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NISCO
TARA TARH
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Table of Contents
Contents
Page
1- General
1.1- Safety
1.4- Training
1.7- Manning
1.9- Manufacturers
10
11
14
40
47
71
83
105
123
Table of Contents
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1- GENERAL
The Employer intends to construct a direct reduction and a material handling plant in Baft
steel company located near Baft city, in Kerman province.
For this propose, implementation of a direct reduction module with nominal capacity of
800,000 TPY-DRI (+5 mm) and raw material handling plant with nominal capacity of
2,500,000 tonne pellet and lump ore per year shall be in the scope of obligations of the
Contractor for the present Project.
The direct reduction plant and raw material handling plant shall be complete in all respects
and any devices which is not included in the specification but is necessary for proper
operation of equipment and process, shall be considered as included within the specification
whether specifically mentioned in this Specification and Data sheets or not.
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1.1- SAFETY
The Contractor shall ensure that the supplied Plant and Material, equipment, machinery
and apparatus are designed in conformity with all those codes and regulations in normal
usage for the type of equipment and machinery being offered.
The Contractor shall list the steps and special design features included in the design of
the Plant, equipment, machinery and apparatus to ensure that all the safety requirements
has been taken into account.
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procedure and a detailed program of the inspections and testing to be carried out. This
program shall conform to general Time Schedule of the Contract. In order to achieve a
uniformity of quality assurance procedures, inspection and testing throughout all aspects
of the Contract Works from design to commissioning, the procedure shall be issued by
the Contractor to all members of his quality assurance organization, to all SubContractors and to all supervising engineers. The document shall also be issued by the
Contractor to the Employer or Employers Representatives carrying out inspection
surveillance. The procedure shall not be
Employers Representative
Section 1
altered
without
shall maintain
a complete list of
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correct updating by
1.3.4- Reports
The Contractor shall provide reports of all visits made by his quality assurance personnel
and any other inspecting engineers appointed and acting on his behalf. The Contractor
shall fully document all quality assurance checks, inspections and tests carried out in his
own works and those of all Sub-Contractors. Four copies of all such reports and
certificates shall be forwarded to the Employers Representative within one week of
testing. Inspections or tests resulting in the discovery of defects, damage or rejections
shall be labeled prominently with a capital 'D' in the top right-hand corner of the first page.
Any discovered damage, defects or rejections which in the Contractors view may prevent
satisfactory completion of the Contract Works, or cause delays to program shall be
advised to the Employer by telex or facsimile and be confirmed by written report within
one week. The Contractor shall submit to the Employer, at intervals of not more than four
weeks, a summary of all quality control, inspection and testing activities which have taken
place in the previous four weeks.
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1.3.5.5. Welding
Welding procedures and tests shall conform to the appropriate A.W.S. Standard. Where
specified welds shall be subjected to an approved crack detection test, for example
dye penetrate or magnetic particle test , the Employers Representative may ask for
additional tests at its discretion.
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1.3.8. Utilities
All Plant, equipment and pipe work shall be tested in accordance with appropriate
ANSI standards, which will be proposed by the Employers Representative .
1.4. TRAINING
In order to enable the Employer to properly operate and maintain the Plant, it is necessary to
train the Employer personnel. Training package shall include training of personnel for
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proper operation and maintenance of equipment .In addition in order to specialize and
familiarize the Employer personnel with the supplied equipment and machinery, the
Contractor shall ensure for the Employer 's personnel a suitable period of staying at his
and/or Sub- Contractor's design and fabrication installations during the relevant stages
of
progress
stock at all times because, in the event of the breakage or failure of such item, the time of
repair or replacement would incur serious deterioration of performance.
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1.7. MANNING
The tenderer shall submit with his tender the recommended manning requirements for
staffing all shifts of the Plant. This manning requirement should be given under different
categories such as, maintenance, operation, management, etc. The tenderer shall also specify
the required qualifications, of the personnel and their brief job description.
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Reference
Number
Description
Weight
1.9. MANUFACTURERS
The Contractor shall insert in the table below and required extensions to it, the names of
the manufacturers of the principal items of equipment which shall include the name of
associated companies and divisions within the Contractor's organization. The table shall
also include the location where the items will be manufactured and tested.
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Place of Manufacture
or Associated Firm
and Testing
maintenance of apparatus similar to that which will be utilized in this Contract who will
supervise the, erection, carry out Site quality assurance, report on erection progress and
make the tests on completion of erection of the Plant and the subsequent commissioning
and setting to work. The Contractor shall prepare erection instruction manuals giving
detailed instructions for the handling, erection, alignment, tolerances and the subsequent
commissioning and setting to work of all items of the Plant. An adequate number of copies
of these instruction manuals shall be made available to the Contractor's erection supervisors
and six copies shall be supplied to the Employers Representative . All levelling, aligning
and bedding onto concrete and walls before grouting shall be carefully checked by
Contractors supervisors.
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to
enable
the Employers
Representative to ascertain the Contractor's compliance with the dates given in tender
program.
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It will be used to form a basis for production by the Contractor of an agreed detailed
program for the Contract Works. It will be used to relate the Contract Works to program
of work of others involved in the Contract and the timing of any inspection, progress
control, verification and expediting functions to be carried out by the Employer and/ or the
Employers Representative.
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suitably updated, extended and revised as agreed by the Employer , will be provided by
the Contractor at intervals of not more than four weeks, from the initial issue until
completion of D.D.U Site delivery of all Foreign Supply and D.D.P Site delivery of all
Local Supply items included in the Contract Works.
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As a whole, the DR. module will include but not limited to the following main parts:
1- Oxide material handling system: for transferring iron oxide material in the form of
oxide pellets to the shaft furnaces as specified in Sub Clause 2.3 of this Specification
and Data sheets.
2- Product material handling system: for transferring the DRI from the shaft furnace to the
storage bins as specified in Sub Clause 2.4 of this Specification and Data sheets.
3- Main part of direct reduction module: in which the direct reduction process will be
performed. In connection with DR module, the units and systems which are
incorporated in which the direct reduction process takes place, may be classified as
follows:
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- Shaft Furnace: where iron oxide is reduced to metallic iron by high temperature
reducing gas.
- Reformer: where the reducing gas is produced.
- Recuperator: a heat recovery unit where the hot exiting flue gas is utilized for
preheating various gas flows including process gas, natural gas, and combustion air.
- Process Gas System: for transferring the gas flow containing oxidized gas
(CO2&H2O) and natural gas for reforming and recycling back to the reduction shaft
furnace.
- Cooling Gas System: for providing the cooled gas required for cooling zone of the
shaft furnace.
- Combustion/dilution Air System: where the combustion and dilution air required in
the reformer is provided by a series of air blowers.
- Flue Gas System: where the combustion exit gases from the reformer, after being heat
recovered and cleaned, is ejected to the atmosphere through the ejector stack.
4- Civil, Building and Infrastructure: including all buildings with their related
infrastructures and HVAC (Heating, Ventilation and Air-Conditioning) systems.
In addition to the main systems as mentioned above, the following auxiliary systems is
considered in connection with the DR plant.
- Seal gas generation and distribution system.
- Utility and water treatment system including cooling water in top gas scrubber and
cooling gas scrubber, clarification and recycling.
- Dust collection systems.
- Compressed air generation (including both plant air and instrument air) and
distribution system.
- Sewage collection and treatment system.
- Fire detection and fighting system.
- Electrical system (including telecommunication system)
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furnace, heating the descending iron oxide to the reduction temperature. Hydrogen and
carbon monoxide remove the oxygen from the feed, yielding a highly reduced product.
The most significant features of the process are:
1- A steady- state process and uninterrupted flow of reducing gas for the removal of
oxygen from the feed and for carburizing the reduced iron.
2- A gas reforming system, which either uses CO2 and water vapor contained in top gas
and natural gas to produce CO & H2 rich reducing gas without formation of soot.
3- Maximum gas utilization by recycling the top gas from the shaft furnace to the process.
The principal components of plant are the gas reformer for the production of the reducing
gas, and the shaft furnace in which the reduction process takes place. In addition, there are
transportation systems for oxide feed material, and metallized product automatically
controlled from control room and water, gas and other utilities circulation systems.
The shaft furnace is divided into two zones with separate gas systems. The upper zone for
reduction and the lower zone for cooling. The iron oxide material descends from the
reduction furnace charge hopper by gravity through a dynamic gas seal system into
distribution pipes which feed the material into the reduction furnace, thereby maintaining a
uniform profile of material in the furnace. The feed rate to the charge hopper is controlled
by the discharge rate of the product from the bottom of the furnace.
The distribution feed pipes and the furnace geometry must be specifically designed to
maintain a uniform flow of material downward through the refractory-lined furnace. The
shape of the oxide material is not changed during the reduction, as most oxide materials are
normally free of swelling. The metallized material is highly porous, as oxygen is removed
from the ore, and tends to reoxidate. Therefore, the hot metallized material must be cooled
before exposure to the atmosphere to prevent any reoxidation. Most chemical constituents
of the raw material are not affected by direct reduction and remain in the metallized
material, however the gangue constituents will show a percentage increase due to oxygen
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removal during the reduction process. The final product analysis will therefore depend on
the iron oxide analysis.
The principal part of reforming equipment is the gas reformer which mainly consists of
radiation fire boxes, in which reforming takes place in the reformer tubes.
The gas reformer generates reformed gas. The reformed gas containing hydrogen, carbon
monoxide and some other gases at a controlled temperature and ratio.
The vertical reformer tubes shall be filled of catalysts. These tubes shall be made of high
quality alloy (heat resistant) with spring supports.
The reformer boxes shall be provided gas tight to avoid cold air leakage into the fire boxes.
Two different systems of burners shall be installed in the reformer that are main burners
and auxiliary burners. The task of the auxiliary burners are as follows:
- They are used as pilot burners.
- During start-up, the reformer will be heated up to nearly operating temperature by them.
- The idling condition: these burners keep the reformer at a temperature slightly below
operating temperature. In idling condition, it is necessary to stop gas flow through
reformer tubes and shaft furnace.
In case the tenderer willing to propose an other process (rather than described above) for
DR-module process it should be proposed as an option.
fines and oversizes. The screened pellets after passing through coating station shall be
transported to D.R. shaft furnance hopper by belt conveyors.
Oxide fine bin elevation shall be suitable for loading the fines to trucks.
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The Contractor shall construct suitable open storage area for stacking the fines.
The oxide materials belt weighers shall be installed on conveyors at proper places.
A complete remet handling system shall be installed for direct reduction plant. For this
propose, a belt conveyor with the capacity of 170 t
discharge conveyor.
A remet hopper and relevant feeder shall be installed in suitable place for remet charging.
The reduced materials in silos shall be passivated by inert gas for prevention of explosion
and sticking so the silos shall be equipped with inert gas distribution system.
A storage area shall be constructed for passivation of DRI in case of the operators can't send
DRI to silos. The dimensions of this area shall be approximately 30mx100m. All the
necessary equipment and facilities for transferring DRI to this storage area and charging
DRI to product material handling system is in the scope of Work. The silos discharge
material shall be handled to the screen station where the fine is separated and stored in the
bin. The fine shall be handled to the cold briquetting plant by conveyors. The fine bin
discharge chute shall be so designed to have the capability to discharge material on belt
conveyor or in truck.
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Water with appropriate specifications will be used as make up water in the open and
close loop cooling water systems.
Industrial water shall be conducted to Industrial water reservoir and then pumped to the
softeners.
IEC 76
IEC 354
o Rated power
to be defined by tenderer
o Ratio
33 2x2.5% / 6.9kV
off load
o Impedance
Max. 10%
o Vector Group
Dyn11
o Cooling system
ONAN / ONAF
o Insulation class
IP54
o Accessories
IEC standard
metal clad
o Insulation voltage
7.2 kV
o Duty voltage
6.6 kV
31.5 kA 1sec
31.5 kA
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SF6/Vacuum-Withdrawable CB
60 kV
20 kV
110 V DC
o Degree of protection
IP 42
o Protection function
o Measuring function
V, I, F, P, Q, Ph, Qh, PF
6.6/0.40kV
2 x 2.5%
o Impedance
about 6%
o Vector group
Dyn11
Solidly grounded
o Placing
Out door
o Accessories
IEC standard
o Rating
By Tenderer
400 V
o Insulating voltage
1000 V
50 kA, 1sec
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By Tenderer
50 kA
o Installation
Indoor
o Protection degree
IP42
Page 24 of 144
Dry type
o Rating
To be defined by tenderer
o Primary voltage
400 V
400 V 230 V
o Impedance
about 4%
o Vector group
Dyn11
Solidly grounded
2 x 2.5%
o Placing
Indoor
o Accessories
IEC standard
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x Main characteristics:
o Rated voltage
6.6/ 3 kV
By tenderer
o Material
o Degree of protection
IP54
fault to ground
x General features:
The panel will be divided in a resistor part and a switchboard part.
The switchboard parts consist of:
o A single pole disconnector
o A current transformer, 5P5
2.7.10- 6.6 kV cables and terminals
x Main characteristics:
o Cables
Conductor
Copper
Insulation type
XLPE
Jacket type
PVC
Shield
Yes
yes
o Terminals
Type
Heat shrinkable
Insulation voltage
>7.2 kV
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o Conductor
copper
o Insulation type
XLPE / PVC
o Jacket type
PVC
Page 26 of 144
400V
Power factor
0.8
Rated voltage
400V
Standard
IEC 34-1
Excitation
Brushless
Enclosure
IP23
Cooling
Self ventilated
Speed
750~1500 rpm
Over speed
1.25urated speed
Winding
Star
Heater
Insulation class
Temperature class
Auto start/stop
Yes
o Diesels:
Section 2
Number of strokes
Starter
DC motor
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2.7.13- UPS
x Main characteristics:
o Input voltage
400/230 V 10%
o Input frequency
50 Hz 5%
400/230 V 2%
50 Hz 0.5%
3%
o Efficiency
> 90%
o Standard
IEC
Yes
o Protection degree
IP51
o Batteries
o Battery duration
30 minutes
o Conductor material
copper
o Enclosure material
Steel
o Insulators
o Short circuit
o Degree of protection
IP 54
o Rated voltage
7.2 kV
80 kA
o Ventilation
Natural
Yes
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2.7.15- Telecom
x Main characteristics:
o Back up battery for central unit of
Intercom. System
2 hours duration
Yes
o Type of mounting
Desk/wall mounted
2.7.16-PFC
x Main characteristics:
o Rated voltage
o Control voltage
110V DC
o Standard
IEC
o Discharge device
<50V, 1min.
o Protection degree
IP54
o Insulation
Dry type
185 mm2
o Conductor type
Acc. To IEEE80
16mmu3m
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Cad weld
PVC insulated
Yes
Lightning rod
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2.8.2- Scope
Contractor should install an advanced DCS control system, all field instrumentation,
cabling and all necessary accessories for direct reduction plant.
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x Scalability (the scalability is defined as the possibility to add new part of system or to
increase the performance of the existent systems to comply with the new
requirements)
and from the Hardware point of view are:
x High similarity
x High redundancy
The design and the implementation of the automation systems for this project should
consider all the above mentioned features.
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measurement selected for the project. All test equipment shall be approved by the
Employers Representative.
General Equipment
1) Workbench for Instrument repairing and calibration
2) Printed circuit board check device
3) Combined pneumatic/electronic portable tester
4) Control valve test bench or test rig.
General Electronic/Electrical Test and Calibration Equipment
5) Digital voltmeters (DVM) portable (minimum 3 portable types) with an accuracy of
+/-0.1% of range or better and with a discrimination of 10 uv or better, incorporating an
internal calibration, standardizing feature and 0.1% calibration resistors.
6) Precision milli volt, volt and milliamp, source measuring device.
7) Portable multi meters (analogue).
8) Insulation resistance testers.
9) Stop-watch and relay contact timing device.
10) Dual beam oscilloscope.
11) Portable, variable mA power supply unit (0 to 50 mA Max.).
12) Portable multi meters (digital).
13) Signal generator.
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Note:
All test instruments shall be provided with test leads complete with test probes, clips and
distribution terminals.
Electrical workshop facilities, including but not limited to the following:
1- Digital multi meter
6- Tacho meter
7- Frequency meter
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10-Soldering
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2.10- LABORATORY
Contractor shall construct and supply a complete laboratory with all laboratory equipment
for carrying out all required analysis and tests in direct reduction and raw material handling
plants.
The facilities indicated in this section are selected to carry out most of the normal analysis
and tests inside the direct reduction and raw material handling plants.
The tenderer shall complete or revise the list according to his experience for above
mentioned purposes.
The tenderer shall submit specification, type, quantity and manufacturer of the laboratory
equipment.
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- Jaw crusher
- Grinding mill
- Cross beating mill
- Crusher
- Automatic press (compression test for DRI)
- Size analysis device (granulometer laser type)
- Grave and crush tests (for DRI)
- Fast DRI metallization measurement device
- Equipment for DRI characterization (drop number and resistance, bulk density)
2.11- WAREHOUSE
The warehouses of DRP shall be constructed by Contractor.
These warehouses shall have necessary equipment, hardware and software for servicing to
the plant in maintenance and operation time. These warehouses are for storing spare parts,
equipment, chemicals and refractories. Warehouses shall be equipped with shelves, ladders,
railing, platforms, lifts, etc which in a modern warehouses for easy handling is required. At
least one three ton capacity fork lift for general purpose shall be provided. Required No. of
hardware (computers, printers, copy machine, etc) and powerful software for handling the
duty shall be provided. The provide system shall be capable of communication with steel
complex MIS/ERP which in future will be provide by Employer.
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The equipment shall be capable of maintaining internal conditions according to the ASHRAE
standard for offices and specification of equipment from manufacturer for electric equipment in
control and electrical rooms.
Suitable internal conditions for control room, electrical room and laboratory are 222oc and
relative humidity equal 45 to 50%.
The air cooling system, without humidity control for the electrical room and air conditioning
system with humidity control for the control room for PLC equipment shall be considered.
Air systems shall be balanced to the conditions set forth in drawings and specifications and
following items shall be performed:
- Balancing air supply, return and exhaust system.
- Balancing chilled water system.
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Detectors
Yes
Detectors signal
4~20 mA DC
Detectors calibration
Generates 24 VDC
Protection degree
IP54
Yes
Yes
Yes
Panel input
Cables
Alarm type
Alarm location
Yes
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Section 3
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In addition to the main systems as mentioned above, the following auxiliary systems shall
be considered in connection with this plant and shall be designed, supplied, erected and
tested by the Contractor:
-
Civil, building and infrastructure including all buildings such as substation, control room,
ware house, office, etc. with their related infrastructures and HVAC (Heating, Ventilation
and Air-Conditioning) systems.
Industrial water for spraying over the belt conveyors at conveyor loading and at dust
return in train unloading station and truck unloading station. (if required), based on
Contractor's design.
Compressed air generation (including both plant air and instrument air) and distribution
system based on Contractor's design.
Warehouse.
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For the articulated Lorry or flatbed, two hydraulic truck unloaders shall be installed by
the Contractor. Each of these units shall have unloading hoppers.
The hoppers shall be designed to accept both unloading trucks by hydraulic truck
unloader and trucks with flatbeds. These hoppers shall be equipped with grating network
for avoiding oversize entrance to hoppers.
The Contractor shall provide five hoppers , each hopper capacity 100 cubic meters and
five feeders with the capacity of 300 t/h .
Raw material shall be transferred to storage area by belt conveyors.
The truck road, truck weigher, provision the suitable parking for the trucks and other
relevant facilities are in the Contractor's scope of Work.
shall be installed in this storage area. The combined stacker reclaimer shall be
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Item
Unit
Oxide pellet
Natural gas
Nm3/hr
Nitrogen
Nm3/hr
Make up water
M3/hr
Nm3/hr
Nm3/hr
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.......
.......
.......
..........
..........
..........
..........
..........
..........
..........
..........
..........
- H2
..........
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- CO
..........
- CO2
..........
- H2O
..........
- CH4
..........
- N2
..........
..........
..........
..........
..........
..........
..........
..........
- Charging system
..........
..........
..........
- Discharging system
..........
..........
..........
- Method of sealing
..........
..........
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..........
- Level of carbon content (%)
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
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..........
..........
..........
..........
..........
..........
..........
- Reforming method
..........
- Feed gas
..........
- Reformer type
..........
..........
..........
- CO
..........
- H2
..........
- CO2
..........
- H2O
..........
- CH4
..........
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Page 52 of 144
- N2
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
- Main burners
..........
- Auxiliary burners
..........
..........
..........
..........
Section 4
..........
..........
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 53 of 144
- Material of tubes
..........
Method of construction
..........
..........
..........
..........
..........
..........
..........
..........
..........
- length (c)
..........
Bottom
..........
Middle
..........
Top
..........
..........
Bottom
..........
Middle
..........
Top
..........
Section 4
..........
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
Section 4
TARA TARH
Page 54 of 144
..........
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 55 of 144
.....
.....
.....
- Output rate
.....
- Manufacturer
.....
- Place of manufacture
.....
Section 4
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 56 of 144
- Heating media
- Preheated gases
- Number of tubes
- Material of tubes
- Method of construction
Section 4
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 57 of 144
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
.....
Section 4
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 58 of 144
..
.....
.....
.....
.....
..
Section 4
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 59 of 144
Dust Collectors
- Item number
..
..
..
.....
.....
- Unit weight
.....
.....
.....
.....
.....
.....
- Manufacturer
.....
- Place of manufacture
.....
.....
Section 4
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 60 of 144
Bag Filter
- Number of bag filter/system
b) Width (m)
c) Height (m)
- Cladding material
- Material of filter
Nm 3
- Slope of sides
(referred to horizontal) (degree)
- Type of dampers
- Number of dampers
Section 4
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 61 of 144
- Manufacturer
- Place of manufacture
Section 4
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 62 of 144
- Type of dampers
- Size of dampers
-Volume
open ( Nm
of
3
air
entrained
when
fully
.
- Manufacturer
- Place of manufacture
- Temperature of actuation
Section 4
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 63 of 144
No. of fans/system
....
Type of fan
Manufacturer
Place of manufacture
Motor manufacturer
Weights
Section 4
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 64 of 144
.
.
.
.
Capacity of valves (m
Manufacturer
..
Place of manufacture
Section 4
..
..
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 65 of 144
General:
- Function
.....
No. of units:
In operation
.....
Stand by
.....
- Manufacturer
- Place of manufacture
Compressor Characteristics:
- Type
- No. of stages
- Fluid handled
Section 4
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 66 of 144
- Bearing type
.....
- Lubrication system
.....
- Coupling type
.....
.....
- Speed (rpm)
.....
.....
Material:
- Casing
.....
- Impeller
.....
- Shaft
.....
- Bed plate
.....
Section 4
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 67 of 144
.....
General:
.....
- Function
.....
- No. of units:
In operation
.....
Stand by
- Manufacturer
.....
- Place of manufacture
.....
Characteristics:
.....
- Type
.....
- Fluid handled
.....
.....
.....
.....
- Capacity (Nm3/h)
.....
.....
.....
Section 4
.....
.....
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 68 of 144
- Material
Section 4
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 69 of 144
- Function/Location
- Type
- Quantity
- Capacity
- Manufacturer
- Place of manufacture
Section 4
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 70 of 144
- Speed (m/s)
- Lift (m)
- Number of stops
- Manufacturer
- Place of manufacture
Section 4
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 71 of 144
Section 5
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 72 of 144
- Total weight(t)
....
- Pile
...
Width
...
Height
...
Belt Conveyor
- Width (mm)
- Speed (m/s)
- Power (kW)
- Length (m)
Travel
- Traveling speed (working speed) (m/min)
- Rail type
Section 5
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 73 of 144
Bucket Wheel
Type :
- Diameter (mm)
- Speed (rpm)
- Power (kW)
Section 5
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 74 of 144
- Dimensions
- Capacity (t)
- Manufacturer
- Other infromation
Section 5
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 75 of 144
...
...
...
- Lift (mm)
...
...
...
- Handling rate (MT/h)
...
- Material handled
...
...
..
...
......
......
- Type of belt
......
- Belt material
Section 5
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 76 of 144
Coating material
Section 5
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 77 of 144
......
..
- Type
..
- Rating (MT/h)
.
.
- No. of decks
- Mesh opening & screening area for each
deck
- Drive system type
.....
.....
.....
Section 5
.....
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 78 of 144
Section 5
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 79 of 144
- No. of units
- Type
- Rating (MT/h)
.....
- Method of suspension
.....
Section 5
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 80 of 144
..
..
..
Section 5
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 81 of 144
- Method of actuation
Section 5
.....
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 82 of 144
- Geometry
.....
Section 5
.....
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 83 of 144
Section 6
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 84 of 144
......
- Place of manufacturer
..
- Number
..
..
..
..
..
..
..
..
..
..
..
- Material
a ) Plate
..
b) Gasket
..
c) Frame
..
Section 6
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 85 of 144
Clarifier
- Number of tanks
..................................................................
- Type of tank
circular
- Capacity (m3/h)
..................................................................
- Detention time
..................................................................
..................................................................
..................................................................
..................................................................
..................................................................
rectangular
..................................................................
..................................................................
..................................................................
a) bridge structure
..................................................................
b) gear
..................................................................
c) motor
..................................................................
d) scraper
..................................................................
e) wheels
..................................................................
f) weir
..................................................................
..................................................................
..................................................................
..................................................................
- weir length
..................................................................
Section 6
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 86 of 144
..................................................................
- material
..................................................................
a) tank
..................................................................
b) bridge structure
..................................................................
..................................................................
d) weir
..................................................................
- protective treatment
..................................................................
a) shot blasting
..................................................................
b) coating
..................................................................
d) description
..................................................................
Section 6
..................................................................
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 87 of 144
Cooling Circuit
- Cooling circuit denomination
..........................................................................
..........................................................................
..........................................................................
..........................................................................
..........................................................................
..........................................................................
..........................................................................
..........................................................................
Section 6
..
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 88 of 144
Cooling Towers
- Manufacturer
..........................................................................
- place of manufacturer
..........................................................................
..........................................................................
..........................................................................
..........................................................................
..........................................................................
- Type of tower
..........................................................................
- Number of cells
..........................................................................
..........................................................................
..........................................................................
a) Length
..........................................................................
b) Width
..........................................................................
c) Height
..........................................................................
..........................................................................
a) Type
..........................................................................
b) Material
..........................................................................
c) Depth
..........................................................................
- Casing
Section 6
..........................................................................
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 89 of 144
a) Material
..........................................................................
b) Protective material
..........................................................................
- Fans
..........................................................................
a) Type
..........................................................................
b) Number of fans
..........................................................................
..........................................................................
..........................................................................
e) Blade material
..........................................................................
- Motors
..........................................................................
a) Manufacturer
..........................................................................
b) Number
..........................................................................
..........................................................................
..........................................................................
e) Speed (rpm)
..........................................................................
f) Electrical supply
..........................................................................
x Voltage (V)
..........................................................................
Phase
..........................................................................
Frequency (Hz)
..........................................................................
Frame size
..........................................................................
Section 6
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 90 of 144
..........................................................................
Enclosure
- Drift eliminators
..........................................................................
a) Material
..........................................................................
..........................................................................
- Make up water
..........................................................................
a) type
..........................................................................
b) temperature (oC)
..........................................................................
c) pressure (kpa)
..........................................................................
..........................................................................
e) analysis
..........................................................................
Section 6
..........................................................................
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 91 of 144
Centrifugal Pumps
- Manufacturer
..........................................................................
- place of manufacturer
..........................................................................
- Type of pump
..........................................................................
..........................................................................
- Function
..........................................................................
- Liquid
..........................................................................
- Capacity (m3/h)
..........................................................................
..........................................................................
- Efficiency (%)
..........................................................................
..........................................................................
..........................................................................
..........................................................................
- Impeller type
..........................................................................
..........................................................................
- Seal type
..........................................................................
- Material
..........................................................................
a) Casing
..........................................................................
b) Impeller
..........................................................................
c) Shaft
..........................................................................
Section 6
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 92 of 144
..........................................................................
- Place of manufacturer
..........................................................................
- Function
..........................................................................
..........................................................................
a) Material
..........................................................................
b) Type
..........................................................................
c) Dimensions (m)
..........................................................................
- Mixer
..........................................................................
a) Manufacturer
..........................................................................
b) Mixer type
..........................................................................
..........................................................................
..........................................................................
..........................................................................
..........................................................................
& diameter
g) Shaft and coupling material
- Dosing pumps
..........................................................................
..........................................................................
a) Manufacturer
..........................................................................
b) Place of manufacturer
..........................................................................
Section 6
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 93 of 144
c) Type
..........................................................................
..........................................................................
..........................................................................
..........................................................................
..........................................................................
Liquid end
..........................................................................
Plunger/Diaphragm
..........................................................................
Packing/Seal
..........................................................................
Section 6
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 94 of 144
Air Compressors
x
Manufacturer
..
Place of manufacturer
..
Type
..
..
Function
...
Number of stages
..
Capacity (Nm3/h)
..
Working pressure
...
Efficiency (%)
..
Rotating speed
Motor
(bar)
(rpm)
..
..
(kW, rpm)
...
o Manufacturer
...
o Place of manufacturer
...
o Protection insulation
...
Compression:
Oil injected
Cooling type
water cooled
x
Material
Air cooled
..
..
Rotor
..
Section 6
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 95 of 144
Air Dryers
x
Manufacturer
Place of manufacturer
Function
.
3
Material
o Vessel
Section 6
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 96 of 144
Air Receivers
x
Item No.
Manufacturer
Place of manufacturer
Type
Number
Function
Design code
Head thickness
Shell thickness
Dimension
o Height
o Diameter
Internal lining
External coating
Material of construction
Section 6
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 97 of 144
Filters
x
Manufacturer
..
Place of manufacturer
..
Type
..
QTY
..
Function
..
Number of stages
..
Capacity (Nm3/h)
..
Working pressure
Max pressure
..
Particle removal
..
Section 6
(bar)
..
..
(bar)
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Page 98 of 144
Contractor shall submit a complete description of heating, ventilation and air conditioning
system offered for the direct reduction plant and raw material handling plant specification of
equipment. Catalogue of equipment shall also be enclosed.
Section 6
16-Sep-07
Rev 0
NISCO
TARA TARH
Page 99 of 144
x Number of units:
o In operation
o Stand-by
.
.
x Type
x Heating data
o Heating load
.
.
x Cooling data
o Total cooling load
.
Fan data
x Capacity
x Motor power
.
Compressor data
x Number
x Condensing temp.
x Refrigerant
Section 6
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Contractor shall submit a complete description of fire detection, alarm and fighting system
offered for the direct reduction plant and raw material handling plant including specification of
equipment. Catalogue of equipment shall also be enclosed.
Section 6
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Fire Alarm
x
Type designation
..
Detector type
..
..
..
Input voltage
..
Protection degree
..
Number of loops
..
Cable type
..
..
..
..
Quality
..
Section 6
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Location
..
Number of cylinders
..
Capacity
..
Height
..
Diameter
..
CO2 pressure at 20 C
..
Test pressure
..
Section 6
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Item No.
..
Number of unit
..
Gas weight
..
Total weight
..
Cylinder material
..
Hose material
..
Working pressure
..
Discharge duration
..
Discharge distance
..
Section 6
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Item No.
..
Number of unit
..
Total weight
..
Cylinder material
..
Hose material
..
Working pressure
..
Discharge duration
..
Discharge distance
..
Section 6
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
......
......
......
x GIS or conventional
......
......
x Number of phases
......
x Number of busbars
......
x Rated voltages
kV (r.m.s)
..
kV (r.m.s)
kV (r.m.s)
A (r.m.s)
o Trafo feeder
A (r.m.s)
o Outgoing feeder
A (r.m.s)
kA (r.m.s)
....(S)
..kV (peak)
......
......
......
......
......
......
......
Section 7
16-Sep-07
Rev 0
NISCO
TARA TARH
......
......
auxiliary switch
x Ground switch type of blade
......
......
x Transformer circuits:
o Primary H.V. fuses
.(A)
.(A)
..
......
......
x Cubicle weight
o Incoming
..(kg)
o Bus-section
..(kg)
o Outgoing
..(kg)
..(kg)
o Cubicle dimensions (L W H)
.....(cm3)
......
......
......
......
......
......
NOTE: For each type of Switchgear an individual data sheet shall be prepared.
Section 7
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
......
......
......
......
x Applicable technical
......
x standards
......
......
......
......
x Minimum clearances:
......
o Between phases
.(mm)
.(mm)
......
......
x Number of phases
......
x Number of poles
......
x Rated Voltages
.....kV (r.m.s)
x Rated frequency
(Hz)
conditions):
o Rated 1 min. power frequency withstand
voltage
.....kV (r.m.s)
..kV (peak)
.. A (r.m.s)
kA (r.m.s)
.(S)
Section 7
16-Sep-07
Rev 0
NISCO
TARA TARH
A (r.m.s)
A (r.m.s)
..
kV (r.m.s)
kA (r.m.s)
kA (r.m.s)
kA (r.m.s)
......
......
..(ms)
..(ms)
..(ms)
..(ms)
..(ms)
..(ms)
...(C)
(kV)
100 A DC
x Breaking current (Asymmetrical)
....(A)
......
Section 7
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Contactors
x Fuse type
......
......
......
x Contactor type
......
......
......
NOTE: For each type of Circuit Breaker and contractors an individual data sheet shall be
prepared.
7.3- Transformers
x
..
..
..
Rated capacity
..
Number of phases
..
Frequency
..
Voltage ratio
..
Cooling
..
..
Windings
..
o H.V.
Rated capacity
..
Voltage rating
..
Connection
..
o L.V.
Voltage rating
..
Connection
..
Section 7
16-Sep-07
Rev 0
NISCO
TARA TARH
..
L.V. Winding
..
o On bushings:
H.V. Winding
..
H.V. Neutral
..
L.V. Winding
..
..
L.V. Winding
..
o On bushings:
H.V. Winding end
..
..
..
Tapping Range
..
..
..
..
Current Ratios
..
Standard
..
..
..
(vi)Terminations
..
H.V.
..
L.V.
..
Section 7
16-Sep-07
Rev 0
NISCO
TARA TARH
..
NOTE: For each type of transformer an individual data sheet shall be prepared.
..
..
x Rating of system:
o
..
..
..
..
..
..
..
x Particulars of cells:
o
..
..
Charging current:
..
Initial (A)
..
..
Continuous (A)
..
Final
voltage
charged (V)
Section 7
per
cell
when
boost
..
16-Sep-07
Rev 0
NISCO
o
o
TARA TARH
..
..
Number of cells
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
..
Standard
..
Input voltage/frequency
..
..
Output voltage
..
Section 7
16-Sep-07
Rev 0
NISCO
Baft Steel Complex
TARA TARH
Output regulation
..
Output ripple
..
Protection degree
..
..
Power rating
..
Transformer type
..
Thyristor type
..
Cooling system
..
7.6- Lighting
x
..
..
..
..
..
..
..
..
..
..
..
..
..
Section 7
16-Sep-07
Rev 0
NISCO
TARA TARH
..(A)
..(1sec.) (kA)
protected connections
x
...(kA)
cubicles?
x
.V (r.m.s)
...kA (peak)
.A (r.m.s)
...kA (r.m.s)
Section 7
16-Sep-07
Rev 0
NISCO
TARA TARH
incomer C.B
.(A)
connections
x
.(kA)
...(kA)
..V (r.m.s)
....kA (peak)
..A (r.m.s)
..kA (r.m.s)
Type of MCB/MCCBs
Type of fuses
Section 7
16-Sep-07
Rev 0
NISCO
TARA TARH
Type of contactors
o Direct on line
o Star/delta
o Soft start
..
Diesel:
o Manufacturers name and country
..
o Type designation
..
o Number of cylinders
..
o Speed
..
o Type of cooling
..
o Coupling
..
..
o Number of strokes
..
o Compression ratio
..
..
..
Section 7
..
..
..
(lit/ kWh)
..
(lit/ kWh)
..
16-Sep-07
Rev 0
NISCO
TARA TARH
..
o Type of fuel
..
Generator:
o Manufacturers name & country
..
o Type of Generator
..
..
..
..
o Power factor
..
o Number of poles
..
o Insulation class
..
..
o Winding Connection
. star
..
o Excitation system
..
o Auto start
..
o Auto atop
..
o Protection system
..
o Cooling system
..
..
..
..
Driven equipment
..
..
Manufacturer
..
Type
..
Model number
..
Frame size
..
Section 7
16-Sep-07
Rev 0
NISCO
TARA TARH
Horsepower/kW output(HP/kW)
..
Confirming standards
..
Voltage (V)
..
Frequency(Hz)
..
Max. Voltage(V)
..
Min. Voltage(V)
..
Max. frequency(Hz)
..
Min. frequency(Hz)
..
..
Phases
..
..
..
..
..
..
..
..
Insulation class
..
..
Enclosures
..
..
..
Indoor(dBA)
..
Outdoor (dBA)
..
..
Heaters
o
Voltage (V)
..
Wattage (W)
..
..
Section 7
16-Sep-07
Rev 0
NISCO
TARA TARH
..
Driven Equipment
..
..
Manufacturer
..
Type
..
Model Number
..
Frame size
..
Conforming standards
..
IEC
..
NEMA
..
ANS I
..
Voltage (kV)
..
Frequency (Hz)
..
..
..
..
..
..
Phases
..
..
..
Service Factor
..
..
..
..
Insulation
..
Insulation Class
..
..
Enclosures
Section 7
..
16-Sep-07
Rev 0
NISCO
TARA TARH
..
(TEFC)
Water-to-Air Coolers
o Water velocity in tubes not to exceed
(m/sec)
o Cooler material with clean fresh water:
..
..
..
..
header material
..
..
header material
..
Air-to-Air Coolers
..
..
..
o
o
..
..
..
..
..
Heaters
o Voltage (V)
..
Wattage (W)
..
..
..
..
7.12- UPS
x
..
Manufacturer / country
..
Section 7
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..
Rating at Cos=0.8
..
..
..
..
..
..
Efficiency
..
Standard
..
..
Protection degree
..
Batteries type
..
..
..
Type designation
Protection degree
Mounting type
Volume control
7.14- PFC
x Plant Unit Number (P.U No.)
x Type
x Voltage
Section 7
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x Rated MVAR
x Control voltage
x Insulation liquid
x Regulator system
x Protection degree
x Connection type
Buildings/structures
Section 7
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8.1- GENERAL
8.1.1- Design Criteria
- How many years the proposed control
system had been in used in direct
reduction plants
- System redundancy:
- Central processing unit
.Yes/No
- Process interface
.Yes/No
.Yes/No
- Power supply
.Yes/No
- Degree of automation
.Yes/No
.Yes/No
.Yes/No
.Yes/No
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- Diagnostics system:
Yes/No
Yes/No
- Resolution
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Section 8
Yes/No
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Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
8.1.4- Availability
- Independent manual control facilities
for all automatic systems.
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
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NISCO
Baft Steel Complex
TARA TARH
Yes/No
Yes/No
Yes/No
Yes/No
- Redundant structure
Yes/No
Yes/No
Yes/No
Yes/No
duties
- Country of origin
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Yes/No
- Accuracy
...
- Country of origin
- Material of sensor
- Accuracy
- Protection class of
indicators/transmitters
- Country of origin
- Material
- Accuracy
Section 8
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- Protection class of
indicator/transmitters
- Country of origin
- Material
- Accuracy
- Protection class of
indicator/transmitters
- Country of origin
Yes/No
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NISCO
Baft Steel Complex
TARA TARH
- Positioner
Yes/No
- Limit switch
Yes/No
- Torque switch
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
- Hydraulic test
Yes/No
- Leak test
Yes/No
- Noise level
Yes/No
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..
- Country of origin
..
- Resolution
..
- Frequency range
..
- Rated speed
..................
- Frequency range
..
- Output format
..
- Power supply
..
b- Incremental encoders
- Manufacturer
..
- Country of origin
..
- Resolution
..
- Number of pulse
..
- Rated speed
..
- Frequency range
..........
- Output format
..
- Power supply
..
..
- Manufacturer
..
- Country of origin
..
- Type
..
- Quantity
..
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- Nominal load
..
..
.....
.....
- Calibration accuracy
- Operating temperature
.Yes/No
...Yes/No
..
..
..Yes/No
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..Yes/No
.Yes/No
- Instrument valves:
- Isolating valves
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Section 8
b. No. of pick-up
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8.2.3- Cabling
- Adaptable box between flexible cables
of field devices and permanent armored
cables
Yes/No
..DCS/PLC
..DCS/PLC
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... Yes/No
... Yes/No
... Yes/No
... Yes/No
- Memory capacity
- Programming device
... Yes/No
Section 8
- Manufacturer of DCS
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Section 8
TARA TARH
- Programming device
.Yes/No
- Redundancy:
.Yes/No
.... Yes/No
.Yes/No
.... Yes/No
- Power supply
.Yes/No
.Yes/No
..Yes/No
..
..
..Yes/No
..Yes/No
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.Yes/No
..Yes/No
b. Control stations:
- Independence of control modules
from each other
..Yes/No
..Yes/No
..Yes/No
..
..Yes/No
- 1-5 V inputs/outputs
..Yes/No
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.Yes/No
- RTD input
..Yes/No
- Pulse input
..Yes/No
- Dry contact
..Yes/No
- BCD signal
..Yes/No
..Yes/No
..Yes/No
..Yes/No
..Yes/No
..Yes/No
..Yes/No
..Yes/No
- Valid-invalid input
..Yes/No
..Yes/No
- Electrical isolation
..Yes/No
.... ms
.... ms
d. HMI:
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- CRT/LCD resolution
- Type of OS
- Number of OS/unit
... Yes/No
- Type of ES
... Yes/No
.... Yes/No
- Printer type
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NISCO
Baft Steel Complex
TARA TARH
- Manufacturer
- Country of origin
.
.
.
Yes/No
Yes/No
g. Alarm system:
h. Power supply:
- Power supply redundancy
... Yes/No
... Yes/No
... Yes/No
... Yes/No
Section 8
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TARA TARH
... Yes/No
...............
- ES operating system
...............
... Yes/No
- Logic functions
... Yes/No
- Continues control
... Yes/No
... Yes/No
... Yes/No
... Yes/No
... Yes/No
... Yes/No
... Yes/No
... Yes/No
- Menu display
... Yes/No
Section 8
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... Yes/No
- Group display
... Yes/No
- Detail display
... Yes/No
... Yes/No
... Yes/No
... Yes/No
... Yes/No
... Yes/No
... Yes/No
... Yes/No
... Yes/No
- Report display
... Yes/No
... Yes/No
... Yes/No
... Yes/No
... Yes/No
... Yes/No
Section 8
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NISCO
Baft Steel Complex
TARA TARH
... Yes/No
... Yes/No
... Yes/No
... Yes/No
... Yes/No
... Yes/No
... Yes/No
... Yes/No
... Yes/No
- Group printing
... Yes/No
- Event printing
... Yes/No
- Sequence reporting
... Yes/No
... Yes/No
- Periodic logging
... Yes/No
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... Yes/No
... Yes/No
... Yes/No
- Type
- Sensitivity
- Accuracy
- Time of analysis
.Yes/No
- Type
- Focus
- Zoom
.Yes/No
Section 8
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NISCO
Baft Steel Complex
TARA TARH
... Yes/No
. Yes/No
8.7.3- Test
- Factory test shall be done and test report ... Yes/No
will be delivered for engineer approvals
8.7.4- Training
-According to section 11.4 of engineering ... Yes/No
standards, instrumentation and control
(Annex IV)
Section 8
16-Sep-07
Rev 0