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INTRODUCTION:
1. Presently there are four opencast mines and one underground mine in
BPA area. Out of four opencast mines Khairagura OCP, Dorli OCP-I and
BPA OC-II extension mine are in operation and the coal winning
operations at Dorli OCP-II were stopped and final mine closure activities
are under progress..
2. The life and production capacities of the three operating opencast mines
is furnished hereunder:
Production capacity in Life w.e.f.
Sl.No Name of the Mine
MTPA 2018-19
1 BPA OC-II Extn 1.0 3
2 Khairagura OCP 3.5 11
3 Dorli OCP-I 2.5 3
3. Further, upcoming projects like Goleti OCP and Dorli OC-I extension are
planned after the exhaustion of reserves in Dorli OC-I and BPA OC-II
extension.
6. Coal Handling Plant has been designed to handle 5.0 Mt. of coal per
annum. Sufficient storage has been provided in the coal handling system
to meet the eventualities of disrupted coal production in the mine or
delay in conveying. The coal handling plant shall have facilities for
receiving coal from lorries with (-) 200 mm size, conveying, storing,
reclamation and conveying through belt conveyors to PWWL System and
loading in to Railway Wagons.
7. The coal handling plant has also been provided with suitable repair,
communication and other auxiliary facilities to meet the day to day
requirement in the plant operation.
LOCATION OF THE PROJECT.
4. The inputs that are required to be placed in the NIT with regard to dust
suppression system needs a different outlook compared to the NITs
floated earlier for other operating CHPs with conventional systems.
6. The following inputs shall be given to the vendors for Pre-vendor meet
which are placed in the file:
A. BASIC DATA
Receiving Storage and loading will be done in three shifts per day and seven
days a week throughout the year
The handling capacity of the CHP has been decided to match with the coal
production of the mines. In order to meet the fluctuations of coal output
from the mine due to irregularities of despatch / transport system and
seasonal fluctuations, the design capacity of the CHP has been fixed at 1200
TPH(1500 TPH-Peak).
The Run-Off-Mine coal from the open cast Project shall be received in to 04
nos. of 60T capacity receiving Hoppers by means of lorries. Receiving hoppers
has been provided with 400 TPH Reciprocating feeders. The ROM coal will be
unloaded into the receiving hoppers. The coal will be reclaimed by
Reciprocating feeders and fed on to C-1 Conveyor. Crushed coal of (-) 200 mm
will be collected by the conveyor(C-1) of 1400 mm wide and 1200 TPH
installed underneath the Receiving hoppers and to carry up to discharge into
tripper trolley conveyor (C-2) of 1400 mm wide and spread over the self
flowing ground bunker(6,000 tonne).
Storage facility of 6,000 T capacity above ground bunker has been provided
to meet the requirement of fluctuation of coal production and despatch. The
bunker shall be constructed of pre-cast concrete slabs, sloping at 55 deg. to
the horizontal with single slit type opening for plough feeder. Below the slits
opening, reclaim conveyor is provided to collect coal from the Plough
feeders. The peak capacity of the reclaiming conveyor and plough feeders
shall be of 1200 TPH. Reclaiming conveyor (C-3) from bunker will discharge
coal into the despatch conveyor (C-4) of same capacity by chute. Coal from
conveyor (C-4) will be discharged in to 400/90 Cu. mtr capacity PWWL System
and there by unloaded in to the Wagons.
The objective of this system is to eliminate the air born coal dust or suppress
the dust at its source. The system involves confinement of the dust within the
dust producing area by a curtain of moisture and wetting the coal dust by
direct contact between the particles and droplet of water. Adequate number
of precision anti-clog nozzles will be installed at suitable locations for
suppressing dust by spraying water mixed with suppressant. Suitable control
for dust suppression shall be provided and the system shall be so inter-locked
that it functions only when the conveyor system is operating or the loading
operation is on.
System Requirement
The unit of Air Compressor is required to erect near the pump House. The
airlines are to be erected near by the water line. There will be two lines for
each header. One line for air and one line for water. The wetting agents can be
used with this system. The control system on basis of dust emission is required
to develop. (See Figure No 1).
Auto control or manual control will govern the system. It has to be ensured
that main tank is filled with water. The water is pumped by feed water pump
from main tank to feed water tank and at the same time metering pump doses
proper quantity of chemical. The feed water pump operation is controlled by
float switch automatically. The pump picks up at low level and stopped at high
level. The interlock with low level of main tank will not allow to pick up the
feed water pump.
The metering pump will stop the operation by sensing low chemicals in tank.
After ensuring proper level the solution pump will start. If the pressure
increase the pressure relief valve keeps the system in recalculations.
The air compressors will run to fill air tank up to desire pressure. There will be
two pressure level for air tank. The high level pressure is for tripping of air
compressor and low level is for pickup of compressor. Safety valve shall be
provided to meet the guide lines of American Society of Mechanical Engineers
(ASME) Code. If the pressure of the compressor rises more than expected due
to any reason (break down of static switch, fiddling with the adjustments etc.),
the safety valve be operated and discharges the excessive pressure.
There will be two solenoid valves for each header. One for airline and other for
water line.
The sensing system for controlling spray at proper header ensures spraying
solution if conveyor is running with coal and will not allow spraying solution if
conveyors are running empty.(See Figure No 2).
The solenoid valves (airline and waterline) of headers are energized if conveyor
is running with coal. If all or some of the solenoid valves for water line are not
energized the system will release the pressure through pressure relief valve,
which protects the system. A solenoid valve for water line is provided with
bypass line, which operates when none of the spray header solenoid valves are
operative.
Annexure-I
A Scope of Work:
Design, Engineering, Procurement, Fabrication/Manufacturing, Testing, Supply,
Installation and Commissioning of Automatic Dust suppression systems at Goleti
CHP on turnkey basis along with 3 years AMC after completion of warranty period
one Year:
The system shall be so designed that shall not contain any cabling along the
Conveyor.
Lay out of CHP along with details of conveyors indicating the location is enclosed
for reference of Tenderer.
To assess actual volume of work, the tenderer is required to visit Goleti CHP, BPA
Area, Telangana state before submission of their offer and take all clarifications/
technical details from the project authorities.
B Design considerations, Requirements of Dust Suppression System:
1 The Dust suppression system shall be designed tailor made to CHP with required
controls to suppress the dust with maximum efficiency and with minimum moisture
addition to coal. Design details along with layouts shall be furnished along with offer.
2 The spray of Dry Fog shall be a fine water droplet to suppress respirable dust
particles from 3 to 10 microns.
3 The capacity of water mist spray nozzles / Dry Fog nozzles shall be suitably
selected to suppress the dust and simultaneously moisture addition shall not exceed
0.5 to 1% of coal handled in case of water mist spray systems and 0.1% in case of
Dry Fog system.
4 The capacity of booster pump set and Compressor with complete Electricals shall
be selected suitably and to submit the parameters
5 Provision shall be made in system design to set to operate on auto mode with
suitable interlock mode as well as manual mode.
6 The system shall be designed to operate automatically where the coal is being
conveyed on the belt conveyors. The system shall automatically stop when the
conveyor is running empty / conveyor is stopped / when lorries are not unloading the
coal into bunkers.
7 Photo-electric sensors to be considered at Lorry unloading points. which activates
solenoid Valves and the dust suppression system shall work only unloading of Coal
in the hopper and spray shall be controlled depending on the vehicle stationed at
hopper .It shall spray when the vehicle starts unloading raw material in to the hopper
& shall stop immediately after unloading of raw material.
8 The water Mist spray / Dry FOG Nozzles shall be made of stainless steel. They
shall be non clogging type provided with self-cleaning mechanism.
9 To provide Cast Steel Globe valves in the pipe lines near every dust suppression
spray enabling to close them manually during maintenance / when dust suppression
is not required.
10 To provide non return valve in each pump delivery to avoid return flow of water to
the pump and to avoid water hammer effect.
11 To provide one pressure relief/unloading valve in pump delivery line to control the
line pressure.
12 A Pressure gauge shall also to be provided in pump delivery line, which helps to
monitor line pressure.
13 Booster pumps, Air Compressors, Motors, control panel, control cables, solenoid
valves, piping with connectors of reputed indigenous make are to be considered in
design of system. Details along with specifications and product literature to be
enclosed along with offer.
14 Stainless steel nozzles of both mist spray and dry Fog, load-sensing units of reputed
make are to be provided . Detailed specification and product literature to be
enclosed along with offer.
15 The make of all-important accessories of system to be furnished in the offer along
with their detailed specifications and product leaflets. All these details are to be
provided in operation, maintenance and spares manuals being submitted along with
system supply.
16 To Provide circular swiveling type water sprinklers having throw radius of 15 meters
(approx) at lorry unloading points .
17 Flow activation stations/ control panels shall be positioned strategically near to the
location to control automation process for the system.
18 The system shall suppress the dust at source (unloading / transfer points ) from
becoming air borne.
19 Plain water type single tip mist spray Nozzle:This type of dust suppression shall be
considered at lorry un loading Bunkers and G/L Bunkers. These nozzles mounted
on spray header shall have built in strainer and shall be made stainless steel. Cast
steel Globe valve shall be arranged to regulate the flow of water as required at each
nozzle header
20 Dry Fog Type Dust suppression System:
This system using mixture of water & compressed air shall create a fine fog of
atomized water droplets ensuring the fine dust particles of size from 3 to 10 microns
suppressed. Moisture addition shall be confined to 0.1% of the material handled.
The nozzles shall be made of stainless. The nozzles shall be non clogging & self
cleaning type and shall be considered at Conveyor transfer points.
21 Pressure Regulating Units: Suitably designed pressure regulating units shall be
provided with pressure gauge and Isolating valve to regulate the required air and
water pressure.
22 Control Panel / desk: Designed to enable the operator to start / stop individual dust
suppression system at either Manual / Remote /Auto mode. It shall have provision
to supply power to flow activation station to ensure spraying taking place only on
loaded belt that is running condition.
23 Auto Control device ofr Conveyors: All the conveyors shall be provided with this unit
which is operating Electro-mechanically. When the conveyor is running empty the
belt shall avoid contact with the driven wheel of the auto control device, thus the in-
built micro switch is open. Similarly when the belt is stationary the wheel will remain
static and micro switch remains open.
The slightest load of coal on the conveyor shall deflect the belt and rotates wheel,
thus closing the micro switch which gives electrical signal to the solenoid valve that
allows water / air to the spray nozzles.
C Scope of supply by tenderer:
1 Suitable capacity water booster pumps along with Electrical Motors & Control panel.
(One unit will be stand by.)
2 Suitable Air compressor along with receiver with Electricals
3 Required piping (both GI & flexible), valves and fittings for both water &
compressed air and also installation of complete pipe line.
4 Control panels & Control cables & Power cables as required.
5 Stainless steel Single tip/Multi tip plain water & dry fog Nozzles of suitable capacity.
6 Auto control devices , sensors, flow activation stations & pressure regulating units.
7 Flexible hoses required for water & air to the dust suppression systems of tripping
trolleys & rotary plough feeders for entire travel lengths.
D Scope of supply by SCCL:
1 We have not considered any kind of civil work e.g. Foundation for pump / Wall open
ing forpiping, Construction of RCC tank / Room for MCP, Pedestal / excavation for st
ockpile pipeline, Insert plates for pipe support.
Any other civil work not mention here in the scope of Tenderer.
2 Providing 440V/550V Power supply & water at pump house.
4 All fabrication work of Skirt Boards, enclosures with its accessories and supports .
5 SCCL will provide electricity, water, at free of cost at site as and when required on
request of the successful bidder for the purpose of Design, Engineering,
Procurement, Fabrication/Manufacturing, Testing, Supply, Installation, testing
and Commissioning of Dust Suppression system.
6 SCCL shall provide the warehouse facility to successful bidder during the period of
erection & commissioning of the Dust Suppression system
E Eligibility Criteria
1 Firms having experience in Design, Engineering, Procurement, Fabrication/
Manufacturing, Testing, Supply, Installation, testing and Commissioning of Dust
Suppression systems in coal handling plants in CIL/SCCL or any PSUs and should
have executed successfully at least 2 nos. of such works .
Experience of having successfully completed similar works during last 7 years
ending last day of month previous to the one in which tenders are quoted are
invited should be either of the following
a) Three similar completed works costing not less than the amount equal to 40%
of the estimated cost.
Or
b) Two similar completed works costing not less than the amount equal to 50%
of the estimated cost.
Or
c) One similar completed work costing not less than the amount equal to 80% of
the estimated cost.
2 The bidder shall furnish a reference list of such projects executed by them. They
shall submit copies of purchase orders along with prices, executed by them in the
last 7 years.
The tenderers shall upload the Satisfactory performance certificate issued by who
has originally awarded the contract and also furnish/ upload the order copies
(against which the satisfactory performance report is enclosed) with necessary
enclosures, such as work completion reports etc.
The work order referred above should have been awarded to and executed by the
Bidder himself.
3 They shall furnish foreign tie up / collaboration if any for Dry Fog dust suppression
system offered by them.
F General Terms & Conditions:
1 Tenderers shall offer a list of non-consumable spares required for one-year trouble
free operation. Unit Price to be furnished for each of spares offered to enable SCCL
to select the spares to be ordered along with system.
2 The complete dust suppression system shall be guaranteed for one year from the
date of commissioning for trouble free operation including any spares required in
addition to guaranteed spares offered above.
3 Service Personnel shall be made available within 48 hours along with required
spares to attend any breakdowns / faults and put back the system in operation
during warranty period..
4 Tenderers shall quote prices for comprehensive AMC after expiry of one-year
warranty period.
5 Training shall be imparted to our Engineers and Technicians at site on the operation
& maintenance of system.
6 Prices shall be offered per meter length basis for water and air pipes, control cables
(Size wise) and payments will be made accordingly as per actual measurements.
7 Flexible hoses, valves, pipe fitting to be offered on lump sum basis.
8 Total quantity requirement of water & compressed air to be indicated.
9 Unit prices shall be offered for Multi-tipped Mist spray nozzles, single tip mist spray
nozzles & dry fog nozzles.
10 Total quantity of nozzles (Type wise) considered in design shall be clearly indicated
in the offer.
G Other Terms & Conditions:
1 The work shall be carried out in compliance with all applicable statutory
provisions without interrupting the existing operations. The successful bidder shall
comply with all labour laws and other statutory laws in force from time to time and
SCCL shall not be responsible for any liability whatsoever.
The successful bidder shall carry out the work as per tender documents,
plans, drawings and specification given either in the tender or subsequently
by SCCL or its authorized representative. The material and work shall be as per
relevant IS/BS/ASTM /DIN or any other equivalent specifications as applicable and
as per instructions of SCCL’s authorized representative and approved drawings.
If the fall in percentage availability is more than 20% (i.e. less than 70%) SCCL will
have the option to reject the equipment, after levying 10% penalty and the
manufacturer shall have to replace the complete / part of the equipment, as
applicable, at his cost, to meet the guaranteed percentage availability.
GM(E&M), OCPs&CHPs
ANNEXURE.II
pH Value: 7.4-8.00
Nitrates as NO3:44mg/ltr
PM10< 100µg/m3
PM2.5< 60 µg/m3
SCCL ACQUIRED LAND BOUNDARY/
PROPOSED COMPOUND WALL
Transfer
Point
/
RY
(3044170.830,
H
997851.6390)
WA NDA
LLA
NK L
S
LL
NA
ND OU
B U 0T G
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tatio
600
CO D LA
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itc h
(3044132.931,
MP
997808.243)
E
Sw
O S U IR
(3044129.693,
997810.295) (3044136.169,
997806.192)
OP CQ
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PR L A
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SC
(3044167.968,
997786.047)
FINAL LOADING
POINT
Rest Shelter
(3044165.400,
997727.818)
Parki ng Shed
Stores
Pit
site office
Sub Station
Indoor
Out Door
substation
EXISTING BRIDGE