A-138 - Jaigarh Port Phase III-MHS - Conv. Tech. Spec. - R1 PDF

JSW Jaigarh Port Ltd.
Expansion of Jaigarh Port

(PHASE III – MHS)
Tender
for
Contract M-02
MATERIAL HANDLING CONVEYOR SYSTEM
FOR BERTH 6A
Part A: Mechanical & Associated Electrical Works
Part B: Structural Steel Works
VOLUME II
TECHNICAL SPECIFICATION
DRAWINGS
SCHEDULES
Grafix Engineering Consultants Pvt. Ltd.

New Delhi
18th Jan 2019
22nd Jan 2019(R1)
Expansion of Jaigarh Port
(Phase III – MHS)
Tender
for
Contract M-02
MATERIAL HANDLING CONVEYOR SYSTEM
FOR BERTH 6A (PHASE III – MHS)
Part A: Mechanical & Associated Electrical Works
VOLUME II
DRAWINGS
SCHEDULES
Contract M-02
MATERIAL HANDLING CONVEYING SYSTEM Date : Jan 2019 (R1)
Technical Specification Page |1
Part A: Mechanical & associated Electrical Works
Table of Contents
1 GENERAL ..................................................................................................................................... 3
2 SCOPE OF WORK ....................................................................................................................... 4
2.1 General ......................................................................................................................................... 4
2.2 Work Included ............................................................................................................................. 7
3 WORK NOT INCLUDED .......................................................................................................... 10
4 DRAWINGS ................................................................................................................................. 11
5 SITE CONDITIONS ................................................................................................................... 12
5.1 Introduction ................................................................................................................................ 12
5.2 Site Information and Climatic Conditions ................................................................................. 12
6 MATERIALS TO BE HANDLED ............................................................................................. 16
7 GENERAL DESIGN REQUIREMENT .................................................................................... 17
7.1 Brief Description of the Facility ................................................................................................ 17
7.2 Duty ........................................................................................................................................... 17
7.3 Standardization .......................................................................................................................... 18
7.4 Design Standards ....................................................................................................................... 18
7.5 Material: Codes and Standards.................................................................................................. 18
7.6 Components: Codes and Standards ............................................................................................ 19
7.7 Belt Conveyor System ............................................................................................................... 19
7.8 Miscellaneous Mechanical Equipment ....................................................................................... 34
7.9 Technological Structure ............................................................................................................. 48
8 ELECTRICAL AND CONTROLS ............................................................................................ 53
8.1 General ....................................................................................................................................... 53
8.2 Codes and Standards .................................................................................................................. 53
8.3 LT Motors .................................................................................................................................. 54
8.4 Local Electrical Control Panels .................................................................................................. 55
8.5 Power Cables ............................................................................................................................. 60
8.6 Cable Trays ................................................................................................................................ 62
8.7 Earthing ...................................................................................................................................... 63
8.8 Control System........................................................................................................................... 63
8.9 Makes of Components ............................................................................................................... 67
9 QUALITY ASSURANCE, INSPECTION, TESTING AND DESPATCH ............................. 68
9.1 Quality Assurance ...................................................................................................................... 68
9.2 Inspection and Testing ............................................................................................................... 69
10 ERECTION AND INSTALLATION ......................................................................................... 71
11 PAINTING ................................................................................................................................... 74
11.1 General ....................................................................................................................................... 74
11.2 Preparation of Surfaces for Painting .......................................................................................... 74
11.3 Specifications of Painting .......................................................................................................... 74
12 FIELD TESTS ............................................................................................................................. 76
12.1 Tests ........................................................................................................................................... 76
12.2 General ....................................................................................................................................... 76
12.3 Adjustments ............................................................................................................................... 77
12.4 No Load Tests ............................................................................................................................ 77
12.5 Load Tests .................................................................................................................................. 77
Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

Employer: JSW Jaigarh Port Ltd. Engineer: Grafix Engineering Consultants Pvt. Ltd.
Contract M-02
12.6 Commissioning .......................................................................................................................... 78

12.7 Reliability Test ........................................................................................................................... 78
12.8 Performance Test ....................................................................................................................... 79
13 TRAINING ................................................................................................................................... 81
14 SPECIAL APPLICATION ......................................................................................................... 83
14.1 Temporary Works ...................................................................................................................... 83
14.2 Contractor's Working Area ........................................................................................................ 83
14.3 Water Supply and Power Supply ............................................................................................... 83
14.4 Temporary Fencing and Security ............................................................................................... 83
14.5 Programme of Works and Progress Report ................................................................................ 83
14.6 Environmental Controls ............................................................................................................. 84
14.7 Design and Drawings ................................................................................................................. 85
14.8 Post Qualification Criteria: ........................................................................................................ 88
15 LIST OF APPROVED MAKES OF MAIN MECHANICAL BOUGHT-OUT
COMPONENTS........................................................................................................................... 89
 TABLES
 ANNEXURES
 SCHEDULES
 DRAWINGS

Contract M-02
1 GENERAL
1.1 The equipment specified herein shall be designed and built for the Cargo Import at Jaigarh Port in
Damankul Bay, near Jaigarh, Maharashtra, India, for JSW Jaigarh Port Ltd. (JSWJPL), the
Employer, with an intention to re-export the imported cargo by Barges/ships to Dharamtar Port,
Maharashtra, for feeding the nearby JSW Steel Plant.
JSW is set to implement expansion of its existing Steel plant from 5 MTPA to ~ 11.0 MTPA capacity.
The proposed material handling system in Phase III expansion is planned to cater to meet the
enhanced steel plant capacity.
The ongoing dispatch of multi cargo (Coal / Iron Ore / Limestone / Dolomite) from existing stockyard
behind berth 1 & 2 through barges at berth 6A planned in Phase III. Cargo unloaded at Berth 1 &
Berth 3A is being stacked in the stockyard and is dispatched by barges at berth 6A using the
existing stockyard conveyors JRD-1A & JRD-1B.
Proposed Phase III-MHS development will be integrated with the existing system to continue with
loading of Barges/Ships at berth 6A.
For information of existing facility and its integrated with the new facility planned under Phase III -
MHS refer Layout Plan at Berth 6A (Drg. No : A138 M02 OL 001 R.0) and Flow Diagram (Drg. No.
A138 M02 OF 001 R.0) showing details of the Berth 6A facility (planned new + existing).
1.2 The Material Handling Conveying System will be designed and built for dispatching cargo from
existing & new stockyard through Barge/Ship Berth 6A and including extension of Berth 6A.
1.3 The existing facility is an operating terminal and the tenderer shall pay special attention to this fact
while detailing/ erection of the equipment under his scope, particularly in the interfacing areas with
the existing facility, to ensure that operation of the terminal are not interrupted/ affected in any way.

Contract M-02
2 SCOPE OF WORK
2.1 General
 The technical specifications and attached drawings outline the conditions and functional
requirements to facilitate understand / assess the nature and scope of work to be carried out by
the tenderer to design, modification in existing facility, manufacture, supply, delivery and store
at site, erection, testing, commissioning and handing-over of the facility covering mechanical,
associated structural and electrical works including furnishing of all labour, material and
services and complete the New Conveyor System in all respects to provide satisfactory
performance as specified herein. In any case, the performance of the installed complete
Conveyor System shall be guaranteed in every detail by the Contractor.
Broad information of existing facility and the new facility planned under Phase III - MHS is
broadly mentioned below:

Contract M-02
Sl. Belt Conveyor System Remarks

No.
Existing facility New facility
a) i) Receiving from Stockyard Conveyors Receiving from Stockyard Conveyors upto JTT-6:
upto Transfer TowerJTT-6:  JD-1A & JD-1B (reclaim conveyors.)
 JRD-1A & JRD-1B Outgoing Conveyors From JTT-6:
ii) Outgoing Conveyors From Transfer  JD-4A & JD-4B (Feeding to barge/ship
Tower JTT-6 to barge berth 6A: loader SL-5 & SL-6 via conveyors JD-5E
 JD-2A & JD-2B & JD-5F respectively)
(Feeding to barge
loader BL-1 & BL-2 via
conveyors JD-5A &
JD-5B respectively)
 Direct feeding to barge
loader BL-3 via
conveyor JD-5C
 JD-3A (Feeding to
barge loader BL-4 via
conveyor JD-5D)
b) Vibrating Feeders: VF-1A & VF-1B and Vibrating Feeders: VF-2A & VF-2B and VF-3A &
VF-4A & VF-4B VF-3B, along with flow control RPG gate
c) Barge loader conveyors: JD-5A, JD-5B, Barge loader conveyors: JD-5E, JD-5F
JD-5C & JD-5D
d) Transfer Towers JTT-3, JTT-4, JTT-5, Transfer Tower JTT-8 & JTT-9
JTT-6 & JTT-7
e) Modification in existing facility:
1) Chute, floor beam modification and
extension of existing conveyors JD-2A &
JD-2B in Transfer Tower JTT-6
Existing Conveyors JD-2A & JD-2B
extended by ~5m and converted to
reversible conveyor for feeding to JD-4A
& JD-4B, any change in drive
components of JD-2A & JD-2B required
due to change from unidirectional to
bidirectional conveyor is also included in
scope.
2) Existing splitter gates in transfer tower
JTT-6 to be replaced with diverter gates
having cargo division option from 0 to
100% on either side.
Modifications in chutes connected with
splitter gate are also included in the
scope, as required.
3) Floor beam modification in Transfer
Tower JTT-6 for stringer short post fixing
of conveyors JD-4A & JD-4B
4) Gallery beam modification in existing

Contract M-02
galleries of reclaiming conveyors JRD-

1A & JRD-1B for fixing/mounting of
stringer short post of conveyors JD-1A &
JD-1B.
5) New yard conveyors JD-1A & JD-1B will
be installed on the existing foundations.
Elevated portion of these conveyors will
be installed in the existing steel galley for
conveyors JRD-1A & JRD-1B.
6) Existing foundations of transfer tower
JTT-8 & JTT-9 as planned earlier shall
be used (ref dwg no: A 138 M02 MG 010
& A 138 M02 MG 011).
 The equipment and materials covered by this specification are subject to the referenced
attachments. The tenderer shall be responsible for and governed by all the requirements of the
specifications and General Conditions of the Contract which shall form part of this document.
 Notwithstanding the details furnished in this document, it shall be the responsibility of the
contractor to complete the work in all respects (with the exception of the items covered in
works not included listed in Section 3.0), Commission, complete the trials and performance
tests to the satisfaction of the Engineer / Employer.
 Drawings covering relevant information have been furnished herein for better
understanding/assessment of the nature/quantum of works covered in this contract. Details/
dimensions, shown in these drawings shall be adhered to as far as possible, unless the
Tenderer has reservations in specific case(s).
Such reservations/deviations shall be explicitly brought out in Schedule 11 – Statement of
Deviations.

Contract M-02
2.2 Work Included

2.2.1 The specifications and attached drawings outlining the conditions and functions covering scope for
the ‘New Belt Conveyor System’ and associated equipment comprising:
2.2.2 New Conveyors are designed for handling Multi-Cargo and are having VFD drive for variable speed.
a) New Conveyors: Yard conveyor JD-1A & JD-1B, JD-4A & JD-4B, barge/ship feeding conveyors
JD-5E & JD-5F.
b) Extension of Conveyor JD-2A & JD-2B (existing unidirectional conveyor) by ~5m and with
changes as required in components of JD-2A & JD-2B to change the conveyor from
unidirectional to bidirectional conveyor, is included in the scope.
c) Existing splitter gates in Transfer Tower JTT-6 to be replaced with diverter gates having cargo
division option from 0 to 100% on either side. Modifications in chutes connected with splitter gate
are also included in the scope, as required.
d) Conveyor technological structure for supporting conveyor components to match the existing
foundations.
2.2.3 All Belt Conveyors shall be complete in all respects as identified in the drawings.
2.2.4 Miscellaneous Mechanical Equipment: Belt Weighers with weigh idlers, Magnets and Metal Detector
on conveyors, Maintenance Cranes / Hoists at the Transfer Towers, Vibrating Feeders including
Rack/Pinion Gates under distribution hoppers.
2.2.5 Associated Electrical equipment:
 Local Electrical Control Panels and local push button stations (LCS) for all items (except belt
conveyor drive motors, by JSW) under the scope including cables, cable trays and earthing
from equipment to local panel.
 VFD and VFD panels for Vibro feeders
 Fabrication (based on GA drawings provided by JSW) and erection of support brackets and
mounting of conveyor safety switches (pull cord, belts / sway, take-up, zero speed, chute plug,
to be supplied by JSW).
 Following Voltages shall be adopted for designing the Electrical equipment:
Power Supply
i) 415 V, 3 Ph, 50 Hz for Variable Speed Motors for Conveyors upto 250 kW (for multi-cargo
handling conveyors). However, for more than 250 kW Motors - 690 V, 3 Ph, 50 Hz.
ii) 415 V, 50 Hz, 3 Ph / 240 V 1 Ph for other equipment.
2.2.6 Erection of all equipment, including items provided by others as “Free Issue Items” such as motors
of conveyor Drive, conveyor safety switches. However motors for drives of all auxiliary equipment’s
are included in the scope.
2.2.7 Seek Engineer’s / Employer’s approval of drawings (to take up fabrication), erection methodology
and quality norms, etc., required for erection.

Contract M-02
2.2.8 Testing, trial run and commissioning of complete integrated New Conveyor System specified under
the scope.
2.2.9 Handing over of the system complete in all respects, functional and free from defects including
furnishing of labour, material and service required for the ‘New conveyor System’.
2.2.10 Necessary modification of existing structure for erection of equipment / integration of the new
conveyor system with the existing conveyors.
2.2.11 Painting (As per clause No.12), Technological structure and all related items/components for ‘New
Conveyor System’
2.2.12 Foundation grouting wherever required for the system for installing the conveyor system, as
applicable. Foundation grouting as required by JSW
2.2.13 Supply of commissioning spares and spares for two years of operation (as indicated in Appendices,
Tables & Annexure) for items supplied under the scope.
2.2.14 All approvals and licenses required by all authorities having regulatory powers to control the
fabrication, erection and operation of the conveyor system within the State of Maharashtra /
concerned statutory Government Authorities.
2.2.15 Management, coordination, planning of the work at all location of the works at site including
occupational health and safety, quality control, design, manufacturer, delivery, inspection, erection,
testing & commissioning.
2.2.16 Erection and fabrication of all temporary structures, tools, rigging, grouting, erection, temporary
power for fabrication, temporary power for erection, testing, adequate site lighting, temporary water
supply, transport logistics in the site, etc.
2.2.17 Supply of all fasteners bolts with plain / spring washers, Nuts / lock nuts as required for the
equipment under the scope.
2.2.18 All consumable materials for welding (make approved by Client / Consultant), erection, fuel for
construction plant of the tenderer, consumables for temporary power, consumables for cleaning of
components / items up to the handing over.
2.2.19 Clean up at site of all debris and temporary structures on a daily basis and final clean up and
handing over.
2.2.20 All electrical safety requirements during site fabrication, erection, testing and commissioning,
including adequate earthing of erection/ fabrication equipment and machines
2.2.21 Proper safe storage (temporary shed / container, etc.) of all equipment and materials delivered at
site in the area designated by the Engineer / Employer in line with the Customs Authority
Regulations, if applicable.
2.2.22 All consumables material including filters, lubricants & Oils, hydraulic fluids, electrical fuse up to
equipment handing over, as applicable.
2.2.23 Supply of all engineer and labour for manufacture, delivery of fully assembled equipment, testing
and commissioning of equipment, including transportation as required, housing, security, temporary
sanitation and safety requirements, up to handling over of equipment.

Contract M-02
2.2.24 Day to day coordination with other contractors in the interfacing areas who will be carrying out works
at site simultaneously.
However, Employer shall be responsible for overall coordination.
2.2.25 Manuals for installation, operation & maintenance, Details of maintenance spares, along with
drawings as required.
2.2.26 Development of land for the fabrication yard with fenced boundary and the complete fabrication yard
as required.
2.2.27 Motors & safety switches for conveyor drives will be ‘free issue item’. However, installation of the
motors and safety switches along with safety switches mounting brackets is in the scope of this
tenderer.
2.2.28 All lifting & shifting equipments, cranes, tools & tackles, etc., shall be in the scope of the Contractor.
2.2.29 Free Issue Item (conveyor drive motors & safety switches) will be issued to the contractor’s stores.
Unloading, Safe custody till erection, internal handling/transport to erection site etc. shall be in the
scope of the contractor.
2.2.30 Anchor bolts, such as, required for mounting drive frame, head frame, tail frame, sheave frame etc.,
on concrete slab in transfer tower and on ground, as required are included in the scope.
2.2.31 Structural steel works (conveyor galleries and transfer towers for the conveyor system) included in
Contract M-02, is covered in separate document i.e. Part B: Structural steel works.

Contract M-02
Technical Specification P a g e | 10
3 WORK NOT INCLUDED

3.1 All Civil works including foundations for Transfer Towers, Trestles, and Take-up Towers and for
equipment as required. However, civil works in floors of Transfer Towers (concrete floor for drive
units, etc.) are included in the scope.
3.2 Structural Work – Conveyor galleries, trestles, and transfer towers complete with cladding. However,
counter weight blocks & counter weight towers required for the New Conveyor System are included
in the scope. Also, anchor bolts, such as, required for mounting drive frame, head frame, tail frame,
sheave frame etc., on concrete slab in transfer tower and on ground, as required are included in the
scope.
3.3 Construction of Berths (existing) and extension of Berth 6A by 40.0 meters.
3.4 Existing Conveyors (in stockyard on wards) JRD-1A/1B, JD-3A, JD-5A, JD-5B, JD-5C & JD-5D and
Transfer Tower JTT-4 & JTT-5 for handling Iron Ore / Coal. However necessary modification in JTT-
6 included in the scope.
3.5 Supply of conveyor Drive Motors, conveyor drive motor VFDs and safety switches for all conveyors
(by JSW). However, motors & VFD for auxiliary equipment’s & erection of conveyor drive Motors &
safety switches for the Conveyor are included in the scope.
3.6 Roads drainage, boundary wall, wind shield.
3.7 Buildings: Sub-Stations, Workshop and stores, Fire Station, Main Water Storage Tank and pump
house for firefighting / main water supply system.
3.8 a) Central Control system for the new conveyors (by JSW)
b) Power distribution system including lighting, communication (by JSW), except for electrical
covered in ‘Works Included’.
3.9 Details of work, if any, (pertaining to the scope of work of this contract) to be carried by others for
installation of items to be supplied by this contractor shall be furnished by the tenderer.
3.10 Payloaders / Backhoe / Dozers.
3.11 HT and LT Power Cables from substation (by JSW) to the Tenderer’s local Electrical Control Panels.
3.12 Central Control PLC interlocks with hardwired Control Cable and Modbus RTU Cables from local
Electrical Control Panel to nearest R-I/O Unit. However, provision for JB/Cable gland plate shall be
considered in the tenderers local electrical control panel.
3.13 Dust Suppression System and Fire Fighting System.
3.14 New Reclaimers (2 nos) in the stockyard
3.15 New Barge/ship loaders (2 nos) at barge berth
3.16 Associated civil foundations for the transfer towers and galleries are excluded from the scope.
However, grouting wherever required for the system for installing the conveyor system is included in
JSW scope.
However, the contractor shall furnish Reaction Loads & other technical data required for designing
and detailing of civil foundations.

Contract M-02
4 DRAWINGS
Typical representative drawings are listed below to enable the Tenderer to understand the system
and its functional requirement. Drawings listed below form part of the specification.
MECHANICAL DRAWINGS (NEW CONVEYOR SYSTEM)

Sl. No. Drawing Number Drawing Description
1. A-138 M02 OL 001 Layout Plan at Berth 6A
2. A-138 M02 OF 001 Flow Diagram at Berth 6A
3. A-138 M02 MP 001 (R1) Profile of Conveyors JD-4A/4B (2 sheets)
4. A-138 M02 MP 002 (R1) Profile of Conveyors JD-5E/5F
5. A-138 M02 MP 003 Profile of Conveyors JD-1A/1B
6. A-138 M02 MP 004 Modification of Conveyors JD-2A/2B
7. A-138 M02 MG 001 (R2) General Arrangement of Conveyors JD-1A/1B
8. A-138 M02 MG 002 (R1) Conveyor Standard Stringer Unit – 1800 BW
9. A-138 M02 MG 003 Conveyor Standard Stringer Unit – 1600 BW
10. A-138 M02 MG 004 Conveyor Standard Stringer Unit – 1400 BW
11. A-138 M02 MG 005 General Arrangement of Vertical Gravity Take-ups
12. A-138 M02 MG 006 General Arrangement of Horizontal Gravity Take-ups
13. A-138 M02 MG 007 General Arrangement of Screw Take-ups
14. A-138 M02 MG 008 General Arrangement of Discharge Chute & Skirt (Typical)
15. A-138 M02 MG 009 Conveyor Hood Arrangement – Typical
16. A-138 M02 MG 010 (R1) General Arrangement of Transfer Tower JTT-8 (2 sheets)
17. A-138 M02 MG 011 (R1) General Arrangement of Transfer Tower JTT-9
18. A-138 M02 MG 012 Modification on Existing Transfer Tower JTT-6 (9 sheets)
19. A-138 M02 MG 013 Modification on Existing Transfer Tower JTT-3 (2 sheets)
Following drawings of the existing system are attached for information of the tenderer.
Sl. No. Drawing Number Drawing Description
1. A-105 000 OL 003 R5 Overall Layout Plan
2. A-105 000 OF 003 R2 Flow Diagram
3. A-105 M6B MG 003 General Arrangement of Transfer Tower JTT-3 (2 sheets)
4. A-105 M6B MG 006 R2 General Arrangement of Transfer Tower JTT-6 (4 sheets)
5. A-105 M6B MG 007 R2 General Arrangement of Transfer Tower JTT-7
6. A-105 M6B MG 016 R2 General Arrangement of Conveyors JRD-1A/1B (2 sheets)
7. A-105 M6B MG 017 R3 General Arrangement of Conveyors JD-2A/2B
Based on the above typical drawings, the Contractor shall prepare relevant engineering and
fabrication drawings for all the conveyors including Detailed General Arrangement drawings for
erection of Conveyor Components of all individual conveyors (similar to GA of JD-1A/1B) and further
drawings will be prepared by the Contractor on the basis.

Contract M-02
5 SITE CONDITIONS
5.1 Introduction
The equipment shall be designed and constructed to operate continuously at the rated capacities
and under climatic and saline ambient conditions outlined in the document. The information provided
on site conditions is given in good faith but the contractor shall satisfy himself regarding correctness
of the same and no claim will be entertained due to any error in the information supplied herein.
5.2 Site Information and Climatic Conditions

5.2.1 General
The site selected for development of port facilities in State of Maharashtra is at Damankul /
Damankul Bay located on the coast near “Jaigarh” village in Ratnagiri District. The site is
approximately 55 km. from the town of Ratnagiri.
Nearest Railway Station is in Ratnagiri. Ratnagiri is connected to NH17, which connects it to
Mumbai and Goa. Jaigarh is around 300 km South of Mumbai and around 290 km North of Panaji.
The tenderer shall visit the site to make on the spot study to get familiar with the site conditions
while quoting for their equipment.
5.2.2 Geographical Location

The location of the proposed all weather port in the Damankul Bay off the Jaigarh Head lies between
latitudes 170 18’ 00’’ and 170 18’ 18’’ North and 730 12’ and 730 13’ East.
5.2.3 Tides and Tidal Currents
A) Tidal Heights
The information on tidal levels for Jaigarh (Lat. 170 17’ 30’’ N, Long. 730 13’ 30’’ E) is
mentioned on the Naval Hydrographic Chart 2011, with reference to the datum of
soundings, as given below:
MHWS +2.8 m
MHWN +2.2 m
MSL +1.8 m
MLWN +1.3 m
MLWS +0.8 m
B) Tidal Currents
The Naval Hydrographic Chart No. 256 shows offshore currents, which are of monsoonal origin,
but tend to follow the trends of the coastline. Between December and January the sets are
mostly north-westerly with rates up to 1 knot. In July and August when the monsoon is well
established, south-easterly sets in with a magnitude of 2.0 knots are experienced. Onshore

Contract M-02
sets up to 1.5 knots are experienced during NE monsoon and up to 3 knots under SW
monsoon.
5.2.4 Climate
A) General
The climate of this region is governed by its location in the tropics and by the monsoon.
Annually recurring monsoons divide the year in to three seasons as follows:
i) The pre monsoon period (spring) from April to May, a time of the year having hot climate,
with the month of May being the hottest
ii) The south-west monsoon prevailing from June to September with mainly south-westerly
winds and
iii) The post monsoon period (autumn) from October to March with Northwesterly winds.
B) Rainfall
The annual rainfall in the area is approximately 3400 mm, 94% of which occurs in the months of
June, July, August and September.
C) Temperature
January is the coldest month with temperatures reaching 19.10 deg. C. Similarly, the month of
May is the hottest month with temperatures up to 33.50 deg. C.
D) Relative Humidity
The average humidity ranges from nearly 90% in August to about 60% in January.
E) Visibility
The general visibility in the area is good. Visibility in the monsoon normally deteriorates during
rains and occasional squalls.
F) Wind
Figures 2.1 and 2.2 show the wind velocities and directions over the year in the region.
(Source: Indian Meteorological Department). The study of the available data related to wind
speed and directions is given in Table 2.1.
Table 2.1 General trends in prevailing wind speed
Duration Predominant Wind Direction Pre-dominant speed – Kmph
October - May NW 13 – 19
June - September SW 30 – 57

Contract M-02
Figure 2.1 Annual Wind Speed and Direction Roses near the site Offshore (For Legend ref
Figure 2.2)

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Figure 2.2 Monthly Wind Speed and Direction Roses near the site offshore.
G) Seismic zone
The site has been categorized as Seismic Zone IV as per IS 1893 to take into account effects of
earthquake.

Contract M-02
6 MATERIALS TO BE HANDLED
The materials and typical characteristics of the materials to be conveyed are given below.
Depending upon the source, the characteristic is likely to vary.
A. Iron Ore
a) Bulk Density 2.1-2.8 tonnes / cu.m; 2.4 tonnes / cu.m. (avg.)
b) Lump Size 0-10 mm, 10-40 mm, 100 mm (max.)
c) Angle of Repose 35 deg. (varies with moisture content)
d) Moisture content 8% (max.)
B. Coking Coal
a) Bulk Density 0.8 to 0.9 tonne/cu.m.
b) Lump Size 0-50 mm (occasionally upto 150 mm)
c) Angle of Repose 35 deg.
d) Moisture content 8 to 10%
C. Limestone
a) Bulk Density 1.4 tonne/cu.m. (max.)
b) Lump Size 0 - 80 mm
c) Angle of Repose About 43 deg.
d) Moisture content 5%
D. Dolomite
a) Bulk Density 1.5 tonnes/cu.m.
b) Lump Size 0 - 80 mm
c) Angle of Repose 35 deg.
d) Moisture -
Note:
1. Cargo will be sluggish during rainy season due to additional moisture.
2. The items / components shall be subjected to the dust laden atmosphere with saline
water spray.

Contract M-02
7 GENERAL DESIGN REQUIREMENT

7.1 Brief Description of the Facility
The Existing Facility at Jaigarh comprising Grab Unloaders, Conveyor System, Covered / Open
Stockyard, Stacker / Reclaimers, Barge loaders presently handles import of multi bulk cargo (Iron
Ore, Coking Coal, Limestone, and Dolomite) and export of the same from Barge Berths to JSW
Steel plant at Dolvi. The present expansion is planned to cater to enhanced requirement of JSW
steel plant and envisages addition of two new reclaimers, two barge/ship loaders on Barge Berth 6A
and these will work in conjunction with the proposed New Conveyor System planned in the facility.
With the proposed expansion, the system will be capable of loading to new barge/ship in addition to
ongoing operation of loading two barges. The existing barge berth 6A will be extended by 40m to
facilitate installation of new barge/ship loaders in Phase III - MHS. The New Conveyor System in
Phase III - MHS will be provided for multi-cargo handling with VFD drives for loading the cargo into
the barges/ships.
In the ongoing operation, multi cargo (iron ore, coal, limestone and dolomite) is unloaded at Berths 1
& 3A and is stacked in stockyard behind berth 1 & 2 (Plot-A) via conveyor JRD-1A & JRD-1B
working in conjunction with stacker/reclaimer (one each on each yard conveyor). For dispatch of
cargo through barges, stacker/reclaimer and yard conveyors JRD-1A & JRD-1B are used and the
cargo so received is divided through splitter gates and vibrating feeders in transfer tower JTT-6 for
further loading onto barge loaders BL-1, BL-2, BL-3 & BL-4.
In the existing multi cargo stockyard behind berth 1 & 2 provision of adding two reclaimer conveyors
JD-1 & JD-1B, two new reclaimer including its connectivity with the barge loading operation in
transfer tower JTT-6 was planned as reflected in the Layout (dwg no.: A 105 000 OL 001) and Flow
diagram (dwg no.: A 105 000 OF 001).
The same forms part of the present Phase III – MHS expansion. The barge/shipe loading at
extended berth 6A will also have provision of receiving coal in future from the existing stockyard
(Plot-B) as shown in Flow diagram (dwg no.: A 138 M02 OF 001).
The present Phase III-MHS development will include integration of operations on the existing Berth
1 & Berth 3A with operations on Berth 6A connected with new stockyard conveyors JD-1A & JD-1B
for reclaiming the Multiple Cargo (Coal, Iron Ore, Limestone and Dolomite) from the stockyard and
further dispatch through Barge/Ship Berth 6A.
The complete system for handling multi cargo with new conveying system is depicted in Flow
Diagram (dwg no: A138 M02 OF 001) and Layout Plan at Berth 6A (dwg no: A138 M02 OL 001)
for Phase III- MHS.
7.2 Duty
The new conveying system offered shall be designed and constructed for continuous duty at
capacities as specified and under climatic and ambient conditions outlined in this specification.

Contract M-02
7.3 Standardization
The Conveyor System assemblies / components, bought-out equipment’s etc shall be standardized
to the maximum extent possible including sourcing from the same supplier of the existing system to
reduce the spare parts inventory to the minimum.
7.4 Design Standards

The materials and components shall be designed and manufactured in accordance with the
requirements of Indian Standards rules and regulations as far as possible. All Belt Conveyors shall
be designed as per IS:11592-2000 / CEMA – Belt Conveyors for Bulk Materials, 5th / 6th Edition or
equivalent international code. For components like idlers and pulley etc IS:8598 and IS:8531 shall
be followed.
a) Unless mentioned otherwise latest edition of all applicable Indian Codes, Regulations, and
Standards shall govern even when the requirement of th ”specification“ are less stringent than
the codes, regulations and standards.
b) Where a suitable Indian Standard Code/Regulation mentioned herein is lacking, the equivalent
including the material shall be designed and manufactured in accordance with International
Standard.
c) Wind Load:
Wind pressure and loads (As per IS:875, Part No-3) shall be calculated using the following
values:-
 Operating Wind  20 m/sec at all levels (25 kg/m2)

 Cyclone Wind Velocity (basic)  Wind speed 44 m/sec. These wind pressure
and loads shall be used in conjunction with
shape and shielding factors AS PER IS:875
d) Design Equipment Temperature: 45° C minimum
7.5 Material: Codes and Standards

Unless otherwise specified, materials shall be of the following specifications or better:
A. Cast iron : IS 210, Grade 20 / BS-3468

Excepting counter weight.
B. Cast steel for gears : IS 2644, Grade 1.
Cast steel for pressure pin assembly : IS 2644, Grade 4 / BS-1504.
Cast steel for general use : IS 1030-1978/2707-1973 Grade 23 – 45 /
BS-3100
C. Wrought steel : IS 1570, C40, Cold Drawn specified /
BS-970 (Part 1 to 6).

Contract M-02
D. Forged steel : IS 1875 / BS-970

E. Structural steel : IS 2062 (Fusion welding quality)
F. High tensile steel : IS 961 (Fusion welding quality)
G. Case hardened steel : IS 1570. C-14 / BS-970, EN-32 & 32C
H. Ductile iron : IS 1865, Grade 1 / BS-2789
I. Tubes & fittings : IS 1239, IS 1161 / BS-1387
J. Tubes for Idlers : IS 9295 / BS-1775
K. Bronze
Gunmetal : IS 306, G-2 / BS-1400
Phosphor bronze : IS 28 / BS-1224
Aluminum bronze: IS 305, Grade 2
Stainless Steel : IS 6911
7.6 Components: Codes and Standards

Generally, items required to be manufactured / fabricated shall conform to IS Code of Practice
unless otherwise specified. Following is the list of items which shall be included, but not be limited
for such considerations.
Other standards and codes, which will ensure an equal or higher quality product, may also be
accepted on written approval of Engineer / Employer.
Component Min. Specification

Wire Rope IS 2266
Drum IS 3177
Wheels IS 3177, IS 1136
Sheaves IS 3177
Steel Rails IS 3443
Conveyor Idlers IS 9295, IS 8598
Conveyor Belting IS 1891
IS 15143:2002 /
ISO 15236-1 for Steel Cord.
Screw Threads & Gearing Profiles ISO/Metric
Design shall be suitable for procurement of such components as above as spare from indigenous
sources in future.
7.7 Belt Conveyor System

7.7.1 General
a) New Belt Conveyors shall be complete in all respects and shall include but not limited to idler
rolls with supports, pulleys, drive units with base frames (including motor, gearbox, high/low
speed couplings), belting, head and tail pulley frames, take-up units including take-up trolley,
skirt boards, scrapers and V-plough, transfer chutes, stringer frames, short supports, hood

Contract M-02
cover, deck plates, (limited to loading zone, except for yard conveyors which shall be provided
with deck plate throughout the travel length of the Reclaimer (by others), gates, etc., as
applicable, and all bolts including anchor bolts and shall be complete in all respects.
b) Basic parameters of belt conveyors envisaged in the facility are mentioned in ‘Table A’ and the
drawings enclosed herewith for functional and design requirements, which shall be adopted by
the tenderer and shall form the basis of designing associated conveyor components/works.
c) The Yard Conveyor vertical supports / stringer posts will be rested on the inter-spaced sleepers
of common track for existing Stacker / Reclaimer and new reclaimers placed on RCC
foundation. Provision for fixing the vertical support will be provided on the sleepers (by others),
refer attached drawing of conveyor profile of JD-1A & JD-B.
d) The conveyor components required for this facility shall be standardized to the extent possible.
e) The details covered in Table ‘A’ have been worked out adopting the basis mentioned below for
information of the tenderer.
i) Artificial co-efficient of Composite friction as 0.022.
ii) Multiple drives have been used in some conveyors (As indicated in Table ‘A’) to keep the belt
tension low.
iii) VFD (by others) has been envisaged to operate the conveyor at variable speed as mentioned
in Table A
f) The components of conveyors proposed in the facility are grouped as per details shown in
Table ‘B’ and further detailed in the specification of components (ref. Annexures – Data
Sheets) with a view to standardise them to the extent possible. Belt width, speed, etc., i.e.
basic parameters, as specified, shall be adhered to. Components like pulley and its shaft
diameters, idlers (Refer Table ‘B’), motor rating, belt rating etc shall be adopted as far as
possible provided the Tenderer is convinced that sizes shown in Table ‘B’ / Data Sheets in
Annexures are suitable to meet the functional and design requirement mentioned in the
specification. The Tenderer may, if required, quote an alternative to suit manufacturer’s
standard. It shall however be ensured that number of groups identified in Table ‘B’ shall
preferably not exceed while standardizing components / items.
Technical requirements and quantities of components specified herein is for information of the
tenderer and the same shall be verified by the tenderer, based on the information provided in
the specification and shall be responsible for the complete works included in the scope.
g) Spares for 2 years’ operation are specified for the components (refer Data Sheets in
Annexures). Additional spares, as recommended by the tenderer, shall be brought-out in the
tender.
h) Minor variation in the conveyor profile and dimensions in the case of conveyors may require to
be carried out to suit the site conditions. However, such changes shall be brought out
specifically to the attention of the Employer / Engineer for approval.

Contract M-02
i) Deviation to technical details provided in the Table B / Annexures (Data sheets) shall be
mentioned in the Deviation List in Schedule -11.
j) Transfer Tower and galleries in the New Conveyor system is included in the scope. However
this contractor will provide the G.A. drawings associated Transfer Tower / galleries as
applicable, with relevant load data, which will form the basis for designing the civil works
(transfer tower/trestles/galleries) by others. Technical requirement of galleries and transfer
towers are covered in cl 7.7.2 and 7.7.5 respectively for information of the tenderer.
7.7.2 Galleries
a) Galleries for conveyors shall be generally open type as specified in the enclosed drawings,
except for conveyors shown in the drawings, which will have covered gallery. The galleries
along with supports shall be made of structural steel. Any other type of construction like pre-
stressed / reinforced concrete for the galleries may be quoted as an alternative.
The belt conveyors will be covered with hoods, wherever applicable and as shown in the
enclosed drawings.
In conveyor galleries the walkway with a minimum clear width of 1 m on one side and 0.750 m
on another side shall be provided. Where more than one conveyor is on the gallery in between
the conveyors will have clear 1.2 m walkway while on extreme side it will be 750 mm wide.
All open sides of walkway shall have hand rails.
Minimum clear height above walkway shall be 2.5 m unless mentioned otherwise in the
drawings.
b) The minimum clearance between the ground and the bottom of the gallery shall be 6.5 M at all
road crossings unless mentioned otherwise in the drawings.
c) In raised galleries the floor shall normally be made of galvanized gratings (Say 25 mm x 25 mm
unless agreed otherwise). When passing over roads, buildings, or work areas galvanized
chequered plate shall be provided in the full width.
d) The floor edges shall be provided with kick toe plates. Inclined/declined galleries having more
than 12 deg slope shall have stepped walkways. Provision shall be made to run the cables
along the conveyor galleries on cable trays (supplied by others).
e) At all the points where equipment parts heavier than 200 Kg have to be handled; either cranes
or monorail hoists of suitable capacity shall be provided unless specified otherwise.
In location where no hoist can be provided a lifting beam shall be sized for winch operation.
f) Provision shall be made in all galleries to facilitate reeving of conveyor belts.
g) Long elevated galleries wherever applicable shall have strong points (towers) located after
every 3 or 4 spans or as approved by the Engineer.
h) Foundations for gallery supporting trestles and transfer towers are excluded in the tenderer’s
scope and shall be adhered to as identified in the attached drawings as far as possible.

Contract M-02
i) Escape routes and cross over shall be provided at spacing not exceeding 200 meters.
Advantage may be taken of the tower locations to provide the stairways.
7.7.3 Conveyor Frame Structure
a) The conveyor structure shall consist of independent prefabricated tables as generally shown in
the attached drawings. The length shall be 6.0 m about for the standard table for supporting
idlers but when required special tables shall be provided. All standard tables shall be supported
generally as shown in the enclosed drawing i.e. conveyor idlers shall not be directly mounted on
the galleries.
b) Stringers shall be channels having size and arrangement as generally shown on the enclosed
drawing. The tenderer may satisfy himself and verify the member sizes of stringer frames (ref.
attached drawings) for the forces these will be subjected to. It shall, however, be ensured that
there are no vibrations in the structure during the operation.
c) Self cleaning V-type deck plates shall be provided under the loading points; extending 1 m
before and after the end of the loading skirts and above the V-plows protecting the return
pulleys. For the stockyard reclaimer conveyors (JD-1A & JD-1B) the deck plate shall be
provided for the entire travel length of the new reclaimers.
d) In no case shall minimum clearance between the floor and the lower most point of the return
belt shall be less than 500 mm. In case of ground conveyor the conveyor vertical supports will
be fixed on a minimum 300 mm high concrete pedestal.
e) The belt conveyors will be covered with a hood wherever applicable. Hood shall be as generally
shown in the attached drawing. Tenderer may quote for an alternative arrangement of proven
design and easy to operate.
f) All anchor bolts required for fixing the conveyor frames are included in the scope of supply.
7.7.4 Take-up Units
7.7.4.1 General
a) The take-up travel shall be 2.5% (Minimum) of the centre to centre distance for Nylon belting
and 0.5% (Minimum) of the centre to centre distance for steel cord belting.
b) Where space allows, an additional length of belt of up to two splices shall be added to the
normal take-up travel to make provision for live storage of belting.
c) Counter weights shall be precast concrete or metal. In all cases space shall be provided for an
addition of 25% of the counter weight. Provision shall be made for dismantling the counter
weight or relieving the tension in the belt.
7.7.4.2 Vertical Take-up Units
a) Vertical gravity take-up units shall have a 0.75 m sand box provided under the counter weight
at ground/floor level. The area below the counter weight shall be guarded to a height of 2.5m
above any access level. Suitable guides shall be provided for take-up travel. The design of the

Contract M-02
vertical members (guides for take-up travel) shall be such that they can be removed between
access platforms on the gravity take-up units.
b) The design of the counter weight assembly shall have a self-cleaning top.
c) Access platforms shall be located at every 3 meters through the travel of the gravity take-up
units and consist of platforms on 3 sides (including access to both bend pulley bearings) and
of minimum width of 1.0 m. Access between these levels shall be by vertical ladder.
d) A lifting beam of capacity about twice the total weight of the gravity take-up unit shall be
provided, located on the centre line of the take-up unit.
e) The bend pulleys shall be located such that they can be easily removed onto the side
walkways. Each bend pulley assembly shall be designed to 75 per cent of the total weight of
the counter weight assembly.
7.7.4.3 Horizontal Take-up Units
a) The pulley slide frame shall be self-cleaning type. The pulley slide carriage shall be equipped
with Vee type wheels attached to shaft running on guide rails. Suitable guide wheels shall also
be provided to arrest uplift of carriage. Buffers shall be provided at both ends of take-up travel
to take the impact arising out of rope / belt snap.
b) Counter weight tower of horizontal take-up units shall be similar to that of vertical take-up units.
Counterweight tower is included in the scope.
c) One end of the counter weight rope shall be reeved on a motorised operated winch mounted at
a suitable location for releasing the counter weight for belt repairs and other maintenance
works. The winch shall be self locking type.
7.7.5 Towers / Transfer Towers and Drive Houses
a) Size of transfer towers, as far as possible, shall be adopted as shown in the attached drawing
unless the tenderer has certain reservations, which shall clearly be brought out in the tender.
Transfer Towers, towers and drive houses shall be sized for future requirements as shown in
the drawings.
b) The sizes of these transfer towers / drive houses may be suitably altered, if required, by the
Contractor to suit the equipment and arrangement proposed by him and the same shall be
brought out in the tender.
c) Working floors and equipment floors shall be enclosed with suitable claddings to ensure full
protection from rain and strong wind. Also claddings shall be designed to provide sufficient day
lighting and ventilation.
d) There shall be a minimum 1.0 m wide clear walkway around drive equipment. Floor
arrangement shall be such that free movement for maintenance and operation purposes is
provided. Generally galvanized gratings (Say 25 mm x 25 mm, unless agreed otherwise) shall
be used for walkway.

Contract M-02
e) Heavy concrete masses shall be provided as mounting platforms for drive units unless
specifically exempted by the Engineer.
f) Suitable hatch openings shall be provided in each floor for lowering/hoisting equipment or part
of the equipment. In exceptional cases handling through side opening may be permitted. All
such side openings shall be provided with hinged doors and hand rails.
g) All floor openings shall be protected by handrails and kick (toe) plates.
h) Monorails shall be provided at all towers/ transfer towers/drives houses for maintenance of
equipment provided where equipment parts heavier than 200 kg have to be handled. Monorails
shall be equipped with electric hoists having pendant control. Hoist speed of electrical hoists
shall not be less than 4 m/min.
i) Ladder with an elevated platform shall be provided for maintenance of each hoist. EOT crane
shall be provided wherever monorail hoist is considered inadequate for maintenance purpose.
For handling equipment parts less than 200 kg, lifting beams shall be provided which shall be
sized for winch operation.
j) Monorails shall be able to reach vertically as far as possible above the components which
require handling during maintenance.
k) As far as practical, all lifting tackles shall be standardised.
l) All floors shall be connected from ground level through stairs having minimum width of 0.8 m.
All staircases shall be provided with handrails on both sides. Circulation areas on floors shall be
provided with grating. Minimum clear height between two floors shall be 2.5 m.
m) In order to facilitate cleaning (Washing) operation tail end of the conveyors to be sloped
backwards for easy collection of dirty water at tail end.
The inclination towards the tail end not to be less than 1:100 and sloping to commence from 1
m ahead of skirt board
All transfer towers (For all inclined as well as horizontal conveyors) floors supporting tail end
shall be provided with washing facility.
Arrangement shall be made in each building for collection of wash water at the ground floor for
drainage.
n) In transfer tower JTT-8, provision of receiving cargo from existing stockyard at Plot-B shall be
considered.
7.7.6 Idler Assembly
a) The different types of idlers for carrying and return belt shall be as follows.
i) All carrying idlers for all belt conveyors shall be Garland type with three roll in line having
freedom of movement in both vertical and horizontal directions.
ii) Fixed type troughed carrying idlers with three roll in line mounted on fixed supports for the
declined portion of the conveyors and Self aligned carrying idler also be provided.

Contract M-02
iii) Garland type return idlers with two rolls, V type, and 15o incline to the horizontal with
articulated joints with freedom of movement in both vertical and horizontal directions.
iv) Fixed type return idlers with two rolls, V type and 15o incline to the horizontal mounted on
fixed supports for the inclined portion of the conveyors and Self aligned return idler also be
provided.
v) Garland type Troughed transition carrying idlers of different troughing angle as given in
the idler schedule.
vi) Single roll flat return idlers for mounting below ‘V’-type scrapers
vii) Garland type Troughed Impact idlers with five roll and three roll including impact absorbing
rubber block 80 mm x 80 mm x 80 mm in line having freedom of movement in both vertical
and horizontal directions, and shall have heavy duty bearing.
b) All troughed Carrying Idlers shall have 45o & 35o troughing roughing angle. Indicative
requirements of all type of idlers are given in “Data Sheet”. Refer Annexure-A (Figs. 01, 02,
04, 05, 06, 07, 08, 09 & 10) for information of the tenderer. Variation in quantities within 10% is
not ruled out. The tenderer to verify the quantities and variation, if any shall be brought-out in
the offer.
c) Outside diameters of carrying and return idler rolls shall not be less than as specified in the Idler
‘Data Sheet’. The tenderer may quote as an alternative in case cost-effective option is offered.
d) Idler rolls shall be made of ERW tube and minimum wall thickness shall be 4.85 mm for 193.7
mm, 159 mm, 152.4 mm and 139.7 mm (refer data sheet) diameter tubes. Mechanical
properties of the idler tubes shall be equivalent or better than YSt 210 grade as per IS: 9295
(Latest).
e) Idlers shall be easily removable type.
f) All idler bearings shall be sealed, lubricated for life' type. Deep groove ball/seize resistant ball
bearings shall be used. The bearings shall be chosen for life L-10 equal to 60,000 hours. All
bearings shall be protected by double labyrinth seals to protect against fine dust. The bearing
seals shall have minimum resistance to rotation. Lubrication fittings for the labyrinth seals shall
be provided in the case of impact idlers for bulk for the purpose of occasional greasing to keep
the dirt and dust out. Felt seals will not be accepted.
g) Bracket for fixed type Idlers shall be of fabricated steel and shall have ample strength and
rigidity to operate under all loading conditions without vibration or chatter. Use of cast iron
support brackets is not acceptable. The bases shall be provided with slotted bolt holes for
mounting on supporting steel work. Minimum two bolts of 16 mm dia shall be used at each end.
h) All Idlers and assemblies shall conform to IS: 8598(Latest) or equivalent.
i) Bearing housing shall be made of minimum 3 mm cold rolled carbon (CRC) deep drawn quality
pressed steel. The bearing housing shall be machined in a single setting and then welded on
both sides of the tube simultaneously on a proper machine under controlled conditions.
j) Idler shaft material shall be EN8 or better steel.
k) The internal rolling friction of Idler roll shall not exceed 0.007.

Contract M-02
l) All the Idlers shall be designed for outdoor, continuous duty.

m) Minimum shaft diameter at bearing for carrying, return and impact idlers shall be as given in the
enclose ‘Data Sheet’ covering Idler schedule. However, the bidder shall verify the idler roll
diameter, bearing / shaft diameter at his end with the conveyor load data as indicated in the
‘Data Sheet’.
n) Idler rolls shall have face run out (TIR) not be greater than 1.0 mm on diameter.
o) All Idlers shall be pre-run in the works for even distribution of grease and also to ensure least
starting resistance.
p) All idler tubes shall be of proper quality pipe and cut to size. The tube shall be bored in a single
setting using double headed boring machine for accuracy as also coaxiality of the bores and the
perfect seating of the bearing housing.
q) Idler shafts shall be machined from tested rods and machined in a single setting. The bearing
diameter shall be ground to finish in a single setting to achieve the accuracy, finish and
coaxiality.
r) Multistage sealing shall be provided in the idlers making the bearing dust and water proof.
s) Frames in case of fixed idlers shall be manufactured in a specially designed fixture with inbuilt
accuracy to ensure the parameters like fixing distance, roughing angle, height of rollers from
bottom are maintained within limits.
t) Linkages for garland type idlers shall be manufactured from high quality steel with proper jigs
and fixtures to ensure accuracy.
u) Make of Idler Bearings shall be FAG / SKF.
v) QAP to be followed by the successful tenderer shall be got approved from the Engineer.
w) Hooks / bolts with washers etc. for idler fixing on conveyor stringer frames are included in the
scope. Tenderer shall supply additional hooks for garland idlers for adjustment at site during
erection / commissioning.
x) Garland carrying idlers shall preferably be equipped with quick release arrangement. Tenderer
shall mention in his offer the name of projects where such arrangement is in operation to
satisfaction of client.
y) Idler Roll shall be tested for Dust proof & Water proof test as per QAP approved by engineer.
z) Technical details required in Annexure-‘B’ shall be duly filled in by the tenderer and shall be
submitted with offer.
aa) Special type idlers required for the Belt Weigher and magnets shall be included in the scope.
7.7.6.1 List of Drawings

[ Refer Annexure A ]
The List of Drawings attached is for information of tenderer and is part of the specification. The
arrangement shown in the drawings shall be adhered to as far as possible.

Contract M-02
Sl.No. Drawing No. Title

3 Roll Troughed Carrying Idlers (Garland Type) for 1400, 1600 &
01 Fig-01
1800 Belt Width.
02 3 Roll Troughed Transition Idlers (Garland Type) for 1400, 1600
Fig-02
&1800 Belt Width.
3 Roll Troughed Carrying Idlers (Fixed Type) for 1400, 1600 & 1800
03 Fig-03
Belt Width.
2 Roll 15 deg V-Type Return Idlers (Garland Type) for 1400, 1600
04 Fig-04
& 1800 Belt Width.
2 Roll 15 deg V-Type Return Idlers (Fixed Type) for 1400, 1600 &
05 Fig-05
1800 Belt Width.
06 Fig-06 Flat Return Idler for 1400, 1600 & 1800 Belt Width
07 Fig-07 3 Roll Impact Idler (Garland Type) for 1400 Belt Width.
08 Fig-08 5 Roll Impact Idler (Garland Type) for 1600 & 1800 Belt Width.
3 Roll 35 deg Trough Carrying Idler (Fixed Type) for 1200 Belt
09 Fig-09
Width.
10 Fig-10 3 Roll 35 deg Trough Impact Idler (Fixed Type) for 1200 Belt Width.
Note: Tenderer shall review the dimensions shown in the above drawing and may make
necessary changes, as required, to ensure that operational requirements are
complied with.
7.7.7 Pulleys
a) The ‘Pulley Schedule’ shown in Annexure-B (Fig.11 R.0 - 2 sheets) covers the features /
technical requirements.
b) The tenderer shall design the pulleys based on the belt tensions specified in the schedule. The
features (pulley / shaft dia, bearing centres, plummer block details, pulley face width, etc.)
mentioned herein shall be adhered to, as far as possible, mainly to achieve the objective of
standardisation and the tenderer shall satisfy himself specifically with regard to shaft dia /
length, bearing centres and hub, shell thickness etc, to meet the design requirements. However
dia of pulley / shaft, length of shaft, bearing centres etc shall not be less than the specified in
the Schedule. Changes, if any, that need to be made in the opinion of the tenderer for
satisfactory performance, shall be brought out in the tender.
Tenderer may adopt his standard design based on his experience regarding shell thickness and
its fixing details with hub, satisfying transmission of specified belt tension / drive torque as
specified.
c) Pulleys shall be made of welded steel and stress relieved,(Method of stress relieving details of
soaking time and corresponding temperature shall be furnished as a drawing) before
machining. Pulley shell joint shall be 100% radiographically tested.
d) All hubs and shafts shall be of forged steel. Hubs and end discs shall be accurately machined
for concentricity.

Contract M-02
e) All pulleys shall be straight faced and pulley faces shall be lagged with hot vulcanized rubber
lagging as mentioned below:
i. All drive pulleys shall have 20 mm thick herring bone/ diamond grooved lagging as
applicable. The herringbone grooving shall be at 120o, 6 mm wide x 6 mm deep spaced at
30 mm centres around the circumference. The apex of the herringbone grooving should
be in the direction of the belt travel. The rubber hardness shall be IRHD 60. However in
case of reversible conveyor diamond grooved lagging shall be provided, as applicable.
ii. All non-drive pulleys shall have plain lagging of minimum 12 mm thick. The hardness of
rubber shall be IRHD 60 for drive and discharge pulleys and IRHD 55 for all other pulleys.
iii. Lagging of existing conveyors JD-2A & JD-2B head and tail pulleys to be changed to
diamond groove type.
f) i. The use of approved type of clamping hubs (Imported ‘Ring Feeder’ type of ‘RING
FEDER’ German make or equivalent) allowing easy removal of shaft from the pulley
assembly is required for all pulleys. Proper selection of locking assembly (series length,
etc.) shall be as recommended by the supplier of locking assembly.
ii. Deflection of all pulley shafts shall not exceed eight (8) minutes.
g) The shell plate thickness before rolling shall be minimum 4 mm more than the finished shell
thickness.
h) Pulley assemblies shall be statically balanced and run concentric when mounted on shaft.
Balancing weight shall not exceed 0.25 percent of the pulley weight, preferably.
i) Pulley shall have face run out not greater than 1.5 mm on diameter on lagging.
j) The pulley face width shall be min. 200 mm more than the belt width. The tolerance of pulley
along the face width shall be +3 mm on the nominal width.
k) All pulleys shall be shop assembled with shaft, bearings, Plummer blocks etc. and shipped as
complete assembles, properly packed in wooden crates.
l) Only one longitudinal weld on pulley shell per pulley shall be permitted and the weld shall be
tested radiographically.
m) All pulley shafts shall be EN-8 or equivalent. Tenderer may quote shaft with better material as
an alternative.
n) Shafts shall not protrude from pillow blocks with closed ends.
o) Plummer blocks shall be 4 bolt centre split type, cast steel construction equipped with double
row self-aligning spherical roller bearings with labyrinth seals and grease nipples suitable for
use in saline atmospheric condition. The spherical roller bearings shall have two rows robust
window type cages of pressed steel or brass with taper bore and adapter sleeve. Supply of
bolts is included in the scope.
p) Tenderer shall submit the sample manual calculation for Shaft dia at hub, shaft dia at bearing,
and Diaphragm & Shell thickness on the basis of provided technical data for Employer’s/
Engineer’s consideration. In case the calculated shaft/bearing/diaphragm/shell are found to be

Contract M-02
on the higher side, the same shall be provided. In case the calculated values are lower,
minimum sizes as specified in the tender shall be provided.
q) Bearing shall be Spherical Roller bearing of SKF/FAG make.
r) All pulleys bearings will have a minimum life of 60,000 hours.
s) In case of shaft design based on strength, the combined shock and endurance factor for
bending and torsion i.e., Km and Kt shall be 1.5 and 1 respectively. All conveyor pulley shaft
shall be checked for deflection i.e., slope of the shaft at two pulley disc shall not exceed 0° 8
minute.
t) Maximum permissible stress for shaft design:
Shear stress : 600 Kg/cm2
Bending stress : 840 Kg/cm2
Bending stress for plates : 948 Kg/cm2
For Key-way, reduce the above values by 25%.
u) All plummer blocks shall be supplied with machined base plates and locking screws. The base
plates shall be minimum 16 mm thick with M16 / M24 locking screws two number each side of
each plummer block.
v) Plummer block centres, as specified in the Data Sheet, shall be maintained in case of all
pulleys, as far as possible.
Necessary lubrication for plummer blocks to be under scope of this contractor.
w) Pulleys shall be suitable for continuous outdoor duty and saline atmosphere.
x) Fig.11 R.0 (2 sheets) showing the profiles of conveyors identifying types of pulleys and
tensions involved in each conveyor is attached herewith. The drawings shall be read in
conjunction with ‘Pulley Schedule’ showing belt forces. The data shown is only for information
of the tenderer.
y) Conveyors handling multiple cargos (Coal, Iron ore, Limestone & Dolomite) are provided with
drive having VFD control.
z) Changes in technical data provided in the ‘Pulley Schedule will be informed to successful
tenderer
7.7.8 Belting
a) Belting for conveyors shall be Nylon-Nylon and ST type and suitable for heavy duty application
as specified in attached ‘Data Sheets’. It shall be able to withstand the tensions and support the
load.
b) The rated maximum allowable working tension shall exceed the calculated maximum running
tension by at least 15% for the Belting. Ratio of breaking strength to working tension shall be 9
for Nylon-Nylon/ EP belting and 7 for ST belting.

Contract M-02
c) Each fabric ply for all belting shall be rubber impregnated and provided with skim coat. Each ply
shall be adhesion tested. Fabric shall be free of longitudinal or transverse wrinkles and cords
shall be straight to ensure proper tension distribution.
d) The belt covers shall be made of synthetic rubber (M24 grade). The belt covers shall be
resistant to moisture, properly vulcanized and finished.
e) Cover rubber thickness of Synthetic Fabric Belt shall be as per Table-B. Minimum 6 mm and 3
mm for top and bottom respectively. For ST belt the top and bottom cover thickness shall be
minimum 8 mm and 5 mm.
f) The rubber used shall be of a quality which has a tensile strength of not less than 2.5 kg/mm 2
and an ultimate elongation of not less than 450%. It shall be suitable to withstand the ambient
temperature specified. All belting shall be pre-stretched.
g) Belts shall not blister or separate in the plies or at the seams or stretch more than 2.5% for
Nylon-Nylon and 0.5% in the case of ST belts respectively belts of their original length within
one year of installation and normal operation. Belt construction shall be such that in case of
edge damage, ply separation and ingress of moisture shall not take place.
h) Belts shall have hot vulcanized joints after erection. Vulcanizing shall be done on single setting
without loss of ply.
i) Belting shall confirm to latest revision of IS 1891 (Part I), IS 11592 and other relevant Indian
standard.
j) Belting/fabric shall be free from any longitudinal joint i.e. belting with a longitudinal joints is not
acceptable.
k) A length allowance for field joints and also for test samples shall be added to all belt lengths as
specified in the ‘Data sheets’ shown in Annexure-C (Fig.12 R.0).
l) Belting shall be suitable for heavy duty application. Belts shall be of cut-edge type for fabric
belting. Steel cord belting shall be of moulded edge construction.
m) Tolerance on belt dimensions shall be as follows:
i) Width (mm) : +3 / - 0
ii) Length : +2% / - 0%
iii) Carcass Thickness (mm) : +0.5 / - 0.0
iv) Composite belt thk (mm) : +0.5 / - 0.0
n) The quality of workmanship, performance and reliability shall satisfy the specifications.
o) Conveyor belting shall be suitable for exposure to sunlight and saline atmosphere.
p) QAP shall be got approved by the Engineer/Employer after award of Contract.
q) Length of Belting specified in ‘Data Sheets’ is based on the profile drawings Fig.12 R.0 of the
conveyors attached herewith. Tenderer may verify the belt length on the basis of profile
drawings. Changes in belt length, if any, shall be brought out in the tender.

Contract M-02
7.7.9 Drive Unit
7.7.9.1 General
a) The type and horse power rating of drive units for all the equipment has already been finalised
as indicated in ‘Table–B’
b) The composite friction factor (artificial friction coefficient) of the horizontal and inclined conveyor
system considered as 0.022.
c) The drive unit shall be complete with motor (free issue), transmission and necessary couplings
to achieve the following functions:
 Soft start of fully loaded conveyor.
 Equal load sharing.
 Possible to run the conveyor at a lower capacity in case of failure of one drive out of multiple
drives.
d) Multi-cargo handling conveyors and conveyors handling only Coal will be provided with VFD
Control. VFD for conveyor drives will be by others.
7.7.9.2 Couplings
A) Pin-Bush Coupling
a) Pin bush type flexible coupling will be mounted between motor and input shaft of the
reducer for power transmission and shall be suitable for variable speed operation of motor
with variable frequency drives (VFD) for continuous outdoor operation.
b) Couplings shall be sized for minimum service factor 2 calculated on motor rating indicated
in the enclosed Coupling Schedule.
c) All couplings shall provide for lateral, angular and longitudinal misalignment of shafts.
d) High speed couplings shall be heavy-duty Pin & Bush type flexible coupling and shall be
provided with proper sealing for protection against dirt and dust.
e) The coupling shall be supplied with finished bore and keyway to suit the reducer / Motor
shafts and keys as required. Approximate bore dimension of the coupling have been
indicated in the Schedule. Exact information about the gearbox and motor shafts will be
furnished later to the successful tenderer.
f) The couplings shall conform to relevant IS codes and shall be suitable for conveyor
application.
g) Pin & Bush coupling hubs shall be manufactured from carbon steel generally conforming to
IS 2008 / IS 1570 and suitably hardened.
h) The Bushes of the couplings shall be manufactured from special quality rubber which shall
remain unaffected due to dust, dirt, moisture & corrosive coastal environment.
i) The complete coupling shall be machined to desired tolerances for proper matching as well
as for interchangeability.

Contract M-02
j) Tenderer shall be responsible to ensure that the couplings will meet the functional
requirement with the matching equipment with regard to smooth transmission of power,
proper fitment and trouble free running. For this purpose all necessary interfacing
information will be furnished to the successful tenderer as required.
k) Coupling shall be supplied with Brake-drum as indicated in the Data sheet specified in
Annexure - D covering ‘Schedule of Pin & Bush Type Couplings’. The Brake Drums
shall be of M S fabricated / cast Steel construction suitably balanced.
l) Equipment Design ambient temperature shall be 45o C.
B) Geared Coupling
a) The Low speed couplings shall be mounted between the pulley shaft and gearbox out-put
shaft of the belt conveyor for power transmission.
b) Low speed coupling shall be suitable for variable speed operation of the motor with
Variable frequency Drives (VFD) for continuous outdoor duty.
c) Low speed coupling shall be flexible and heavy duty geared type with self-contained
lubrication and proper sealing.
d) Low speed couplings shall be provided with suitable grease nipple at each half of the
coupling for lubrication as specified in the data sheet shown in Annexure - E.
e) Low speed couplings shall be matched with their respective drive units for torque and
power requirements.
f) The service factor on mechanical rating shall be 2.0 on motor power.
g) The coupling shall be supplied with finished bore and keyway matching with pulley shaft
and gearbox output shaft, including supply of keys Necessary interfacing details shall be
provided to the successful tenderer.
h) Low speed couplings shall be provided for lateral, angular and longitudinal misalignments
of shafts.
i) The body of the Low speed coupling shall be suitable to the site conditions for corrosive
coastal environment and dust laden atmosphere.
j) Equipment Design ambient temperature shall be 45o C.
7.7.9.3 Reducers (Gear Box)
a) All Gear boxes shall be parallel shaft, foot mounted, and solid shaft design with single / double /
triple helical construction. The Tenderer, however, shall also quote for perpendicular shaft type
gear boxes as an alternative. However for conveyors JD-1A & JD-1B and JD-4A & JD-4B, Gear
boxes shall be perpendicular shaft type, due to space constraint in the transfer tower.
b) Existing Conveyors JD-2A & JD-2B are converted into reversible conveyors.

Contract M-02
c) Gear boxes shall be suitable for variable speed operation of the motor with variable frequency
drives (VFD) for continuous outdoor duty. The different operating speeds for different material
are indicated in Annexure - F for information of the tenderer.
d) Gear boxes shall be steel fabricated, stress relieved and machined, oil & dust tight enclosures
for gears and bearings. The housing shall be split on centre line of shafts. The fabricated
reducer casing shall be stress relieved in the furnace with auto-generated time/temp curves.
e) All gear boxes shall have inspection openings, lifting lugs, an oil filling cap, a visible oil level, a
side located oil drain plug, an air breather and a permanent magnet plug.
f) Gear boxes durability service factor and strength factor shall not be less than 1.5 & 2.5
respectively based on motor power.
g) The thermal capacity shall be equal to or greater than the maximum motor power rating at
ambient temperature 45oC. Thermal rating of the gear box shall in any case never exceed 80oC.
External fan cooling coil system as far as possible may be avoided, unless justified. External fan
cooling where not suggested shall be clearly specified with type of cooling required.
h) Bearings shall have labyrinth seals (Tactonite type) to prevent oil leakage and ingress of
contaminates into the bearings. All bearings shall be SKF/FAG make only.
i) The base of the housings shall be machined level and shall be suitable for bolting to base plate.
j) There shall be no axial movement of the shaft of the reducers. Plain shafts can be of medium
carbon steel. But pinion shafts shall be of alloy steel only.
k) All gears shall be of single / double / triple helical design. They shall be made from high quality
alloy steel forgings or castings, heat-treated for optimum combination of wear resistance and
strength. Pinion shall be integral with their shafts.
l) Gears and bearings shall employ the same lubricant. The method of lubrication shall be such as
to supply continuous lubrication to gears and bearings when the reducer is in operation.
m) Reducers shall be designed for transmitting torque in both directions and should not be self
locking type.
n) All gearboxes shall be manufactured as per relevant Indian Standards.
o) Gearboxes shall be selected for continuous duty and shall meet the parameters specified in the
enclosed Gearbox Schedule shown in Annexure - F.
p) All gearboxes shall have permanent magnet plug.
q) The gearbox quoted shall be with first fill of lubricant separately.
r) The quantity and first fill lubricant specification shall be provided.
s) The weight of input/output couplings will be confirmed later to the successful tenderer.
t) The length of input shaft to be provided shall be adequate to match the coupling half.
Necessary details in this regard will be furnished to the successful tenderer.

Contract M-02
u) Holdbacks shall be selected for a minimum service factor of 1.5 based on maximum torque from
driven equipment. Thermal rating of backstops shall be such that there shall be no undue
temperature rise while running in the direction of the pulley or when backstop is applied.
v) Holdbacks shall be fully enclosed roller or sprang type. The design of the holdback shall be
such that its operation is not affected by dust, grease, moisture & extreme temperature
conditions.
w) One make of bearings shall be provided in all the Gear Boxes as far as possible.
7.7.9.4 Brakes
a) All brakes shall be Thrustor (and fail safe in operation), complete callipers, thrustor and
hydraulic system, etc.
b) Brakes shall be equally effective in both directions of shaft rotation.
c) Brakes shall generally be mounted between the motor & gearbox on the Brake drum, for
conveyors provided with variable speed for handling multiple cargo. Brakes will be mounted on
the brake drum supplied with pin-bush coupling. However for conveyors handling coal
exclusively brakes will be mounted on brake drum supplied with fluid coupling. For conveyor D-
10 brake shall be provided at the tail pulley.
d) Brakes shall be capable of exerting a restraining torque of minimum 1.5 times the braking
torque, given in the data sheet shown in Annexure - G.
e) The thermal capacity shall be adequate to limit the contact surface temperature within the
permissible limit recommended by brake liner manufacturer for similar application.
f) Suitable devices / limit switches shall be installed to ensure that motor does not start before the
brake releases.
g) All brakes shall be continuously rated, foot mounted, suitable to the site conditions for corrosive
coastal environment and dust laden atmosphere.
h) Brake torque shall be fully adjustable over the range of 30% - 100% of rated torque.
i) Brakes shall be capable of dissipating the energy released by stopping the conveyor 10 times
per hour. The ambient temperature shall be 450 C.
j) Brake pads shall be asbestos free.
k) New conveyors (JD-1A, JD-1B, JD-4A, JD-4B, JD-5E & JD-5F) shall be provided with brakes.
7.8 Miscellaneous Mechanical Equipment

7.8.1 Belt Weigher
a) One Belt Weigher shall be mounted on each conveyor, as shown in the attached Flow Diagrams,
and shall be complete in all respects including Local Control Panel and special Idlers.

Contract M-02
Conveyor No. Belt Width / Trough Qty. (No.) Remarks

JD-1A 1800 mm / 45 deg. 1 Refer Table A for carrying capacity
JD-1B 1800 mm / 45 deg. 1 and speed of the conveyors
b) Belt Weigher shall be electronic type and microprocessor based suitable for accurate
performance under all loading and temperature conditions mentioned under design criteria.
c) Load Cells shall be suitably temperature compensated and hermetically sealed.
d) The equipment shall be designed to operate continuously under all operating conditions.
e) The guaranteed accuracy shall be +0.5% or better, which shall be achieved within the loading
range of 20-120% of the nominal capacity. The belt weigher shall be suitable to weigh, read and
to record weighment up to 120% of the rated capacity.
f) It is the supplier’s responsibility to obtain approval for the belt weigher from concerned statutory
bodies in India.
g) Calibration of Belt Weigher shall be carried with calibration weight and chain, which is included in
the scope of supply.
h) Test load required for calibration shall form part of the supply.
i. The belt weigher shall be complete with the following:
i. Digital meter with 8 digit rate read-out and totaliser tonnage counter with tonnage read-out.
The same shall be reflected in Central Control System through ModBus RTU interface.
ii. Inter-connecting cables and required Terminal Blocks among the items supplied by contractor
e.g. local control panel, junction boxes, load sensors, speed sensors, RTU Interface etc.
iii. The Belt Weigher shall also be provided with necessary wiring and interface terminals
(potential free contacts/ModBus RTU RS 485) in local panel for indications at Central Control
Room (CCR) but not limited to the following:
 Equipment healthy
 Belt overload
 Flow rate and total value
 Belt Weigher communication between CCR is Healthy
 Belt Weigher power supply “on”
 Belt Weigher ‘on/off’ command from PLC.
 Belt Weigher ‘on/off’’ feedback to PLC [Local and remote mode].
 Reset totalizer value
 Non-resettable totalizer
j) The standby battery power shall be provided to protect the operational data being wiped out
during power breakdown periods.
k) Control panel shall be dust and vermin proof and enclosure protection shall be IP 65. It shall be
suitable for outdoor location near to the adjacent tower and wall / pedestal mounting.

Contract M-02
l) The speed sensor shall be mounted on the tail pulley.

m) The belt weigher wherever installed on the inclined position of belt, “cosine Pendulum” shall be
provided for maintaining the desired accuracy level. (Refer attached drawings).
n) The belt weigher shall be suitable for 45°C ambient temperature. However the validation records
for electronic circuits shall be upto 60°C.
o) All Idlers (carrying) for conveyors carrying material in bulk will be three roll Garland type and
interchangeable rolls suspended from stringer frames. Special machined Idlers (TIR 0.2 mm on
outer dia.) with support required for the Belt Weighers including preceding and succeeding idlers
are included in the scope.
7.8.2 Magnets and Metal Detectors
7.8.2.1 Magnets
a) One no. suspended type magnet each shall be mounted on the carrying side of Conveyors as
indicated in the enclosed Flow Diagram and detailed below These shall be complete with
suspension slings, collecting chutes, local control panel, interconnecting cables between
magnet and metal detectors to the control panel and interfacing (at panel level) with Central
Control System.
Conveyor Belt Width / Trough Magnet Metal Detector

JD-1A 1800 mm / 45 deg 1 No. 2 Nos.
JD-1B 1800 mm / 45 deg 1 No. 2 Nos.
Note: Refer Table A for carrying capacity and speed of the conveyors.
b) The suspended magnets shall be followed by Metal detectors (before and after the suspended
magnets) which shall detect presence of any foreign matters and subsequently send signal to
the magnet for removing it.
c) Magnets shall be of robust construction, electrically excited, air cooled as far as possible and
rated for continuous duty.
d) The suspension arrangement shall provide for adjustment in height of magnet above the
conveyor and move the magnet in transverse direction. Cross belt magnet shall be provided
with collecting chute.
e) The electromagnet shall be fabricated from high permeability, low carbon steel. Magnet coil
shall be made from high conductivity electromagnetic grade copper conductors conforming to
relevant Indian Standard specifications. The coils shall be vacuum-dried and impregnated under
pressure. The coils shall be fibreglass covered and conforming to insulation class “H”. The
magnet gauss strength shall be uniform across the magnet / Conveyor belt and shall be able to
pick-up tramp iron, anywhere throughout the belt width and from below ~400 mm (minimum)
material depth.
f) Operating height of the Magnets shall be to suit the conveyor cross section with Garland type
idlers as shown in the enclosed drawing. The height of magnets shall be adjustable.

Contract M-02
g) Weight of the tramp iron to be removed from the material on the running belt shall be 15 Kg.
max. by weight and 150 mm x 350 mm by dimension. Tenderer shall also give guarantee to
pick MS Bolt of M12, M16, minimum length equal to 5 times the diameter of bolt.
h) The magnet shall be supplied with AC to DC conversion unit and other control accessories
housed in a dust- proof sheet steel enclosure to be mounted locally.
i) Suitable magnet guards shall be provided to contain the magnetic induction so as to exclude
conveyor structure.
j) Tenderer to quote alternatively for Copper as well as Aluminium coils (calculation of magnetic
field strength-Gauss to be provided).
k) Magnets shall have the arrangement for switching-Off both from local control panel and central
control room PLC. Status of metal detector shall be updated in Central Control System.
l) Special non-magnetic idlers, as required for installing below the magnets are included in the
scope.
m) Spare TB / Cable channel for terminating spare cables.
7.8.2.2 Metal Detectors
a. Metal Detector will be used for detecting tramp metals on the conveyor belts.
b. It is proposed to mount the Metal Detector on belt conveyor as stated above for magnet [Ref.
Cl.7.8.2.1(a) and the Flow Diagram].
c. The detector shall be double channel type consists of adequate number of search coils and be
suitably dimensioned for positioning near the conveyor belt. The search coil shall be suitably
reinforced and insulated. The system shall be such that as soon the tramp metal is detected by
the sensing device of the detector, signal light is actuated and the detector will give signal to the
magnet & the magnet gets energised to pick up the tramp iron. In case the tramp metal is not
picked up by the magnet, one succeeding Metal detector will again give a signal followed by
colour dye spotting the metal piece or sand bag is dropped on or near the approx. location of
the metal piece which shall be picked up manually.
d. The electronic accessories shall be enclosed in a dust and weather proof steel cabinet/local
control panel with IP-65 protection enclosure.
e. It shall be possible to detect different sizes of tramp metal pieces by the detector from operating
depth of ~400 mm (min.) material depth in the bed. In the system Magnet & Metal Detectors are
working in combination, it shall be possible to remove tramp iron of 15 kg – 20 kg max. by
weight and 150 mm x 350 mm by dimension and also the following:

Contract M-02
1800 mm Belt width

Aperture Height ~ 550mm
In Sphere In Cube In Nut
Ferrous 65 48 M42
Non-Ferrous 105 75 M68
Stainless Steel 316 150 100 M95
f. A green lamp shall be provided to indicate the detection system is “ON”. As soon as the tramp
metal piece is detected by the detector, a green lamp shall switch “OFF” and a red lamp shall
be switched “ON”. A continuous alarm shall get initiated which shall not go “OFF” until reset
manually. The lamps shall be cluster LED type and have legend plates. Indication lamp shall
also be provided for Fault/Fault trip indication for fault in metal detector / magnet. Indications
and alarms shall, also be communicated to the central control room.
g. Metal Detector local control panel shall have Mod-Bus RTU RS485 interfacing with central
control room PLC for sequence interlocking, indication of metal detection, ON/OFF &
fault/health status and other required information to meet the functional requirement.
h. Local Control Panel
i) Main SUPPLY
3 Ph., 4 wire, 415 V ±10%, 50 Hz ±3%
ii) Controls supply
110V, 1 Ph,50 HZ, 2 wire AC or 24 V DC by providing control transformer/electronic rectifier
modules of required rating in the local control panel.

Contract M-02
iii) Construction
Sheet steel clad, fabricated out of 14 G sheet, Powder coated with paint shade RAL7032.
Free standing floor mounted/ wall mounted, compartmentalised and shall have hinged door
for access to the compartment
iv) Enclosure Protection
Totally enclosed IP 65 weather-proof protection for outdoor mounting with suitable rain hood,
dust and vermin proof with neoprene gasket
v) Grounding Bus
50 x 6 GI STRIP.
vi) Indicating Lamps
7 segment LED Indication lamps for “ON’ “OFF”, Tripped due to fault, Metal detected, Magnet
over excited, and any other as proposed by the tenderer or by purchaser.
vii) Push –Buttons / Control switches
Shall have minimum 2 NO + 2 NC contacts.
viii) Lockable Local / off/ Remote selector switches and the status shall be provided to Central
Control System accordingly
One on each local control station
ix) Wiring
2.5 sq mm stranded copper conductor PVC insulated wires. Inside the panel, wiring shall be
1.5 sq.mm. stranded cable for control system.
x) Components
MCCB’s, contactors, control transformers, lockable 2 pole 2 way local/remote selector,
switch, push buttons, Control fuses and other associated equipment or controls required for
the system.
xi) Potential free contacts for input and output circuits shall be provided in the local control panel
but not limited to the following:
Metal Detector
Metal Detector On feedback - To PLC
Metal detected status – To PLC
Metal Detector Healthy status – To PLC
Magnet
On off command - From local control panel with feedback to PLC
Local / Remote selector switch in local mode – To PLC
Local / Remote selector switch in remote mode – To PLC

Contract M-02
Local / Remote selector switch in Off mode – To PLC

Local On/Off Push Button’s operated – To PLC
Magnet In Under Excitation – To PLC
Magnet in Normal Excitation – To PLC
Magnet in Over Excitation – To PLC
Metal detector & Magnet reset –To PLC
The quantity of the signal exchanged between Central Control Room and the Magnet and
Metal Detector shall be subject to the Approval and the same shall be completely wired up to
terminal blocks including ModBus RTU interface.
i) Terminal Blocks
As required plus 20% spares of each type and rating.
j) Cables
11 kV grade aluminium / copper conductor, PVC insulated, armoured, PVC overall sheathed
cables.
Minimum size of conductor:-
6 sq mm Aluminium, 2.5 sq mm Copper.
Control Cable : 2.5 sq mm Copper.
7.8.3 Belt Cleaners & V-Plough
7.8.3.1 External Belt Cleaners
a) The Cleaners (Scrapers) shall be located beneath the discharge pulley drum of all conveyors.
The cleaners installed shall ensure effective cleaning of the belts with no spillage on return.
b) The cleaners shall consist of adjustable frames, rigidly mounted to the conveyor. It shall have
two transverse support bars and a number of diagonally extending cleaning members between
the bars. The uppermost support bar is located inwardly of the over-hang portion of the pulley
and the lower support bar is located near the tangent of the belt and the pulley.
c) A flexible cleaning member shall be used so that the elastic tension in the flexible cleaning
member translates to a thrust on the conveyor belt surface.
d) The primary scraper (Pre Cleaner) shall be provided for removing the heavy residue of materials
adhering to the belt surface on the return side of belt.
e) The blades of primary scraper shall be made of abrasion resistant polyurethane material, inclined
against the direction of belt travel, ensuring maximum cleaning of higher density cargo like iron
ore fines & other cargo with minimum wear and tear of belt surface.
f) The primary scraper shall be self adjusting, compatible with reversible belt, easy to install and
minimum maintenance.

Contract M-02
g) The secondary scraper shall be provided with automatic adjustment function (Elastomount)
which helps in maintaining permanent contact with the belt.
h) The cleaning member of secondary scraper shall comprise of a series of scraper elements of
tungsten carbide, threaded onto stainless steel flexible base. The scraper elements are
separated by stainless steel spacer springs so that the scraper elements are kept perpendicular
to the belt surface but allow the elements to deflect to permit obstructions, such as mechanical
fasteners, to pass without snagging and damaging the belt or the scraper assembly.
 The belt cleaners shall fulfill the following requirement:
 Operate on the face of the discharge pulley.
 Withstand temperature as specified.
 Withstand corrosion.
 Resilient to obstructions and safe for the belt.
 Large number of small, thin blades.
 Ensure contact of the blades at all points across the dirty section of the belt for effective
cleaning under all operating conditions.
 Simple to maintain and maintenance free for a minimum period of 6 (six) months.
 Efficient at any moisture content.
 The wear and tear of the top belt cover shall be minimum so that belt life is enhanced.
 Self adjusting.
 Easy to install.
 Tenderer to confirm that the blade material selected shall be suitable for the abrasive
nature of the handled material, particularly Iron Ore & Coal, and the moisture content.
7.8.3.2 Internal Belt Cleaners (V-Plough Type)
a) The V-Plough (Internal) scrapers shall be fitted in front of tail pulley and take-up pulley to
prevent the material which is falling on the top surface of return belt. This scraper should be V-
type with 60o included angle and vertex should point to the head end of the conveyor. It should
ride on and be supported by the conveyor belt.
b) V-Plough (Internal) for cleaning the interior surface of the belt shall consist of following:
 Self-adjusting torsion arms to maintain cleaning pressure.
 Suspension arrangement to keep the plough parallel to the belt.
 Easily replaceable cleaning blade – Polyurethane.
 Provision of chain to maintain constant pressure and contact with the belt.
 Provision should be provided so that the metallic parts do not touch the belt in case of
blade worn out.

Contract M-02
c) Elastomount arrangement fitted with an automatic locking device shall be provided to prevent
the rigid cleaner parts from coming into contact with the belt and damaging it after the cleaner
blade is worn away.
7.8.4 Monorail Hoist / Crane
a) Monorail Hoists/Cranes shall be provided in towers, transfer towers, drive houses, and other
areas, as required, where equipment parts heavier than 200 Kg are to be handled for
maintenance.
b) Monorails shall have electric hoists with pendant control. The pendant control shall be operable
from the nearest floor.
c) The lifting hook of the cranes/hoists shall as far as possible be able to reach vertically above the
components to be handled. The cranes/hoists shall be able to lift/lower the components from/to
the ground up to/from the required floor. Hoist speed shall not be less than 4 m/min.
d) As far as possible the lifting tackles shall be standardized.
e) The electric hoists shall be complete with festoon cable system including supply of junction box,
cables up to local control panel, pendent control, travel limit switches, etc.
f) The tenderer’s scope includes supply of the hoists with festoon cable system, local control
panels, etc.
g) Monorail Hoists / Cranes shall be in accordance with IS 3177.
7.8.5 Gates (Diverter Gates)
a) Gates, as applicable, shall be provided at locations shown in the attached Flow Diagram
drawing No. A138 M02 OF 001.
b) The gates shall be complete with drive system/ actuator, local control panels, limit switches,
frame for supporting the gate from nearest floor and all accessories.
b) Cables emanating from the device like torque switch, limit switch, power cable for motor shall
be brought to a local control panel placed near the equipment.
d) Dust and weather proof limit switches shall be provided to indicate the position of the gate on
local control panel and in the central control room.
e) The gates shall be provided preferably with Manganese Steel liner plates alternatively Hardox
500 of removable type design. The weight of any one piece of liner shall not exceed 30 kg. The
liner shall be minimum 15 mm thick. The liners shall be fixed by counter sunk bolts on the
mother plate.
f) Bearings shall be antifriction bearings, cast steel plummer blocks, grease nipple, etc. Make of
bearings shall be SKF / FAG.
g) All bearing housings and pillow blocks shall be fitted with horizontal double labyrinth seals,
suitable for operation in an atmosphere containing very fine and abrasive dust. The plummer
blocks shall be four bolt mounting type with split at centre line.

Contract M-02
7.8.6 Take-Up unit with Counterweight

A. General
a) The Take-up unit shall be complete with counterweight, guide, rope & sheaves, heavy duty
outdoor type travel limit switches, take-up trolley with rails, motorized winch with grooved
wire rope drum at Take-up tower, etc. Typical GA of take-up arrangement is attached
herewith.
b) The take-up travel shall be 2.5% (min.) of the centre to centre distance for Nylon belting
and 1.5% (min.) of the centre to centre distance for EP belting and 0.5% for steel cord
belting as generally shown in the attached drawings.
c) Where space allows, an additional length of belt of up to two splices shall be added to the
normal take-up travel to make provision for live storage of belting.
c) Counter weights, shown in the attached drawing, shall be precast concrete or metal. In all
cases space shall be provided for an addition of 25% of the counter weight. Provision shall
be made for dismantling the counter weight or relieving the tension in the belt. This shall be
achieved by a motorized winch, attached to one end of the take-up rope as shown in G.A of
horizontal take-up drawings, or use of hoist (at monorail beam) and the motorised winch.
d) Supply of RCC /metallic counter weight are included in the scope of this contract.
B. Vertical Take-up Units

a) Vertical gravity take-up units shall have a 0.75 m sand box provided under the counter
weight at ground/floor level. The area below the counter weight shall be guarded to a
height of 2.5m above any access level. Suitable guides shall be provided for take-up travel.
The design of the vertical members (guides for take-up travel) is included in the scope and
shall be such that they can be removed between access platforms on the gravity take-up
units.
b) The design of the counter weight assembly shall have a self-cleaning top.
C. Horizontal Take-up Units

a) The take-up trolley shall be complete with trolley frame, wheels, sheaves, wire rope,
supporting structure (foundations are excluded), etc., pulley slide frame shall be self-
cleaning type. The pulley slide carriage shall be equipped with Vee type wheels attached to
shaft running on guide rails. Suitable guide shall also be provided to arrest uplift of
carriage. Buffers shall be provided at both ends of take-up travel to take the impact arising
out of rope / belt snap. Take-up trolley shall be fabricated adopting good engineering
practice.
b) Counter weight tower of horizontal take-up units shall generally be similar to that of vertical
take-up units.
D. Motorised Winch at Take-up Tower

One end of the counter weight rope shall be reeved on a electrically operated winch mounted at
a suitable location for releasing the counter weight for belt repairs and other maintenance

Contract M-02
works. The winch shall be self locking type with hoisting speed of about 2 m/min, so that the
counter weight is prevented from coming down once it is in lifted position. It shall be complete
with local electrical Control Panel, interconnecting cables. The winch shall be suitable to lift the
counter weight for travel as identified in the horizontal take-up drawing No.A138 M02 MG 006.
7.8.7 Vibrating Pan Feeder

a) Vibrating Pan Feeders, complete with panels, will be installed below the Distribution Hoppers
2 & 3; total 4 Nos. (i.e. 2 Nos. under each distribution hopper) in transfer tower JTT-6.
Feeder design rating shall be 2750 TPH / 2200 TPH (2500 TPH / 2000TPH rated) for Iron Ore /
Coal and shall be suitable for continuous outdoor duty. It shall be able to withstand impact of
the falling cargo.
b) Drive shall be provided with variable speed to regulate withdrawal of material from the
hopper.
c) Steel coming in direct contact with the materials shall be abrasion and corrosion resistant.
Feeder pans shall be made of minimum 8 mm thick mild steel plates with minimum 12 mm
thick manganese steel liners with work hardening properties.
d) Means shall be provided for adjustment of trough inclination to regulate the feed rate and
handling of different cargo, if required.
e) Mounting arrangement shall be impact resistant type so as to transfer least vibrations to floor
beams.
f) Vibrating feeders shall be complete with local control panel having required switchgear,
MCCB, contacts control/auxiliary items, VFD drives. Interconnecting power control cable.
VFD panel shall be located in the air conditioned electrical/control room (room and air
condition by JSW). All power and control cables from there panels to vibro feeder shall be in
the scope of the tenderer.
7.8.8 Miscellaneous Items (Bought-out Items)
7.8.8.1 Bearings, Bearing Seals & Pillow Blocks

a) Wherever practicable, bearings shall be of the antifriction type, with a minimum life expectancy
compatible with the class of the mechanism with which they are used, unless specified
otherwise.
b) On shafts supported by two bearings, one bearing shall be fixed type and the other floating type
to allow for thermal expansion of the shaft.
c) All bearing housings and pillow blocks shall be fitted with multi labyrinth-type seals, suitable for
operation in an atmosphere containing very fine and abrasive dust and saline water spray.
d) Pillow blocks shall be of cast steel construction four bolt centre split type. Base plates for pillow
blocks shall be provided with lockable adjusting screws for accurate bearing alignment.

Contract M-02
e) Plain bearings shall have bronze bushings. The bearing pressure on plain bearings shall not
exceed the manufacturers recommended ratings for the material used and the application
conditions.
f) The plain bearing shall have grease grooves and preferably a labyrinth type of seal to prevent
entry of dust particles to the bearing.
7.8.8.2 Wire Ropes

a) All wire ropes shall conform to IS:2266. The tensile strength of the wire shall be 175-190
Kg/sq.mm.
b) All wire ropes shall be pre-formed or IWRC, ordinary lay construction, unless otherwise
specified. Opposite lay (Right Hand and Left Hand) shall be used where rope is used in pairs to
suspend moving loads.
c) The fleet of the rope shall not exceed 1 in 12 for any relative position of the sheave/drum
assemblies.
d) All wire rope terminations shall be made with solid forged thimbles and splices shall be
mechanical splices made with aluminium or copper ferrules.
e) Unless otherwise specified, factor of safety for wire ropes shall not be less than 6, based on the
nominal breaking strength and the working tension of the rope.
7.8.8.3 Wire Ropes Sheaves

a) Wire rope sheaves shall be made of cast steel or fabricated with groove surfaces hardened to
320 BHN minimum.
b) The sheaves shall have machined grooves of uniform diameter accurately turned and finished
smooth. The groove depth, contour, angle and radius shall be as per recommendations in
IS:3177.
c) The diameter of the sheaves measured at the bottom of the groove shall be as per
recommendation in IS:3177.
d) Minimum diameter of sheave with respect to rope dia shall be as recommended in relevant IS
code.
7.8.8.4 Wire Rope Drums

a) Drums shall be grooved and made of fabricated from structural steel conforming to the relevant
materials specification.
b) The size, length, diameters, grooving, anchorage and strength of the grooved drums shall be as
specified and recommended in lS:3177.
c) Grooved drums shall not have more than one layer of rope on the drum when the rope is in its
fully wound position.
d) The thickness below the rope groove in no case shall be less than the rope dia.

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7.8.8.5 Shafts and Axles

a) All shafts less than 50 mm dia. shall be made of cold drawn wrought steel. All shafts over 50
mm dia. shall be of forged steel. Shafts shall be machined all over and the finish under the
bearings shall be to the degree and tolerance required by the bearing manufacturer.
b) Generous fillets or long taper shall be provided at each end of the swell.
c) Truck (Trolley) axles shall be of forged steel.
d) In the case of design of shafts and axles based on strength, the computed bending and
torsional moments in the shaft or axle shall be multiplied by the load service factors Km and Kt
respectively.
Load Service Factors

Nature of Load
Km Kt
Stationary Shafts & Gradually Applied Loads 1.0 1.0

Axles Suddenly Applied Loads 1.5 to 2.0 1.5 to 2.0
Gradually Applied & Steady Loads 1.5 1.0
Rotating Shafts & Suddenly Applied & Minor Loads 1.5 to 2.0 1.5 to 2.0
Axles
Suddenly Applied & Heavy Shock 2.0 to 3.0 1.5 to 3.0
Loads
e) In addition to designing shafts and axles for strength as specified above, shafts and axles shall
be checked for deflection and slope as specified below.
f) The deflection of shafts and axles shall not exceed 1/1500 of the distance between bearing
centres.
7.8.8.6 Pins
a) All pins except those used for rotation or oscillating duty shall be of wrought steel (cold drawn)
and machined all over. All pins subjected to wear due to rotation or oscillation shall be case
hardened, ground and polished. Surface hardness shall be 80 to 85 Shore and the depth of
case hardening 1 mm minimum.
b) The maximum permissible stresses in the design of pins shall be as follows:
Stress Mode Permissible Stress

Bending Stress 33% of Yield Stress
Shear Stress 22.5% of Yield Stress
Bearing Stress 40% of Yield Stress

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7.8.8.7 Wheels
a) The diameter and strength of each wheel shall be dependent upon the total maximum wheel
load imposed by static and dynamic forces on the equipment. However, tread diameter of trolley
wheels shall not be less than 300 mm.
b) Wheels shall have cylindrical treads with double flanges. Tread diameter and flange dimensions
shall be according to IS:1136 and IS:3177 respectively. Width of tread shall be as specified or
shown on drawings attached to the specification.
c) Wheels shall be of forged/cast steel. The treads shall be hardened to minimum 300 BHN. All
wheels shall be tested ultrasonically and test certificates furnished to Engineer.
7.8.8.8 Fasteners and Keys

a) All gears, pinions, wheels, couplings, etc. subjected to torsion shall be keyed to the shafts using
parallel keys and keyways in accordance with IS:2048. Fits and tolerances shall be in
accordance with IS:919, IS;210 and IS:2709.
b) Set screws shall not be used for transmitting torsion but may be used for holding keys or light
parts in place.
c) Unless otherwise specified all holding down bolts and machinery bolts shall conform to IS:1363
for bolts of 6 to 39 mm dia and to IS:3138 for all bolts larger than 39 mm.
d) Friction grip bolts, if used, shall conform to IS : 3757.
e) Plain washers conforming to IS : 2016 shall be used under bolt heads and nuts, whenever the
material is softer than the bolts themselves. Spring or lock washers shall be used throughout for
assembly of all machinery subject to vibration loads.
f) All bolts, nuts and washers shall be galvanized.
7.8.8.9 Castings
a) All castings shall be sound and free from pin holes or imperfections. Outside surface shall be
well sand blasted and smooth. Critical castings shall be checked for internal flaws by x-ray
and/or ultrasonic methods.
b) All castings shall have well-rounded corners and generous fillets to avoid stress concentrations.
c) All boss facings under bolt heads shall be machined.
d) Steel castings shall be stress relieved by suitable heat treatment.
7.8.8.10 Holes
a) All holes for fitting bolts and pins shall be drilled / reamed. Flame cut or punched holes will not
be accepted.
b) Unless otherwise specified, clearance holes for metric bolts shall be as per IS:1821 (medium)

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7.8.8.11 Items not covered above but required to complete the conveyor system shall be finalised by the
contractor to meet the operational requirements. The tenderers shall take approval of the name of
the component manufacturer/supplier before ordering.
7.9 Technological Structure

7.9.1 General
Fabrication of Technological Structures shall include but not be limited to the following:
Supply of steel required including procurement transportation to site, cutting, wastage, fabrication
and erection is covered under the scope of this contract.
a) Standard and Non-standard stringer frames and deck plates
i) The conveyor structure shall consist of independent prefabricated tables. The length shall
be as shown in the attached drawings for the standard table for supporting idlers but when
required special tables shall be provided. All standard tables shall be supported generally
as shown in the enclosed drawings.
ii) Stringers shall be channels having size and arrangement as generally shown on the
enclosed drawing. The channel size for stringers shall be minimum 250 mm / 200 mm / 150
mm as shown in the attached drawings.
iii) Self-cleaning V type deck plates shall be provided under the loading points; extending 1.0
m before and after the end of the loading skirts and above the V-plows protecting the return
pulleys. For conveyors JD-1A/1B, i.e. conveyors working in conjunction with Reclaimer,
continuous deck plate shall be provided.
iv) In no case shall minimum clearance between the floor and the lower most point of the
return belt shall be less than 500 mm or as indicated in the enclosed drawings. In case of
ground conveyor the conveyor vertical supports will be fixed on a minimum 200 mm high
concrete pedestal or as indicated in the drawings.
v) All conveyors, are provided with hoods.
However, for conveyors JD-1A & JD-1B, hood will be provided in the remaining length
where equipment (Reclaimer) will not be operating.
vi) All anchor bolts required for fixing the conveyor frames / components (under scope of this
contract) are included in the supply.
b) Transfer Chutes / Spout Liners
i) All chutes are provided with deflector plate to break the material impact. The chutes shall
be of Mild steel plates with welded steel fabricated section assembled by bolted joints.
Minimum 10 mm plate thickness of chutes and liners (20 m thick) shall be abrasion
resistant manganese steel plates (As per IS:276, Manganese content 11%-14%) with work
hardening property as shown in the attached drawings of chutes. The liners shall be
removable type. The weight of any one plate of liner shall not exceed 20 kg. The liners
shall be fixed to the chute by countersunk screw. Tenderer may quote for an alternative

Contract M-02
liner which, in his opinion, has equivalent work hardening and abrasion resistance
properties of Manganese and with better flowability properties.
Chutes shall be suitably designed considering wall mounted vibrators and installing air
blasters, particularly to ensure flowability of Iron Ore.
The supports must be designed to withstand the weight of a plugged chute, as applicable.
ii) Each section of the chute to have its own inspection door. It is mandatory to have the doors
located and designed to allow the opening of the door during operation without spillage or
danger to personnel. Doors shall be hinged and shall be dust tight when closed. The
minimum size of one door opening shall be 500 mm.
iii) The chute and spout opening cross section to be adequate for the flow of materials. The
valley angle is to be 65 deg. to ensure material flow and that there is no material build-up in
the chute. Discharge pulley elevation may be suitably raised wherever required.
iv) Stone boxes shall not be provided for breaking the impact of the material trajectory.
v) The discharge chute of a conveyor to extend backward to contain both belt scrapers, to
collect the dribble released by the scrapers.
If found necessary, the conveyor elevations shall be suitably modified.
vi) Chutes shall be suitable for installing dust suppression system and provision of installation
of safety switches (by others) where necessary.
vii) Deflector Plate in the Chutes shall be adjustable type with motor operated actuator.
c) Drive Base Frames
i) All drive units shall have common base plates of welded steel construction. They shall be
designed with sufficient depth and stiffness to ensure rigidity of drive assembly.
ii) All machinery mounting surfaces shall be machined. Base plates shall be suitable for
erection on both concrete and structural steel base.
iii) Base plates shall be provided with lockable adjustment screws to facilitate alignment of
heavy gear reducers, motors, in the horizontal plane.
d) Pulleys – Supporting Frames
Pulleys shall be mounted on structural frame suitably designed to withstand the belt tension.
Arrangement of supporting structure is shown in the respective G.A drawing of Transfer Tower.
Configuration of the supporting structure shall ensure easy removal/ maintenance of pulleys.
Pulley Plummer blocks shall be under compression due to belt forces, as far as possible.
e) Skirt Board with Sealing
i) All bulk loading points on the conveyors to be equipped with skirt boards.
ii) Distance between skirt-boards to be 2/3 of belt width.
iii) Length of skirt-boards to be extended minimum 4 m after the end of the loading area.
Skirt-boards to be flared towards the direction of belt travel for guiding the conveyed
material and shall terminate above an idler.

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iv) It is desirable that the skirts/guide plates are independent of the chutes, being supported on
the conveyor stringers.
v) The lower edge of the skirt-boards to have a minimum 40 mm clearance between the metal
part of the skirt and the belt surface.
vi) The gap between the skirt and the belt to be closed or controlled by exterior rubber strips of
50-60 durometer hardness. The rubber strip to be min. 175 mm deep and minimum 20 mm
thick. The rubber strips to be held in position by steel clamps. The rubber strips to be
adjustable in height for minimum 100 mm.
vii) Distance between steel clamps not to exceed 400 mm. The depth of the skirt board shall
be min 750 mm or to suit the requirement of dust suppression system whichever is more.
Continuous covers with dust hood to be provided to reduce dust emission. Rubber curtain
to be provided at the discharge ends of covered skirt-boards.
viii) Skirt-boards to be provided with replaceable liner wherever material is likely to come in
contact with chute. Lining material to be preferably manganese steel (IS:276), min. 16 mm
thick with work hardening property.
ix) The fastening arrangement of liners shall ensure that the liners are easily removable.
x) The gap between the liner plates shall be minimum and shall not exceed 10 mm.
xi) Skirt Boards shall have adequate height and length for installation of water spray nozzle
banks (by others), where applicable.
f) Take-up trolley and sheaves: supporting structure of take-up trolley as required.
g) Metal Detectors, Belt Weighers: supporting structure as required.
h) Safety Switches (Pull Cord, Belt Sway, Zero Speed): Brackets for mounting the safety
switches, as required.
i) Minor missing items: as required / directed by the Employer.
The indicative quantities of Technological Structure are given in Table-C.
7.9.2 Guidelines for Material and Fabrication
a) Drilling and punching of holes for bolts shall be done as per 11.2.4 of IS:800 - 1984, unless
otherwise specified by the Employer.
b) Drilling of holes for bolts during assembly shall not cause enlargement of holes beyond
permissible limit or damage the metal.
c) Holes for bolted connections should match well to permit easy entry of bolts. Gross mismatch of
holes shall be avoided.
d) Material of construction is given in Appendix –1.
7.9.3 Assembly for Fabrication
a) Fabrication of all structural steel work shall be in accordance with IS: 800- 1984 and in
conformity with various clauses of this specification, unless otherwise specified in the drawings.

Contract M-02
b) Fabrication of structures shall preferably be taken up as per the sequences of erection.

c) All Erection units shall bear erection mark number and reference drawing number at a
prominent location on the structures for easy identification at work site.
d) All the components of structures shall be free from twist, bend, damage etc.
e) Assembly of structures shall be carried out by using suitable jigs and fixtures in order to obviate
distortion during welding.
f) Cutting of items specially for stringer frames, chutes, drive & pulley frames, take-up trolley etc,
shall be done only after checking of sizes as per ground lay out.
g) Surfaces, where machining is specified, shall be either planed or milled or ground to ensure
maximum contact.
h) If pre-bending of the plate is required to avoid welding distortion, it shall be done in cold
condition.
i) Splice joints of flange and web shall preferably be staggered.
j) Sufficient trial assembly of fabricated components (dispatch elements) shall be carried out in
the fabrication work site to control the accuracy of workmanship.
k) Where necessary, washers shall be tapered or otherwise suitably shaped to give the heads of
bolts and nuts satisfactory bearing.
l) The threaded portion of each bolt shall project through the nut at least by minimum of four
threads.
7.9.4 Welding of Steel Structures

7.9.4.1 General Instructions
a) The Contractor shall work out welding procedure at his own responsibility for Employer’s
approval, prior to commence work on the project. Welder qualification details to be furnished to
the Client / Engineer.
b) Electrodes shall be stored in a dry place. Electrodes whose coatings are damaged due to
absorption of moisture or due to any other reason shall not be used.
c) Welding surface shall be smooth, uniform, and free from fins, tears notches or any other defect,
which may adversely affect welding.
d) For multi-run weld deposit, every subsequent run shall be done only after thorough removal of
slag and proper cleaning of surface of the previous run.
e) Fillet weld shall have the correct profile with smooth transition into parent metal. Dressing of
welds, if specified, shall be done by such method, which does not cause grooving and other
surface defects on the weld or on the parent metal.
f) Fillet weld shall not be stopped at corners but shall be returned round them.
g) Welding shall not be done under such weather conditions, which might adversely affect the
efficiency of the welding.

Contract M-02
7.9.4.2 Rectification of Defects in Welds

In case of detection of defects in welds, the rectification of the same shall be done as follows by the
Contractor at his own cost.
a) All the craters in the weld and breaks in the weld run shall be thoroughly filled with weld.
b) Undercuts in the weld, beyond acceptable limit, shall be repaired with dressing so as to provide
smooth transition of weld to parent metal.
c) Welds with cracks and also welds with incomplete penetration, porosity, slag inclusion, etc.
exceeding permissible limits shall be rectified by removing the length of weld at the location of
such defects plus 10 mm from both ends of defective weld, and shall be re-welded. Defective
weld shall be removed by chipping hammer, gouging torch or grinding wheel .Care shall be
taken not to damage the parent material.

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8 ELECTRICAL AND CONTROLS

8.1 General
The electrical equipment shall be in accordance with the basic requirements described in the
tender document. All apparatus, equipment and works shall be so designed that they provide
satisfactory service and without any harmful effects for prolonged and continuous periods in the
worst climatic conditions. Particular attention should be paid to internal and external access to the
electrical equipment in order to facilitate inspection, cleaning and maintenance.
The reference design ambient temperature for all electrical equipment shall be taken as 45 deg.C.
and relative humidity shall be 95%. Appropriate derating factors should be applied for equipment
as applicable based on published data against the most severe conditions encountered in the site,
by reducing the permissible temperature rise above the ambient level.
8.2 Codes and Standards

The design and manufacture of the electrical equipment shall conform to applicable codes
regulations and standards:
 Indian Electricity Rules
 BIS Bureau of Indian Standards
 ISO International Organization for Standardization
 IEC International Electro-Technical Commission
 IEEE Institute of Electrical & Electronics Engineers
Following is the list of some of the applicable Indian standards. Any other relevant Indian
Standard, not mentioned here will also be applicable.
 IS: 60947 Low Voltage Switchgear and Control Gear
 IS: 8623 Low Voltage Switchgear & Control Gear Assemblies
 IS: 12021 Control Transformers
 IS: 3043 Code of Practice for Earthing
 IS: 732 Code of practice for Electrical wiring installation
 IS: 1255 Code of practice for installation & maintenance of power cables
 IS: 5216 Guide for safety procedure to practices in Electrical work.
 IS: 60529 Degree of Protection provided by Enclosures

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8.3 LT Motors( for equipment other than conveyor drives)

8.3.1 General
Motors shall be suitable for the duty requirement of the driven equipment for the system/plant
requirement. The motor shall be suitable for continuous running with full load at 75% of voltage
for 5 mins. Motors shall not stall due to voltage dip with system causing momentary drop in
voltage to 70% of the rated value.
Motors shall be of TEFC type with degree of protection IP- 55 and provided with protection guard.
Motors shall be for operation in saline, humid atmosphere and containing fine abrasive dust. All
fasteners used shall be corrosion resistant against salinity.
Motor shall be capable of withstanding occasional overloads of 50% for 2 minutes. Motors shall be
suitable for running at 120% speed for 2 minutes.
The starting torque of the motors shall be as per system and operational requirement. The starting
torque of motor shall be co-ordinate with the requirement of the driven equipment on the basis of
minimum voltage of 80% rated voltage at motor terminals. There shall be sufficient margin of
motor torque over the torque requirement to obtain proper accelerating torque so that the starting
time is minimized.
Double shaft extension shall be provided for motors with brakes.
Brakes, limit switches, speed relays etc. as required for individual equipment shall be
provided by the tenderer.
The noise level shall conform to the requirements of IS: 12065 and the amplitude of vibration
shall be within the limits specified in IS: 12075.
Lifting arrangement shall be provided for motors.
8.3.2 Class of Insulation

Motors shall have class ‘F’ insulation and permissible temperature rise limited to class B.
Windings shall be vacuum impregnated to make them non hygroscopic and oil resistant.
Motors shall have fungus protection including special treatment of insulation and metal
against fungus, insects, and corrosion. Motors to be installed in coastal areas and tropical
treatment should be given .
8.3.3 Winding
Motor winding leads shall be brought out through seal off “bushings”. Cable shall not be used
for connecting the windings to the terminal boxes.
Both the winding leads of each phase shall be brought out to the terminal box with necessary
shorting links for achieving desired winding connections at site.
8.3.4 Bearing
All motor shall be provided with adequate grease lubricated ball or roller bearings as required
to ensure reliable operation. The bearings shall be housed in dust-tight bearing end shields
and shall be provided with easily accessible grease nipples and valves for ejecting excess

Contract M-02
grease. The bearings should be provided with labyrinth seals to prevent loss of grease or
entry of dust and moisture. Bearing life shall be more than 50000 hours.
8.3.5 Terminal Boxes

All motors shall be provided with cable termination boxes with removable undrilled gland
plates suitable for terminating aluminium armoured cables of required size. Double
compression glands should be provided. The box shall be provided with gaskets.
Each terminal box shall be fitted with earthing studs of suitable size.
Unless otherwise approved, the terminal boxes shall be capable of being turned through 360
deg in steps of 90 deg, the position for the main terminal box will be on the right hand side as
seen from drive end of the motor however it should be interchangeable from left to righ t at
site.
Terminal box shall be of IP-55 degree of protection.
8.3.6 Cooling and Cooling Fans

The motor shall be in general fan cooled type having the fans as integral parts of the motors
themselves.
The cooling fans for each motor shall be of such design that the motors can turn in any
direction without/with minor medication at site.
8.3.7 Earthing
Two separate earthing terminals on opposite sides of motor body.
8.4 Local Electrical Control Panels

8.4.1 LT Switchgear Panels
Switchgear shall be made of cold rolled annealed sheet steel metal minimum 2 mm thick for
load bearing members and 1.6 mm thick for doors and covers, enclosed, compartmentalized,
Draw-out type for Incoming ACB (rating above 630A) & fixed for incoming MCCB( 630A &
below) & outgoing feeders, indoor, floor mounted free standing type. Incomer feeders shall
have CT’s, Ammeter with selector switch, Voltmeter with selector switch, R,Y,B indicating
lamps. Incomers of rating 400A and above shall also have multifunction meters.
All sections of the enclosure shall conform to degree of protection IP: 54 for indoor (when
installed in substation/electrical room) and IP:65 for outdoor installation/ installation in
transfer towers and provided with anti-vibration pad.
Switchgear shall be suitable for cable entry from bottom / top as per site requirement.
Neopropene Gaskets shall be used between all adjacent units and beneath all covers to
render all the joints effectively dust proof.
Panel shall have three phase and neutral bus bars of rated current capacity and short circ uit
withstand capacity of 50 kA (or higher kA based on transformer secondary short circuit
current) current for 1 sec. Busbars shall be of conductivity electrical grade aluminium alloy or

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High Conductivity, Electrolytic Copper and provided with heat shrink able appropriate coloured
(for various phases & for neutral) insulating sleeves.
Maximum operating height shall not exceed 1800 mm for any switch/meter and minimum
operating height shall be 250 mm min. Each vertical section of Switchgear shall comprise
i) Horizontal bus chamber
ii) Vertical bus chamber
iii) Cable alley
iv) Feeder units (with individual doors) arranged in tiers
v) Earth bus chamber
The switchgear panels shall also have earth bus bar apart from four (4) main (3 Ph and 1
neutral) busbars running through the whole length of the Switchgear. All items/equipment
mounted in the Switchgear shall be connected directly to this earth bar for this earth
connection structural steel/cover sheets of the Switchgear shall not be used.
Number of feeder modules in one vertical section shall in no case be more than six.
The compartment doors shall be so interlocked that it shall not be possible to open the door
with the switch/circuit breaker/MCCB in closed position. It shall however be possible for
skilled representative to defeat this interlock using a screwdriver in case of emergency. After
interlock has been defeated, it shall be possible to close the door again by defeating the
interlock.
Facility shall be provided to padlock the switches in off position.
Ant icondensation heater with thermostat shall be provided in panels.
Facilities for extension of Switchgear on both sides shall be provided.
MCC and Local Control Panels shall have all the required switchgear, protection, controls
and auxiliary components as required for plant operation. These shall be coordinated with all
control and safety devices and Central control system.
Component Specification
a. Air Circuit Breaker

For Incomer / Feeder rating above 630A, Air Circuit breakers shall be provided. The
circuit breakers shall be of manually and electrically operated and shall be of draw out
design conforming to the Indian standards / International Standards. All the breakers of
the boards shall be from the same family of breakers having the desired rating to ensure
the uniformity of the design, maintenance and spares & inter-changeability. The circuit
breakers shall have breaking capacity of 50 kA (or higher kA based on transformer
secondary short circuit current) and shall withstand system fault level kA f or short time
duration of 1 sec. ACB’s shall be 4 pole type with microprocessor based protection
releases (Latest model) for overload, short circuit and earth fault with adjustable current
and time settings and characteristic curves.

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Incomers shall have 3 CT’s with Multifunction meter, MP Base protection relays
(Protections - 50, 51, 50N, 51N, 86, 95), T/N/C Switch, Auto/manual Selector Switches,
Ammeter with AS, Voltmeter with VSS, Emergency stop Push Buttons, Reset PB,
Indicating lamps R,Y,B phase; On, Off, Trip, ACB service, ACB Test, Spring Charge,
Control Supply ON, TCH.
Castle key interlock shall be provided between the two incomers in addition electrical
interlocks shall also be provided in closing and tripping coil circuits.
All the breakers shall be provided with an auxiliary switch with sufficient number of NO
and NC contacts for schematic wiring and at least 4 NO and 4 NC contacts should be
free and available for interlocking purposes.
b. Moulded Case Circuit Breakers
For Incomer / Feeder rating from 32A upto 630A, Moulded Case Circuit Breakers shall be
provided.
MCCB’s shall be 3 pole ( A.C.) for motor feeder and 4 pole (A.C.) for Incoming &
outgoings having breaking capacity and short time current withstand rating 50kA.
MCCB’s of 100A & above rating shall be provided with adjustable micro processor based
releases with O/L, S/C & E/F protections and below 100A shall be provided with TM
based releases with O/L & S/C protections.
For motors up to 30 kW, MPCB shall be provided.
c. Variable Frequency Drives for Vibro Feeders
The VFD for Vibro Feeders shall be provided in local Electrical Control Panel, which shall
be located in JSW’s new Electrical Room ( location will be provided by JSW)
VFD Panel should have MCCBs, input filter, converter, inverter, output choke and
contactor (for safe mode isolation and operation through VFD). The VFD and output
choke should take care of the long distance of cables (upto 300 m) from the VFD Panel
in ER-1 to the Vibro Feeder Motors in the transfer towers. It shall have c ommunication
with Central Control PLC System on universal serial data protocol.
d. Contactors
Contactors for A.C. shall be 3 pole air break electromagnetic types suitable for making
and breaking locked rotor current of the motor which is equal to around six ( 6) times the
full load current. Reversible motor contactors shall be mechanically and electrically
interlocked with each other. Contactors in the VFD control cabinets or adjacent to such
shall be rated for 415V, 690V as applicable, 3 phase, 3 pole air break electro-magnetic
type suitable for making and breaking locked rotor currents equal to six times the motor
full load current. Reversible motor contactors shall be mechanically and electrically
interlocked with each other. The Contactors shall be suitable for uninterrupted duty, AC3
utilisation category for unidirectional, and AC4 for reversible motor duty. The contact
materials shall have anti-weld properties. Insulating class of operating coils shall be
class E or better, the operating voltage shall be 110 volts +/-10%, 1 phase, AC or to suit

Contract M-02
the Contractors design. Auxiliary NC/NO contacts shall be provided for control purposes,
operated in tandem with the main contactor contacts.
Minimum power contactor rating shall be 16A.
e. Motor Protection Numerical Relays
For motor rated above 90 KW, microprocessor based numerical motor protection relay
shall be provided, it shall have protection trip and alarm contacts for overload, earth
fault, stalling/locked rotor / short circuit, single phasing / phase reversal / n egative
sequence and prolonged start condition.
The motor feeder shall also have thermistor relay for connection to embedded thermistor
in the winding.
f. Overload Relays
For motor rated above 30 kW and upto 45 kW, bimetallic thermal overload relay shall be
provided. The contactors shall be provided with 3 element (AC) ambient temp.
Compensated time lagged hand reset type bimetallic thermal overload relays with
adjustable setting range and single phase prevention.
Overload relay shall have least one NO & NC change-over contact.
Relays shall be either direct connected or CT operated depending on the rated feeder
current. The relays shall be so chosen that it will not operate during the starting time of
the motor.
For motors upto 30 kW, MPCB shall be provided.
For Motors 31 kW to 131 kW, SIM CODE or equivalent system with communication port
(MODBUS/ Profinet/ TCPIP) to be provided.
For motors above 131 kW , soft starters shall be provided .
g. Auxiliary Contactors / Relays
The auxiliary contactors/relays shall be provided as per circuit requirement, and also for
interlocking and multiplying contacts. Auxiliary contacts shall be capable of carrying the
maximum estimated current. In any case their rating must not be less than 5A at 240 V
AC and 2 A at 110 V DC (inductive load). The auxiliary contactors shall have at least 5
contacts in contact combinations as per plant operational and control system
requirement.
h. Push Buttons
Push buttons rated 10 Amp AC shall be of Employer's approved make and type with
silver tipped contacts to withstand minimum 1000 switching operations. The push buttons
shall have at least 2 NO and 2 NC contacts.
i. Space Heater
The space heaters for panels shall be suitable for continuous operation on 240V AC 50
Hz, single phase supply and shall be automatically controlled by thermostats. Provision

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for power supply to space heaters for motors shall be kept in motor feeders rated 30 kW
and above.
j. Indicating Lamps
The indicating lamps shall be panel mounting large industrial 7 segment LED type and
shall be interchangeable. Indicating lamps shall be with translucent lamp covers. The
lamp covers shall be mounted flush on the front panel door and shall be replaceable from
the front of the cubicle.
k. Current Transformers and Potential Transformers
Instrument Transformers for ammeters and relays as required shall be dry cast resin type
and of reputed and approved make and type conforming to IS:2705 and IS:3156. They
shall be able to withstand thermal and mechanical stresses resulting from the short
circuit and the momentary current ratings of the breaker/switches. For incomer feeders
CT shall be in general 15VA, and for outgoing feeders 10 VA. The VA ratings of CTs for
incomer and outgoing feeders may have to be increased for system VA demand as
required during detailed engineering.
l. Ammeter
Ammeters shall be capable of withstanding sustained overload under fault conditions
without damage or loss of accuracy. It shall be analog type.
Ammeters shall be current-transformer operated and shall be suitable for current
transformer secondaries as the case may be.
The ammeter shall display current in each phase and in each line by suitable selection
on the display pad.
Performance of Ammeter shall conform to IS: 6236.
m. Voltmeter
The voltmeter shall display voltage in each phase and across each line by suitable
selection on the display. The meter shall operate off 110 volts VT secondary voltage. It
shall be analog type.
Performance of the voltmeter shall conform to IS: 6236.
n. Multi function meters
Digital multi function meters shall be provided for incoming & outgoing feeders. These
meters have accuracy class of 0.5 or better.
Meter shall be provided with KWH pulse output & RS-485 Communication port.
The digital metering unit shall have provision to display the following:
o Phase and line voltage
o Phase and line current
o kVA, kW, kVAR, kVAH, kWH and kVARH,
o Maximum Demand kVA, kW

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o Power factor
o Phase Angle
o Frequency
o Harmonics
o. Painting
The L.T. switchgear shall be subjected to pretreatment as below:
All structural steel components need to be protected permanently and effectively against
any formation of rust thus avoiding weakening of the cross sections. Protection against
corrosion shall be achieved by painting. The switchgear and control panel enclosures
shall undergo seven – tank process of painting.
a) Degreasing
b) Rinsing
c) Pickling for complete rust removal
d) Rinsing
e) Phosphating
f) Rinsing
g) Chromate passivation
Powder coating of approved method is acceptable. Dry Film Thickness will be 80 -120
Microns. Colour Shade RAL 7032
8.5 Power Cables

8.5.1 LT Cables (System Particulars)
(a) Voltage Grade : 1100 V
(b) Normal system voltage : 415V + 10%
(c) Frequency : 50 Hz + 3%
8.5.2 Conductors
The conductors shall be composed from electrical purity aluminium and shall confirm to IS:
8130 conductors shall be stranded and circular in cross section upto the size of 25 sq.mm
and above shall stranded & shaped. Minimum cross of conductors power shall be 6 sq.mm.
and for lighting shall be 2.5 sq.mm.
8.5.3 XLPE Insulation (For LT Power Cables)

The insulation shall be chemically cross linked polyethylene conforming to the physical,
electrical and ageing properties as required by IS:7089 (Part I & II). Only natural unfilled
compounds shall be used for insulation of cables. The insulation shall be free from
microvoids and shall be heat resistant.

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8.5.4 Inner Sheath

For all cables having two or more cores, the individual cores shall be laid up and then be
surrounded by common covering applied by extrusion a thermoplastic material. A proofed or
plastic tape may be applied over the common covering when a wrapped common covering is
employed. It must be ensured that the circularity of the cable is maintained. The thickness of
the sheaths shall be as per relevant standards.
8.5.5 Armouring
Armouring shall be arranged over the inner sheath for the cable consisting of two or more
cores. The armour of cables shall be either of galvanized steel wires or galvanized steel
strips. In case of high voltage grade cables, armouring shall be arranged over the bedding.
8.5.6 Outer Sheath

A tough outer sheathing of PVC FRLS insulating material in standard colours shall be
provided over the armouring to offer a high degree of mechanical protection against abrasion.
For high voltage grade cables, outer sheathing shall consist of a complete layer or la yers of
suitably compounded hessian materials. Additional compound shall be applied under and
over each layer in order to prevent adhesion, a coating of lime wash or other suitable material
shall be applied to the outside of the cable. The thickness of the sheaths shall be as per
relevant standards.
8.5.7 Colour Scheme for Identification of Cores

Cores shall be identified by colour scheme of PVC, XLPE insulation. The following colour
scheme shall be adopted:
Phase A : Red
Phase B : Yellow
Phase C : Blue
Neutral : Black
Earth : Green/Yellow
8.5.8 Current Rating

The current rating shall be based on the conditions of installation described below. For other
conditions corresponding rating factors shall be applied:
1. Maximum continuous conductor temperature for XLPE cables 90 deg.C

2. Maximum short circuit conductor temperature for XLPE cables 250 deg.C
3. Ambient air temperature 45 deg.C
4. Ground temperature 30 deg.C
5. Depth of laying to (to the highest point of cable laid direct in the 75 cm (1.1 kV)
ground)

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6. Thermal Resistivity of PVC 650 deg.C cm/W

7. Thermal Resistivity of Soil 150 deg.C cm/W
8.5.9 Bending Radius

Cables shall have the following bending radius:
XLPE Cables:
Multi-core cables upto 1.1 kV 12 D

Where D is the overall diameter of the cable.
8.5.10 Manufacturer's Identification

The manufacturer shall be identified throughout the length of the cable by manufacturer's
name or trade mark, voltage grade and year of manufacture of the cable indented or
embossed on the cable. The indentation or embossing shall be done only on the outer
sheath.
Sequential meter marking shall be indented or embossed on every one meter interval of
cable outer sheath .
8.6 Cable Trays

This system of cable laying shall be adopted throughout the conveyor route in conveyor
galleries, transfer towers, substation, electrical rooms and along cable corridor and cable
racks.
Cable racks to be fabricated & erected along the conveyors for cable tray installation. From
these racks branch cable trays shall be installed inside transfer towers to cater the power to
various equipments installed in Transfer Towers.
The size of cable tray shall be to the suit the cable requirement of the particular section with
30% space for future addition.
Cable trays shall be supplied complete with coupler plates and necessary reducers, bends,
crosses, tees ceiling hangers, fasteners, nuts and bolts etc as per below technical
Cable Trays Technical Specification
Prefabricated type trays shall consists of side rails and Horizontal ladder rungs. The side rails
and ladder rungs shall be fabricated out of hot rolled sheet steel of min. thickness 2.0 mm.
Horizontal rungs shall be welded to the side rail & they shall be 250 mm apart. The elbows,
reducer trees, etc. shall be fabricated out of min. thickness 2.0 mm mild steel sheets having
similar side rails & slotted ladder lungs .All cable trays & accessories shall be hot dip
galvanized & galvanizing thickness shall be min 65 microns/average 80 microns and
Galvanization shall confirm to IS 2629/2633/4759.
The cable trays shall be in piece length of 2.5 Mtrs. The width & length of trays & accessories
shall be within a tolerance of + 3 mm.

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Cable trays shall be provided with coupler plates of suitable size with 8 nos. holes per plate
with M8 x 20 electroplated 304 nut bolts (8 nos. with washers.).
 Thickness of material : min 2 mm.
 Side channel size : 100 mm for 300 mm and above cable trays.
75 mm for below 300 mm cable trays.
 Rung size : 40 mm x 20 mm for 300 and above cable trays.
35 mm x 15 mm for below 300 mm cable trays.
 Interval of Rungs : 250 mm Maximum
 Holes on each side : 4 nos. x 2 sets on each end Coupler plates
 Length per Piece : 2500 mm
 Weight : To be specified by supplier
8.7 Earthing
Earthing shall conform to the provision of Indian Electricity Rules and applicable code of practice
for earthing IS: 3043. The Sizes of GI earth bus and earth wires shall be as follows:
- Local Electrical Control Panels 25 x 6 mm GI strip
- Terminal boxes, field instruments, gland earthing 8 SWG GI Wire
- Motors up to 1.1 kW 8 SWG GI Wire
- Motors above 1.1 kW up to 22 kW 25 x 3 mm GI strip
- Motors above 22 kW up to 55 kW 25 x 6 mm GI strip
8.8 Control System

8.8.1 Control Devices by the Tenderer
The following items shall be furnished, installed (supplied by the tenderer), connected, and
integrated into the system by the tenderer in accordance with these specifications.
To match the potential between PLC--I/O Input Modules and Contractor supplied Control
Modules, Control Supply shall be 24 V DC
8.8.2 Local-Off-Auto Control Station (LCS’s)
Each motor shall have two modes of operation; ‘Local’ and ‘Auto’/’Remote’, manually selectable
by a three position selector switch “Local-Off-Auto’ Each heavy duty selector switch shall be
located close to and within view of each drive motor. Start-Stop, Forward-Reverse (wherever
required) push button shall be provided next to or integrated with each L-O-A as required. It shall
be feasible to lock the L-O-A switch in the ‘Off’ position, so that the locking key can be retained by
maintenance staff for working on the driven equipment in safety.
The emergency stop switch shall have at least three sets of NC/NO potential free contacts rated
10 amp at 110 V DC in an IP-65 protected enclosure. A red mushroom type of actuator shall be
used. There shall be two cable entries suitable for double compression glands (or better) for up to

Contract M-02
10 x 2.5 sq mm copper conductor armoured control cable. Earthing terminals shall be provided on
the enclosure. The terminal block should have terminals suitable for termination of two (2) Nos. of
2.5 sq mm size stranded copper conductor wires or wire of any size up to 6 sq. mm.
It shall have illuminated start push button to ensure the supply is ‘ON’ while operating in Local
Mode.
8.8.3 Limit Switches

All travel/End/Torque and Heavy duty limit switches shall have IP 65 protected enclosure. The
limit switches supplied by the Contractor shall be wired to the local control station or Local Control
Panels, and the provision to Central Control System interface and interlock shall be provided in
the LCS and Local Control Panels respectively in hardwired mode or serial data interfacing mode.
The field safety devices such as Pull Cord Switches, Belt Sway Switches, Chute Jam Switches,
Belt Take UP Switches, Zero Speed Switches shall be provided as “free issue” and fitted by this
contractor
Two numbers of earthing terminals suitable for 8 SWG GI wire shall be provided on the body of
the switch.
All position limit switches are required to be non-contact type limit switches unless it is
unavoidable.
8.8.4 Local Control Panels

Panels shall be made of cold rolled annealed sheet steel metal (2 mm thick for load bearing
members and Min. 1.6 mm thick for doors and covers) enclosed, indoor, floor mounted or free
standing type. Proper Illumination shall be provided.
All sections of the enclosure shall conform to degree of protection IP: 54 for indoor (inside
substation/Electrical room) and IP:65 for outdoor with anti-vibration pad.
Viewing Glass shall be provided.
It shall have controller units/ circuit breaker/Connectors / terminal blocks / Rail mounted terminal
blocks / Base module terminal blocks / PCB terminal blocks / Relay/Contactor module with
terminal blocks.
These panels shall have required cable entry and cable gland to suit the requirements of plant
operation. However all the control panels shall have provision of control cables supplied by others
which is to terminate to the nearest Field Junction Boxes (supplied by others) for interfacing and
interlocking with the Central Control System to meet the functional requirements.
Terminal blocks should be made out of Nylon 6.6 VO grade with excellent anti-tracking index of
CTI 600, as per IEC 60 112, modified Nylon, free of halogens, fluorocarbons, chlorinated
hydrocarbons, silicon, asbestos, cadmium and formaldehyde and shall be built for 105°C
temperature on continuous basis, fitted with electrolytic copper, hard and extra hard copper
having contact surface of Special tin alloy coated/plated up to 15 micron thickness, with built in
clamping spring (Cage Clamp) made from high quality chrome nickel high tensile strength which
has proven its resistance to corrosion in many years of practical use, Cage Clamp clamping unit
pressed conductor with high contact pressure into the soft tin/lead layer so as to make a Gas tight
connection and act as a protection against corrosion.

Contract M-02
Terminal blocks shall be of 650 volts grade, rated for 10 amps and in one piece moulding. It shall
be complete with insulation barriers, clip on type terminals and identification strips. Marking on
terminal strip shall correspond to the terminal numbering on wiring diagrams.
Terminal blocks for power and control wiring shall be provided with adequate clearness.
At least 20% spare terminals for connections shall be provided and these spare terminals shall be
uniformly distributed on all terminal blocks.
All terminal blocks (power and control) upto 6 sq.mm. shall be spring clamp type and lugs shall be
insulated ferrule. Control/Power Cable terminations shall be numbered with heat shrinkable
printed PVC ferrule/sleeves.
All terminal blocks shall also be suitable for terminating on each side, two (2) Nos. of 2.5 sq mm
size stranded copper conductors and 0.5 sq.mm signal or data cables for Modbus RTU-RS485
communication interfaces..
All terminals shall be numbered for identification and grouped according to the function. Engraved
white-in-black labels shall be provided on the terminal blocks.
Wherever duplication of a terminal block is necessary it shall be achieved by solid bonding links.
8.8.5 Terminal Boxes

These shall have Rail mounted terminal blocks / Base module terminal blocks with terminal blocks
and cable entry as required to interface with Central Control System and also the Contractor
supplied equipment.
Terminal blocks shall be of 650 volts grade, rated for 10 amps and in one piece moulding. It shall
be complete with insulation barriers, clip on type terminals and identification strips. Marking on
terminal strip shall correspond to the terminal numbering on wiring diagrams.
At least 20% spare terminals for connections shall be provided and these spare terminals shall be
uniformly distributed on all terminal blocks.
All terminal blocks shall be suitable for terminating on each side, two (2) Nos. of 2.5 sq mm size
stranded copper conductors.
All terminals shall be numbered for identification and grouped according to the function. Engraved
white-in-black labels shall be provided on the terminal blocks.
Wherever duplication of a terminal block is necessary it shall be achieved by solid bonding links.
All terminal blocks shall also be suitable for terminating on each side, two (2) Nos. of 2.5 sq mm
size stranded copper conductors and 2 Nos. of 1.0 sq.mm signal or data cables for Modbus RTU-
RS485 communication interfaces.
All terminal blocks (power and control) upto 6 sq.mm shall be spring clamp type and lugs shall be
insulated ferrule.
8.8.6 Multi Core Control Cables (2.5 sq.mm)
This specification covers the requirements for Voltage Grade 1100 V armoured, multi core XLPE
insulated, FRLS cables for control purposes.

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All cables shall be designed and manufactured such that no damage occurs during transportation,
installation and operation of the cables under stipulated conditions.
The cables shall be suitable for laying in trays, pipes, ducts, closed trenches and directly buried
underground. All cables shall be armoured type.
Required discrete signal / analog signal shall be considered in hardwired mode and shall be
terminated in the nearest R-I/O panel. Vibro feeder shall also have local control station for
maintenance purpose and same shall be updated in Central Control Room. The Cables shall be
1100 V grade, FRLS sheathed heavy duty armoured type.
Cables shall be provided with additional overall Shielding with Aluminium mylar tape with 100%
coverage and 25% overlap on laid up cores for shielding against static/electromagnetic
interference. The 10% spare core cable shall be provided and shall be subject to the approval of
Engineer/Employer. The spare cable shall be terminated properly in the respective spare Terminal
Blocks of the Junction Box (J.B). Ferruling for spare cable shall be provided.
A. Conductors
The conductor shall be of plain annealed high conductivity copper stranded wires which
before stranding shall be generally circular in section, smooth, uniform in quality and free
from scale spills, splits and other defects. The conductors shall confirm to IS:8130. The
stranded conductor shall be clean and uniform in size and shape and its surface shall free
from sharp edges.
B. Colour Scheme for Identification of Cores
The following colour scheme shall be adopted:

Upto five cores - Red, Yellow, Blue, Black and Grey.
For cables having more than five (5) cores, two adjacent cores (counting and directional) in
each layer may be coloured blue and yellow respectively and the remaining cores may be
light grey.
C. Manufacturer's Identification
The manufacturer shall be identified throughout the length of the cable by manufacturer's
name or trademark, voltage grade and year of manufacture of the cable indented or
embossed on the cable. The indentation or embossing shall be done only on the outer
sheath.
8.8.7 Serial Data Cable (RS 485)
These shall be shielded twisted pair copper cable with minimum of four cores. These cables shall
be insulated and PVC sheathed FRLS cables for serial data communication purposes.
All cables shall be designed and manufactured such that no damage occurs during transportation,
installation and operation of the cables under stipulated conditions.
These cables shall transmit/receive serial data signal (RS-485) at the specified baud rate. The
baud rate shall remain unchanged at the minimum cable length of 800 meters; however, repeater
or line buffer/amplifier shall be used to maintain the baud rate (if required). These cables shall be

Contract M-02
immune to electro-magnetic interference, radio frequency interference or voltage surges. It shall

provide great transmission reliability. The size of the cable shall be considered to meet the above
requirement at minimum cable length of 800 meters.
8.9 Makes of Components

Make of the equipment under supply items shall be selected as per the following list. Employer,
however, reserves, the right to select the particular make during detailed engineering for uniform
design and inventory. Approval of makes for items not mentioned in this list shall be obtained from
Employer / Engineer.
LT Motors ABB / Siemens / CGL / Bharat Bijlee

LT Motor (Inverter duty) ABB / Siemens / CGL / Bharat Bijlee
VVVF (LT) ABB / Siemens / L&T
Ammeters, Voltmeter Enercon / Siemens / GE / L&T / Rishab / AE
MFM Satec / Schneider / Siemens
Numerical Protection Relays ABB / Siemens / Schneider
Auxiliary Relays Schneider / Siemens / Alstom / ABB / L&T
CTs & PTs KAPPA / KALPA / Pragati
LT Switchgear (ACB, MCCB, ABB / L&T / Schneider / Siemens
MPCB, MCB's, etc.)
LT Switchboard and Distribution Panel Board manufacturer shall mutually agreed
Boards between JSW and Successful Vendors.
Socket Outlets BCH / MDS / Havells / Pustron / Hensel
Lighting Switchboards and Crabtree / North-West / MDS / Havells
Switches
Indicating Lamp (cluster LED only) Schneider / GE / BCH / Vaishnav / Siemens / L&T
PLC and relevant hardware ABB / Siemens
Field Switches AG System / Jayashree / Honeywell
LT Power Cable and Control CCI / Universal / Finolex / KEC / KEI / Polycab
Cable
Instrumentation Cable KEI / Thermo Cables / Special Cables / Delton / Lapp
Control Transformer Indcoil / AEP / Indusree / Kalpa / Kappa.
Selector Switch and Push Button Schneider / GE / BCH / Vaishnav / Siemens / L&T
Copper Wires Finolex / Polycab / Havells
Glands and Lugs Braco / Dowells / Comet
Cable Trays Cable Tray manufacturer shall mutually agreed
between JSW and Successful Vendors
Approve make list attached separately.

Contract M-02
9 QUALITY ASSURANCE, INSPECTION, TESTING AND

DESPATCH
9.1 Quality Assurance
9.1.1 General
The Contractor(s) shall ensure manufacturing of the equipment backed up with an effective control
of the quality of works, provide test facilities and conduct all tests necessary to demonstrate
conformance of the works to the requirement of the contracts. The quality assurance requirements
shall apply to all Sub-contractor(s) / Sub-supplier(s) also.
9.1.2 Documentation
The Contractor(s) shall provide, but not be limited to the following documents to permit audit and
surveillance of his quality system including the inspection and test at its & it’s vendors premises
during execution of the contract.
i) Quality Assurance Plan (QAP)
ii) Field Quality Plan (FQP)
iii) Inspection and Tests Procedures
iv) Records
a) The Quality Assurance Plan and Field Quality Plan shall include
 The organization structure indicating separately the QA / QC dep’t structure.
 Identification of specific quality Inspection requirements implemented for the contract;
 Outline the procedures for reviewing, updating and controlling the quality inspection plans
and the referenced documents;
 Details of special processes and procedures;
 Details of design verification activities to ensure compliance to design requirements;
 Method of control of sub-contracted work;
 Method of vendor’s qualification and approvals including the product inspection and
acceptance procedures
 Details of quality inspection records preparation and maintenance.
b) The Inspection and Tests Procedures shall include

 Identification of Tests/Inspections against specific requirements of the contract;
 Hold points and witness points; (Hold points means the stage in production beyond which
work shall not proceed without verification and inspection or written waiver by the Engineer /
Employer. Witness points identify inspection cycles in the production stages with option of
witnessing the tests lying with the Engineer / Employer.
 Identification of records to be maintained;
 Details of test equipment to be used.

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c) Records
 Maintain a system of records with an objective of documentary evidence for conformance of
requirements of the contract. The records shall be maintained by the Contractor(s) (with
immediate submission of a copy to Employer at every stage/sequence inspection) till the
expiry of Defects Liability Period and afterwards hand-over such records to the Employer.
9.2 Inspection and Testing

9.2.1 Shop Tests and Inspection
a) Contractor(s) shall provide samples of materials for examination or testing as requested by the
Engineer/Employer. Mill test certificates shall be furnished by the Contractor(s).
b) The Engineer/Employer or his representative reserves the right to determine by any method
whether any of the material including finished items offered or delivered for use in the work are
suitable for the purpose. Test(s) will be as per the procedures specified in the relevant
standards/codes decided by the Engineer / Employer. Cost of such tests will be to the account
of the Contractor(s). In the event the test reveals that the equipments/material is faulty the
Engineer/Employer may have the option to repeat the test. The cost incurred for such repeat
test will also be to the account of the Contractor(s).
c) Sampling and testing of materials for approval and testing as called for under appropriate Indian
Standard or international standard or any other relevant codes / specifications shall be done
free of charge well before fabrication and use. Samples provided to the Engineer / Employer or
his representative shall be in labelled boxes suitable for storage. Late submission of samples
and test values shall not be accepted as valid reason for delay in completion of the contract.
The discretion of sample selection shall be with the engineer / Employer or its representative.
d) At the discretion of the Engineer / Employer, all materials and workmanship may be subjected
to inspection by the Engineer / Employer or his representative at the place of manufacture or
fabrication of the Contractor(s) and/or the Sub-contractor(s) or at the site of the work. The
Contractor(s) shall advise Engineer / Employer sufficiently in advance so that in case of
rejection, the rectification work involved does not delay the progress of the contract.
e) In case of subletting to other Contractors or manufacturers or suppliers by the Contractor, the
Engineer / Employer will reserve the right
i. that, inspection and/or testing will be carried out at the manufacturer's works; or
ii. that, inspection will be carried out at site by the Engineer's/Employer's Representative; or
iii. that, inspection will be waived subject to the Contractor(s) furnishing a certificate of
compliance with specification by a competent authority recognised by national/inter-
national institutes. Decision of inspection waiver is the right of Engineer/Employer.
f) The Contractor(s) shall notify the Engineer / Employer of the dates on which manufacture or
fabrication of items is to be carried out at the supplier's factory or the dates on which item of
standard manufacture will be available for inspection and/ or ready for despatch. In the case of
items in the manufacture of which intermediate stages are to be inspected as the work
proceeds, the Contractor(s) shall notify the Engineer / Employer from time to time the dates at
which such inspection can be made.

Contract M-02
The Contractor(s) shall give at least two weeks’ notice for the Engineer / Employer to make
arrangements for inspection or give permission for despatch as the case may be.
g) Notwithstanding the fact that a material or a piece of equipment has passed the inspection
carried out during the stage of manufacture, the Contractor(s) is not relieved from his
obligations to conform to the quality, workmanship, guarantee of performance etc. as per the
relevant terms of this contract.
h) Any defective material, equipment or workmanship which may come to the notice of the
Engineer / Employer or his representative after erection and installation shall be liable for
rejection, and the Contractor(s) shall have to replace such materials, equipments, etc. or rectify
the defects at his own cost.
i) Welding work, castings and forgings shall be subjected to radiographic or ultrasonic testing or
any other test as instructed by the Engineer / Employer, as applicable, and test certificates shall
be furnished. The Engineer/ Employer or his representative reserves the right to examine the
radiographic films of welding joints independently. In case of difference of opinion on a
radiographic film about the soundness of any welding joint between the Contractor(s) and the
Engineer / Employer, the opinion of any testing laboratory/institute in India approved by Indian
Standard Institute shall govern.
i. Suitable means shall be adopted in identifying each radio graphically tested joint with
reference to the radiographic films even after commissioning and the same information
shall be furnished to the Board at the time of delivery of the equipment for documentation.
 Minimum 300 mm for each 1000 mm length of welding joints shall be radiographically
tested in the following cases:
 Wherever design/manufacturing drawings call for testing.
ii. In case of additional welding, joints of the major load carrying members to make up the
dimensional lengths, etc.
iii. Engineer / Employer reserves the right to test radiographically about 3% length of any other
welding joints which are not covered by 10.2.1(i)(ii).
iv. If any of the tests shows defective welding, further tests shall be carried out. All such tests
shall be at Contractor's cost.
j) All radiographic quality welding joints shall be principally grade 'black'. However, grades 'blue'
and 'green' will also be acceptable subject to the approval of the Engineer / Employer on
tension and shear load carrying members respectively provided they are of short lengths.
9.2.2 Shop Assembly
Equipment shall be shop assembled prior to shipment to the extent required to ensure satisfactory
field erection. All critical dimensions shall be verified, all motions checked and equipment tested in
the shop prior to shipment. All sub-assemblies and parts shall be match-marked and metal tagged
with parts numbers to facilitate field assembly. The Tenderer shall furnish the list of such
components. The components shall be shop assembled for inspection by the Employer / Engineer
before despatch to site.

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10 ERECTION AND INSTALLATION

10.1 General
The scope of work under erection includes but not limited to the following:
The total conveyor system comprising of all components / items, Motors (free issue item) and
fabricated items listed in earlier section. Contractor (to complete the short supply if any) shall be
erected in the Transfer Towers, galleries, and other areas, as applicable to make conveyor system
operational in all respect, including
 Laying/aligning of conveyor belting including hot vulcanizing for complete new conveyor system.
 Alignment of complete conveyor components / items.
 Supply of tools and tackles, consumables, materials, labour and supervision.
 Fabrication of minor missing items and Execution of all minor rectification / modifications as
required.
 Removal of bends, kinks, twists etc. for parts damaged during transportation and handling.
 Verification of the position of embedded anchor bolts and inserts.
 Rectification at site of the damaged portions of shop primer by cleaning and application of primer
and touch-up paint.
 Grouting of the gap between the base plate and top of foundation with concrete of approved
quality.
 Erection of items shall be carried out under supervision of the respective supplier.
10.2 The Contractor(s) shall prepare erection drawings, programme, list of equipment to be used for
erection of each component and shall submit to the Engineer/Employer for review prior to erection.
The programme shall include, but not be limited to
o Sequence of erection of equipment / structure.
o Handling and Cranage
o Details of Temporary Bracing and Guying
1. The sequence of erection shall match the erection schedule of galleries / transfer towers
 Erection drawings should show size and location of all members, give complete locations and
details for setting anchor bolts, indicating elevations of all bases, extent of bolted or welded
connections and all details necessary for erection.
 While planning the cranage requirement, site conditions and access roads thereto shall be taken
into account. Cranage and spreader beams shall be positioned under load points as necessary.
The supplier shall take into account the load carrying capacity of the area.

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 Prior to commencement of erection, the Contractor shall examine the existing works of other
Contractors on which this work is dependent and report to the Employer or his representative
anything that may affect his work.
 Planning of erection procedures including provision of necessary guying / temporary works shall
be carried out to ensure safety and trueness of the structure under all conditions of wind and
erection loads occurring during construction period.
The contractor shall provide facilities such as adequate temporary access, ladders, gangways, tools
& tackles instruments for stage inspection by Employer / Engineer.
10.3 Storage
 Storage of structures shall preferably be done in such a manner that erection sequence is not
affected.
 While storing, care shall be taken so that structures do not come in direct contact with the earth
surface and accumulated water.
 Stacking of the structures / equipment shall be done in such a way that, erection marks are
viable easily and handling does not become difficult. Wherever required, wooden sleepers /
grillage may be used.
10.4 Alignment and fitting of machinery shall be carried out by skilled and experienced machinery fitters.
10.5 Driving or hammering in of pins in holes will not be permitted. If at any time during or after the
erection it has been established that any machinery was so assembled, it shall be dismantled at
Contractor's expenses and suitable modifications made as advised by the Engineer/Employer.
Guarantee restriction on time shall not apply in such a case.
10.6 It shall be the responsibility of the Contractor(s) to provide steel or other temporary supports during
erection.
10.7 Improper Fits, Adjustments, Tolerances
10.7.1 Any error in the shop fabrication or deformation resulting from handling and transportation which
prevents proper assembling and fitting of parts by moderate use of drift pins, moderate reaming
cutting shall be reported to the Engineer/Employer immediately and his approval of the method for
correction obtained. The correction shall be made in his presence. The Contractor(s) shall be
responsible for all damage, errors and replacements.
10.7.2 In all cases of critical specialized adjustments to equipment supplied by Sub-contractors or others
the Contractor(s) shall obtain the advice of the relevant equipment supplier and shall advise and
obtain the approval of the Employer.
10.7.3 Maximum permissible tolerances in erected structure / equipment shall conform to any international
standard / code / practice. Wherever applicable, it shall conform to FEM / JIS / DIN Standards.
Tenderer may refer permissible tolerances in erected structure / equipment given in Appendix-2.
10.7.4 All field connection shall be carried out as per good engineering practice.

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10.8 It shall be the responsibility of the Contractor(s) to provide all lubricants/hydraulic fluids/fuel oil for
startup and up to and the completion of commissioning and performance tests, unless specified
otherwise, and shall include services for application of such material as and where required.
10.9 The sequence of erection of the structure shall be such that no member is stressed beyond what it is
designed for.
10.10 It shall be the responsibility of this Contractor(s) to co-ordinate with the other Contractors regarding
allocation of time, space, erection equipment and other facilities. This shall be done with the
approval of the Employer.
10.11 The Contractor(s) shall strictly adhere to the approved erection schedule. Advancing of the erection
schedule may be approved by the Employer provided the activities that are inter-related to /
dependent on other contractors’ work are not strained.
10.12 Selection of the type of equipment to be used for erection shall be based on the consideration that
the design live loads are as follows:
(i) Stockyard : 10 T/m2
(ii) General : Standard Class AA (wheeled vehicle) as per IRC Code of Practice for Road Bridges
(Section 11- Loads & Stresses) or Uniform Live Load of 1 T/m2.
The above information will however be confirmed to the successful tenderer.

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11 PAINTING
11.1 General
All structural steel components need to be protected permanently and effectively against any
formation of rust thus avoiding weakening of the cross-sections. Protection against corrosion shall
be achieved by painting. The paint coating is effective only if it adheres completely and permanently
to the steel surfaces and if the paint resists quick wears.
11.2 Preparation of Surfaces for Painting

11.2.1 All surfaces of components to be painted shall be thoroughly cleaned of all foreign matters adhering
to the steel surface to Swedish Standard specification Sa 2½ by means of blasting with shot. Use of
scraper wire brush and pig hammer is acceptable wherever blasting is not possible due to lack of
access.
11.2.2 The thoroughly cleaned surfaces shall receive the paint within 6 hours following the removal of rust.
If this period of 6 hours is not observed, due to any reasons whatsoever, the surfaces intended to be
painted shall have to receive a new cleaning by sand blasting before the coat of paint is applied.
11.2.3 Any removal of rust adherent to steel surfaces by means of chemical solvent is prohibited.
Subsequent to the removal of rust, oil and grease deposits shall be removed with chemical solvents.
Wet surfaces shall be dried and painting shall generally be done immediately after cleaning.
11.2.4 Welding areas shall not be painted until after the completion of welding operations.
However, wherever welding has to be carried out after erection at site, the shop coat of paint shall
be removed thoroughly unless specifically permitted because of use of appropriate electrodes and
paints, before welding and the adjoining steel surface including welding area shall be repainted after
proper cleaning as specified herein.
11.2.5 In case of interrupted welding seams, the front points shall be thoroughly cleaned from rust.
12.2.6 The surfaces intended to be painted shall be inspected and approved by the Engineer prior to
painting.
11.2.7 Shot blasting shall be carried out in fully enclosed shed complying with all statutory & environmental
norms. In case shot blasting to be carried out in monsoon season necessary precautions shall be
ensured.
11.2.8 The approved manufacturers for all paints shall be JSW, SHALIMAR, ASIAN PAINTS and BERGER
PAINTS.
11.3 Specifications of Painting

11.3.1 Two coats of epoxy base zinc rich primer (92% zinc on dry film) shall be applied by airless spray.
The dry film thickness of two coats shall be 60 microns minimum.
11.3.2 Internal surfaces of box girders shall also be painted with two coats of zinc rich primer (two coats of
60 micron total film thickness)

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11.3.3 After the application of primer, all surfaces shall receive two coats of high build epoxy compatible
with the primer. The finish paint shall be applied by airless spray to establish an endurable protection
of the prime coat. It shall be resistant to atmospheric heat, reflect heat and rays and withstand
mechanical stresses without crumbling. The total dry film thickness for these 2 coats shall be 200
microns minimum. The colors for the finishing coats shall be as approved by the Engineer/Employer.
Inner sides of box girder plates shall be painted with primer.
11.3.4 Total dry film thickness for the system to be 260 microns minimum.
11.3.5 For steel work intended to be painted later, i.e. any item kept for a long period after fabrication
(Maximum beyond 72 hours), a primary coat of Red Oxide Zinc Chromate shall be given at the shop
before dispatch as a temporary protection.
11.3.6 All paints shall be of approved make & shade & prior approval of JSW engineer shall be obtained by
contractor.

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12 FIELD TESTS
12.1 Tests
12.1.1 The tests shall comprise the following:
a) Equipment / Unit assembly test.
b) Adjustments, alignments and settings.
c) Satisfactory completion of No Load Tests for each equipment in the system.
d) Final operational tests such as Commissioning, Reliability and Performance Guarantee Tests of
the Conveyor System / equipment under the scope.
12.1.2 Before any electrical system is put to use, the contractor shall put to use the following tests at site in
the presence of and to the satisfaction of the Engineer.
 Insulation resistance tests on cables, motors etc.
 Polarity tests wherever applicable.
12.2 General
12.2.1 Contractor(s) shall be responsible for testing individual components / equipment, commissioning of
the conveyor system as a whole.
12.2.2 For the period of adjustments and setting, the Contractor(s) shall provide services of adequate
number of teams of personnel which shall include, but not be limited to, engineers, foremen, fitters,
welders, electricians, etc., who apart from their technical experience are well acquainted with all the
machinery and equipment.
12.2.3 All tests shall be carried out in the presence of the Employer and the Engineer and any corrections
found necessary shall be approved by the Engineer and the Contractor(s) shall be responsible for
producing all necessary work sketches and drawings for the approval of the Engineer. The
Contractor(s) shall be responsible for obtaining the services of sub-contractors (as and when
necessary).
12.2.4 Final operational tests by the Contractor(s) with the cargo will depend on the availability of material,
Ship Unloaders, Stacker / Reclaimer, Barge Loaders, etc. and interfacing equipment / system falling
under the scope of other contractors. The Employer will set the date for operational tests after
receipt of the notice(s) from the Contractor(s) and the Contractor(s) will be informed of this date in
advance. The Contractor(s) shall be responsible for any adjustments or corrections found necessary
during these tests.
12.2.5 Employer / Engineer will ensure that interfacing equipment/system (by others), such as Unloaders,
Stacker/Reclaimers, Barge Loader, etc. are ready to work in conjunction with the conveyor system
falling under the scope of the Contractor(s).
The Contractor(s) shall be responsible to coordinate/exchange of technical inputs, as may be found
necessary during load trials with the other Contractors.

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12.2.6 Interruption / delay due to malfunctioning / adjustments in the system by other Contractor(s) during
commissioning may occur. The Contractor(s) shall account for such interruptions / delay during the
tests (except the Performance Tests).
12.2.7 The Contractor(s) shall during the period of Field Tests instruct the Employer’s staff in the operation
of the conveyor system and acquaint them with the adjustments that are made. The Employer’s staff
shall be given reasonable opportunity to become conversant with the operating features of the
equipment.
12.3 Adjustments
12.3.1 Contractor(s) shall be responsible for all necessary alignment and adjustment of machinery and
equipment to obtain efficient operation.
12.3.2 All critical and specialized adjustments shall be carried out in the presence of Engineer/Employer
and suppliers of ‘Free Issue Items’. Procedures and necessary precautions in regard to such
adjustments shall be conveyed to the Engineer / Employer in writing.
12.3.3 Special attention shall be given to final adjustment of:
 Brakes, Back-stops,
 Various interlocks and safety devices.
 Counter weight.
 Belt training
 Fluid Coupling
12.4 No Load Tests

12.4.1 Employer shall provide electricity at relevant payout points.
12.4.2 After completion of the erection, the works under this contract shall be tested. The facility shall be
run without load and all necessary adjustments shall then be completed. The no load tests are
intended to demonstrate that all components will function successfully, separately and as
components of an integrated system, at the specified speed, in accordance with the requirements of
the contract documents. Assistance may be sought from supplier(s) of the ‘Free Issue’ Items’, if
required. Individual segments of conveyor system shall be tested before taking up of full integrated
No Load trials.
12.5 Load Tests

Load Tests shall be undertaken in two phases:
Phase A
As envisaged in Clause 13.1.1(c) system testing of all components as a dry run. Each system or
component shall first be run individually under manual control, then in automatic mode to check
interlocks and the associated schematics.
At this stage each equipment shall be completed in all respects excluding minor items like painting,
etc.

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Phase B
When Phase ‘A’ is completed to the satisfaction of the Employer/Engineer, and subject to all
statutory clearances obtained by the Contractor(s), the Employer shall furnish ship / barge and
associated equipment (by others) as the case may be for carrying out the following tests :
 Commissioning
 Reliability Test
 Performance Test
Each equipment system can be tested independently / simultaneously.
12.6 Commissioning
A) Employer shall supply barge/ship for loading the Cargo in barges/ships reclaiming from
stockpile by using stacker/ Reclaimer, new reclaimers Employer shall supply the ships with
cargo for unloading and convey to new/existing stackyard, or direct despatch by barges and
convey by using Receiving Conveyor Stream and also the number of personnel trained by the
Contractor(s), within 10 days of the above notice provided the time for completion has been
adhered to. In case of delay in completion by the Contractor test dates will be fixed subject to
clause 13.2.4.
B) If the Employer’s obligations under the above sub-clause are fulfilled, Contractor(s) shall
commence commissioning under the supervision of the Employer/Engineer. The Employer will
be responsible for Co-ordination with all Contractors Concerned.
C) Commissioning tests by the Contractor(s) shall include but not necessarily be limited to the
following:
i) Check that all system is complete, clean and clear of obstructions and ready to test.
ii) Limit switches checked for location and that they operate satisfactorily adjust as necessary.
iii) Conveyor belts to be run and tracking of belt checked and corrected where necessary while
operating in conjunction with equipment supplied by others.
iv) Dust suppression system to be operated (by others).
v) All centralized controls, monitoring devices, safety devices, visual and audible indications,
etc., to be tested as applicable.
Records shall be kept of the tests carried out, faults/defects noticed and corrections made, and
four copies of such records shall be submitted to the Engineer/ Employer by the Contractor.
The Contractor will ensure calibration of weigh scale installed on the conveyors.
12.7 Reliability Test

A) Within 2 months from the date of commissioning the Facility, the Contractor(s) shall complete
the Reliability Test while working in conjunction with equipment (Unloaders, Reclaimers,
Stacker/ Reclaimers, Barge/ship Loader) supplied by others.
B) Duration of Reliability Test

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i) One vessel for Iron Ore and Coal of capacity parcel/load each 55,000 DWT or 2 MBCs
of 8000 DWT per reclaiming conveyor stream bulk cargo per receiving and stacking
conveyor stream.
ii) 100,000 tonnes of bulk cargo (Iron Ore and Coal combined) per reclaiming and despatch
stream. remove
iii) Each equipment / sub-assembly shall be operated on rated capacity or part thereof and for
duration agreed between Engineer / Employer and the Contractor(s).
iv) In Case the performance of the system is observed to be affected by the imperfect erection
of any free issue material the contractor shall rectify the erection defects at his cost.
The contractor shall be responsible for any consequential effects of defective or wrong
erection of free issue materials.
C) The Employer shall provide fuel and other materials at no cost to the Contractor(s).
D) The Contractors shall continue to be responsible for the care of the system under his scope and
handling of cargo with the assistance of the Employer's personnel under the training of the
Contractor(s).
12.8 Performance Test

A) Performance Test shall be conducted within 3 months from the date of successful completion of
Reliability Test. However, the Performance Test may be conducted immediate after successful
completion of during the Reliability Test at the last phase.
Duration of full capacity test (stacking & reclaiming at rated capacity) shall be 02 01 hours for
Reclaiming Stacking operation of Iron ore & Coal and 04 hours for Reclaiming operation for Iron
Ore and Coal each. Tenderer shall list the conditions, if any, for carrying out and achieving the
performance in the bid.
B) When the facility has operated under stable conditions, the Contractors shall give the Employer
a notice that the Facility is ready for Performance Test.
C) Immediately after the notice above, the Performance Test shall be conducted by the
Contractors provided it is agreed by the Employer/Engineer.
D) The Performance Test shall be carried out in parts, if required.
E) After successful completion of the Performance Test the Contractors shall give Notice to the
Employer for Taking-over.
F) Within 10 days of the Notice to the Employer for Taking-over, the Employer shall issue the
Taking Over Certificate listing out the minor shortcomings noticed with commitment to attend /
rectify / replace by an agreed Performance Test, which should be attended / rectified/replaced
by an agreed schedule.
G) Minimum levels of Performance Guarantee acceptable by the Employer with or without payment
of liquidated damages shall be
i. Conveyor Operations for sustained durations at the rated capacity as applicable.

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ii. Power installed – 5% above guaranteed figures, as applicable.
Condition of contract shall be referred for commercial implications arising due to non-fulfillment
of the Performance Guarantee.
Notes:-
1. The Contractor shall put his best effort to ensure least stoppage of unloading
operation during carrying out all the tests when ship/barge is waiting.
Cumulative breakdown time shall not be more than 30 min per shift of 8 hrs
while operating the ship/barge.
2. Generally minor shortcomings shall be those which, according to the
Engineer shall not affect safe operation and achieving peak output. Items
which could be considered ‘minor’ would depend on the nature of
malfunctioning and such decisions shall be taken solely by the Engineer
after completion of the Performance Tests.
3. While conducting the tests mentioned in this section/specification and/or any
other test(s) mutually agreed upon prior to the beginning of such test, the
performance of other systems like, dust suppression, gates, etc., shall also be
tested both in manual control and in automatic modes, as long as the
connected system will be in operation.
4. The Contractor shall arrange for responsible representatives and competent
engineers to be present throughout the tests.
5. The Contractor shall have the option to carry out the tests/trials/handling of
cargo during non-tests/trial period upto taking-over mentioned herein either
entirely with his own personnel or assisted by the Employer's personnel. In
either case Employer shall be informed in advance.
6. All materials and equipment which fail the tests during various tests shall be
replaced by the Contractor without any extra cost to the Employer and the
tests shall be repeated on the new equipment/item unless it is agreed
otherwise by the Employer/ Engineer. All instruments and tools required for
tests shall be supplied by the Contractor at no extra cost to the Employer.
7. Belt scales installed on the conveyor system shall be used for weighment
record unless agreed otherwise by the Employer/Engineer. The belt scales
shall be calibrated prior to Performance Test. The Employer/Engineer at
their discretion may get the belt scale recalibrated by the
Contractor/Supplier either during the test or at the end of the test. The
Employer/Engineer at their discretion may take note of corrective factors for
calculating the capacity of the respective equipment during Performance
Guarantee Test.
8. In case, in the assessment of the Employer, the tests are unreasonably
delayed or prolonged once a ship has been provided for testing, the
Employer may discontinue the tests to release the ship and instruct the
Contractor to reschedule fresh tests.

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13 TRAINING
13.1 The Contractor(s) shall train the Employer’s staff (Operators, Technicians, etc.) in operation and
maintenance of the equipment.
13.2 Training in Different Disciplines

The scheme shall cover the disciplines of mechanical, electrical, electronics and communication
engineering encountered in the various equipment to be installed under this contract.
13.3 The Contractor(s) shall make available experienced and competent instructor for the formal training
of operating and maintenance personnel, who can communicate with the trainees in English
language.
13.4 The training shall be sufficiently comprehensive to enable the nominated person to operate and
maintain the equipment in a safe, efficient and workmanlike manner. Training in the maintenance of
equipment shall include routine maintenance level, breakdown maintenance level and other levels
as required.
13.5 The instructors shall be fully qualified and conversant with the installations and with the details
contained within the approved Operating and Maintenance Instructions.
13.6 All training methods shall have content consistent with the Operating and Maintenance Instructions
provided by the Contractor(s).
13.7 All necessary training aids, such as videos, models, etc., shall be provided and retained by the
Employer for future training.
13.8 The Contractor(s) shall involve the Employer’s operations and maintenance staff to become familiar
with the machine and the installed equipment during their erection and commission time.
13.9 The Contractor(s) shall allow for a minimum training period of 6 weeks for operating and
maintenance personnel for the equipment during the erection and commissioning. The Tenderer
may suggest increase or decrease in the duration in his offer. Date of commencement of training
under the contractor’s scheme shall be decided in consultation with Employer.
13.10 The training programme shall include but not be limited to

 Class-room training,
 Familiarization during erection,
 Hands-on training with the help of similar equipment operating elsewhere (preferably
supplied by the same Contractor),
 During Field Tests identified in Conditions of Contract.
13.11 During the Contractor(s)’ training scheme to the Employer documentation, but not be limited to the
following, shall be made available as part of the training scheme:
 Course material for class room / site instructions to trainees – all disciplines.

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 Charts, formats, reporting system, paper work models for maintenance, data logging,
management information, etc.
 Audio-visual aids used for illustrations.
 Write-ups, notes on equipment / components of critical nature.
 Typical case histories / studies of the equipment in other installations exemplified during
training.
 Safety emphasis.
All these documentation shall be distributed to the trainees as applicable and three (3) copies
of all the paper documentation shall be supplied to the Employer for use and library record.
13.12 Price
The Contractor(s) shall quote for the above scheme, indicating the details by a write -up
supported by data sheets with a separate price under the head “Training of E ngineering /
Operating Personnel” in Schedule 2A. However, the Contractor(s) is also required to quote
unit rate for the training personnel / experts beyond the fixed sum quoted for the purposes of
continuation, if necessary of such expertise, over and above the training scheme envisaged.
The Contractor(s) in his proposal shall recommend the required number of persons category -
wise to be trained for the Employer’s assessment and recruitment action.
All travelling and living expenses for the engineering/operation personnel of the Employer to be
trained during the total period of training will be borne by the Employer. The above personnel while
undergoing training shall be responsible to the Contractor abiding by the regulations in respect of
discipline.
13.13 The Engineer will not have any role in this regard.

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14 SPECIAL APPLICATION
14.1 Temporary Works

The Contractor shall furnish such details of his Temporary Works as may be called for by the
Employer and the Contractor shall satisfy the Employer as to their safety and efficiency. The
Engineer may direct that Temporary Works which he considers unsafe or inefficient shall be
removed and replaced in a satisfactory manner.
The contractor at his own expense, and subject to the approval of the Employer and statutory
authorities, construct offices, stores and workshop in the area allocated to him and removes the
same as per the orders of the Employer on completion of the Contract.
14.2 Contractor's Working Area

The Contractor shall be given open area near the Site as far as possible for construction of his site
offices, stores and working area. The Contractor may have to carry out some cutting and filling for
preparing his working area. The cost of all such works shall be deemed to be included in the prices
quoted for the Works and no extra payments shall be made on this account.
14.3 Water Supply and Power Supply

Permanent high-voltage power at individual motors and 415 V power supply at Tenderer’s electrical
panels will be made available for operations by others.
Construction power and water shall be arranged by the Contractor, which shall be deemed to
have been included in the prices quoted for the Works and no extra payment shall be made
on this account.
Employer will provide power for the equipment 15 days prior to start of NO LOAD TESTS.
14.4 Temporary Fencing and Security

The Contractor shall, at his own expense, construct and maintain in good condition temporary
fences and gates along the boundary of the area assigned to him for the purpose of the execution of
the Works and storage of steel and other components.
The Contractor shall, except when authorised by the Employer confine his men, materials and plant
within the Site of which he is given possession. The Contractor shall not use any part of the Site for
purposes not connected with the Works unless prior written consent of the Employer / has been
obtained.
14.5 Programme of Works and Progress Report

The Contractor shall submit to the Employer / Engineer
i. Daily Progress Report

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ii. Monthly progress report (within first week of every month a progress report showing upto
date progress achieved for all sections of work in relation to the scheduled progress as per
detailed CPM schedule).
iii. Material reconciliation Report with monthly RA bill.

The Contractor shall prepare and submit (both hard copy and soft copy) to the Employer / Engineer
within 30 days of receipt of Letter of Acceptance by the Contractor detailed CPM schedule showing
the various activities of the work using MS Project available on MS Windows Operating System to
match with the project CPM maintained by the Employer In this connection, the CPM shall be
prepared in consultation with and as instructed by the Employer. The detailed CPM schedule shall
be updated every month and shall be sent to the Employer / Engineer The cost of making such
detailed CPM schedule is deemed to be included in the price.
14.6 Environmental Controls

All Site operations should be so controlled to minimize pollution in the surroundings and the
seawater. No oil and greasy wastes should be let into the sea water/surroundings. The successful
contractor(s) shall comply the following Clauses and assist the Employer in monitoring the site
condition during construction phase.
(A) Dust
Identify all dust generation sources, during the construction period and provide water sprinkling
facility at all such places.
(B) Vehicular Emissions
On account of increased volume of vehicular traffic in the area vehicular emissions also will
increase resulting in deterioration of ambient air quality. This situation has to be evaluated with
reasonably accurate estimates of traffic volume on different roads and measures shall be taken
to control the emission, to comply with PCB norms. A mobile task force shall be created in co-
ordination with the RTA to check the vehicles periodically to ensure that they comply with the
emission standards.
(C) Noise and Protection of Workman
All equipment used for the construction activity shall be properly maintained to ensure least
generation of noise, and also workers shall be protected with ear muffs. The moving parts of the
machines shall be properly oiled and greased to reduce noise generation. The workmen with
loose fitting garments shall not be permitted and all works shall be provided with protective
clothing, helmets, protective goggles and appropriate shoes and gloves, etc, wherever required.
(D) Campus for Construction Workers
These shall not be provided in the port area unless permitted by the Employer. However, these
camps, even for the location outside the port, shall have water supply and sanitary facilities and
canteen provided by the Contractor. The liquid waste shall be treated in septic tanks followed by
a tile field of absorption trenches properly designed. The canteen waste water shall be treated
for removal of oil. The garbage generated shall be disposed by sanitary landfill. Where it is

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unavoidable to locate a camp, outside the port area prior permission shall be obtained from the
local authority. All shelters provided shall be of temporary nature and shall be dismantled after
the construction work is completed and the same shall be restored to original state.
(E) Fuel Oil Storages
The construction equipment vessels and vehicles used in construction work and for transport of
materials, require fuel oils. If providing storage facility for such fuel oils shall be well designed,
and protected against fire hazards and provided with a compound wall, to prevent access to
unauthorized elements. All surface run offs from such storage areas shall pass through oil water
separator, before it finds access to any storm water drainage course or sea.
(F) Fire Fighting Facilities
All fire prone areas during the construction phase shall be provided with fire detection and fire
fighting facilities with adequate water storage in consultation with the Employer/ Directorate of
Fire Fighting / Regional Offices of the Department.
(G) Shot Blasting
Shot blasting shall be carried out in fully enclosed shed complying with all statutory and
environment norms.
(H) Safety
The Contractor shall adhere to safety norms and ensure availability of qualified safety officer
during work execution.
14.7 Design and Drawings

14.7.1 General
The drawing listed under Clause 3 of this Volume is issued only for information and guidance on
general system requirements and specifications. Contractor shall make all arrangement and design
drawings to suit his equipment and submit the same for approval to the Engineer. Detailed
Engineering shall be done by the Contractor.
The Contractor shall submit for the Engineer’s approval within the indicated periods from the date of
receipt of the letter of acceptance three copies of the following:
 Design and selection of components included in the Scope of Work - within 30 days.
 Cross sections and other details showing important particulars such as overall dimensions,
clearances, etc. – within 45 30 days.
 Power Requirement (installed and peak demand loads) of procured components – within 45 30
days.
 Other interface details as described in Section 3 – within 45 30 days.

Contract M-02
14.7.2 Design Drawings
The Contractor shall submit progressively for Engineer's approval three (3) copies each of the
following documents at least two months prior to the starting of manufacture / placement of order of
these items. The scope of these drawings etc. shall include but not be limited to the following:
A. Calculations pertaining to selection of components, as applicable.
B. General Arrangement drawing of each conveyor / assemblies.
C. General arrangement drawings of assemblies like, Magnets, Metal Detectors, Belt scales
etc, Movable head pulley, winch at Take-up tower, vibrating feeder, etc.
D. Specification / catalogues / drawings of all standard ‘Bought-out Items’.
E. Drawings other than shop fabrication / manufacturing drawings. These will include, but not
be limited to typical arrangement of technological structure, support structures, chutes, skirt
board, take-up system, and pulley supporting structure, drive base frame, etc.
F. General Arrangement drawings, Single line diagram, wiring diagram, indicating ratings /
location/fixing of Local electrical and control panels, Field Junction boxes and Field devices
equipment inter-connection diagrams, cable schedule & termination diagram.
14.7.3 Design Calculations
The design calculations shall be written in English language, computer print outs of only the results
of analysis will not be accepted in lieu of written design calculations.
14.7.4 Programme of Submission
On receipt of Letter of Acceptance by the Contractor, he shall submit the following:

 CPM Schedule covering major activities (within 15 days of LOI)
 List of designs/drawings along with their schedule of submission (within 15 days of LOI)
14.7.5 Approval by the Engineer
The Engineer will signify his approval or otherwise to the submission under sub-clauses above
within 15 days of receipt of such submissions. If the Engineer will not approve any drawing/design
so provided, the same shall be forthwith modified to meet the requirements of the Engineer and shall
be resubmitted. Approved drawings will be signed or otherwise identified by the Engineer.
14.7.6 Inspection of Drawings at Site
The Engineer/Employer shall have the right at all reasonable times to inspect at the premises of the
Contractor all drawings or call for any drawing to be given to Engineer's office.

Contract M-02
14.7.7 Manuals and Technical Data

A) Manuals
The Contractor shall supply six prints and two sets of soft copies of erection or installation
manuals, operation manuals, spare parts manuals and inspection and maintenance manuals
prior to the starting of erection. Recommendations of the manufacturer in respect of preventive
maintenance, trouble shooting, and breakdown maintenance and over haul shall be brought out
in the inspection and maintenance manuals.
B) Technical Data
On completion of the works and before handing over possession to Employer, the Contractor
shall supply six prints and one soft copy of all drawings and documents of the following, which
shall include all corrections/changes as built:
 All As-built Drawings in Auto CAD format (latest release)
 Shop drawings of all wearing parts and also major assemblies and minor assemblies which
require unit replacement;
 Complete technical data and dimensional drawings of all bought out product items such as
bearings, seals, couplings, gear reducers, brakes, valves, limit switches, switchgear, PLCs
and controllers, field safety level sensors, etc., and such other items in the equipment;
 And also six copies of the following:
 List of recommended spare parts.
 Parts catalogues in the case of all equipment /assemblies illustrated with part
numbers in drawings both for electrical and mechanical items.
14.7.8 Tools and Maintenance Equipment

 A complete set of tools and instruments required for satisfactory maintenance of the equipment
shall be provided for each type of requirement.
 A set of hydraulic jacks / jacks shall be provided where the design of the equipment dictates
that the jacks are required for maintenance.
14.7.9 Time for Completion

Time for completion for the complete Scope of Work shall not exceed 8 months from the date
of receipt of Letter of Acceptance.
Note:- Contractor shall always submit soft copy of each document in editable format
along with all hard copy submissions. The Engineer will advise the Contractor
the application and versions related to the soft copy.

Contract M-02
14.8 Post Qualification Criteria:

Price Bids of only those renderer’s who, in the opinion of the Employer/Engineer, have substantially
fulfilled the following post-qualification criteria, will be opened.
Belt Conveyors : 1 Conveyors – minimum rated capacity shall not be less then min 60% of
specified capacity in the Tender Specification ~5000 TPH (Iron Ore), ~4800
TPH (Coal); Belt Speed ~2.3 m/sec. & 4.5 m/sec. (Iron Ore & Coal
respectively, minimum length of conveyor ~1 km.
The tenderer must have at least been awarded contracts for supply of the relevant equipment.

Contract M-6B Date : Feb 2015
Technical Specification MATERIAL HANDLING CONVEYING SYSTEM P a g e | 89
FOR BERTHS 1 & 3A (PHASE III – 10 MTPA)
15 LIST OF APPROVED MAKES OF MAIN MECHANICAL

BOUGHT-OUT COMPONENTS
Sl.No. Item Description Vendors

1. All Bearings SKF / FAG
2. Plummer Blocks SKF / Masta
3. Brakes EMCO Precima / Stromkraft / Sibre / Elecon
(as applicable)
4. Hoists Hercules (Indef) / Eddycrane (Elemech) / WMI / Tractel
5. External Scrapers Kaveri / Martin Engg
6. Skirt Sealing Kaveri / Hosch / Technofab / Martin Engg
7. Vibro Feeder Elecon / Sandvik / McNally Bharat / Kerry Jost
8. Magnets Power Build / Elecon
9. Metal Detectors Power Build / Elecon
10. Belt Weigher Schenck Process / PBL
11. Idler Assembly Elecon
12. Pulley Assembly Elecon
13. Gearbox Shanthi / Elecon / Premium
14. Fluid Coupling Elecon / Premium / Voith
15. Conveyor Belting Phoenix / Sempertrans
16. Gear Coupling Wellman Wacoma / Elecon
Notes:-
1. For items and makes not listed above proposals shall be accompanied by sufficient
reference, product information and manufacturer’s particulars for prior approval of
client.
2. Multiple vendors have been indicated for a particular item so that a wide selection is
possible. However, JSW reserves the right to insists upon a particular vendor from
among the approved vendors.
Approve make list attached separately.
Project : PHASE- 2 EXPANSION OF COAL TERMINAL AT ENNORE PORT

Employer: Chettinad International Coal Terminal Pvt. Ltd. Engineer: Grafix Engineering Consultants Pvt. Ltd.
Contract M-02
TABLES
 Table – A : Basic Parameters of Conveyors
 Table – B : Features of Major Components
 Table – C : Schedule of Technological Structures .

A-138 TABLE-A
DATE:17.01.2019 (R0)
JSW JAIGARH PORT LTD.

EXPANSION OF JAIGARH PORT (PHASE-III - MHS)
CONVEYOR PARAMETERS
JD-2A JD-2B
(Existing Conveyor) (Existing Conveyor)
Sl No Item Unit JD-1A JD-1B JD-4A JD-4B JD-5E JD-5F
(Now Reversible (Now Reversible
conveyor) Conveyor)
1 Material Characteristics
Coal, Iron ore, Lime Coal, Iron ore, Lime Coal, Iron ore, Lime Coal, Iron ore, Lime Coal, Iron ore, Lime Coal, Iron ore, Lime Coal, Iron ore, Lime Coal, Iron ore, Lime
1.1 Material Conveyed
stone, Dolomite stone, Dolomite stone, Dolomite stone, Dolomite stone, Dolomite stone, Dolomite stone, Dolomite stone, Dolomite
Iron Ore - 2.1-2.8 Iron Ore - 2.1-2.8 Iron Ore - 2.1-2.8 Iron Ore - 2.1-2.8 Iron Ore - 2.1-2.8 Iron Ore - 2.1-2.8 Iron Ore - 2.1-2.8 Iron Ore - 2.1-2.8
Coal - 0.8-0.9 Coal - 0.8-0.9 Coal - 0.8-0.9 Coal - 0.8-0.9 Coal - 0.8-0.9 Coal - 0.8-0.9 Coal - 0.8-0.9 Coal - 0.8-0.9
1.2 Bulk Density mt / m3
Lime stone - 1.4 Lime stone - 1.4 Lime stone - 1.4 Lime stone - 1.4 Lime stone - 1.4 Lime stone - 1.4 Lime stone - 1.4 Lime stone - 1.4
Dolomite - 1.5 Dolomite - 1.5 Dolomite - 1.5 Dolomite - 1.5 Dolomite - 1.5 Dolomite - 1.5 Dolomite - 1.5 Dolomite - 1.5
Iron Ore - 100 (max) Iron Ore - 100 (max) Iron Ore - 100 (max) Iron Ore - 100 (max) Iron Ore - 100 (max) Iron Ore - 100 (max) Iron Ore - 100 (max) Iron Ore - 100 (max)
Coal - 0-50 Coal - 0-50 Coal - 0-50 Coal - 0-50 Coal - 0-50 Coal - 0-50 Coal - 0-50 Coal - 0-50
1.3 Maximum Lump Size mm
Lime stone - 0-80 Lime stone - 0-80 Lime stone - 0-80 Lime stone - 0-80 Lime stone - 0-80 Lime stone - 0-80 Lime stone - 0-80 Lime stone - 0-80
Dolomite - 0-80 Dolomite - 0-80 Dolomite - 0-80 Dolomite - 0-80 Dolomite - 0-80 Dolomite - 0-80 Dolomite - 0-80 Dolomite - 0-80
1.4 Moisture Content %(max) 20 20 20 20 20 20 20 20
Iron Ore - 35 / 20 Iron Ore - 35 / 20 Iron Ore - 35 / 20 Iron Ore - 35 / 20 Iron Ore - 35 / 20 Iron Ore - 35 / 20 Iron Ore - 35 / 20 Iron Ore - 35 / 20
Angle of Repose / Coal - 35 / 20 Coal - 35 / 20 Coal - 35 / 20 Coal - 35 / 20 Coal - 35 / 20 Coal - 35 / 20 Coal - 35 / 20 Coal - 35 / 20
1.5 Deg
Surcharge Angle Lime stone - 43 / 30 Lime stone - 43 / 30 Lime stone - 43 / 30 Lime stone - 43 / 30 Lime stone - 43 / 30 Lime stone - 43 / 30 Lime stone - 43 / 30 Lime stone - 43 / 30
Dolomite - 35 / 20 Dolomite - 35 / 20 Dolomite - 35 / 20 Dolomite - 35 / 20 Dolomite - 35 / 20 Dolomite - 35 / 20 Dolomite - 35 / 20 Dolomite - 35 / 20
1.6 Material Temperature Deg C Ambient Ambient Ambient Ambient Ambient Ambient Ambient Ambient
2 Capacity
Iron Ore - 5000 Iron Ore - 5000 Iron Ore - 2500 Iron Ore - 2500 Iron Ore - 2500 Iron Ore - 2500 Iron Ore - 2500 Iron Ore - 2500
Rated Capacity Coal - 4000 Coal - 4000 Coa l- 1500 Coa l- 1500 Coal - 2000 Coal - 2000 Coal - 2000 Coal - 2000
2.1 TPH
Lime stone - 4000 Lime stone - 4000 Lime stone - 1500 Lime stone - 1500 Lime stone - 2000 Lime stone - 2000 Lime stone - 2000 Lime stone - 2000
Dolomite - 4000 Dolomite - 4000 Dolomite - 1500 Dolomite - 1500 Dolomite - 2000 Dolomite - 2000 Dolomite - 2000 Dolomite - 2000
Design Capacity Coal - 4800 Coal - 4800 Coal - 1800 Coal - 1800 Coal - 2200 Coal - 2200 Coal - 2200 Coal - 2200
2.2 TPH
3 Belt Width mm 1800 1800 1200 1200 1400 1400 1600 1600
Iron Ore - 2.8 Iron Ore - 2.8 Iron Ore - 2.8 Iron Ore - 2.8 Iron Ore - 2.3 Iron Ore - 2.3 Iron Ore - 1.8 Iron Ore - 1.8
Coal - 4.2 Coal - 4.2 Coal - 4.2 Coal - 4.2 Coal - 3.4 Coal - 3.4 Coal - 2.6 Coal - 2.6
4 Belt Speed (Nominal) m / sec
5 Troughing angle deg 45 45 35 35 35 35 35 35
~116 ~76
6 Horizontal Length m ~909 ~909 ~172 ~132 ~12 ~16
(old length = ~111) (old length = ~71)
7 Lift m ~16.8 ~16.8 ~4 ~4 ~14 ~14 0 0

NOTE:
1) Regarding Drive units of Conveyors Refer Table -'B' - Features of Major Components.
2) The lengths of the conveyors are approximated.
3) Motor 6 Pole 1000 RPM with VFD, constant torque operation (0 - 1000 RPM) and Constant Power Operation (>1000 - 1500 RPM)
4) Existing Conveyor JD-2A & JD-2B are extended by ~5 m and converted to reversible conveyor .
5) Yard Reclaimer conveyors JD-1A & JD-1B will be installed using the existing foundations on sleepers in yard for supporting rails of stacker/reclaimers. Similarly tail pulley frame will be supported on
existing foundations. Raised portion of the conveyors JD-1A & JD-1B will be installed in the existing gallery of the conveyors JRD-1A & JRD-1B which has space provision for the same.
6) JD-4A & JD-4B were originally planned with ~6.5m lift. However to facilitate barge/ship loading operations at extended barge berth, the conveyors are provided with ~14m lift.
7) For conveyors JD-2A & JD-2B components details needs to be verified with the components as installed. Information will be provided by JSW.
Consultants: Grafix Engineering Consultants Pvt.Ltd.
1 of 1
A-138 TABLE-B
DATE: 17.01.2019(R0)
SCHEDULE OF MAIN COMPONENTS OF THE CONVEYORS
JD-2A JD-2B
Sl (Existing Conveyor) (Existing Conveyor)
Item Unit JD-1A JD-1B JD-4A JD-4B JD-5E JD-5F
No (Now Reversible (Now Reversible
conveyor) conveyor)
1 Material Characteristics
Coal, Iron ore, Lime Coal, Iron ore, Lime Coal, Iron ore, Lime Coal, Iron ore, Lime Coal, Iron ore, Lime Coal, Iron ore, Lime Coal, Iron ore, Lime Coal, Iron ore, Lime
a Material Conveyed
stone, Dolomite stone, Dolomite stone, Dolomite stone, Dolomite stone, Dolomite stone, Dolomite stone, Dolomite stone, Dolomite
Iron Ore-2.1-2.8 Iron Ore-2.1-2.8 Iron Ore-2.1-2.8 Iron Ore-2.1-2.8 Iron Ore-2.1-2.8 Iron Ore-2.1-2.8 Iron Ore-2.1-2.8 Iron Ore-2.1-2.8
3 Coal - 0.8-0.9 Coal - 0.8-0.9 Coal - 0.8-0.9 Coal - 0.8-0.9 Coal - 0.8-0.9 Coal - 0.8-0.9 Coal - 0.8-0.9 Coal - 0.8-0.9
b Bulk Density mt / m
Lime stone-1.4 Lime stone-1.4 Lime stone-1.4 Lime stone-1.4 Lime stone-1.4 Lime stone-1.4 Lime stone-1.4 Lime stone-1.4
Dolomite-1.5 Dolomite-1.5 Dolomite-1.5 Dolomite-1.5 Dolomite-1.5 Dolomite-1.5 Dolomite-1.5 Dolomite-1.5
Iron Ore- 100 (max) Iron Ore- 100 (max) Iron Ore- 100 (max) Iron Ore- 100 (max) Iron Ore- 100 (max) Iron Ore- 100 (max) Iron Ore- 100 (max) Iron Ore- 100 (max)
Coal- 0-50 Coal- 0-50 Coal- 0-50 Coal- 0-50 Coal- 0-50 Coal- 0-50 Coal- 0-50 Coal- 0-50
c Maximum Lump Size
Lime stone-0-80 Lime stone-0-80 Lime stone-0-80 Lime stone-0-80 Lime stone-0-80 Lime stone-0-80 Lime stone-0-80 Lime stone-0-80
mm Dolomite - 0-80 Dolomite - 0-80 Dolomite - 0-80 Dolomite - 0-80 Dolomite - 0-80 Dolomite - 0-80 Dolomite - 0-80 Dolomite - 0-80
d Moisture Content %(max) 20 20 20 20 20 20 20 20
Iron Ore -35 / 20 Iron Ore -35 / 20 Iron Ore -35 / 20 Iron Ore -35 / 20 Iron Ore -35 / 20 Iron Ore -35 / 20 Iron Ore -35 / 20 Iron Ore -35 / 20
Angle of Repose / Coal- 35 / 20 Coal- 35 / 20 Coal- 35 / 20 Coal- 35 / 20 Coal- 35 / 20 Coal- 35 / 20 Coal- 35 / 20 Coal- 35 / 20
e
Surcharge Angle Lime stone-43 / 30 Lime stone-43 / 30 Lime stone-43 / 30 Lime stone-43 / 30 Lime stone-43 / 30 Lime stone-43 / 30 Lime stone-43 / 30 Lime stone-43 / 30
Deg Dolomite - 35 / 20 Dolomite - 35 / 20 Dolomite - 35 / 20 Dolomite - 35 / 20 Dolomite - 35 / 20 Dolomite - 35 / 20 Dolomite - 35 / 20 Dolomite - 35 / 20
f Material Temperature Deg C Ambient Ambient Ambient Ambient Ambient Ambient Ambient Ambient
2 Conveyor Data
Rated Capacity Coal - 4000 Coal - 4000 Coa l- 1500 Coa l- 1500 Coal - 2000 Coal - 2000 Coal - 2000 Coal - 2000
a
TPH Dolomite - 4000 Dolomite - 4000 Dolomite - 1500 Dolomite - 1500 Dolomite - 2000 Dolomite - 2000 Dolomite - 2000 Dolomite - 2000
Design Capacity Coal - 4800 Coal - 4800 Coal - 1800 Coal - 1800 Coal - 2200 Coal - 2200 Coal - 2200 Coal - 2200
b
c Belt Width mm 1800 1800 1200 1200 1400 1400 1600 1600
Belt Speed (Nominal) m / sec
d Dolomite - 2.8 Dolomite - 2.8 Dolomite - 2.6 Dolomite - 2.6 Dolomite - 2.3 Dolomite - 2.3 Dolomite - 1.8 Dolomite - 1.8
e Troughing angle deg 45 45 35 35 35 35 35 35
~116 ~76
Horizontal Length m ~909 ~909 ~172 ~132 ~12 ~16
f (old length = ~111) (old length = ~71)
g Lift m ~16.8 ~16.8 ~4 ~4 ~14 ~14 0 0
3 Drive System
a Type of drive control VFD control VFD control VFD control VFD control VFD control VFD control VFD control VFD control
b Total power consumed Kw
For Iron Ore ~730 ~730 ~172 ~138 ~170 ~160 ~44 ~47
For Coal ~670 ~670 ~79 ~67 ~155 ~150 ~30 ~31
c No of drives 2 2 1 1 1 1 1 1
3.1 Drive Motor kW

a Rating 2 x 600 2 x 600 200 160 315 315 90 90
3.2 Gear Box

a Type Parallel / perpendicular shaft foot mounted
b Ratio (considering Lagging) 19.4 19.4 13.0 13.0 24.0 24.0 28.6 28.6
c Hold back provided Yes Yes Yes Yes Yes Yes Yes Yes
3.3 High speed coupling

a Type Pin bush / Resilient flexible coupling
Rating (on installed power)
Kg-m 2 x (390 - 590) 2 x (390 - 590) 130 - 190 105 - 152 210 - 310 210 - 310 59 - 86 59 - 86
b (without service factor)
3.4 Low speed coupling

a Type Geared coupling
Rating (on installed power) 2 x (11370 - 7570) 2 x (11370 - 7570) 2470 - 1690 1970 - 1353 7255 - 4910 7255 - 4910 2660 - 1850 2660 - 1850
b (without service factor) Kg-m
3.5 Brake Yes Yes Existing brake to be checked Yes Yes Yes Yes
Drive Pulley Diameter

1000 1000 630 630 1000 1000 800 800
4.0 (without lagging) mm
5.0 Belting
a Type ST ST NN NN NN NN NN NN
b Designation 1400/5 1400/5 800/5 800/5 1000/5 1000/5 1250/5 1250/5
c cover M-24, 8/5 M-24, 8/5 M-24, 6/3 M-24, 6/3 M-24, 6/3 M-24, 6/3 M-24, 6/3 M-24, 6/3
6.0 Take-up HGTU HGTU VGTU VGTU VGTU VGTU Screw T-up Screw T-up
7.0 Idlers
a Carrying idlers
3 Roll garland & 3 Roll garland & 3 Roll garland & 3 Roll garland &
Type 3 Roll garland Type 3 Roll garland Type 3 roll garland Type 3 roll garland Type
i Fixed Type Fixed Type Fixed Type Fixed Type
ii Roll dia x shaft dia at Brg mm 159 x 45 159 x 45 152.4 x 30 152.4 x 30 152.4 x 40 152.4 x 40 159 x 45 159 x 45
b Return Idlers
2 Roll Vee Type 2 Roll Vee Type 2 Roll Vee Type 2 Roll Vee Type
i Type 2 Roll Vee Type 2 Roll Vee Type 2 Roll Vee Type 2 Roll Vee Type
(garland & Fixed ) (garland & Fixed ) (garland & Fixed ) (garland & Fixed )
ii Roll dia x shaft dia at Brg mm 139.7 x 35 139.7 x 35 139.7 x 25 139.7 x 25 139.7 x 30 139.7 x 30 139.7 x 30 139.7 x 30
c Impact idlers
i Type 5 roll garland Type 5 roll garland Type 3 roll Fixed Type 3 roll Fixed Type 3 roll Fixed Type 3 roll Fixed Type 5 roll garland type 5 roll garland type
Notes:
1) Conveyors to be designed for Artificial composite friction factor of minimum 0.022.
4) Existing Conveyor JD-2A & JD-2B are extended by ~5 m and converted to reversible conveyor
5) Yard Reclaimer conveyors JD-1A & JD-1B will be installed using the existing foundations on sleepers in yard for supporting rails of stacker/reclaimers. Similarly tail pulley frame will be supported on
1 of 1 Consultants: Grafix Engineering Consultants Pvt.Ltd.

A-138 Dated: 17.01.2019 (R0)
22.01.2019(R1)
TABLE - C
Schedule of Technological Structure
Project : Expansion of Jaigarh Port, Phase III - MHS
Conveyor Chutes /Skirt /Conveyor Hood

Pulley Supporting Base frame for
Stringers Including
S.No. Belt Conveyor Frames Drive Unit Liners (Manganese Steel) Remarks
deck plate M.S Plate
(Tonnes) (Tonnes)
(Tonnes) (Tonnes) Weight 20 Thick Area 16 Thick Area
Thickness (mm)
(Tonnes) (m2) (m2)
1 JD-1A 130 12.00 3.00 17 11 57.5 16 20/16
2 JD-1B 130 12.00 3.00 17 11 57.5 16 20/16
3 JD-2A (modification) 1.3 0.25 0.00 3 1.25 6 2 20/16
4 JD-2B (modification) 1.3 0.25 0.00 3 1.25 6 2 20/16
5 JD-4A 15 6.50 1.00 9 5.5 19 18.5 20/16
6 JD-4B 12 6.50 1.00 8 5.5 19 18.5 20/16
7 JD-5E 1.5 2.50 0.70 4 3 14 7 20/16
8 JD-5F 1.8 2.50 0.70 4 3 14 7 20/16
Total 292.90 42.50 9.40 65.00 41.50 193.00 87.00

NOTES:
1) The Quantities shown are indicative and are provided for information of the Tenderer.
2) The above quantites do not include items like supporting structure for vertical gravity take-up guide column, HGTU counter weight tower & counter weight for VGTU & HGTU.
3) Steel such as stiffeners for supporting stringer frames from existing floor beams/foundations, bracket for safety switches etc are not included.
Grafix Engineering Consultants Pvt.Ltd 1 of 1

Contract M-02
ANNEXURES
Annexure A : Data Sheet for Idlers with Figs. 01, 02, 04 to 10
Annexure B : Data Sheet for Pulleys with Fig. 11 (2 Sheets)
Annexure C : Data Sheet for Conveyor Belting with Fig. 12 (2 Sheets)
Annexure D : Data Sheet for Pin Bush Coupling
Annexure E : Data Sheet for Geared Coupling
Annexure F : Data Sheet for Gear Reducers
Annexure G : Data Sheet for Gear Reducers

A-138 ANNEXURE-A
Date: 17.01.2019-R0
CONTRACT M-02
CONVEYOR SYSTEM
DATA SHEET FOR IDLERS & QUANTITY OF IDLERS FOR BELT CONVEYORS
Weight on the Idler Type
Belt
Belt Speed Idlers assy. Weight on 3 Roll
Conveyor Troughing 5 Roll Festoon Transition Idlers
Conveyor Design Belt Width m/sec. due to material the Idler 3 Roll Festoon Idlers Idlers 2 Roll Festoon 2 roll Fixed Single Roll Impact
Sl. No. Conv. No. Length Belt Type carrying/ 3 Roll Fixed Type Type Impact
Capacity (TPH) (mm) (Depending on (Kg.) assy. due Type Carrying Below under Belt Type Return type Return Fixed Type Idler with
(M) Return Carrying Idler Idler with Rubber
material) (Without to Belt (Kg) Idler Magnet weigher Idler-V Type Idler Return Idler Rubber
(Deg.) Block 9 deg. 18 deg. 27 deg. 36 deg.
Imapct) Block
Iron Ore - 6000 Iron Ore - 2.8

1800
Coal - 4800 Coal - 4.2
1 JD-1A ~909 (For Multiple ST 45 / 15 600 ~45 650 160 5 4 210 - 12 12 - 2 2 2 2
Lime stone - 4800 Lime stone - 2.8
Cargo)
Dolomite - 4800 Dolomite - 2.8

1800
Coal - 4800 Coal - 4.2
2 JD-1B
Lime stone - 4800
~909 ( For Multiple ST
Lime stone - 2.8
45 / 15 600 ~45 650 160 5 4 210 20 12 12 - 2 2 2 2
Cargo)
TOTAL QTY FOR 1800 MM BELT WIDTH 0 1300 320 10 8 420 20 24 24 0 2 2 2 2

1 JD-5E 12 1600 ~36 - 3 - - 2 - 2 6 5 2 2 2 -
Coal - 2200 Coal - 2.6
( For Multiple NN 35 / 15 425
2 JD-5F 16 Cargo) ~36 - 5 - - 3 - 2 6 5 2 2 2 -
TOTAL QTY FOR 1600 MM BELT WIDTH 0 8 5 0 4 12 10 4 4 4 0
1 JD-4A 172 NN 340 ~32 85 73 - - 26 24 2 - 14 2 2 2 -

1400
Coal - 2200 Coal - 3.4
( For Multiple 35 / 15
Cargo)
2 JD-4B 132 NN 340 ~32 35 73 - - 14 25 2 - 14 2 2 2 -
TOTAL QTY FOR 1400 MM BELT WIDTH 120 146 0 0 40 49 4 0 28 4 4 4 0

JD-2A
~5 Extended
(Existing Conveyor)
1 (Old NN 355 28 - 60 - - - 1 - - 6 - - - -
(Now Reversible Iron Ore - 3000 Iron Ore - 2.6
Length=111) 1200
conveyor) Coal - 1800 Coal - 3.8
( For Multiple 35 / 15
JD-2B Lime stone - 1800 Lime stone - 2.6
~5 Extended Cargo)
(Existing Conveyor) Dolomite - 1800 Dolomite - 2.6
2 (Old NN 355 28 - 69 - - - 1 - - 6 - - - -
(Now Reversible
Length=71)
conveyor)
TOTAL QTY FOR 1200 MM BELT WIDTH 0 129 0 0 0 2 0 0 12 0 0 0 0
Idlers
3 Roll Festoon 3 Roll Fixed 2 Roll Festoon 2 Roll Fixed NOTES:

Single Roll
Sl. No. Type Type Carrying Type Carrying Type Return Type Return Remarks SPARES : 10 % of total quantity for each type of idler 1. Variation in idler quantities given in Data Sheet by ± 10% cannot be ruled
Return Idler
Idler Idler Idler Idler out. Exact to be worked out by the tenderer.
Minimum Tube 2. For inclined portion of conveyor carrying idlers shall be garland type &
1 4.85 4.85 4.85 4.85 4.85
Thickness (mm) return idlers shall be fixed type.
3. For declined portion of conveyor carrying idlers shall be fixed type &
2 Roller dia. (mm)
return idlers shall be garland type.
4.Fixing hooks / bolts with washers etc to conveyor stringers are
1800 159 - 139.7 139.7 152.4
included in scope.
5. Existing Conveyor JD-2A & JD-2B are extended by ~5 m and converted
159
1600 - 139.7 139.7 152.4 to reversible conveyor .
6.For handling capacities of multiple cargo conveyors refer TABLE-A
7.Data sheet is to be read in conjunction with fig
1400 152.4 - 139.7 139.7 152.4
01,02,04,05,06,07,08,09 &10.
45 35 35 45 For 1800 Belt
Minimum Bearing
3 45 - 30 30 40 For 1600 Belt
dia. (mm)
40 - 30 30 40 For 1400 Belt
Grafix Engineering Consultants Pvt.Ltd. 1 of 1

EXPANSION OF JAIGARH PORT (PHASE III - MHS)
3 ROLL IMPACT IDLER - GARLAND TYPE

5 ROLL TROUGHED IMPACT IDLER - GARLAND TYPE

A-138 CONTRACT M-02 ANNEXURE-B
Date: 17.01.2019 (R0)

DATA SHEET FOR PULLEYS
(PULLEY FORCES AND TORQUE)
BELT WIDTH
BELT TENSION (KG), SHELL FACE SHAFT DIA SHAFT DIA BEARING Drive shaft
SL. Conv. TYPE OF (MM) & Pulley Type of
TORQUE (KG-M) & DIAMETER WIDTH AT BEARING AT HUB C/C projection from QTY. Spares
NO. No. PILLEY Speeds Type Drive
WRAP ANGLE (DEG) (MM) (MM) (MM) (MM) (MM) plummer block
(m/s)
centre (MM)
35000
Head
/Primary o 550
1 180 1000 2000 300 320 2800 2 D1 VFD
drive (Refer Notes)
22800
Torque=11400
22800
1st Bend 0
2 130 800 2000 260 280 2500 -- 2 ND1
after primary
drive
22800
22800 22800
2nd Bend 0
3 150 800 2000 260 280 2500 -- 2 ND1
after primary
drive
JD-1A & 1B (Multiple cargo)
o 550
4 Secondary 180 1000 2000 300 320 2800 2 D1 VFD
(Refer Notes)
drive
22800 10800 BW-1800
Torque = 11400 Coal-4.2
10800 Iron ore, Ref.Note 06
1st Bend Lime stone
5 0 630 2000 220 240 2500 -- 2 ND2
before 90 Dolomite-2.8
T-Up
10800
10800
TAKE-UP 800 2000 260 280 2500 -- 2 ND1

6 180o
10800
10800
1st BEND
7 630 2000 220 240 2500 -- 2 ND2
after T-UP 60o
10800
10800
2nd BEND
8 630 2000 220 240 2500 -- 2 ND2
after T-Up 65o
10800
11800
9 TAIL 800 2000 260 280 2500 -- 2 ND1

o
180
11800
5500
DRIVE/ 500
1 630 1400 160 180 1900 1 VFD
HEAD o (Refer notes)
180
(Extended by ~5m and converted to reversible Conveyor)
2700
Torque=2470
2700
BEND
2 before 400 1400 120 140 1800 --- 1
JD-2A ( Multiple cargo)
T-Up 90o
BW-1200
Existing Conveyor
2700
2700 2700 Coal-3.8
Iron ore,
Ref.Note 06
3 TAKE-UP 500 Lime stone 1400 140 160 1800 -- 1
180o
&Dolomite-
2.6
2700
BEND After
4 400 1400 120 140 1800 --- 1
T-Up
90o
2700
2750
5 TAIL 500 1400 140 160 1800 -- 1

180o
2750
4400
DRIVE/ 500
1 630 1400 160 180 1900 1 VFD
HEAD 180
o (Refer notes)
2450
Torque=2470
2450
BEND
2 before 400 1400 120 140 1800 --- 1
(Existing made Reverisble)
90o
JD-2B ( Multiple cargo)
T-Up
Existing Conveyor
2450 BW-1200
2450 2450 Coal-3.8
Iron ore,
3 TAKE-UP 500 1400 140 160 1800 -- 1 Ref.Note 065
180o Lime stone
&Dolomite-
2450 2.6
BEND After
4 400 1400 120 140 1800 --- 1
T-Up
90o
2450
2500
5 TAIL 500 1400 140 160 1800 -- 1

180o
2500
1 of 2
A-138 CONTRACT M-02 ANNEXURE-B
Date: 17.01.2019 (R0)
DATA SHEET FOR PULLEYS

(PULLEY FORCES AND TORQUE)
BELT WIDTH
BELT TENSION (KG), SHELL FACE SHAFT DIA SHAFT DIA BEARING Drive shaft
SL. Conv. TYPE OF (MM) & Pulley Type of
TORQUE (KG-M) & DIAMETER WIDTH AT BEARING AT HUB C/C projection from QTY. Spares
NO. No. PILLEY Speeds Type Drive
WRAP ANGLE (DEG) (MM) (MM) (MM) (MM) (MM) plummer block
(m/s)
centre (MM)
10700
0 550
1 Drive/Head 180 1000 1600 180 200 2300 1 D2 VFD
(Refer Notes)
4100
Torque = 7255
4100
Bend
2 before Take- 0 630 1600 140 160 2100 -- 1 ND4
90
JD-4A (Multiple Cargo)
up
4100 BW-1400
4100 4100 Coal-3.4
Iron Ore Ref.Note 06
3 TAKE-UP o
800 Lime stone & 1600 160 180 2100 -- 1 ND3
180 Dolomite-2.3
4100
BEND after 0
4 90 630 1600 140 160 2100 -- 1 ND4
T-Up
4100
4150
5 TAIL 800 1600 160 180 2100 -- 1 ND3

o
180
4150
10300
0 550
1 Drive/Head 180 1000 1600 180 200 2300 1 D2 VFD
(Refer Notes)
4050
Torque = 7255
4050
Bend
2 before Take- 0 630 1600 140 160 2100 -- 1 ND4
90
JD-4B (Multiple Cargo)
up
4050 BW-1400
4050 4050 Coal-3.4
Iron Ore Ref.Note 06
3 TAKE-UP o
800 Lime stone & 1600 160 180 2100 -- 1 ND3
180 Dolomite-2.3
4050
BEND after 0
4 90 630 1600 140 160 2100 -- 1 ND4
T-Up
4050
4100
5 TAIL 800 1600 160 180 2100 -- 1 ND3

o
180
4100
6600
JS-5E (Multiple Cargo)
0
1 Head 180 800 1800 180 200 2300 -- 1 ND5
BW-1600
6600 Coal-2.2
4200 Iron Ore,
Lime stone &
o 550
2 Tail/Drive 180 800 Dolomite-1.5 1800 180 200 2300 1 D3 VFD
(Refer Notes)
6600
Torque=2660 Ref.Note 06
6750
JS-5F (Multiple Cargo)
0
1 Head 180 800 1800 180 200 2300 -- 1 ND5
BW-1600
6750 Coal-2.2
4200 Iron Ore,
Lime stone & 550
o
2 Tail/Drive 180 800 Dolomite-1.5 1800 180 200 2300 1 D3 VFD
(Refer Notes)
6750
Torque=2660
Note:-
1) The drives with Variable Frequency Drive (VFD) are provided with Pin Bush Flexible coupling (High Speed Coupling).
2) Shaft extension for the drive pulleys mentioned in the schedule is indicative and exact details of the same will be coordinated with successful bidder.
3) Overall shaft length of pulleys shall be decided by the Tenderer.
4) Shall be read in conjunction with FIG. No. 11 R0 (2 sheets)
5) The details of Pulleys JD-2A/B are provided for information, changes in Pulleys, as required to be included in the scope.
6) SPARES: One No. each type
7) Motor Gpole 1000 RPM with VFD. Constant Torque operation (0-1000 RPM), Constant Power operation (> 1000 upto 1500 RPM)
8) Lagging of existing conveyors JD-2A & JD-2B head and tail pulleys to be changed to 'Diamond Groove Type'.
Yard Reclaimer conveyors JD-1A & JD-1B will be installed using the existing foundations on sleepers in yard for supporting rails of stacker/reclaimers. Similarly tail pulley frame will be supported on
9)

2 of 2
A-138 CONTRACT : M-02 ANNEXURE-C
CONVEYOR SYSTEM Date: 17.01.2019(R0)

Data Sheet for Conveyor Belting
JD-2A JD-2B
Item Unit JD-1A JD-1B (Existing Conveyor) (Existing Conveyor) JD-4A JD-4B JD-5E JD-5F
(Now Reversible conv) (Now Reversible conv)
1 Conveyor Details
1.1 Capacity
Coal - 4000 Coal - 4000 Coal - 4000 Coal - 4000 Coal - 2000 Coal - 2000 Coal - 2000 Coal - 2000
Rated TPH
Coal - 4800 Coal - 4800 Coal - 4800 Coal - 4800 Coal - 2200 Coal - 2200 Coal - 2200 Coal - 2200
Design TPH
1.2 Belt Width mm 1800 1800 1200 1200 1400 1400 1600 1600
1.3 Belt Speed (Nominal)
m/s Dolomite - 2.8 Dolomite - 2.8 Dolomite - 2.8 Dolomite - 2.8 Dolomite - 2.3 Dolomite - 2.3 Dolomite - 1.8 Dolomite - 1.8
1.4 Troughing angle deg 45 45 35 35 35 35 35 35
~116 ~76
1.5 Horizontal Length m ~909 ~909 ~172 ~132 ~12 ~16
(old length = ~111) (old length = ~71)
1.6 Lift m ~16.8 ~16.8 ~4 ~4 ~14 ~14 0 0
1.7 Maximum Tension (Operating) tonnes ~26 ~26 ~5.5 ~4.5 ~12 ~11.7 ~6.6 ~6.8
2 Belting
2.1 Belt Selection Tension kN/m 169.87 169.87 ~45 ~37 84.00 84.00 ~46 ~46
2.2 Fabric ST ST NN NN NN NN NN NN
2.3 Cover Grade ( Ref Note 1) M-24 M-24 M-24 M-24 M-24 M-24 M-24 M-24
2.4 Cycle Time (Iron Ore) Sec 649 649 649 649 150 115 13 18
2.4 Cycle Time (Coal) Sec 433 433 433 433 101 78 10 12
2.5 Min Top Cover Thickness (min) mm 8 8 6 6 6 6 6 6
2.6 Min Bottom Cover Thickness (min) mm 5 5 3 3 3 3 3 3
15 15
2.7 Quantity m 1977 1977 374 287 27 27
(Add. Length Required) (Add. Length Required)
2.8 Proposed belt Rating ( Ref Note 2) ST 1400 ST 1400 NN 800/5 NN 800/5 NN 1000/5 NN 1000/5 NN 1250/5 NN 1250/5
2.9 Minimum Joint Efficiency % 100 100 80 80 80 80 80 80
2.1 Type of Joint HOT VULCANISED
2.11 No of Conveyors 1 1 1 1 1 1 1 1
3 Spare a) 1800mm belt : ST 1400 = ~ 500 m,
b) 1400 mm Belt : NN 1000/5 = ~ 250 m ,
c) 1600 mm Belt : NN 1250/5 = ~ 25m
Note:
1) Cover grade of all the conveyors shall be M-24.
2) Belt selection tension indicated are based on pullyes with Rubber lagging.
4) Changes in belt lengths, if required, will be informed to the sucessful tenderer. The quantity of belt mentioned is indicative.
5) Tenderer may suggest revised quantities, if in his opinion, the spares specified are not adequate for 2 years
6) Existing Conveyor JD-2A & JD-2B are extended by ~5 m and converted to reversible conveyor. For conveyors JD-2A & JD-2B components
details needs to be verified with the components as installed. Information will be provided by JSW.
8) Brakes are provided in all conveyors.
9) The Data sheet shall read in conjunction with Fig.12 R0 (2 Sheets)
Page 1 of 1 Grafix Engineering Consultants Pvt. Ltd.

A‐138 CONTRACT : M‐02 ANNEXURE‐D
DATA SHEET FOR PIN BUSH / RESILIENT COUPLING

Torque (Kg-m)
Consumed Motor No. of
Belt Conv. Coupling (without service Total No of Brake
S.No Power Rating coupling / Spares
No. RPM factor) on consumed Drives
(Kw) (KW) drive unit
Power
1 JD-1A 1000-1500 730 - 670 2 x 600 390 - 590 1 2 Yes
2 JD-1B 1000-1500 730 - 670 2 x 600 390 - 590 1 2 Yes

JD-2A
3 1024-1500 172 - 79 200 130 - 190 1 1
1 No each type
(Existing)
JD-2B
4 1024-1500 138 - 67 160 105 - 152 1 1
(Existing)
5 JD-4A 1000-1500 170 - 155 315 210 - 310 1 1 Yes
6 JD-4B 1000-1500 160 - 150 315 210 - 310 1 1 Yes
7 JD-5E 1023-1500 44 - 30 90 59 - 86 1 1 Yes
8 JD-5F 1023-1500 47 - 31 90 59 - 86 1 1 Yes

Notes:
1). Drive units of the conveyors are provided with VFD control.
2). Couplings for Conveyors shall be quoted separately for
a). Coupling without brake
b). Coupling with brake
3). Existing Conveyors JD-2A & JD-2B are extended by ~5 m and converted to reversible conveyor. For conveyors JD-2A & JD-2B components
details needs to be verified with the components as installed. Information will be provided by JSW.
A‐138 CONTRACT : M‐02 ANNEXURE‐E
CONVEYOR SYSTEM Date:17.01.2019(R0)

DATA SHEET FOR GEARED COUPLING
Torque (Kg-m)
Consumed No. of
Sl. Belt Conv. Motor RPM Motor rating Coupling (without service Total No
Power coupling / Spares Remarks
No. No. (Syn) (Kw) RPM factor) on of Drives
(Kw) drive unit
consumed power
JD-1A 1000-1500 730 - 670 2 x 600 51.4 - 77.2 11370 - 7570 1 2

1
JD-1B 1000-1500 730 - 670 2 x 600 51.4 - 77.2 11370 - 7570 1 2
2
JD-2A
1024-1500 172 - 79 200 78.9 - 115.2 2470 - 1690 1 1
1 No each type
3 (Existing)
JD-2B
1024-1500 138 - 67 160 78.9 - 115.2 1970 - 1353 1 1
4 (Existing)
JD-4A 1000-1500 170 - 155 315 42.3 - 62.5 7255 - 4910 1 1
5
JD-4B 1000-1500 160 - 150 315 42.3 - 62.5 7255 - 4910 1 1
6
JD-5E 1023-1500 44 - 30 90 33 - 47.7 2660 - 1850 1 1
7
9 JD-5F 1023-1500 47 - 31 90 33 - 47.7 2660 - 1850 1 1
Note 1). Drives units of the conveyors are provided with VFD control.
2). Existing Conveyors JD-2A & JD-2B are extended by ~5 m and converted to reversible conveyor. For conveyors JD-2A & JD-2B
components details needs to be verified with the components as installed. Information will be provided by JSW.
Grafix Engineering Consultants Pvt. Ltd
A-138 CONTRACT : M-02 ANNEXURE-F
DATA SHEET OF GEARBOXES FOR BELT CONVEYORS

JD-2A JD-2A
Sl (Existing Conveyor) (Existing Conveyor)
Item Unit JD-1A JD-1B JD-4A JD-4B JD-5E JD-5F
No (Now Reversible (Now Reversible
conveyor) conveyor)
1 Drive System
Direct Drive Direct Drive Direct Drive Direct Drive Direct Drive Direct Drive Direct Drive Direct Drive
Type Of Drive
a. (VFD) (VFD) (VFD) (VFD) (VFD) (VFD) (VFD) (VFD)
Consumed Power
b.
per motor
Iron Ore kW 730 730 172 138 170 160 44 47
Coal kW 670 670 79 67 155 150 30 30
c. No of Drives 2 2 1 1 1 1 1 1
Drive Pulley RPM (with
d. rubber lagging)
Iron Ore RPM 51.40 51.40 78.90 78.90 42.30 42.30 35.80 35.80
Coal RPM 77.20 77.20 115.20 115.20 62.50 62.50 52.50 52.50
e. Belt Speed (approx) m/sec
2 Drive Motor
a. Rating kW 2 x 630 2 x 630 200 160 315 315 90 90
b. Syn Speed for Coal RPM 1500 1500 1500 1500 1500 1500 1500 1500
Syn Speed for Iron Ore RPM 1000 1000 1024 1024 1000 1000 1023 1023
c. Duty Continuous Continuous Continuous Continuous Continuous Continuous Continuous Continuous
d. Mounting Foot Foot Foot Foot Foot Foot Foot Foot
e. Qty 2 2 1 1 1 1 1 1
Drive Pulley Diameter
f. mm 1040 1040 670 670 1040 1040 840 840
(with rubber Lagging)
Gearbox
a. Type PARALLEL / PERPENDICULAR SHAFT FOOT MOUNTED
b. Ratio (Nominal) 19.43 19.43 13.02 13.02 24.00 24.00 28.57 28.57
c. Mechanical rating kW 1.5xmotor Kw 1.5xmotor Kw 1.5xmotor Kw 1.5xmotor Kw 1.5xmotor Kw 1.5xmotor Kw 1.5xmotor Kw 1.5xmotor Kw
d Holdback Provided Yes Yes Yes Yes Yes Yes Yes Yes
e. Mounting Foot Foot Foot Foot Foot Foot Foot Foot
f. Quantity 2 2 1 1 1 1 1 1
Note:
1) Gearbox ratio can be suitably selected according to the manufacturer's standard without effecting the carrying capacity of the conveyor.
2) Motor RPM for Iron Ore will be 1000 RPM & Coal will be 1500 RPM
3) Existing Conveyor JD-2A & JD-2B are extended by ~5 m and converted to reversible conveyors, For conveyors JD-2A & JD-2B components details needs to be verified with the components as installed. Information will be
provided by JSW. Gear box to be checked for reversible operation.
5) Spares 1 no each type
Page 1 of 1 Grafix Engineering Consultants Pvt. Ltd.

A‐138 ANNEXURE‐G
CONTRACT M‐02 Date: 17.01.2019(R0)
CONVEYOR SYSTEM

DATA SHEET FOR BRAKES
Motor No. of
Belt Conv. Motor RPM Total No
Sl. No. Rating brake Spares Remarks
No. (Syn) of Drives
(KW) /drive
1 JD-1A 1000-1500 2 x 600 1 2
2 JD-1B 1000-1500 2 x 600 1 2
1 No of each type
JD-2A
3 1024-1500 200 1 1
(Existing)
JD-2B
4 1024-1500 160 1 1
(Existing)
5 JD-4A 1000-1500 315 1 1
6 JD-4B 1000-1500 315 1 1
7 JD-5E 1023-1500 90 1 1
8 JD-5F 1023-1500 90 1 1
Note: 1). Drive units of the conveyors are provided with VFD control.
2). Details of the brake drum with Pin-bush coupling will be discussed with the successful
tenderer.
3). The location of brakes are indicative however the tenderer may suggest or optimise
providing of brakes on conveyors depending on their costing time.
4). Existing Conveyors JD-2A & JD-2B are extended by ~5 m and converted to reversible
conveyor. For conveyors JD-2A & JD-2B components details needs to be verified with the
components as installed. Information will be provided by JSW.
Grafix Engineering Consultants Pvt. Ltd
Contract M-02
SCHEDULES

Contract M-02
LIST OF SCHEDULES
SCHEDULE NO. TITLE PAGE No:
1 PARTICULARS OF TENDERER 94
2 TENDER PRICE 95 - 96
3A SPARE PARTS LIST 97
3B SPARE PARTS LIST WITH PRICES 98
4A CHECK LIST 99 to 102
4B TECHNICAL DATA 103 to 116
5 TRAINING SCHEME 117
6 WORK SCHEDULE 118
7 QUALITY ASSURANCE 119
8 SUB-CONTRACTORS 120
9 ORGANISATION CHART 121
10 DETAILS OF EQUIPMENT, TOOLS, TACKLES 122
11 STATEMENT OF DEVIATIONS 123
12 DETAILS OF SIMILAR WORK DONE DURING THE PAST FIVE YEARS 124
13 CONCURRENT WORKS AND COMMITMENTS 125
14 FINANCIAL TURNOVER 126
15 DECLARATION OF SITE VISIT BY THE TENDERERS 127

Contract M-02
SCHEDULE: 1
PARTICULARS OF TENDERER
1. Name of the Tenderer
2. Address
3. Bid Reference No.
4. Date of Proposal
5. Design / Construction / Fabrication / Manufacturing

Location(s) for Structural, Electrical, Electronics
and Mechanical items.

Contract M-02
SCHEDULE: 2
TENDER PRICE
The prices to be entered below shall be for the complete work item supplied from factories/shops and work
carried out at Site in conformity with the specification. Prices shall be quoted in the following format:
Sl. Required Price in Indian

No. Description No. Rupees
1. Ex-works/CIF Price
a) New Belt Conveyors complete in all respects as detailed out in
Section 2 – Scope of Work, and Technical Specification.
b) Electrical Works
2. Ex-works Price for 2 years spares
3. Taxes and duties (as applicable) on supply
 Customs Duty
 Excise Duty
 Central Sales Tax / VAT
 Octroi / Entry Tax
 Service Tax
 Works Contract Tax
 Any other Central and State Levies
4. Inland Transportation to Site including Insurance + Service Tax (to
be shown separately) on Transportation
5. Cost of erection, testing and commissioning including handling,
storage and preservation of equipment and material at site +
Service Tax on erection, testing & commissioning (to be shown
separately)
6. Cost of operation during testing, commissioning, trials and upto
taking-over
7. Cost of Fabrication, Erection of structural steel work for Galleries,
Transfer Towers, etc. for the belt conveyor System including
interfacing with existing transfer towers / galleries.
8. Cost of Training + Service Tax (To be shown separately).
9. Tenderer’s alternative, if any (to be identified separately with price)
10. Price of Imported Items, if any
11. Price for optional items + Taxes and Duties as applicable
(The tenderer to furnish a list of such items)
GRAND TOTAL
Notes:
1. Schedule-2 as well as 3B shall be submitted in separate covers.
2. Indicated Price shall be total for the required numbers in respective type.

Contract M-02
3. Conversion rate of Foreign Currency to Indian Rupee with date shall be indicated in the bid,
which shall remain unchanged for the Contract implying fluctuation in currency conversion shall
not be considered.
4. Prices of commissioning spares considered shall be included in item ‘1’ above. A list of
commissioning spares considered shall be shown separately in Schedule 3A.
5. Taxes and duties under item 3 above are taxes and duties on complete equipment. Taxes and
duties on raw material and components are not to be shown against each item. Such taxes and
duties are deemed to be included in Ex-works Price.
6. The material available with the Employer / ‘Free Issue’ by the Employer shall be collected from
the Employer’s Stores or any other stores in the Employer’s premises and the Contractor shall
bear the cost of loading, transporting to site, unloading, storing under cover, security, etc., as
required.
7. The cost of MS erection bolts, washers, electrodes, putty, gauges, cost of straightening the raw
material, cutting of flats from plates & providing splices, paints, tools, plants, etc., as required
for the work shall be deemed to have been include in the quoted rates.
8. All handling & transport charges of raw material & fabricated structure including double
handling, supply of cranes / equipment required for erection as required for completion of work
in accordance with time schedule, shall be deemed to have been included in the quote rates.

Contract M-02
SCHEDULE: 3A
SPARE PARTS LIST
A complete list of spare parts and replacements as recommended inventory for two years operation, i.e. two
years after taking-over of the equipment and the commissioning spares, i.e. spares required upto successful
Performance Test shall be given in the following format.
Description Qty. Manufacturer
A. Operating Spares
B. Commissioning Spares

Contract M-02
SCHEDULE: 3B
SPARE PARTS LIST WITH PRICES
The Prices of Operating Spare Parts identified in Schedule 3A shall be furnished in the following format.
Description Manufacturer Qty. Ex-works Taxes Total

Price
Note: The Schedule 3B shall be submitted in a separate cover.

Contract M-02
SCHEDULE: 4A
SCOPE MATRIX
(Part-A & Part-B)
(Shall be read in conjunction with the Scope under Cl.2.0 and 3.0)
Scope of Supply
Sr. Confirmation
Description Vendor /
No. Grafix JSW from Vendor
Contractor
/ Contractor
A. Engineering & Approvals
1 Tender Specifications for Conveyor System -
Contract M-02 (Mechanical works, Part –A),
Y
Comprising schedules & Annexures covering
relevant details.
2 a) Engineering Layout, Basic Engineering,
Conveyor GA / Profile drawings, Conveyor
drive ratings, Typical drawings for
Technological structure, Skirt & belt
Y
Scrappers, take-up arrangement etc.
including Schedules & Annexure of
Mechanical components (Gear Box,
Couplings, Pulley, Idlers, Belting, etc.)
b) Tenderer shall include missing items, if any,
as required to comply with the functional
Y
requirement envisaged in the tender
specification.
3 Complying with the layout and responsibility
of Design verification for Sr No 2 to be done Y
during tendering & detail engineering stage.
4 Design and Engineering of Electrical System
required for auxiliary equipment / system lie,
but not limited, Vibrating Feeder, Air Blaster,
Vibrators, Actuators, Gear Box Cooling
System, Gates, Magnet, Metal Detector, Y
Motorised Winches, Belt Weigher, hoist/EOT
Cranes, etc. inclusive of Starter & Control
Panel, VFD, related all type of cabling and
earthing, JB’s, Limit Switch, Instruments, etc.
5 Typical Structural GA drawings for Transfer
Tower, Trestle & Gallery, etc. during
Y
tendering which have been enclosed with the
tender specification.
6 Design verification for Sr No. 5 to be done
during tendering stage & design/preparation
of G.A. of all structural steel works (refer Y
Sl.Nos. 5 & 10) during detailed engineering
stage.
7 Approval of drawings/ documents for all
mechanical & associated electrical
Y
components and design/drawings of typical
structure.

Contract M-02
Scope of Supply
Sr. Confirmation
Contractor
/ Contractor
8 Preparation of General Arrangement
drawings (Mechanical) of conveyor system &
Y
fabrication drawings for Technological
structures including quantity take-offs
9 Review & Approval of General Arrangement
drawings (Mechanical) of conveyor system & Y
drawings for Technological & structures.
10 Load data required for design of structural (by
others). Also modification of
drawings/preparation of new modification Y
drawings, if any required to match the 'As-
cast foundations at site' by others.
11 Preparation of fabrication drawings for
structural steel (transfer tower, galleries Y
including sheeting etc)
B. Supply Scope
12 Supply of all Mechanical & associated

electrical components / equipment’s to make
the conveyor system complete in all respect,
Y
not limited to items specified in tender
document (if need be) including concrete &
metallic counter weights
13 Supply of electrical system required for
auxiliary equipment / system like, but not
limited to, Vibrating feeder, Air blaster,
Vibrators, Actuators, Gear Box cooling
system, Gates, Magnet, Metal detector, Y
motorised winches, belt weigher, hoist, EOT
Cranes, etc. inclusive of starter & control
panel, VFD, related all type of cabling &
earthing, JB's, limit switch, instruments, etc.
14 Supply of Main Conveyor drive motors,
conveyor drive VFD. However, the tenderer
shall provide the outline specification of each
Y
motor in the offer and shall provide the
detailed specification of each conveyor motor
within 60 30 days of receipt of LOI.)
15 Field safety limit switches/devices like PCS,
BSS, ZSS, Chute Jam Switch, Belt take-up
Switch, Hooter, etc., main conveyors.
(However, the tenderer shall provide outline
Y
specification of each in the tender and shall
provide the detailed specification of each
conveyor motor within 60 30 days of receipt
of LOI).
16 Supply of paint for all Technological
Y
structures

Contract M-02
Scope of Supply
Sr. Confirmation
Contractor
/ Contractor
17 Supply of technological Structures including
steel (For Drive base, stringer frames, chutes
& skirt boards with liners, pulley supports,
take-up unit including trolley and its
Y
supporting structure, conveyor hoods, deck
plate, counter weight towers complete in all
respects, gates, for modification in existing
facility etc.)
18 Supply & Erection of Air blasters, vibrators
(as applicable) with necessary equipment,
Y
piping & related accessories for all chutes /
steel hopper.
19 Belt vulcanising material, Oil & Lubricants
(flushing & first fill) for all conveyor & related Y
equipment’s/components
20 Foundation bolts for all equipment/
components at all levels concrete floor
(including ground floor) for drive frame, head Y
frame, tail frame, sheave frame etc in transfer
towers of the conveyor & related system.
21 Supply of steel structural steel works (transfer
tower, galleries, sheeting, chequer plate, Y
hand rail, etc.)
22 Concrete work for conveyor drives Y Y
C. Fabrication, Erection & Painting Works
23 Fabrication & erection of Technological

structures, transfer tower & galleries including Y
sheeting and side cladding
24
Erection of complete Mechanical, Free Issue
Y
electrical Items
25 Blasting & Painting of all Technological

structures within this package and structural Y
steel works
D. Civil Works
26 Civil Work for conveyor drives on the floors

of transfer towers, counter weight towers,
Y Y
take-up trolley and associated sheaves,
motorised winches (as required)
27 Foundations at ground level for Transfer
Y
tower, galleries, trestles etc.
28 Grouting below Conveyor equipment’s ,
Y Y
Take-up tower, bolt pockets, etc.

Contract M-02
Scope of Supply
Sr. Confirmation
Contractor
/ Contractor
E. Testing, Commissioning, Operation & Performance Tests.
29 Testing, Commissioning, Operation &

Y
Performance Tests
Notes :
1 The above Check List covers major activities for the Mechanical Package. However, this is not
an exhaustive list of complete works to be carried out by the contractor. And it does not
absolve the contractor from its responsibilities & obligations of scope of work as per
contractual terms & conditions.
2 The above Check List is to be read in conjunction with Tender Technical Specifications &
attached documents required for successful completion of all Mechanical/scope works &
conveyor system performance.

Contract M-02
SCHEDULE: 4B
TECHNICAL DATA
1.0 General
Tenderer shall provide all information requested in this Schedule and in specification. The items requiring
description shall not be limited by the list that follows. Tenderer shall ensure that the variation in data
furnished now and after detail design stage shall be within ±10% in respect of cases such as weight of
the equipment, installed HP, peak power requirement, etc. In case the variation exceeds the specified
limit, the Engineer will examine whether it is liable to the penalized for exceeding the limit.
Any deviation from the technical specifications shall be clearly indicated under a separate heading
“DEVIATION FROM TECHNICAL SPECIFICATIONS” otherwise it will be construed that there is no
deviation from the technical specifications.
2.0 Weight Breakdown
2.1 Total weight of Belt Conveyor System, excluding Galleries, Transfer Towers, Drive Houses (separately
for each Conveyor) and supporting structure.
 Steel Structures including Stringer Frames, Pulley Supports, Drive Bases, etc.
 Weight of one standard Stringer Frame.
 All pulley assemblies with Plummer Blocks and Bearings.
 Carrying Idlers with supporting brackets
 Return Idlers
 Impact Idlers
 Chutes, Skirt Board, Deck Plate, Scrapers, etc.
 Belting
 Drive unit including Motor, Reducer, Couplings, Brake, Back Stop, etc.
 Take up units with trolley, Movable head pulley arrangement, supporting structure, tower.
 Take up counter weights
 Vibrating Feeder
2.2 Belt Weigher
2.3 Magnets and Metal Detectors
2.4 Vibrating Feeders
3.0 Design Data
3.1 General
A. Minimum head room clearance maintained below gallery at roads / rail crossing.
B. Clear walkway available on elevated portion of the conveyor.

Contract M-02
C. Conveyor hood details – Please submit a sketch. Also mention its type, material type and its
thickness can the hood be opened for inspection anywhere in its length.
D. Tolerances adopted
3.2 Belt conveyor (Separately for each Conveyor)

A. Capacity
 Nominal
 Designed
 Belt speed, Belt width & trough
B. Idler Spacing (Separately for Fabric Belting and Steel cord Belting)
 Carrying side including impact rolls.
 At return side
3.2.1 A) Carrying Idler Assembly
 Make, trough, construction details. Mention whether the tube to the machined for fixing of
bearing housing
 Idler diameter, length
 i) Tube thickness
ii) Steel grade
 Bearing type, size
 Life in hours
B) Arrangement proposed at the impact point of the material transfer
 Using Impact Idler
i) Idler diameter, length
ii) Tube thickness, diameter
iii) Rubber disc/cover
- Outside diameter
- Thickness
- Shore hardness
- Description including fixing arrangement of rubber discs/cover
- Shaft dia and bearing size
 Using Rubber Block (For 5 roll garland type idlers)
- Size
- Hardness
- Fixing Brackets / U-clamps Particulars
c) Weight of rotating parts of carrying and impact idler per roll.
d) Shaft diameter and material

Contract M-02
e) Bracket and housing (material)

f) Details of bearing seals
g) Details of connecting links and suspension arrangement of garland idler.
h) Lubrication details
3.2.2 Return Idler Assembly
 Make, trough (wherever applicable), construction details. Mention whether machining of tube is
necessary for fitting of bearing housing.
 Idler diameter, length
 Tube thickness
 i) Bearing type, size
ii) Life in hours
 Weight of rotating parts per roll
 Shaft diameter and material
 Details of suspension arrangement in the :
i) Inclined portion of the conveyor
ii) Straight portion of the conveyor
 Details of bearing seals
 Lubrication details
3.2.3 Drive (Separately for each Conveyor)
 Describe the drive arrangement covering number of drives provided in the head and tail ends,
if any, of the conveyor. The description shall cover sequence of starting / stopping and time lag
between the drive units in case of multiple drives.
 Describe the take-up arrangement
 Carrying capacity of the conveyor in case of failure of one drive out of multiple drives.
 Motor
i) HP and RPM
ii) Type, class of insulation
iii) Make
iv) WR2 value
 Reducer
i) HP rating
ii) Ratio
iii) Type
iv) Make
v) If shaft mounted, how
vi) If shaft mounted, how reducer will be fitted with pulley shaft?

Contract M-02
vii) Lubrication details

viii) WR2 value (At input shaft0
 High Speed & Low Speed coupling
i) Location
ii) Torque rating
iii) Type
iv) Make
v) WR2 value (At input Shaft)
 Brakes
i) Number
ii) Location
iii) Torque rating and drum diameter
iv) Type
v) Make
vi) WR2 value
vii) Furnish a list showing the conveyor with brakes and without brakes.
 Back stop (hold back), if any
i) Location
ii) Torque rating
iii) Type
iv) Make
v) Mounting method
vi) WR2 value
vii) Lubrication
 Safety devices, give list
3.2.4 Belting (Separately for each Conveyor)
a. Belt Length
Information to be furnished in the following format :
Conveyor Belt Length (metres) No. of Pieces of Shipment
Note : Belt length indicated above shall include splicing length.

b. Belting particulars for each type :
i) Belt width and type
ii) Allowable working tension

Contract M-02
iii) Number of piles

iv) Factor of safety
v) Weight of belt
vi) Carcass specification and cover rubber specification
vii) Total belt thickness
viii) Cover rubber thickness
 Top
 Bottom
ix) Expected life of belting
x) Maximum temperature belting top cover can withstand
xi) Details regarding construction of belting, tensile strength, ultimate elongation, etc.
xii) Shore hardness of top cover
xiii) Elongation expected after one year operation
xiv) Other details, such as features in the steel cord belt against ripping
3.2.5 Belt take-up
a. Details of belt take-up highlighting the location(s) it is provided, shall be furnished in the
following form. Description of lowering arrangement of take-up assembly shall also be
furnished.
Conveyor Type of Take- Locations of Take-up Counter Weight
up Take-up Travel
Qty. Material
b. Describe in detail the operations of winch take-up units highlighting its sequence of switch
on/switch off operations, its controls, interlocks with conveyor drive and safety devices.
c. Winch details :
i) Rope tension at operating condition
ii) Wire rope
- diameter and construction
- factor of safety
- type of splice
iii) Winding / unwinding speed of the rope on the drum
iv) Drum details :
- material, its thickness and construction
- pitch diameter and length of drum
- shaft dia and type of bearings, material of shaft
- drum RPM
v) Drive details

Contract M-02
- motor type, make, HP and RPM

- reduction ratio and how is it achieved.
vi) Describe tension detection device
vii) Brake
- Make and location
- torque rating
- type
viii) Rope sheaves :
- Material and construction
- Pitch diameter
- Shaft diameter and its material
- Type of bearing
ix) Lubrication system
x) List out safety devices
xi) Other details
3.2.6 Transfer Points
a) Chutes and Spouts
i) Material
ii) Thickness
iii) Liner
- Location
- Material
- Thickness
- Hardness
- Fixing arrangement
- Other details
iv) Minimum valley angle
v) Safety devices, list. Describe chute level switch.
3.2.7 Stringer Supporting Frames (Separately for conventional type and pipe conveyor)
a. Details of stringer frame
b. Sizes of different structural members of Stringer frames.
c. Give details of construction of deck plates with plate thickness and locations.
3.2.8 Skirt Board (Separately for different application)
a. Clear minimum width and height for different widths
b. Arrangement of holding skirt rubber
c. Material and thickness of skirt plate

Contract M-02
d. Thickness and shore hardness of skirt rubber

e. Liner Material and Thickness
3.2.9 Scrapper & Plough (separately for different application)
a. Description with drawing
b. Details of material including thickness and hardness of scraper blade(s)
c. Locations
d. Method of adjustment

Contract M-02
3.3 Belt Weigher

(Separately for different applications)
1 Type
2 Make / Model no.
3 Weight
a) Guaranteed accuracy
 120% rated capacity
b) What is the minimum rate of loading to maintain guaranteed
accuracy? Accuracies to be mentioned considering the location of
individual belt weigher
4 Details of calibration equipment

5 Details of flow rate indicator, chart recorder, totaliser, etc.
6 Details of recorder, totaliser, etc. It is possible to print out the

summary of the day weighment.
7 Details of battery unit
8 Incoming power supply
9 Whether cosine pendulum provided.
10 Carrying idlers with brackets included in scope
11 Carrying Idler specification
a) Tube dia.
b) Minimum wall thickness
c) Shaft dia at bearing
d) Roller O/D machined (Yes/No), Tolerance
e) Preceding / succeeding idlers provided ((Yes/No), Qty
12 Local Control Cabin
a) Enclosure Protection
b) Whether suitable for outdoor duty (YES/NO)
c) Mounting
d) Dimensions
13 Digital read-out meters
a) No. of digits
b) Display size
c) Whether reset-able type (YES/NO)
d) Dimensions

Contract M-02
14 Tonnage counter
a) Type
b) Size
15 List of indications and controls located on local control panel
16 Whether terminals provided for equipment healthy and belt
overload for remote?
17 Chart Recorder
a) Type
b) Size
c) Make
18 Load Cell
a) Type & Qty per Weigher
b) Make
19 Confirm cabling upto local control panel is included in the scope.
3.4 Magnets
1 Weight and Dimensions

2 Make and Type
3 Indicate the operating height, Maximum & minimum size and
weight of the object (tramp iron) that the magnet will be able to lift
from the belt.
4 Confirm that the power supply mentioned in the specification is
suitable.
5 Input power supply.
6 Power consumption (KW)
a) Cold
b) Hot
7 Strength of Magnet (gauss) over full area
8 Coil
a) Insulating material
b) Material of conductor
c) Class of insulation
d) Details of encapsulation
e) Temperature rise over ambient
f) Permissible maximum temp for the coil
g) Selection criteria of the Magnet
h) Enclosure protection
Whether system is suitable for remote operation (Yes/No)

Contract M-02
9 Suggested location & distance of the Metal detector with respect

to the Magnet
10 Interfacing between Metal detector & Magnet included
11 Details of idlers below the magnet
12 Cabling Between Metal detectors to Magnet & Metal
Detectors/Magnet to Control Panel Included in scope.
13 Minimum size of metal to be sensed by metal detector.
14 Type of cooling of magnet
15 Suspension slings included in scope
16 Technical data Sheet for Metal Detectors with dimensioned
sketch to be furnished with the offer.
17 Tenderer to mention item(s) to be provided by others to make
each magnet functional.
3.5 Metal Detector

A. Give detailed description of the equipment and its operations.
B. Search Coil
a. Type
b. Size
c. Type of insulation used
d. Alternating effect of foreign body on search
C. Detector Electronics
a. Sensitivity
b. Whether adjustments possible
c. Whether enclosure is dust proof.
d. Details of the device used to mark the area where the tramp metal is present.
3.6 Cranes / Monorail Hoists

Furnish a table showing the locations, types capacities, lift, speed, duty class etc. of Cranes / hoists
being provided.
3.7 Vibrating Feeder

a. Make & Type
b. Capacity (Design/Rated)
c. Power
 Type of Drive
 Power (Required/Installed)
d. Trough
 Size (L x B x H)

Contract M-02
 Material and Thickness of Mother Plate

 Liner – Type and Thickness
 Inclination
e. Discharge Rate (Max. & Min.) and method of controlling the discharge rate.
f. Mounting details on the floor and how is it ensured that vibrations are not transferred to the floor.
3.8 Miscellaneous Items
a. Typical Arrangement of
 Rod Gate
 Rack & Pinion Gate
 Diverter Gate
b. Material / Thickness, Liner Type and Thickness, Drive Details (Rack & Pinion, Diverter Gate) shall
be provided.
3.9 Electrical
Electrical Load Data for Drive Motors for Conveyors (as proposed by tenderer)
Equipment Voltage V Number of Installed Running Load Running Load
Description Drive Motors Power / rating (for iron ore) (for coal) kW
of each motor kW
kW
Conveyor Name
JD-1A
JD-1B
JD-2A (existing
conv. and
converted to
reversible conv.)
JD-2B (existing
conv. and
converted to
reversible conv.)
JD-4A
JD-4B
JD-5E
JD-5F
Note: Motors will be 6 pole 1000 RPM constant torque 0-1000 RPM, Constant power above 1000-1500
RPM
Electrical Load Data (for equipment other than conveyor drive motors)
Equipment Description Voltage V Installed Power kW Running Load kW
Brakes for Conveyors (where applicable)

Contract M-02
Electrical Load Data (for equipment other than conveyor drive motors)
Equipment Description Voltage V Installed Power kW Running Load kW
Vibro Feeders
Rack & Pinion Gates
Diverter Gates
Belt scales
Electrical Hoists / EOT in Transfer Towers (mention number and kW of each) considered in the Transfer
Towers
Vibrators / Air Blaster
Actuators (linear/rotary)
Magnet & Metal Detector Normal Under Over

Condition excited excited
Any other item (not listed above but required for system)
-
-

Contract M-02
3.10 Electrical Technical Data

Sl. Description
No.
1. Motors for equipment other than conveyors
(give data for each rating)
a) Equipment driven / Application
b) Make & type
c) Output rating (kW) at ambient temp. 45 deg. C
d) Speed (RPM)
e) Rated voltage (Volts)
f) Number of phases and frequency (HZ)
g) Degree of protection for enclosure
h) Method of starting
i) Class of insulation
j) Maximum temp. rise over 45 deg. C. ambient
2. Local Electrical / Control Panels
a) Degree of protection of enclosure
b) Busbar Material
c) VFD Rating (for Vibro Feeders)
d) Cable distance limitation from vibro feeder VFD to Motor (m)
e) Interfacing with JSW’s Central Control System
3. Cables
a) Make & type
b) Voltage Grade
c) Material of Conductor
d) Material of Insulation

Contract M-02
Sl. Description
No.
4. Field Safety Devices / Switches for diverter gates/R&P gate
a) Degree of Protection Offered
b) Contact Rating
c) No. of Potential Free Contacts (N.C/N.O)

Contract M-02
SCHEDULE: 5
TRAINING SCHEME
The Tenderer shall describe in detail the training scheme that he is proposing for the Operators, Technicians and
Supervisory Personnel, if any, for efficient functioning, i.e. operation and maintenance of all equipment to be
supplied by him. The scheme shall indicate the nature of training required for respective operation, the duration
of training for each function, etc. The Tenderer shall identify the critical areas which need special attention and
shall elaborate his proposal for the same.
The following particulars shall be furnished in the format given below:
Sl.No. Description of the Type of Training Duration for No. of No. of

Function – (Class Room, Field each function Personnel Personnel,
Equipment wise Visit, Hands-on, etc.) and Type to be Proposed to be
Trained engaged by the
Tenderer

Contract M-02
SCHEDULE: 6
WORK SCHEDULE
Tenderer(s) shall submit along with the bid(s) a Work Schedule. The schedule shall be a detailed programme
with date and methodology showing the approach to the work. The detailed programme in the form of a Bar
Chart or CPM network shall include all activities starting from issue of LOI to commissioning (loading of first
ship).
In order to complete the system in totality, including commissioning, the tenderer shall indicate the availability of
the following from others to enable erection of equipment under the Scope of Work; considering erection to start
from conveyor R-1A/1B onwards.
1 Transfer Towers (please indicate conveyor wise)
2 Conveyor Galleries (please indicate conveyor wise)
3 Power supply for testing and commissioning
4 Submission of technical data and interface details

required for works to be done by others
(within 45 days of LOI).
To be furnished progressively based on agreed
work priority. May start from 30 days of LOI.
5 Any other item required to complete the system.
The completion time for this contract shall be 8 months.

Contract M-02
SCHEDULE: 7
QUALITY ASSURANCE
The Tenderers shall submit in substantial detailed quality assurance plan with inspection and test procedures
indicating all activities step by step at various stages such as manufacturing / fabrication / erection / assembly /
painting & testing at premises including site to carry out the work to meet the requirement of this specification
and international standards / regulations / good engineering practices, to enable comprehensive assessment of
its merits and reliability.
This shall also include the Employer / Engineer, stages of inspection & testing before & during the manufacturing
/ fabrication / erection / assembly / painting & testing for “all items and activities as referred and /or relevant to
complete the equipment under reference.

Contract M-02
SCHEDULE: 8
SUB-CONTRACTORS
The Tenderers shall submit the name, address of persons, firms or companies, proposed by him as sub-
contractors for carrying out the work under the Contract together with particulars of work to be carried out by
each party. Written confirmation from such contractors shall be submitted along with the bid.
Particulars of Work to be carried out Details of Earlier Working Names and addresses of
Experience proposed parties
Description Design / Fabrication /
Construction /
Manufacturing /
Installation

Contract M-02
SCHEDULE: 9
ORGANISATION CHART
The tenderer is to indicate the following:-
1. The organisation he proposes to set up for execution of the work both at design/manufacturing stage as
well as site execution stage. It is understood that this will be augmented from time to time depending on
the requirements for timely completion of work, as directed by Employer or Engineer's representative.
Tenderers shall confirm that working area indicated in the enclosed drawing is adequate for contract
execution and shall submit his plan for the utilisation of the area along with the bid.
Designation of Name and Short Resume of

Key Personnel Experience
2. Estimated labour force at site:
a. Peak :
b. Average :
3. Estimated power requirement at site:
a. Peak / day :
b. Average / day :
c. Duration :
4. Estimated water requirement at site:
a. Peak / day :
b. Average / day :
c. Duration :

Contract M-02
SCHEDULE: 10
DETAILS OF EQUIPMENT, TOOLS, TACKLES
The Tenderers shall submit herein details of equipment, tools, tackles, etc. required for erection, testing and
commissioning and shall indicate in each case whether the same is (a) already owned by tenderer and available
for use on this Contract, (b) anticipated to be hired by Contractor(s) or (c) anticipated to be purchased by
Contractor(s). In case of (a) present location shall be stated. In case of (b) and (c) location of Lessor or Supplier
shall be stated.
No. of Description, Make Model & Category Location Remarks, if

Items Capacity (a) or (b) or (c) above any
Note: Being an operating terminal, the tenderer shall list out in detail the expectation from the Employer on
the availability of resources at site to fulfill the contractual obligations in the light of other Schedules, like
Schedule 6, Schedule 9, etc.

Contract M-02
SCHEDULE: 11
STATEMENT OF DEVIATIONS
The Tenderer(s) shall indicate in the format given below the deviation(s), if any, he proposes against specific
clauses. It is to be noted that in case no deviation is listed herein, it shall be considered that the Tenderer has
agreed to comply with all the requirements of the Tender Documents.
Proforma for Statement of Deviations
Clause No. Deviation Remarks (including justification)
Note: Where there is no deviation, a statement "No Deviation" shall be made, duly signed and enclosed with
the Bid.

Contract M-02
SCHEDULE: 12
DETAILS OF SIMILAR WORK DONE

DURING THE PAST FIVE YEARS
Sl. Full Postal Description Value of Completion Date of Actual Year of Remarks
No. Address of of the Work Contract Time as Commence- Completion Completion
Employer stated in the ment of Time
Tender Work (weeks)
(weeks)
1 2 3 4 5 6 7 8 9
Note:-
1. Tenderers are specifically requested to furnish all the details about the last assignment done for the
Employer.
2. Completion date should be mentioned in the Completion Certificate given by the Employer.
3. Only a format in which the information is to be given is indicated above. The Contractor shall attach
additional sheets of bigger sizes to accommodate the necessary information, if required.

Contract M-02
SCHEDULE: 13
CONCURRENT WORKS AND COMMITMENTS
The Tenderer(s) shall furnish in the format given below, details of the current works in hand and other contractual
commitments:
Sl. Employer with Description of Value of Completion Percentage Remarks

No. Address the Work Contract Time as Completion
stated in the
Contract
1 2 3 4 5 6 7
I. Current Works in Hand
II. Immediate Commitments
Only a format in which the information is to be given is indicated above. The Tenders shall attach additional
sheets of bigger sizes to accommodate the necessary information, if required.

Contract M-02
SCHEDULE: 14
FINANCIAL TURNOVER
The Tenderer shall furnish in the format given below details of its financial turnover during the last five years.
Year: 2009-10 2010-11 2011-12 2012-13 2013-14

Home
Abroad
Total:
Only a format in which the information is to be given is indicated above. The tenderer shall attach additional
sheets to accommodate the necessary information.

Contract M-02
SCHEDULE: 15
DECLARATION OF SITE VISIT BY THE TENDERERS
We hereby declare that we have visited the said Site of Work and have acquainted and satisfied thoroughly with
the existing Site Condition. The site condition are taken into consideration ‘as is where is basis’ and all necessary
arrangements required for subject scope of work will be assured by us.
Signature _____________________________________
Designation____________________________________
_____________________________________________
(COMPANY SEAL)
Company ___________________________________
___________________________________________
Date _______________________________________

Contract M-02
DRAWINGS


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JSW Jaigarh Port Ltd.

Expansion of Jaigarh Port

Grafix Engineering Consultants Pvt. Ltd.

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

12.6 Commissioning .......................................................................................................................... 78

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

Sl. Belt Conveyor System Remarks

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

galleries of reclaiming conveyors JRD-

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

2.2 Work Included

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

3 WORK NOT INCLUDED

3.3 Construction of Berths (existing) and extension of Berth 6A by 40.0 meters.

3.6 Roads drainage, boundary wall, wind shield.

3.10 Payloaders / Backhoe / Dozers.

3.13 Dust Suppression System and Fire Fighting System.

3.14 New Reclaimers (2 nos) in the stockyard

3.15 New Barge/ship loaders (2 nos) at barge berth

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

MECHANICAL DRAWINGS (NEW CONVEYOR SYSTEM)

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

5.2 Site Information and Climatic Conditions

5.2.2 Geographical Location

5.2.3 Tides and Tidal Currents

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

7 GENERAL DESIGN REQUIREMENT

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

7.4 Design Standards

 Operating Wind  20 m/sec at all levels (25 kg/m2)

d) Design Equipment Temperature: 45° C minimum

7.5 Material: Codes and Standards

A. Cast iron : IS 210, Grade 20 / BS-3468

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

D. Forged steel : IS 1875 / BS-970

7.6 Components: Codes and Standards

Component Min. Specification

7.7 Belt Conveyor System

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

7.7.3 Conveyor Frame Structure

7.7.4 Take-up Units

7.7.4.2 Vertical Take-up Units

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

7.7.4.3 Horizontal Take-up Units

7.7.5 Towers / Transfer Towers and Drive Houses

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

7.7.6 Idler Assembly

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)

l) All the Idlers shall be designed for outdoor, continuous duty.

7.7.6.1 List of Drawings

Project :EXPANSION OF JSW JAIGARH PORT (Phase III – MHS)