TECHNICAL SPECIFICATIONS FOR MANUFACTURE AND SUPPLY OF

PLC & Drive PANELS FOR PROJECT – AEIPL-PLANT3.

1. CPL001: Material Transport PLC panel ( for White Cement and Other Materials) comprising of:
a) Digital and Analog IO configuration:
DI DO AI AO
80 48 - -
b) 7”Touch Screen HMI for Operator Interface
c) Housing starter as under:
Requirement of Starters
Code Description Motors HP kw Starter Type
DC101 Dust collector for dump hoppers 1 5 3.75 DOL
VS102 Vibrating screen 1 3 2.25 DOL

2. CPL002: Fly Ash and Cement Handling PLC panel comprising of:
a) Digital and Analog IO configuration:

DI DO AI AO
72 48 4 -
b) 7”Touch Screen HMI for Operator Interface
c) Housing starter as under:
Requirement of Starters
Code Description Motors HP kw Starter Type
RB201 Roots blower 1 40 30 Y/D
RB202 Roots blower 1 40 30 Y/D
RAL201 Rotary feeder - FLY ASH 1 3 2.25 DOL
RAL202 Rotary Feeder - CEMENT GREY-A 1 3 2.25 DOL
RAL203 Rotary Feeder - CEMENT GREY-B 1 3 2.25 DOL
VS201 Vibrating screen 1 3 2.25 DOL

3. CPL003: Sand Handling PLC panel comprising of:

a) Digital and Analog IO configuration:
DI DO AI AO
72 40 4 4
b) 7”Touch Screen HMI for Operator Interface
c) Housing starter as under:
Requirement of Starters
Code Description Motors HP kw Starter Type
BC301 Belt conveyor-Wet sand 1 5 3.75 VFD
BE301 Wet sand bucket elevator 1 5 3.75 VFD
SD301 Sand Drier (2Nos.)
Centrifugal air blower 2 3 2.25 DOL

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 Oil pump 2 1 0.75 DOL
Screw Conveyor 2 5 3.75 VFD
Main Drive 2 7.5 5.625 VFD
SC301 Dry Sand Screw Conveyor 1 5 3.75 DOL
VS301 Vibrating Screen 1 3 2.25 DOL
BE302 Dry sand Bucket elevator 1 7.5 5.625 DOL
RAL301 Rotary feeder 1 3 2.25 DOL

4. CPL004: Weighing & Batching PLC panel comprising of:

a) Digital and Analog IO configuration:
DI DO AI AO
144 124 8 -
b) 7”Touch Screen HMI for Operator Interface
c) Housing starter as under:
Requirement of Starters
Starter
Code Description Motors HP kw Type
RAL601 Rotary Feeder - FLY ASH 1 2 1.5 DOL
RAL602 Rotary Feeder - CEMENT GREY-A 1 2 1.5 DOL
RAL603 Rotary Feeder - CEMENT GREY-B 1 2 1.5 DOL
RAL604 Rotary Feeder - CALCITE GRADE-A 1 2 1.5 DOL
RAL605 Rotary Feeder - HAC 1 2 1.5 DOL
RAL606 Rotary Feeder - SILICA FLOUR 1 2 1.5 DOL
RAL607 Rotary Feeder - CEMENT WHITE 1 2 1.5 DOL
RAL608 Rotary Feeder - SILICA SAND 60 1 2 1.5 DOL
Rotary Feeder - QUARTZ SAND(-30+40
RAL609 MESH) 1 2 1.5 DOL
RAL610 Rotary Feeder - QUARTZ SAND 60 MESH 1 2 1.5 DOL
RAL611 Rotary Feeder - HYDRATED LIME 1 2 1.5 DOL
VS602 Vibrating Screen- CEMENT GREY-A 1 3 2.25 DOL
VS603 Vibrating Screen - CEMENT GREY-B 1 3 2.25 DOL
VS605 Vibrating Screen - HAC 1 3 2.25 DOL
VS607 Vibrating Screen- White cement 1 3 2.25 DOL
SCD601 Screw Doser - FLY ASH 1 3 2.25 VFD
SCD602 Screw Doser - CEMENT GREY-A 1 5 3.75 VFD
SCD603 Screw Doser - CEMENT GREY-B 1 5 3.75 VFD
SCD604 Screw Doser - CALCITE GRADE-A 1 5 3.75 VFD
SCD605 Screw Doser - HAC 1 5 3.75 VFD
SCD606 Screw Doser - SILICA FLOUR 1 3 2.25 VFD
SCD607 Screw Doser - CEMENT WHITE 1 5 3.75 VFD
SCD608 Screw Doser - SILICA SAND 60 1 5 3.75 VFD
Screw Doser - QUARTZ SAND(-30+40
SCD609 MESH) 1 5 3.75 VFD
SCD610 Screw Doser - QUARTZ SAND 60 MESH 1 5 3.75 VFD
SCD611 Screw Doser - HYDRATED LIME 1 3 2.25 VFD
DC701 Dust Collector for HAND ADD Stations 1 5 3.75 DOL

PLC control panel - Specs with pricing format.doc Page 2 of 9

 VS701 Vibrating Screen - Micro material dosing 1 1 0.75 DOL
VS702 Vibrating Screen - Micro material dosing 1 1 0.75 DOL
5. CPL005: Mixing and Packing PLC panel comprising of:
a) Digital and Analog IO configuration:
DI DO AI AO
104 80 4 -
b) 7”Touch Screen HMI for Operator Interface
c) Housing starter as under:
Requirement of Starters
Code Description Motors HP kw Starter Type
PSM701 Plough Shear Mixer
Main shaft motor 1 100 75 VFD
Chopper motor 4 15 11.25 VFD
Hydraulic power pack 1 5 3.75 DOL
PSM702 Plough Shear Mixer
Main shaft motor 1 100 75 VFD
Chopper motor 4 15 11.25 VFD
Hydraulic power pack 1 5 3.75 DOL
MPM701 Manual packing machine 1 3 2.25 MCCB 10A
Stitching machine 1 0.5 0.375 DOL
Belt conveyor 1 3 2.25 DOL
MPM702 Manual packing machine 1 3 2.25 MCCB 10A
Stitching machine 1 0.5 0.375 DOL
Belt conveyor 1 3 2.25 DOL
MPM703 Manual packing machine 1 3 2.25 MCCB 10A
Stitching machine 1 0.5 0.375 DOL
Belt conveyor 1 3 2.25 DOL
MPM704 Manual packing machine 1 3 2.25 MCCB 10A
Stitching machine 1 0.5 0.375 DOL
Belt conveyor 1 3 2.25 DOL
Transfer belt conveyor for MPM701 and MPM702 1 3 2.25 DOL
Transfer belt conveyor for MPM703 and MPM704 1 3 2.25 DOL

6. SCADA for Data Logging and Supervisory control:

SCADA package with Run-Time license for Networking of above 5 Nos. PLC panels to a central
control station for the purpose of:
a. Supervisory control
b. Logging of Data from different processes.
c. Avoid human error during hooking up of conveying line in Ware House.
Computer configured for Smooth running of SCADA operation to be quoted by the vendor. The
system should have pre-installed LICENSED Operating System.

PLC control panel - Specs with pricing format.doc Page 3 of 9

 7. Requirement of Control Stations, Bag Filter Timer Panels and
Junction boxes:
Sl.No Description UOM Qty

1. Power distribution and Control Signal termination box for level Nos. 1
switch comprising of 220VAC power supply terminals with fuse
protection for 22 Nos. Level switches and provision for wiring 2
sets of control signals from each level switch. The powder
coated sheet steel enclosure will be suitably sized to house the
above hardware.
2. Power distribution box for Bag Filter Timer Panels comprising of Nos. 1
220VAC power supply terminals with fuse protection for 11 Nos.
Bag filter timers. The power supply will be switched through
suitably sized relay. The relay will be controlled by PLC panels.
The powder coated sheet steel enclosure will be suitably sized
to house the above hardware.
3. Push button stations comprising of 5 sets of On/Off push Nos 9
buttons, 1 Nos 3 Position Switch, 4 Nos. Indicating lamps duly
wired to 2.5 sq.mm terminals housed in a suitably sized, powder
coated, sheet steel enclosure.
4. ON/OFF push button station for Dust Collectors and RAL below Nos. 2
dust collector
5. Bag Filter timer comprising of 6 channel sequential timer (EAPL Nos. 16
Make) duly wired to 2.5mm terminals housed in a suitably sized,
powder coated sheet steel enclosure
6. Bag Filter timer comprising of 10 channel sequential timer (EAPL Nos. 1
Make)duly wired to 2.5 sq.mm terminals housed in a suitably
sized, powder coated sheet steel enclosure
7. Supply of powder coated field termination junction box Nos 23
containing 75 terminals of 2.5sqmm

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General instructions for design of PLC panel.
1. All Digital Inputs are 24 VDC PNP type.
2. All Digital Outputs are 24VDC Transistor.
3. Interposing relay card to be considered for all Digital Outputs
4. All Analog Inputs / Outputs should be 0-10VDC / 2-20mA (Field Configurable).
5. The panels should have suitable sized Incomer ISOLATOR.
6. The panels should have 24VDC SMPS suitable sized for the application.
7. All Panels will have STATIC MIMIC showing the status of field instruments.
8. All panels should have Audible alarm
9. Wherever Variable Frequency Drives are employed for speed control, the RS485 communication
between the PLC and DRIVE on MODBUS protocol is preferred.
10. For PLC panels with VFD, Suitably rated line chokes to be used.

PLC control panel - Specs with pricing format.doc Page 5 of 9

 ANNEXURE - 2
Technical Specifications for PLC Panels

1. Application  Indoor

2. Material of construction  To be fabricated out of 2mm CRCA sheets for load bearing members
and 1.5mm sheet for non- load-bearing members.
 Free standing panels to be made of sheet steel frames.
 Stiffeners to be provided at corners and between modules to make the
panels rugged.

3. Type  Totally enclosed Free standing, floor mounted, dust proof.

4. Protection Class  IP 40 / 32

5. Voltage  220 VAC / 24VDC – Control Voltage.

6. Bus bars  -NA-

 Only earthing bus bar to be provided.

7. Indicating instruments  -NA-

8. Indicating lamps  All indication lamps shall be Cluster LED type and shall be suitable
for 220 VAC / 24VDC application. It shall be provided with
translucent lamp covers of the required color.

9. Operating height  1800mm max. height level.

 300 mm min. height from ground level.
10. Wiring  Control wiring to be carried out using 660 V grade PVC Insulated
flexible copper wires. Each wire will be identified at both ends with
PVC Ferrules.
 1 Sq. mm. for control wiring.
 2.5 sq. mm. for CT wiring.
 Insulated Pin / “U” type lugs of suitable size should be used at all the
connecting and terminating points of the wires.
 Maximum of 2 wires to be connected per connecting point.

11. Cable entry  Bottom.

 3mm thick gland plate to be provided at the cable entry point.

12. Doors  To be provided with lift-off type hinges.

 Quarter turn knobs to be provided for proper locking of doors.
 Flexible copper braids to be provided for earth continuity.
 Neoprene or synthetic gasket shall be provided all the side the
door to ensure proper sealing from dust entry.

13. Labels  Lettering to be in white color on dark background and size of the
letters to be of 6 mm. unless otherwise specified.

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  Labels to be properly fixed by screws / Revits to prevent distortion.
14. Painting  Color – Powder coated Siemens Grey / RAL7032.
 All the surfaces of the panel to be thoroughly cleaned, degreased,
pickled and rinsed in 7 tank process before powder coating.
15. Base  Integral ISMC 75, painted black should be provided all along the
periphery of the base.

16. Operating Temperatures  35- 40 Deg. C

ANNEXURE - 3

List of approved Makes.

Sl. No. Equipment / Component Make

1. Plant protection circuit breakers. Siemens / ABB / GE.

2. MCCB Siemens / ABB / GE.

3. Contactors Siemens

4. MCBs. Siemens / INDO kopp.

5. Push buttons & Indicating lamps. Siemens / Tecnic.

6. Selector switches Salzer

7. Auxiliary Contactors Siemens.

8. Changeover relays Paramount / OMRON.

9. Timers EAPL / Siemens.

10. PVC Copper wires Finolex / LAPP KABEL

11. PVC Cable trough Salzer

12. Bus bars Standard.

13. Luggs Dowells.

14. Terminals Connectwell.

PLC control panel - Specs with pricing format.doc Page 7 of 9

 ANNEXURE – 4
Pricing Schedule

Design, Manufacture, Supply, Installation and Commissioning of:

Sl# Description Price
1 CPL001: Material Transport PLC panel ( for White Cement and Other
Materials)
2 CPL002: Fly Ash and Cement Handling PLC panel
3 CPL003: Sand Handling PLC panel
4 CPL004: Weighing & Batching PLC panel
5 CPL005: Mixing and Packing PLC panel
6 SCADA SYSTEM
Total
Excise Duty
Vat
Grand Total
 For the above panels, provision for mounting VFD to be considered.
 Price for VFDs to be quoted separately as below.

Code Description Motors HP Unit Price Total Price

BC301 Belt conveyor-Wet sand 1 5
BE301 Wet sand bucket elevator 1 5
SD301 Screw Conveyor 2 5
Main Drive 2 7.5
SCD601 Screw Doser - FLY ASH 1 3
SCD602 Screw Doser - CEMENT GREY-A 1 5
SCD603 Screw Doser - CEMENT GREY-B 1 5
SCD604 Screw Doser - CALCITE GRADE-A 1 5
SCD605 Screw Doser - HAC 1 5
SCD606 Screw Doser - SILICA FLOUR 1 3
SCD607 Screw Doser - CEMENT WHITE 1 5
SCD608 Screw Doser - SILICA SAND 60 1 5
SCD609 Screw Doser - QUARTZ SAND(-30+40 MESH) 1 5
SCD610 Screw Doser - QUARTZ SAND 60 MESH 1 5
SCD611 Screw Doser - HYDRATED LIME 1 3
PSM701 Main shaft motor 1 100
PSM701 Chopper motor 4 15
PSM702 Main shaft motor 1 100
PSM702 Chopper motor 4 15
Total
Excise Duty
Vat
Grand Total

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Design, Manufacture, Supply, Installation and Commissioning of:
Sl.No Description UOM Qty Unit Price Total Price

1. Power distribution and Control Signal termination box for Nos. 1

level switch comprising of 220VAC power supply terminals
with fuse protection for 22 Nos. Level switches and
provision for wiring 2 sets of control signals from each level
switch. The powder coated sheet steel enclosure will be
suitably sized to house the above hardware.
2. Power distribution box for Bag Filter Timer Panels Nos. 1
comprising of 220VAC power supply terminals with fuse
protection for 11 Nos. Bag Filter timers. The power supply
will be switched through suitably sized relay. The relay will
be controlled by PLC panels. The powder coated sheet steel
enclosure will be suitably sized to house the above
hardware.
3. Push button stations comprising of 5 sets of On/Off push Nos 9
buttons, 1 Nos 3 Position Switch, 4 Nos. Indicating lamps
duly wired to 2.5 sq.mm terminals housed in a suitably
sized, powder coated, sheet steel enclosure.
4. ON/OFF push button station for Dust Collectors and RAL Nos. 2
below dust collector
5. Bag Filter timer comprising of 6 channel sequential timer Nos. 16
(EAPL Make) duly wired to 2.5mm terminals housed in a
suitably sized, powder coated sheet steel enclosure
6. Bag Filter timer comprising of 10 channel sequential timer Nos. 1
(EAPL Make)duly wired to 2.5 sq.mm terminals housed in a
suitably sized, powder coated sheet steel enclosure
7. Supply of powder coated field termination junction box Nos 23
containing 75 terminals of 2.5sqmm
Total
Excise Duty
Vat
Grand Total

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