
VFC ON
Control supply ON
RYB phase indication lamps
Inverter ready
DOL ready
b) Facia Annunciation Windows
Panel fan failure
Semi conductor fuse failure
Over current
Over load
Under voltage
Over voltage
Phase failure
Loss of feed back
Earth leakage
Regulator fault
Motor winding temp high
Spare

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The above faults shall provide visual indication only on the panel. Any fault
shall energise the common fault relay for composite fault signalling to the
plant composite fault signalling to the plant control system. TEST, ACCEPT
and RESET push buttons shall be provided for these faults.
18 4-20 mA DC isolated signals to be : a) Current
provided for b) Speed
19 Provision for interfacing with the PC : The interfacing details of VFC panel
shall be incorporated by the bidder as
per Purchaser/ Consultant
requirements
20 Wiring : a) Power and control cables
will be laid separately.
b) All the wires will be ferruled at
both the ends
21 Field Mounted Control Unit
Housing
a) Construction : Fabricated out of 14 SWG CRCA Steel
Sheet. Top cover shall be canopy type
b) Enclosure Protection : Totally enclosed, dust and vermin proof,
neoprene gasketed IP 54.
c) Mounting : Suitable for Pedestal/Wall
d) Installation : Outdoor
e) Paint Finish : As per light grey shade
Controls & Indication
a) Increase (speed raise) and decrease (speed tower) push buttons
b) Start push button (forward/ Reverse push buttons for Reversible Drives)
c) Stop push button - Mushroom headed, lockable in pressed condition
d) Speed indicating meter
e) Armature current Ammeter
f) Remote Panel field mode selector switch
g) Test service mode selector switch
h) Voltmeter with selector switch
i) Ammeter with selector switch

Other Features
a) The components in the control box shall be complete with wiring,
interconnections and multiway terminals. A total of 35 numbers terminals
shall be provided.
b) The front cover of the control box shall be hinged type.
c) The bottom of the control box shall have undrilled, removable gland plate
at the bottom.

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d) External inscription plates and internal identification tags shall be
provided.
e) The box shall have two numbers external terminals for earthing.
f) Terminals shall be of stud type.
g) The drive shall provide serial interfaces with Rs 485 and Rs. 422 data
links. Necessary hardware e.g. gates, cables etc. if required shall be
included in the scope. The supplier shall furnish the interface protocol
details to the C&I supplier during engineering.
h) The drive may be placed at a distant place from motor. The chokes etc. if
required shall be included in the scope.

4.12. SUBCONTROL SYSTEM

4.12.1 GENERAL REQUIREMENTS
Electrical control systems supplied by the Bidders as integral part of a
machine/equipment system performing specific functions related to that machine
in an efficient and proven manner are considered as sub-control systems
(SCS).
Sub-control systems which are included as part of the mechanical equipment,
have to be clearly defined. This definition shall include specifications of
equipment, quantity and make.
The list of the sub-control systems included in the suppliers scope shall be
submitted along with the tender.
Commissioning and start up of sub-control system shall be the responsibility of
the Supplier.

4.12.2 SPECIFICATION OF SUB-CONTROL SYSTEM (SCS)

Interface and internal control of SCS shall comply with the principles of drawing
No. A4-04310-I2-4-01 Rev. 0 enclosed. Equipment within a SCS shall be
standardised as much as possible.
Fuses shall be used for special applications only. Spare fuses, lamps, etc. shall
be included within the main delivery.
The holding current principle shall be applied to all control circuits. This means,
that cable breakage as well as loss of voltage shall be detected and treated as
fault.
Unless otherwise specified the SCS shall be delivered complete with all SCS
internal motors, Power and Control Components, sensors, cable connectors,
special cables including flexible cable and special installation material.
A workshop function test of the SCS shall be performed.
The details of each individual SCS shall be discussed and approved prior to its
execution.
Power will be supplied from a low voltage distribution (MCC), 3-phase, with earth
wire E. The power feeders will provide the SCS with the required power and will
include the protection of the feed cable. Thermal protection of the drives as well
as the provision of the internal control voltage is responsibility of the SCS
supplier.

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All switching contactors/ auxiliary relays interfacing with main plant control
system shall be provided with RC snubber circuit.
Sub-control system shall provide necessary ports for communication on data
highway (Profibus). The necessary hardware e.g. gates etc. if required shall be
included in the scope. The supplier shall furnish protocol details to the C&I
supplier during detailed engineering.
Information required from SCS supplier :

-Nominal current :...... A

-Peak current :...... A
-Connected load :..... kW

Interface terminal have to be installed in the SCS in defined groups as follows:

-Power supply terminals

-Control interface terminals
-Internal power terminals
-Internal control terminals

Special terminal plans have to be delivered.

4.12.3 DEFINITION OF INPUT AND OUTPUT CIRCUITS

Signal : CD
The ON/OFF command affects the SCS as whole. Contact closure (relay
energised) causes the SCS to start-up automatically with the correct sequence
and carry out its service (if internal circuits are correct). Contact opening (relay
not energised) causes the SCS to stop automatically in the correct sequence and
terminate its services.
Relay - Specification :

Signal : C =
The setpoint will be supplied in form of an active 4 - 20 mA signal. The signal
has to be completely galvanically isolated (against ground and possible power
supply) in the SCS unit.

Signal : Cz
The actual value shall be a 4 - 20 mA signal. The signal has to be galvanically
isolated (against ground and possible power supply). An external load of up to
600 Ohm shall be allowed.

Signal : CK
The availability contact affects the SCS as a whole. The information available
shall signal to the process control the readiness of the SCS before operation. It is
not dependent on whether the run signal is present or not.
The following conditions must be continuously fulfilled, in order that this contact
may remain closed.
(i) Control voltage available

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(ii) No fault in the system (neither overload nor emergency nor off-
switches, etc. must be activated)
(iii) All switches service or remote must be in the remote position.
If any of the conditions given above is no longer fulfilled, the contact availability
will open immediately.

Signal : CR
The run is the feedback signal after a normal start. It means that the SCS is
carrying out its service. If the run signal does not appear within ON/OFF
command (CD) is de-energised by the process control.
All the above mentioned signals have to be provided from each SCS. The
following signals are to be included as required by the specific control
application:

Signal : CW
The warning signal is a pre-alarm which does not (or not yet) stop the normal
run of the SCS. The warning contact shall remain open as long as the warning
condition prevails.

Signal : CF
The fault signal is an alarm which causes the SCS to stop automatically. The
fault contact shall open until the fault has been locally reset.

4.13 GAS ANALYSERS AND PROCESS INSTRUMENTS

4.13.1 General
01 The supplier shall include suitable compact instrument incorporating
latest technology with solid state modular plug-in construction. The
instruments shall have profibus compatibility for control and data exchanged.
02 Supplier shall include necessary companion flanges and other accessories to
make the system complete and operational. Any device not included in the
specification but considered necessary for proper erection, mounting
and operation of the equipment shall be deemed to be within the scope of
supply under this specification.
03 Field mounted instruments should be suitable for satisfactory operation under
the environmental working conditions existing in a cement plant and shall
necessarily have dust proof sheet metal enclosure. Care should also be
taken to ensure that rats, lizards and other creeping reptiles cannot enter the
instrument enclosure. Additional enclosure, if required, to give better safety
should be included in the scope of supply.
04 To reduce inventory, as far as possible, standard equipment in standard sizes
and ratings should be offered. The purchaser reserves the right to select the
equipment of a particular manufacturer and the supplier shall supply
equipment of that particular make, if so required.
05 The openings for ventilation and forced draft etc. shall be suitably protected
with screens. When screens are provided on top of the equipment, means
shall be provided to protect them form falling objects.

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06 The equipment should be designed so as to ensure safety of operating and
maintenance personnel. Aspect of ease of maintenance, testing and repair
should be given due consideration while designing the equipment.
07 The equipment offered should be sturdy and continuous duty type. The
instruments must retain their guaranteed accuracy/ sensitivity/ repeatability
under the conditions existing in a cement plant i.e. heat, dust and vibration.
08 The equipment offered should be tropicalised and given protective dips to
prevent any damage due to fungus, mildew etc.
09 The instruments and their accessories shall bear tag no. and name plate
inscription. Text of tag no. or Name plate shall be given by purchaser to the
supplier.
10 Alarm contacts wherever provided shall be 1NO + 1NC rated for 1 amp. at
220V, 50 Hz and shall be potential free. The response time of the alarm
system shall be less than 20 m sec.
11 The power supply available at the plant site is 415+ 10%, 3 phase,4 wire, 50
+ 5% Hz. It shall be provided at one point only. Any other voltage/distribution,
if required shall be arranged by the supplier.

12 a) Standard analogue signal for the measuring circuits shall be 4-

20 mA DC and shall be isolated.
b) The output signal (4-20 mA DC) for the measuring devices shall
be galvanically isolated from the input signal and from the AC
power supply ground/earth bus.
c) The admissible burden (external load) connected to the 4-20 mA
DC output of a measuring device shall be approx. 0-600 Ohms.
d) Appropriate 4 wire/2 wire transmitters with galvanically isolated 4-20 mA
DC signal for remote measuring indication will be provided in sub-control
systems (e.g. DC drive, actuator with remote position indication, AC
current and power measurement etc) which are being supplied by other
manufacturers.
13 The digital indicators shall be 4 digit scale with LCD display blanked.
14 All panel mounted instruments shall have smallest possible front size
commensurate with good degree of resolution of indicating scale and
readability.
15 All control loops shall include fail safe provisions and shall be stable
for all process conditions. Cyclic stability in general will not be
acceptable.
16 All the tapping points shall be provided by the equipment supplier.
17 All steel work shall undergo a process of degreasing, pickling, cold
rinsing, phosphating and passivating. It shall be given two coats of high
corrosion resistant primer and finished by application of synthetic
enamel paint of shade 631 of IS:5. The final finished thickness of the
paint film shall not be less than 100 micron.

4.13.2 Gas Analysers

The Microprocessor controlled gas analysers shall consist of following:
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Single gas sampling probe with closed circuit water cooling, motorised probe
retraction device with automatic compressed air cleaning for kiln inlet and
precalciner outlet.
Two sampling probes with automatic compressed air cleaning for
Gas Analysers at other locations.
Probe mounted heaters
Probe mounted coarse filters
Minimum 3 stages of gas filtering consisting of series of coarse and fine
filters.
Refrigeration type gas cooler with automatic condensate drainage
PVC diaphragm filter
5 way cock for connection of zero and span gas to analyser
Filter of glass fibre
Sampling pump
Flow monitor for sample gas and cooling water with adjustable flow
switch. All safety and protection alarm viz. water temperature high, water flow
low with potential free contacts. Water flow low condition shall automatically
initiate retraction of probe.
PLC controlled and programmable scavenging sequences. Weather
proof scavenging panel with lamps depicting the functional cycle in progress.
Automatic and over - riding manual operations. Combined moisture trap, air
filter and regulator for compressed air.
Paramagnetic type oxygen analyser with range of 0-10 vol % O2
with an output of 4-20 mA DC and with 21% point calibration and shall be
rated for 220V AC, + 10%, 50 Hz + 3%. Unit shall have built in limit value
monitor for low and high units.
Infra-red CO gas analyser with a range of 0-2% Vol % CO with
selection, an output of 4-20 mA DC and rated for 220V, + 10%, 50 Hz + 3%
AC supply. Unit shall have built-in limit value monitor for high level.
Closed cubicle panel completely wired and fused for mounting all
above times.
6/4 (OD/ID) mm, SS impulse pipe line subject to a max. of 40
metres with each probe at each location along with straight connectors to
extend standard tube lengths.
Isolation valve one with each probe.
Standard Gas Cylinder containing N2 & CO each of 10 litre
capacity for calibration of Analyser. Concentration of CO 2 shall be 80%
of analyser scale and that of N2 shall be 99.99%
with traces of O2 and CO nil. O2 analyser shall calibrated with
room air.

NO
Application - Estimation of burning zone temp. by
measurement of NO

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Type - NDIR for NO measurement
Range - Selectable multi-range 10 PPM to
10,000 PPM
Detection time - 0.5% of span
Response time - T 90 < 15 sec
Linearity - 1% of span
Repeatability - < .5%
Ambient temp. - 20 deg. C to 50 deg. C
Process pressure - 1000 mmWG negative
Power supply - 220 Volts, 50 Hz.
Instrument output - 4-20mA linear on all ranges isolated
Special features - Working of instrument shall be under
normal pressure and temp. existing in
any cement plant.
Sample is heavily laden with dust and
having dew point of nearly 30/35 deg. C
and hence sample conditioning shall be
in-built
Accessories - Gas cylinder containing 10 litres of span gas
for calibration of NOX analyser

Calibration Cells

For Gas Analysers, calibration cells shall be provided.

4.13.3 Process Instruments

4.13.3.1 Thermocouple, Temp. Transmitters and Compensation Cables
01 Thermocouple
a) Limit of error : Fe-K - 3 deg. C for temperature up to 300 0 C and +
1% for temperature above 300 deg. C irrespective of
actual immersion length.
Cr-Al - +0.75% of actual temperature irrespective of
immersion length.
Pt-13% Rh-Pt - +0.75% of actual temperature
irrespective of immersion length.
b) Max.temp. : Fe-K .. 800 deg. C
withstand Cr-Al i) 1000 deg. C continuous
capacity ii) 1200 deg. C intermittent
Pt-13% .. 1600 deg. C
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Rh-Pt
c) Element : Fe-K .. 1.2 mm
diameter Cr-Al .. 1.2 mm
Pt-13% .. 0.5 mm
Rh-Pt
d) Insulation : Twin bore ceramic beads
For Preheater cyclone material temp. pad type.
Thermo couple shall be provided and the same
shall be mineral insulated with 6 mm diameter
stainless steel flexible sheathing.
e) Protective : Fe-K & .. Heat resistance
Sheath and Cr-Al sheet SS 316. Over-all diameter
overall dia 21 mm +1 mm

Pt-Rh-Pt .. SS tube of overall dia. 28

with reinforcement of STELLITE of 1
mm thick below 200mm from the head.

f) Hot junction : Insulated hot junction.

assembly
g) Head : Screwed type, dust and drip proof cast aluminium
with 1/2" BSP Double compression type cable
glands suitable for armoured cable and porcelain
terminal block.
h) Mounting : Adjustable leak proof flange of cadmium coated MS
for mounting thermocouple at desired immersion
length.
i) Accessories : i) Matching flange mounted on protection tubing
of 50 mm dia, 400 mm long MS tubing for
insertion in the process nuts, bolts etc.
ii) 25 Meters of compensating cable with
appropriate size glands on both sides with each
thermo-couple.
02 Smart Temperature Transmitter
a) Input : Fe-K/Cr-Al/Pt 13% Rh-Pt thermocouple.
b) Output : 4-20 mA DC isolated, linear with temp.
c) Range : 0-1200 deg C
d) Connection : 2 wire system
e) Accuracy : Better than + 0.5%
f) Linearity : Better than 0.5%
g) Enclosure : IP-54 with field mounting case
h) Accessories : Field mounting plate/case, nuts, bolts etc.
i) Special Feature : Input/Output galvanically isolated.
- Built-in lineariser circuit
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- Thermocouple break protection upscale
- Ref. junction compensation at 20 0 C
with facility for continuous cold junction
compensation over the range of 0-60 deg. C.

- Double compression type cable

glands for armoured cable entry.

- Local Indicator integral with the transmitter body.

- Smart transmitter shall be provided with

communication link with plant control
system facilitating remote re-ranging
calibration and diagnostics

03 Compensation Cable
Three core compensation cable with standard conductor of size 3 x 22
SWG each lead with double fibre glass lapping insulated by Silicon varnish
and then each lead lapping with moisture resistant tape and then with
common asbestos braiding for both leads with silicon varnish and provided
with copper wire braiding or copper tape shielding.
25 metre long compensation cable shall be supplied with each
thermocouple. Unit rate of compensating cable shall be quoted.

4.13.3.2 Resistance Thermometer

a) Limit of error : + 0.05% or 1.5 deg. C of actual temp. whichever
is less.

b) Max. temp. with- : 400 deg. C continuous.

stand capacity

c) Type : Duplex RTD, 3 wire

d) Type of element : Pt 100, 25 SWG

e) Insulation : Mineral insulated, elements embedded in highly

compacted magnesium oxide insulation within a
seamless metallic tube.

f) Protective sheath : SS 316, overall dia 16 mm.

and overall dia

g) Mounting : Adjustable leak proof flange of MS for mounting

suitable immersion length.

h) Head : Screwed type, dust and vermin proof, cast

aluminium, 1/2 BSP double compression type cable

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glands suitable for armoured cable and porcelain
terminal block.

i) Accessories : Matching flange mounted on protection tubing of

50mm dia, 400 mm long MS tubing for insertion in
the process, nuts, bolts etc.

4.13.3.3 Tempmax Transmitter

a) Application : Monitoring the bearing and winding temperature of

HT motors, where a maximum temperature amongst
a group of RTDs is required.

b) Input : RTD, Pt-100

c) Input range : 0-250 deg C

d) Output : 4-20 mA DC corresponding to channel having

maximum temperature.

e) Power supply : 220 V AC

f) Temp. Indication : 3 1/2 digit LCD display
g) Input channels : 8
h) Output channels : 2
i) Accuracy : +0.25%
j) Mounting : Field or back of panel
k) Housing : Cast Aluminium

4.13.3.4 Smart Pressure/Differential Pressure/Draft Transmitters

a) Type : 2 wire system capacitance type.
b) Accuracy : +0.5% Calibrated span
c) Repeatability : + 0.05% of calibrated span.
d) Span & Zero : Continuously adjustable externally, span turn down
ratio of 10
e) Output : 4-20 mA DC linear with draught/pressure.
f) Mounting : Pedestal/pipe
g) Flange & Adapter : Cadmium plated carbon steel
h) Bolts : Cadmium plated carbon steel
i) Paint : Epoxy base
j) Process : 1/4" NPT
connection
k) Items to be provided along with transmitter:
- Double compression type brass cable glands for armoured cable.

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- Impulse pipeline approximately 30 metres on each leg, 12 mm dia
straight couplings for extending standard lengths, end tube fittings etc.
- Mounting bracket/pipe with base plate for pipe mounting
- 3 valve manifold
- Local Indicator integral with transmitter body
- Dust pots/catchers - 2 nos. with each transmitter

l) Primary element material shall provide good creep fatigue resistance and
low hysteresis.
m) Smart transmitter to be provided with communication link with plant control
system facilitating remote re-ranging, calibration and diagnostics.
n) All transmitters shall be Differential Pressure type which can be converted to
Pressure/Draft type by plugging the ports.

4.13.3.5 Smart Flow Transmitter

a) Type : 2 wire system capacitance type

b) - Accuracy : + 0.5% of calibrated span.

- Linearity : Better than 1%
c) Repeatability : +0.05% of calibrated span
d) Span & Zero : Continuously adjustable externally, span turn down
ratio of 10
e) Output : 4-20 mA DC (linear with flow)
f) Mounting : Pipe mounted type.
g) Flange & Adapter : Cadmium plated carbon steel.
h) Bolts : Cadmium plated carbon steel.
i) Paint : Epoxy base.
j) Process : 1/4" NPT
connection
k) Special features : - Built in square root extractor
- Built in NTP correction module

l) Items to be provided along with transmitters:

- Double compression type brass cable glands for armoured cables.
- Mounting bracket pipe
- 3 valve manifold.
- Impulse pipe line 30 metres, 12 mm on each leg with straight
connectors for extending standard lengths, end tube fittings etc.
- Local Indicator integral with transmitter body.
- Dust pots.

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m) Smart transmitter shall be provided with communication link on profibus with
plant control system facilitating remote re-ranging, calibration and
diagnostics.

4.13.3.6 Level Switch (Capacitance Type)

a) Electronic Controller

(i) Power supply : 220 V AC + 10%, 50 Hz +5%

(ii) Alarm contact : 2 NO + 2 NC contacts rated for

3 Amp. at 220 V AC.

(iii) Mounting of : Wall mounting in cast Aluminium

Controller housing

(iv) Local indication : Green LED for Normal and Red LED for High
level

b) Sensor Probe

(i) Exposed material : SS 304

(ii) Insulation : Teflon (Low Temp.) Vitreous Enamel (high temp.)

(iii) Material Temp. : 250 Deg. C (Low Temp)

400 Deg. C (High Temp)

(iv) Probe Housing : Cast Aluminium

The switch shall provide immunity for false actuation in the event of
coating and clinging in silo/hopper and also on probe.

4.13.3.7 Conductivity Level Limit Switches

a) Application : Detection of liquid levels

b) Power supply : 220 V AC +10%, 50 Hz +5%

c) Output : One set of potential freechangeover contact per

channel rated for 6 Amp. at 220 V AC.

d) Housing : Cast aluminium weather proof or sheet

steel.

e) Calibrating range : 0 to 50 K ohms

f) Operating temp. : -20 deg C to +60 deg C

g) Available : A - Max.2 for single point operation

B - Max.2 for pump logic

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C - Max.2 for Control and 1 for high level alarm.

h) Cable entry : 1/2"

i) Special features : Fail safe high/low field programmable

: Alarm/Normal indication by one red and

one green LED per channel.

: Long cable connection permissible

between probe and evaluation unit.

4.13.3.8 Converter (kW/mA, A/mA)

a) Enclosure : Sheet steel, suitable for outdoor installation.

b) Power supply : 220 V +10%, 50 Hz + 5%

c) Input : 0-1 A from CT 110 V AC from PT

d) Output : 4-20 mA DC (linear with input)

galvanically as well as optically
isolated

e) Overload capacity : 6 times normal input for 60 sec

4.13.3.9 R/mA Converter

a) Type : R/mA
b) Supply Voltage : 220V AC + 10% 50 Hzz
c) Input : 1K/5K
d) Output : Single, 4-20 mA (Optically and
galvanically isolated)
e) Load : 750 Ohms
f) Accuracy : + 5% of span
g) Housing : Cast Aluminium

4.13.3.10 Field Hooter

a) Type : Motorised

b) Range : 200 meter radius

c) Power supply : 220 V AC

d) Mounting : Field mounted

e) Protection : IP55

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f) Tone : In case of electronic hooter, tone
adjustment shall be possible.

4.13.3.11 Pressure switch

a) Type : Diaphragm/Bellows

b) Repeatability : 0.5%

c) ON/OFF : adjustable
Differential

d) Switching : Snap acting microswitch suitable for

5 Amps at 220 V AC, change over contact

e) Mounting : Field

f) Working pressure : Adjustable over entire 0-10 Kg/cm sq. range.

g) Accessories : Nipple and isolation valve, 150/200 mm long

impulse tubing for mounting on process pipe line.

4.13.3.12 Kiln Refractory Management System

01 Sensor

Type : High speed digital Infrared lines scanning

Scanning : Reflective mirror optics assembly, Revolving assembly

with scanning rate of 20 Hz to achieve single brick
resolution, 100 field of view. Scanning rate shall be
variable by a heavy duty brushless DC motor, to match
the process.

Calibration : On-line calibration through in-built micro

black body references.

Range : 100-700 o C

Accuracy : + 4o C for 100 to 250 o C

+ 1.5% for 250 to 700 o C

Detector : Mercury cadmium Telluride, thermo-electrically cooled air

stability.

Air purging : Air purging to maintain dust free viewing window.

Enclosure
protection : IP 62 for optics compartment.

Water Cooling : Water cooling jacket for optics and electronics housing

02 Processing Electronics

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Control : Micro processor controlled scanner functions e.g.

detector, motor, speed, black body.

Integral Software : Real time execution of Thermal linearisation, Dynamic

signal averaging print area and zone temperature
measurement, alarms and temperature maps, data
storage and communication to system computer via a
high speed digital interface (RS 422/485).

Enclosure : IP65 for electronics compartment

protection

03 System Computer

Type : PC/Work station with 19 VDU monitor and keyboard.

Operating system : Windows

Software for : Evaluation of Kiln flame, coating

- Supervision of riding ring clearance/Kiln tier slip
- Evaluation of brick lining (long term tendency)
- Planning of brick lining
- Storing and easy retrieval of actual and historical data of
temperature profiles and of brick data.

4.13.3.13 Two Colour Radiation Pyrometer For Kiln Inlet

The two colour radiation pyrometer system shall comprise of the following
equipment:

a) Radiation pyrometer with built-in transducer, built-in brightness switch and

refraction device.
b) Power supply unit for radiation pyrometer with peak value memory and
average value memory card. Power supply unit shall be suitable for 220V
AC +10%, 50 Hz + 5%. Output signal corresponding to temp shall be 4-20
mA.
c) Blower for supplying scavenging air, shall be suitable for 415 V + 10%, 50 Hz
+ 5% AC 3 phase supply.

d) 10 meter long hose with clamps for scavenging air

e) Connection head with quick action locking device

f) Connection head for scavenging air connection

g) Sighting tube for installation to furnace wall

h) Swivelled type mounting flange. Swivelled type flange shall be suitable to

swivel up to 15 degree.

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i) Auxiliary accessories like scavenging air nozzle, cooling clamp, flow switch
with 1 NO+ 1 NC contacts with flow rate setting facility for cooling water flow
monitor, shut off valves, plug and socket metal filter etc.

j) Automatic shut off in case of air failure to protect sighting lens

k) In case of water cooled type, closed circuit water conditioning unit, water
cooler with filter etc shall be included.

l) All protection failure potential free alarm contacts shall be included.

m) Sighting tube at kiln inlet application shall be blanked by S.S. plate suitable
to withstand 1200 deg C temp.

4.13.3.14 Level Monitors for Continuous Level Indication

ELECTRO-MECHANICAL STEEL TAPE TYPE
a) Application : Detection of solids/level in silos
b) Operating : Plumbing of distance from the op of the principle silo to
the surface of material
c) Enclosure : Sheet steel suitable for outdoor installation.
d) Output signal : 4-20 mA DC corresponding to zero and span.
e) Power supply : 220V +10%, 50 Hz +5% AC
f) Accessories : Umbrella weight, subtracting pulse
counter, digital/analog converter, memory for last
measurement, external enable/disable
interlock, sun protection cover, etc.
g) Operation : Manual from field and remote from CCR. A selector
switch for this purpose to be provided.
The unit shall accept signal from external for its
operation. A close contact shall be provided as an
enable signal.

4.13.3.15 Close Circuit Television

a) Type : High temperature close circuit camera with

temp. measuring device (Optical prometer).

b) Application : To view burning zone of kiln and cooler grate bed (with
built in kiln burning zone temperature measurement).
Sintering zone is self illuminated.

c) Components & accessories camera

- Temperature range up to 1600 deg.C
- Solid state colour image sensor
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- Horizontal resolution 800 lines at centre
- 625 lines per frame as per CCTV standard
- Video output - 1 volt peak to peak with 75 Ohm termination.
- Provision for both internal and external synchronisation
- Lens of 16mm fixed focal length for sintering zone and with adjustable
focus over a range of 5 metres to 30 metres distance.
- Tube shall be provided with water cooling jacket and air purging
system
- Suitable for mounting in any direction.
- Approx. 10 metres length of hose pipe shall be included from blower to
camera and blower shall be made suitable for above hose pipe length.

d) Video monitor :
- Screen diagonal : 51 Cm Colour
- Angle of deflection : 110 deg
- Video band width : 12 M Hz
- Lines : 625
- Field frequency : 50 Hz
- Video input signal : 1 V peak to peak
- Input resistance : High resistance
- Monitor casing : Al. sheet
- Special features : Video changeover facility with necessary control
unit.

e) Accessories to be supplied
- Coaxial cable for connecting camera to monitor shall be supplied with
system length-300 m)
- Cooling water adjustment cabinet (Closed circuit cooling system)
- Air control cabinet with necessary arrangement for automatic
withdrawal of the camera in case of cooling water failure
- Power supply unit for supplying power to camera shall be
suitable for 220 V +10%,50 Hz +5% supply
- Blower for supply of scavenging air shall be
suitable for 415 V +10%, 50 Hz +5% AC 3 phase supply
- Protection failure sensing facility.
- Automatic camera withdrawal under abnormal conditions.
- Hose pipe for connecting blower to camera shall be supplied with system
(length - 15 inches)
- Chitter unit to maintain outlet water temperature at 10 deg. C from 35
deg. C water temp. It shall be supplied along with pump, filter and
monitoring system for temperature, pressure and flow.

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4.13.3.16 Zero Speed Switches

a) Application : Under speed/stand still monitoring of rotating

machine/linearly moving belts.
b) Type : Non contact type/proximity type
c) Range : Covering 30 rpm to 3000 rpm in multirange
d) Protection : IP 55/IP 65
e) Power Supply : 220 V +10%, 50 Hz +5%
f) Output : 2 NO+2NC alarm contacts
g) In-built features : - Range selection switch on front
- LED Indication for power supply ON
- LED Indication for under-speed
- Adjustable time on delay control
- Adjustable trip point control.
h) Accessories : Target plate for sensor with mounting
arrangement.
Proximity type sensor/probe with cable (20 m
length). Cable, end connector, Female connector
for extension cable shall be supplied loose.

4.13.3.17 Dust Density Monitor

a) Measuring : The optical measurement system measures

Principle dust concentration by co- relating energy loss of light
along optical path across stacks of Bag house/ Electro
static Precipitators. The quantity of dust contained
in the irradiated gas is proportional to absorbance
of light.

The instrument operates according to the Time-Division-

Multiplex (TDM) technique, which allows the measuring
and reference light paths to be clearly differentiated.

b) Set - Up : On one side of the stack, the optical system consists of

light source and receiver, on the other, the reflector.

Both sides are aligned precisely to one another with

their alignment fixtures.

The light from the source lamp is focused by a lens and

transmitted through the chopper wheel. Shaped into a
beam it emerges into the exhaust stack through
the beam splitter (semi-transparent mirror) and objective
lens.

The reflector returns the light back through the exhaust

stack where it passes through objective lens to beam

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splitter, which in turn deflects it through the receivers
condenser lens on to the receiver.

The chopper wheel and the timing wheel are on a

common axis. Rotation of the disc generates modulated
light at 1.2 Khz, which eliminates the effects of
ambient light that can occur in the exhaust stack.

The timing wheel is shaped so that with each quarter

revolution it either opens the light path through the
exhaust stack or interrupts the light path, reflecting the
source light.

The timing wheel has opposite slots at two different

radii. Two photo electric sensors set on either side of
these radii, alternately switch the receiver signal to
measured valve memory or to reference valve
memory.

In the evaluator, the reference-value is compared to the

set point of highly constant reference-value source and
is automatically adjusted if it fluctuates.

To detect zero point drift or a sensitivity change in the

monitor a zero point reflector and check filter
automatically swing into the light path once an hour.

The check filter is a screen filter that produces a specific

light attenuation. The zero - point reflector interrupts the

light path on the stack side in front of the objective lens

so that contamination of optical surfaces is also
checked.
c. Accessories
01 Fail Safe Shutter
Mounted on both sides between the flange and sender/Receiver unit or
reflector. If the air purging unit fails, the flange opening to the exhaust stack
closes.
02 Weather hoods
Fiberglass reinforced plastic that protects the monitor and air purging blower
from exposure to the weather.

03Air purging unit

d. Technical Data
Supply Voltage : 220 V AC + 10%, 50 Hz + 3 %
Source Lamp : Incandescent
approximately 10 W
Average life approximately 20000 hrs.
Measured variable : Dust quantity per volume (mg/Nm3)
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Range shall be adjustable at site through
multiple selectable ranges
Measured value output : 4-20 mA DC isolated into load
resistance of 600 Ohms

Relay outputs : System error and limiting valve suitable

for 220 V AC switching
Enclosure type : IP 64
Ambient temp. : 45 deg. C

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