Tender Document Main Oven with motorized trolley drive system … · 2017-11-03 · Main oven, Internal Mandrel water circulation system,Agni Oven, Electrical, Instrumentation and

Main oven, Internal Mandrel water circulation system,Agni Oven, Electrical, Instrumentation and control Systems

P a g e |1 of 208

Tender Document

Main Oven with motorized trolley drive system and internal Mandrel Water circulation system & Agni Oven

and

Electrical, Instrumentation & Control Systems

Satish Dhawan Space Centre SHAR

Indian Space Research Organization

Sriharikota

October 2017


P a g e |2 of 208

Table of Contents

1. Scope of the Tender .................................................................. 8

1.1. Introduction ............................................................................ 8

2. General Terms and Conditions .................................................. 8

2.1. Instruction to Bidders .............................................................. 8

2.2. Schedule Price ....................................................................... 12

2.3. Customs Duty ....................................................................... 13

2.4. Publicity Related to Tenders ................................................... 14

2.5. Site Visit ................................................................................ 14

2.6. Validity of Offer: ..................................................................... 14

2.7. Cost of Bidding ...................................................................... 14

2.8. Applicable Language .............................................................. 14

2.9. Project Monitoring ................................................................. 15

2.10. Arbitration ............................................................................. 15

2.11. Applicable Law & Jurisdiction ................................................ 16

2.12. Acceptance and Rejection ...................................................... 17

2.13. Suspension ............................................................................ 17

2.14. Performance Bank Guarantee ................................................ 17

2.15. Foreign Exchange Outgo and Variation .................................. 18

2.16. Liquidated Damage ................................................................ 18

2.17. Security Deposit .................................................................... 18

2.18. Earnest Money Deposit .......................................................... 18

2.19. Force Majeure ........................................................................ 19

2.20. Extension of Time .................................................................. 20

2.21. Warranty ............................................................................... 20

2.22. Payment Terms ...................................................................... 21

2.23. Delivery ................................................................................. 22

2.24. Packing & Forwarding ............................................................ 23

2.25. Exclusion of Tenders ............................................................. 23

2.26. Drawings ............................................................................... 23

2.27. Arrangement of Bid ................................................................ 24

3. Documents Comprising the Bid ............................................... 25

3.1. Part – I Technical and Unpriced Commercial .......................... 25

3.2. Part – II Priced Commercial Bid .............................................. 26

3.3. Bid Submission ..................................................................... 26

3.4. Bid Evaluation ....................................................................... 27

3.5. Determination of Responsiveness ........................................... 28

4. Scope of Works: ....................................................................... 31

4.1. Main Oven with motorized trolley & Internal Mandrel water circulation system ................................................................. 31

4.2. Agni Oven .............................................................................. 31

4.3. Instrumentation and Control Systems.................................... 31

4.4. Electrical Systems ................................................................. 31

4.5. Inspection & Testing .............................................................. 32


P a g e |3 of 208

4.6. General Description ............................................................... 32

4.7. Equipment & Services to be provided by the Supplier............. 34

4.8. Instructions during Fabrication ............................................. 39

4.9. Codes and Standards ............................................................. 40

4.10. Safety .................................................................................... 40

4.11. Painting ................................................................................. 41

4.12. Summary of Data to be furnished by Party ............................. 41

5. Main Oven with Motorized trolley and internal water circulation system 44

5.1. Basis of Design & System Description .................................... 44

5.2. Outside Atmospheric Conditions ............................................ 46

5.3. Oven Parameters ................................................................... 46

5.4. Oven Construction ................................................................. 47

5.5. Air Distribution System ......................................................... 48

5.6. Heating System...................................................................... 50

5.7. Power Supply ......................................................................... 52

5.8. Temperature Uniformity ......................................................... 52

5.9. Interlocks .............................................................................. 53

5.10. Motorized Trolley ................................................................... 53

5.11. Wiring ................................................................................... 59

5.12. Internal Mandrel Water Circulation System............................ 59

6. AGNI Oven .............................................................................. 69

6.1. Basis of Design & System Description .................................... 69

6.2. Specification of AGNI Oven .................................................... 71

6.3. Interlocks .............................................................................. 71

6.4. Atmospheric Conditions ......................................................... 72

6.5. Oven Parameters ................................................................... 73

6.6. Oven Construction ................................................................. 73

6.7. Air Distribution System ......................................................... 74

6.8. Heaters & Heater Battery ....................................................... 75

6.9. Electrical Requirements ......................................................... 76

7. Electrical Systems................................................................... 79

7.1. Scope of Work – Electrical Systems ........................................ 79

7.2. General Terms ....................................................................... 79

7.3. Intelligent Motor Control Centre (i-MCC) ................................ 80

7.4. Feeders for Intelligent Motor Control Centre (i-MCC) .............. 87

7.5. Motor Management System (MMS) ......................................... 93

7.6. Measuring & Monitoring Requirements .................................. 95

7.7. Operation Modes ................................................................... 97

7.8. i-MCC Configuration for Operating Modes .............................. 98

7.9. Terminal Blocks and Labels ................................................... 99

7.10. Power & Control Cables ....................................................... 100

7.11. Cable Termination ............................................................... 101

7.12. Control Wiring ..................................................................... 102


P a g e |4 of 208

7.13. Cable Trays ......................................................................... 102

7.14. List of Cables ....................................................................... 102

7.15. Inspection – FAT & SAT ....................................................... 103

7.16. Erection & Commissioning ................................................... 104

7.17. Training ............................................................................... 105

7.18. Standards ............................................................................ 105

7.19. Spares ................................................................................. 106

7.20. Technical Specifications (Data Sheets) ................................. 107

8. Instrumentation & Control Systems ...................................... 120

8.1. Scope of Work ...................................................................... 120

8.2. Equipment & Services to be supplied by the Party................ 120

8.3. General Instructions to the Party ......................................... 121

8.4. Design & Reviews ................................................................ 124

8.5. Inspection – FAT & SAT ....................................................... 124

8.6. Training ............................................................................... 125

8.7. The PLC system ................................................................... 126

8.8. The SCADA system .............................................................. 132

8.9. Data Acquisition & Control System (DACS) programming ..... 136

8.10. Power Supply Systems ......................................................... 138

8.11. Safety Systems .................................................................... 139

8.12. Cables ................................................................................. 140

8.13. Earthing .............................................................................. 140

8.14. Equipment or Services not in the scope of the contract ........ 141

8.15. IO Details – Main Oven ........................................................ 141

8.16. IO Details – AGNI Oven ........................................................ 151

8.17. IO Details – Control Room .................................................... 160

8.18. IO Channel / Module Summary ........................................... 162

8.19. Instrumentation Items ......................................................... 164

8.20. Technical Specifications (Data sheets) .................................. 170

9. Suggested Vendors ................................................................ 202

9.1. Main Oven, AGNI Oven & Sub Systems – Mechanical ........... 202

9.2. Electrical Systems ............................................................... 203

9.3. Instrumentation & Control Systems ..................................... 204


P a g e |5 of 208

List of Figures

Fig. 1. Motorized Trolley ........................................................................ 55

Fig. 2. Control Consoles ...................................................................... 196

List of Tables

Table 1. Specifications of the Ovens ..................................................... 32

Table 2. Codes and Standards............................................................. 40

Table 3. Ovens Parameters .................................................................. 46

Table 4. Drive System Specifications.................................................... 55

Table 5. Pump Specifications ................................................................ 62

Table 6. List of Items for Water Circulation System ............................. 63

Table 7. Specification of AGNI Oven ..................................................... 71

Table 8. Interlocks of AGNI Oven .......................................................... 71

Table 9. Feeders for i-MCC – Main Oven .............................................. 87

Table 10. Feeders for i-MCC – AGNI Oven .............................................. 89

Table 11. Parameters – Digital & Analog................................................ 95

Table 12. Power Cables – Quantity – Main Oven ................................. 102

Table 13. Power Cables – Quantity – AGNI Oven ................................. 103

Table 14. List of Standards .................................................................. 105

Table 15. List of Spares – Main Oven ................................................... 106

Table 16. List of Spares – AGNI Oven................................................... 106

Table 17. Specifications of Switch Gear - ACB ..................................... 107

Table 18. Specifications of Switch Gear - MCCB .................................. 108

Table 19. Specifications of Switch Gear - MPCB .................................. 108

Table 20. Specifications of Switch Gear - MCB .................................... 109

Table 21. Specifications of Switch Gear - Contactor ............................. 109

Table 22. Specifications of Switch Gear – Aux Contactor ..................... 110

Table 23. Specifications of Switch Gear - OLR ..................................... 110

Table 24. Specifications of Earth Leakage Relay ................................. 110

Table 25. Specifications of Power & Control Cables ............................. 110

Table 26. Specifications of Soft Starter ................................................. 111

Table 27. Specifications of VFD for BOGIE MOTOR .............................. 112

Table 28. Specifications of Electric Motors – Blowers & Pumps ........... 112

Table 29. Specifications of Electric Motors – Bogie Motor ..................... 113

Table 30. Specifications of Thyristor Controller .................................... 114

Table 31. Specifications of Heater Banks – Hot Water Tank ................ 115

Table 32. Specifications of Heater Banks – Main Curing Hot Air ......... 116

Table 33. Specifications of Heater Banks – AGNI Curing Hot Air ......... 117

Table 34. Analog Inputs – RTD Inputs .................................................. 141

Table 35. Analog Inputs – RTD Inputs for Hardwire ............................ 142

Table 36. Analog Inputs – IO Panel ...................................................... 142

Table 37. Digital Inputs ........................................................................ 144

Table 38. Digital Outputs...................................................................... 150

Table 39. Analog Outputs ..................................................................... 151


P a g e |6 of 208

Table 40. Analog Inputs – RTD Inputs .................................................. 151

Table 41. Analog Inputs – RTD Inputs for Hardwire ............................ 152

Table 42. Analog Inputs – IO Panel ...................................................... 152

Table 43. Digital Inputs ........................................................................ 154

Table 44. Digital Outputs...................................................................... 159

Table 45. Analog Outputs ..................................................................... 160

Table 46. Analog Inputs – Control Room .............................................. 160

Table 47. Digital Inputs – Control Room ............................................... 161

Table 48. Digital Outputs – Control Room............................................. 162

Table 49. Instrumentation Items – List ................................................. 164

Table 50. RTD Sensors ......................................................................... 170

Table 51. Temperature Transmitter ...................................................... 171

Table 52. Pressure Transmitter ............................................................ 171

Table 53. Single Loop Controllers (SLC) ................................................ 172

Table 54. Level Switch.......................................................................... 173

Table 55. Level Transmitter .................................................................. 173

Table 56. Proximity Sensors ................................................................. 174

Table 57. Isolators & IS Relays ............................................................ 174

Table 58. Low Air Pressure Switch ....................................................... 175

Table 59. Water Flow Switch................................................................ 175

Table 60. DC Voltage Transducer ......................................................... 176

Table 61. DC Current Transducer ........................................................ 176

Table 62. UPS Voltage Transducer ....................................................... 177

Table 63. UPS Current Transducer ....................................................... 177

Table 64. 24 V DC Power Supply ......................................................... 178

Table 65. IO Rack ................................................................................. 178

Table 66. Programmable Logic Controller ............................................. 180

Table 67. DI Modules ............................................................................ 181

Table 68. DO Modules .......................................................................... 181

Table 69. Temperature Input Modules .................................................. 182

Table 70. Analog Input Modules ........................................................... 182

Table 71. Analog Output Modules ........................................................ 183

Table 72. Supervisory Control and Data Acquisition system ............... 183

Table 73. Server for SCADA / Historian ............................................... 185

Table 74. Operator Workstation ........................................................... 186

Table 75. Thin Client Unit ..................................................................... 188

Table 76. Programming Station (Laptop) .............................................. 189

Table 77. Ethernet Switch – L2 (Field) .................................................. 190

Table 78. Ethernet Switch – L2 (Control Room) .................................... 190

Table 79. Ethernet Switch – L3 (Control Room) .................................... 191

Table 80. Surge Suppressor ................................................................. 194

Table 81. Control Consoles ................................................................... 194

Table 82. Server Rack .......................................................................... 196

Table 83. 43 Inch LED TV ..................................................................... 197

Table 84. 16 Pair Signal Cables ........................................................... 198

Table 85. 1 Pair / 3 Pair Signal Cables ................................................ 199


P a g e |7 of 208

Table 86. Heat Resistant Cables .......................................................... 201

Table 87. Optic Fiber Cables ................................................................ 202

Table 88. Suggested Vendors - Mechanical .......................................... 202

Table 89. Suggested Vendors – Electrical Systems .............................. 203

Table 90. Suggested Vendors – Instrumentation & Control Systems ... 204


P a g e |8 of 208

1. Scope of the Tender

1.1. Introduction

1.1.1. SDSC SHAR invites tenders from reputed firms with proven ability in Design of ovens, preparation of drawings, fabrication, inspection and testing of sub systems at vendor/sub vendor works, site fabrication, erection, commissioning, inspection, testing and carrying out trial runs of following ovens and associated systems as per the technical specifications enclosed to the tender document for SDSC SHAR, Sriharikota as per the scope and specifications.

1.1.2. Scope of work includes

Realization of Hot Air recirculation type curing oven with

motorized trolley including internal mandrel water

circulation system for segment curing operation. – 1 No

Realization of Hot Air recirculation type curing oven

complete with double leaf manual door and thermally

insulated bottom structure for Agni Grain & Carton curing

operations. – 1 No

Supply, Erection and commissioning of Electrical Systems

and interfacing with various sub-systems at Curing

Facilities.

Supply, Erection and commissioning of Instrumentation

and Control System (ICS) and related accessories at

Curing Facilities.

1.1.3. Arrangements shall be made by the supplier for the inspection and testing during different stages of manufacture starting from the raw materials till the completion of all works by the SDSC SHAR, at supplier’s site and at out site, as per the approved Quality Assurance Plan (QAP).

2. General Terms and Conditions

2.1. Instruction to Bidders

2.1.1. One set of proposal document along with the drawings is issued. Bidder shall sign and stamp each page of proposal as a token of his acceptance & submit along with his offer. Document shall be scanned and uploaded in e-procurement portal.


P a g e |9 of 208

2.1.2. Proposal documents shall remain the property of Department and if obtained by one intending Bidder shall not be utilized by another without the consent of the Department.

2.1.3. The proposal shall be completely filled in all respects and shall be submitted together with requisite information. Any offer incomplete in any particulars is liable for rejection.

2.1.4. Bidders shall set their quotations in firm figures and without qualifications or variations or additions in the terms of the Proposal documents. Proposal containing qualifying expressions such as "subject to minimum acceptance" or "subject to prior sale" or any other qualifying expressions or incorporating terms and conditions at variance with the terms and conditions incorporated in the Proposal documents are liable for rejection.

2.1.5. Annual turnover of the tenderer during the last three years should be at least 9 crore.

2.1.6. Price shall include all costs for complete execution of the entire scope of work of the party, as envisaged in the document. Price quoted shall be firm and fixed.

2.1.7. Price shall be quoted in Indian National Rupee only.

2.1.8. Tenderer should have at least 5 years of experience in the field of design, fabrication, erection, testing and commissioning of hot air recirculation type of ovens.

2.1.9. Successful Bidder shall identify a project team, submit project execution plan and work break down chart, detailing the methodology of execution (process plan) within 15 days from the date of issue of purchase order.

2.1.10. Bidder Should have configured, designed, manufactured, erected and commissioned at least 1 no. of hot air recirculation type of oven of size 4.6m ×4.6m ×7m or with an oven chamber volume of 175 m3 during the last 5 years. Documentary evidence in the form of PO.

2.1.11. Vendor should have executed single order value of worth minimum 3 crore for the last 10 years

2.1.12. Bidder Should have experience in design, fabrication, erection and commissioning of trolley of 60 t capacity with inbuilt drive mechanism for loading and un loading of job / articles from the oven.

2.1.13. Bidder should award any part of the work under the scope of this tender to any sub vendor only after obtaining necessary approval from the department. Bidder shall submit relevant


P a g e |10 of 208

information as required by the department to evaluate the capabilities of sub vendor. Department has every right to accept or reject the proposal submitted. Approval of the department is no way relieves the bidder from his responsibility and the bidder is wholly responsible for execution of work as per the specifications, terms, and conditions mentioned in this document.

2.1.14. Bidder Should have in-house team for fabrication, erection of ovens.

2.1.15. If the party has only engineering staff and planned to outsource, details and credentials of sub contract vendors shall be provided in the bid.

2.1.16. If bidder is planning to subcontract any part of this tender document, then the bidder shall indicate clearly such of those works planned to offload to his sub-vendor in their offer.

2.1.17. The Sub-Vendor shall meet following conditions specified.

2.1.18. Sub-Vendor should have minimum 5 Years of experience in the field of Control systems and minimum 2 years of experience in the field of Electrical systems proposed make along with proof.

2.1.19. Sub-Vendor should have executed at least 1 project of worth more than 1 crore for similar Instrumentation & control system and electrical system proposed. Proof shall be submitted to consider the offer.

2.1.20. Annual turnover of the sub-vendor executing Electrical, instrumentation and control systems during the last three years should be at least 1 crore.

2.1.21. The conditions of the sub-contracts if any, shall be framed by the bidder such that interest of the Department and its rights are protected in accordance with the original contract terms and conditions.

2.1.22. The erection works at this facility requires that, the party (successful bidder) shall adhere to good daily housekeeping practices. During erection, the party shall keep all work and storage areas used by them free from accumulation of waste materials. Scrap shall be removed from the site to the satisfaction of the purchaser.

2.1.23. Satish Dhawan Space Centre – SHAR (SDSC-SHAR), Sriharikota is declared as prohibited place under official secrets act 1923. Hence during execution of site works necessary security requirements enforced by the department from time to time shall be followed strictly.


P a g e |11 of 208

2.1.24. SDSC SHAR shall have the right of inspection and supervision of the manufacturing process adopted by the Supplier for the manufacture of equipment at various stages through their authorized representatives. In case the manufacturing process adopted is not found suitable and commensurate with the desired quality of the equipment, the Supplier will be advised to adopt the correct manufacturing process which will be binding on the Supplier. SDSC SHAR’s decision regarding the quality of work and its acceptability shall be final and binding on the Supplier.

2.1.25. Defects in the steel raw materials like fractures, cracks, blow holes, laminations, pitting, etc., are not acceptable.

2.1.26. During the erection, testing and commissioning of equipment at site in Sriharikota, the supplier has to make his own arrangements for boarding, lodging and transportation of his men and materials. However, subjected to availability, hostel accommodation may be provided by the Purchaser (SDSC SHAR) on chargeable basis.

2.1.27. Free electricity and water will be provided by the Purchaser at one location close to the site (SDSC SHAR) for the erection, testing and commissioning works. Bidder shall take this into account while quoting the price. Distribution of water and electricity from site to the required location shall be taken care by the party.

2.1.28. Before starting the site work (at SDSC SHAR), the party shall provide insurance as per workman compensation act to all his personnel working at site in Sriharikota against accidents. Insurance for the same shall be borne by the party.

2.1.29. While performing the contractual work, the contractor must ensure compliance with all the existing statutory labour enactment/ regulations under Contract Labour (R & A) Act, 1970 & rules framed thereunder. The Contractor is to comply with all the provisions of the Act including the following important requirements under the Act.

2.1.30. Till commissioning of equipment, the safe storing and handling of all equipment is in the scope of supplier.

2.1.31. The transfer of title to the Purchaser (SDSC SHAR) will take place only after satisfactory erection, testing and commissioning of the all the equipment by the supplier and full acceptance by the Purchaser (SDSC SHAR).

2.1.32. Transportation & Transit Insurance are fully in the scope of supplier and the same shall be borne by the party.


P a g e |12 of 208

2.1.33. GST: Supplier has to clearly indicate the percentage of GST applicable along with applicable HSN & SAC. Documentary proof for the same shall be submitted along with invoice for final payment.

2.1.34. Necessary care shall be taken during erection and commissioning of equipment at our site. Any damage to the property of Department shall be adequately compensated by the Party.

2.1.35. The BIDDER shall confirm the size / rating of all equipment / components based on the requirements and meet all system guarantees during testing & operation of oven.

2.1.36. The clear dimensions indicated in the GA drawing no. MEC/10JN/11/11/35D/0016 for the oven are minimum dimensions. The SS 304 sheet cladding shall not get encroached the clear oven space indicated.

2.1.37. Upon completion of work at site, Bidder shall remove all his equipment and material from the site within one month or time mutually agreed. Bidder at all times shall keep site in clean condition and remove all unwanted material at regular intervals. In case bidder fails to remove all his equipment and material within the mutually agreed time it is deemed that Department will arrange to remove the same at the bidder’s cost besides imposing penalty for failure.

2.1.38. Should there be any ambiguity or doubt as to the meaning of any of the tender clause/condition or if any further information is required, the matter shall be immediately brought to the notice of Head, Purchase & Stores, SDSC SHAR in writing for necessary clarifications prior to the opening of the tenders.

2.2. Schedule Price

2.2.1. CONTRACT price shall include all costs of “Design of ovens, preparation of drawings, fabrication, inspection and testing at vendor/sub vendor works, site fabrication, supply, erection, commissioning, inspection, testing and carrying out trial runs of main oven, Agni curing oven & associated system” as per the technical specifications enclosed to the tender document, Shop floor testing, packing, forwarding, transport to site, unloading, storage, all risk coverage, erection, installation, supply of spares required, training, testing & evaluation and commissioning of equipment including associated minor civil work and any other cost for proper and complete execution of the CONTRACT.

2.2.2. CONTRACT prices shall also include all travelling expenses,


P a g e |13 of 208

living expenses, salaries, overtime, benefit and any other compensation for engineers, supervisors, skilled, semiskilled workmen, watch and ward staff, labourer and other staff employed by the Bidder, cost of tools and tackles required for erection and other consumable material required, and all taxes, duties, and levies as applicable on the date of submission of bid.

2.2.3. Price quoted shall be firm & fixed. The price shall be filled in the format available in e-procurement portal. The bidder shall also fill up the format enclosed (Annexure 5)without price figures and shall confirm by filling the appropriate fields as “QUOTED”.

2.2.4. Quote shall be based on DAP (Delivery at Place) Sriharikota.

2.2.5. All rates of taxes/duties/levies applicable with details of percentage and applicable portion of the price should be spelt out clearly in the offer.

2.2.6. The taxes applicable for supply, erection & commissioning shall be indicated separately in terms of percentage in the price bid. If

the offers submitted by the bidders are silent on taxes, it will be presumed that quoted rates are inclusive of taxes & duties and no claim in this regard will be entertained later.

2.3. Customs Duty

2.3.1. SDSC-SHAR is eligible for Customs Duty exemption. This may be taken into account while considering the pricing of the imported items.

2.3.2. To avail of customs duty exemptions, the Bidders are required to produce “Custom Duty exemption” certificate and “Not Manufactured in India” certificate at the appropriate time.

2.3.3. Bidder should indicate the list of items with quantities that are identified for import to be indicated clearly along with bid. Customs Duty exemption will be provided for the items listed only.

2.3.4. Party shall enclose the list of items in the format given below.

S. No. Item / Description Qty Remarks

1

2

3


P a g e |14 of 208

2.4. Publicity Related to Tenders

2.4.1. Advertisements, press release or other specialized publicity documents, which are related to or reveal the existence of a tender and are intended by the Bidder for public distribution and/or the press, broadcasting, or television, shall be cleared/approved by the Department.

2.4.2. The Department may direct the Bidder to withhold such publicity or to require modifications to the publicity material. The Bidder shall comply with such direction.

2.5. Site Visit

2.5.1. Bidders may visit and examine the site and its surrounding to familiarize themselves of the existing facilities and environment and may collect all other information which may be required for preparing and submitting the Bid. Bidders shall visit within 10 days from the date of tender enquiry.

2.5.2. Claims and objections due to ignorance of existing conditions or inadequacy of information will not be considered after submission of the Bid and during implementation.

2.6. Validity of Offer:

2.6.1. Bid shall remain valid for acceptance for a period of six months from the due date of submission of the Bid.

2.6.2. The Bidder shall not be entitled during the said period to revoke or cancel his Bid or to vary the Bid except and to the extent required by Department in writing.

2.6.3. Bid shall be revalidated for extended period as required by Department in writing.

2.6.4. In such cases, unless otherwise specified, it is understood that validity is sought and provided without varying either the quoted price or any other terms and conditions of Bid finalized till that time.

2.7. Cost of Bidding

2.7.1. All direct and indirect costs associated with the preparation and submission of Bid (including clarification meetings and site visit, if any), shall be to Bidder's account and the Department (SDSC SHAR) will in no case be responsible or liable for those costs, regardless of the conduct or outcome of the Bid process.

2.8. Applicable Language

2.8.1. The Bid and all correspondence incidentals to and concerning


P a g e |15 of 208

the Bid shall be in the English Language. For supporting document and printing literature submitted in any other language, an accurate English Translation shall also be submitted. Responsibility for correctness in translation shall lie with the Bidder.

2.9. Project Monitoring

2.9.1. Bidder shall provide details of project team within 10 days from the date of placement of order.

2.9.2. Party shall submit the project status report every 15 days mentioning the status of various activities w.r.t. planned schedule for realization.

2.9.3. Party shall depute their Project team/ engineers for Monthly meeting to review the status and discuss/ resolve minor issues related to project execution at SDSC SHAR/ party’s site based on mutually agreeable dates.

2.10. Arbitration

2.10.1. In the event of any question, dispute of difference arising under these conditions or any conditions contained in the Purchase Order, (except as to any matters the decision of which is specially provided for by these conditions) the same shall be referred to the sole arbitration of the Director SDSC SHAR Office or some other person appointed by him, it will be no objection that the arbitrator is a Government Servant that he had to deal with matter to which the contract relates or that in the course of his duties as Government Servant he had expressed views on all or any of the matters in disputes or difference. The award of the arbitrator shall be final and binding on the parties of this contract.

2.10.2. If the arbitrator be the head of the purchase office.

(a) In the event of his being transferred or vacating his office by resignation or otherwise, it shall be lawful for his successor-in office either to proceed with the reference himself, or to appoint another person as arbitrator, or.

(b) In the event of his being unwilling or unable to act for any reason, it shall be lawful for the Head of the Purchase Office to appoint another person as arbitrator: or

2.10.3. If the arbitrator be a person appointed by the Head of the Purchase Office in the event of his dying, neglecting or refusing to act, or resigning or being unable to act, for any reason, it


P a g e |16 of 208

shall be lawful for the Head of the Purchase Office either to proceed with the reference himself or to appoint another personas arbitrator in place of the outgoing arbitrator.

2.10.4. Subject as aforesaid, the Indian Arbitration and Conciliation Act, 1996 and the rules there under and any statutory modifications thereof for the time being in force shall be deemed to apply to the arbitration proceedings under this Clause. The arbitrator shall have the power to the extent with the consent of the Purchaser and the Contractor the time making and publishing the award.

2.10.5. The venue of arbitration shall be place as the purchaser in his absolute discretion may determine. Work under the purchase order shall, if reasonably possible, continue during arbitration Proceedings.

2.10.6. In case order is concluded on the public Sector Undertakings, the following Arbitration Clause will be applicable.

(a) In the event of any dispute or differences relating to the interpretation and application of the provisions of contracts, such dispute or difference shall be referred by either party to the Arbitration of one of the Arbitrator in the Department of Public Enterprises to be nominated by the Secretary to the Government of India in-charge of the Bureau of Public Enterprises.

(b) The Indian Arbitration and Conciliation Act, 1996 shall not be applicable to the Arbitration under this clause.

(c) The award of the arbitrator shall be binding upon the parties to the dispute provided; however, any party aggrieved by such award may make a further reference for setting aside or revision of the award to the Law Secretary, Department of Legal Affairs, Ministry of Law & Justice, Government of India. Upon such Additional Secretary when so authorized by the Law Secretary whose decision shall bind the parties finally and conclusively.

(d) The parties to the dispute will share equally the cost of arbitration as intimated by the arbitrator.

2.11. Applicable Law & Jurisdiction

2.11.1. The contracts shall be interpreted in accordance with the laws of the Union of India. Any legal issue or dispute arising out of the contract are within the jurisdiction of Courts of Andhra Pradesh, India only.


P a g e |17 of 208

2.12. Acceptance and Rejection

2.12.1. On completion of the work or part of the work as specified in the contract by the bidder, bidder shall inform the same to the department as soon as possible. The department / its representative shall inspect as per mutually agreeable schedule.

2.12.2. If the ordered systems, sub-systems etc., do not meet the prescribed specifications or are damaged at the time of delivery or fail during inspection/testing, they shall be rejected and the Bidder / manufacturer shall replace them at their own cost.

2.12.3. Purchaser has the right to reject the goods on receipt at site during final inspection though the goods have already been inspected and cleared at pre-dispatch stage by the purchaser’s inspector, if they found not meeting the overall performance requirements.

2.12.4. Goods accepted by the purchaser at initial inspection and in final inspection in terms of the contract shall in no way dilute purchaser’s right to reject the same later, if found deficient in terms of the warranty clause of the contract.

2.13. Suspension

2.13.1. Department may notify the Bidder to suspend performance of any or all of his obligations under the Contract. Such notice will specify the reasons for suspension and the effective date of suspension. Bidder there upon shall suspend the performance of such obligations until ordered in writing to resume performance of Contract by Department.

2.13.2. If Bidder’s performance or his obligations remain suspended or the rate of progress is reduced, then, the time of completion will be suitably extended and all costs incurred by Bidder as a result of suspension or reduction in rate of progress will be paid to Bidder provided that the suspension or reduction in the rate of progress is not by reasons of Bidder’s default or breach of Contract.

2.14. Performance Bank Guarantee

2.14.1. PBG at 10% of the value of the Purchase Order shall be submitted through bank guarantee from any of the Scheduled Banks executed on non-judicial stamp paper of appropriate value, and shall be valid for a period of sixty days beyond the date for completion of warranty period.


P a g e |18 of 208

2.15. Foreign Exchange Outgo and Variation

2.15.1. The foreign exchange component shall be included in the lump-sum price quoted /unit rates quoted. Foreign exchange variation if any shall be borne by the party and will not be compensated.

2.16. Liquidated Damage

2.16.1. Time is the essence of this order. If the supplier's defined scope of work is not made by the end of delivery period, liquidated damage will be levied @ 0.5 % per week or part thereof subject to a maximum of 10% of value of undelivered stores.

2.17. Security Deposit

2.17.1. Party shall submit security deposit, within 10 days of Order Acknowledgement, for 10% of the total order value. Security Deposit shall be obtained through Bank Guarantee or fixed deposit receipt from any of the Scheduled Banks executed on non-judicial stamp paper of appropriate value, and shall be valid for a period of sixty days beyond the date for completion of the Purchase Order.

2.17.2. In case the vendor fails to furnish the security deposit within the specified date or extended due date, the Purchase Order/Contract shall be cancelled, and the EMD, if any, made earlier shall be forfeited, and, in addition, appropriate penal action will be taken.

2.17.3. Central PSUs/PSEs/Autonomous Bodies shall be exempted from the payment of Security Deposit, and instead, an Indemnity Bond shall be submitted by them in lieu of the Security Deposit.

2.18. Earnest Money Deposit

2.18.1. Party shall submit EMD of Rs.5.0 Lakh. EMD shall be submitted in a single instalment through Demand Draft / Banker’s Cheque / Fixed Deposit Receipts or Bank Guarantee from any of the Scheduled Banks executed on non-judicial stamp paper of appropriate value.

2.18.2. Central PSUs/PSEs/Autonomous Bodies, Micro and Small Enterprises, KVIC, National Small Industries Corporation etc. are exempted from the payment of EMD.

2.18.3. Parties who are registered (registered and empaneled) at Satish Dhawan Space Centre e-procurement portal are also exempted from the payment of EMD.


P a g e |19 of 208

2.18.4. In case of bank guarantee, it shall be valid for a period of 45 days beyond the final tender validity date.

2.18.5. Any tender not accompanied with EMD shall be treated as invalid tender and rejected. Vendors seeking exemption from payment of EMD shall submit necessary proof like registration number, etc.

2.18.6. EMD of a vendor shall be forfeited if the tenderer /Contractor withdraws or amends his tender or deviates from the tender in any respect within the period of validity of the tender.

2.18.7. Failure to furnish security deposit by a successful vendor within the specified period shall also result in forfeiture of EMD.

2.18.8. EMD shall be refunded to all the unsuccessful vendors within thirty days after placement of the Purchase Order.

2.18.9. EMD shall be refunded to the successful tenderer/Contractor after payment of the Security Deposit or may be adjusted against the Security Deposit.

2.18.10. EMD shall be refunded to all the participants in cases where the tender is cancelled or withdrawn by the Centre/Unit, within thirty days from the date of such cancellation or withdrawal.

2.19. Force Majeure

2.19.1. Force Majeure is an event beyond the control of the supplier and not involving the supplier’s fault or negligence and which is not foreseeable. Such events may include, but are not restricted to, acts of the purchaser either in its sovereign or contractual capacity, wars or revolutions, hostility, acts of public enemy, civil commotion, sabotage, fires, floods, explosions, epidemics, quarantine restrictions, strikes, lockouts, and freight embargoes.

2.19.2. If there is delay in performance or other failures by the supplier to perform its obligation under its contract due to event of a Force Majeure, if a Force Majeure situation arises, the supplier shall promptly notify the purchaser in writing of such conditions and the cause thereof within twenty-one (21) days of occurrence of such event.

2.19.3. Unless otherwise directed by the purchaser in writing, the supplier shall continue to perform its obligations under the contract as far as reasonably practical, and shall seek all reasonable alternative means for performance not prevented by the Force Majeure event.


P a g e |20 of 208

2.19.4. There may be a Force Majeure situation affecting the purchase organization only. In such a situation the purchase organization is to take up with the supplier on similar lines as above for further necessary action.

2.20. Extension of Time

2.20.1. If the completion of deliveries of equipment and / or work is delayed due to reason of Force Majeure the Bidder shall without delay give notice to the Department in writing of their claim for an extension of time. The Department on receipt of such notice may agree to extend the Contract period or delivery date as may be reasonable but without prejudice to other terms and conditions of the Contract.

2.20.2. Both parties shall keep a record of the circumstances referred to above which are responsible for causing delays in the execution of the services and shall give notice to the other bidder of any such cause as soon as it occurs. An event of Force Majeure, where so ever it occurs, provided it affects either bidder in fulfilling its obligations under this contract, shall justify the affected bidder’s claim of Force Majeure.

2.20.3. Should one or both the parties be prevented from fulfilling their contractual obligations by a state of Force Majeure lasting continuously for more than a month, the parties shall consult with each other regarding the future execution of the contract.

2.21. Warranty

2.21.1. The Equipment and related accessories shall be warrantied against any manufacturing defects for a period of 12 months from the date of commissioning. For defects noticed during the guarantee period, replacement rectification should be arranged at free of cost within a reasonable period of such notification.

2.21.2. Party shall carryout mandatory checks as mutual agreed. During this period, party shall replace/ rectify them of defective/ failed parts at free of cost.

2.21.3. Party has to attend unlimited breakdown calls.

2.21.4. Upon oral or written notification of defects or malfunctioning of the goods during the warranty period which require corrective action, bidder shall send the necessary personnel to job site to supervise and assume responsibility for repairs and/or replacement, if necessary, of the defective goods or material at his own cost.

2.21.5. If Party does not respond, within seven (7) days after receipt of


P a g e |21 of 208

notification, the department has got every right to resolve reported problem and Department may do so at the cost and expense of the Party. Party shall reimburse to the Department all expenses incurred by Department to repair or replace malfunctioning or non-conforming goods and Forfeit the performance security.

2.21.6. Department has no obligation to discover defects, patent or otherwise, and this shall be sole responsibility of Bidder. Inspection and clearance for shipment by Department’s inspectors or Inspection agency appointed by Department shall not relieve Bidder of any of his obligation and duties under the terms and conditions herein.

2.21.7. Where defects in items are remedied under warranty, the period for which the warranty operates shall be extended by such period, as the items were not available to the Department. Where defective items are replaced by new ones, the full warranty period stipulated in the contract shall apply to such replacement items as from the date of their delivery.

2.21.8. Party shall obtain similar warranty from each of his sub-vendors. However, the overall responsibility shall lie with the Bidder.

2.22. Payment Terms

2.22.1. Our standard payment term is 80% of supply cost including taxes and transportation cost within 30 days after receipt and acceptance of sub-systems in finished form at SDSC SHAR. 20% of supply portion and 100 % of erection and commissioning charges along with taxes will be paid after successful commissioning and handing over of the ovens at SDSC SHAR on submission of Performance Bank Guarantee.

2.22.2. Wherever advance payment is requested, maximum of 30% will be provided upon furnishing Bank Guarantee from any Nationalized Bank/Scheduled Bank. In case of advance payments, if the party is not supplying the material within the delivery schedule, interest will be levied as per the Bank Lending Rate plus 2% penal interest. This is in addition to LD clause.

2.22.3. Interest will be loaded for advance payments/stage payments as per the lending rate of Bank and will be added to the landed cost for comparison purpose. In case of different milestone payments submitted by the parties, a standard and transparent methodology like Net Present Value (NPV) will be adopted for evaluating the offers.


P a g e |22 of 208

2.23. Delivery

2.23.1. Party shall follow the following schedule for executing the contract

S. No Mile Stone

Expected

date of

completion

1 Purchase order date T

2

Submission of GA drawing of oven, hot air

circulation system, water circulation

system, iMCC, PLC and SCADA

configuration.

T + 3 weeks

3

Submission of detailed design calculations

of major Systems and subsystems with

respect to mechanical, structural, Electrical

and Electronics.

T + 4 Weeks

4

Submission of Design and fabrication

drawings, P&I diagrams including

specifications and details of all bought out

components.

T + 6 weeks

5 Final drawings. T + 8 weeks

6 Order placement for all bought out

components. T + 10 weeks

7

Pre-delivery inspection of sub systems and

receipt of all items in finished / semi-

finished/brought out items at SDSC SHAR.

T + 8 months

8 Oven Erection & Commissioning T + 12 months

NOTE: Micro schedule shall be submitted by the party after

placement of order

2.23.2. Party shall inform the Department within 30 days of any occurrence that is likely to cause delay in delivery. The Department shall determine, in the light of circumstances reported, whether or not any respite or modification of the delivery requirements of the contract can be permitted on this account.

2.23.3. An extension of the time limit for execution or postponement of delivery shall be granted only in the respect of delay, which is not attributable to the fault or the negligence of the Bidder. An extension of the time limit for execution shall be granted to the


P a g e |23 of 208

bidder to the extent that he establishes force majeure events.

2.24. Packing & Forwarding

2.24.1. The tenderer will be held responsible for the stores being sufficiently and properly packed for transport by rail, road, sea or air, to withstand transit hazards and ensure safe arrival at the destination. The packing and marking of packages shall be done by and at the expenses of the Contractor.

2.25. Exclusion of Tenders

The following tenders shall be summarily rejected from the procurement process

2.25.1. Tenders of vendors who have been removed from the vendor list or banned/debarred from having business dealings.

2.25.2. The tenders which materially depart from the requirements specified in the tender document or which contain false information.

2.25.3. The tenders which are not accompanied by the prescribed Earnest Money Deposit.

2.26. Drawings

2.26.1. Each drawing submitted by the Bidder shall be clearly marked with the following details.

a) Name of the Owner: Satish Dhawan Space Centre, ISRO

b) Project Title:

Main & Agni Ovens, ICS, i-MCC & Accessories

c) Purchase Order No:

d) Title of the Drawing clearly identifying the system, equipment or part.

e) Drawing, Revision Number and Date.

f) Name of the Bidder: In case of Sub-Vendor or Manufacturer's drawing, name of the Bidder and Sub-Vendor or Manufacturer shall be incorporated.

g) Drawings duly signed in "checked" and “approved" columns.

h) Scale to which the drawing is drawn.

i) Cross references to all relevant drawings.

j) All relevant notes to the drawing: All notes necessary for understanding and execution of work shown on a drawing shall be presented on the same drawing.


P a g e |24 of 208

k) All legends to all notations.

l) Details of revisions carried out

m) Bill of materials shall be tabulated, wherever required.

n) All titles, noting’s, markings and writings on the drawing shall be in English

o) All the dimensions shall be in metric units.

2.26.2. If standard catalogues are submitted, the applicable items shall be highlighted therein.

2.26.3. The drawings shall indicate all dimensions and details of equipment, materials of construction etc.

2.26.4. For all revisions of the drawing, Bidder shall ensure that all revisions are clearly encircled with revision numbers marked on the drawing.

2.26.5. Bidder shall also ensure that general details of revisions are indicated for each revision in the revision block of the drawing along with the date and signed by the approving authority.

2.27. Arrangement of Bid

2.27.1. The Bid shall be neatly presented and shall not contain any terms and conditions which are not applicable to the Bid.

2.27.2. The Bid and all details submitted by the Bidder shall be signed and stamped on each page as token of acceptance by a person, legally authorized to enter into agreement on behalf of the Bidder. Corrections/ alteration, if any, shall also be signed by the same person. Bidder shall submit Power of Attorney in favour of the person who signs the Bid and subsequent submissions on behalf of the Bidder.

2.27.3. Department will not be bound by any Power of Attorney granted by the Bidder or changes in the constitution of the firm made subsequent to submission of the Bid or after the award of the contract. Bidder may however, recognize such Power of Attorney and changes after obtaining proper legal advice, the cost of which will be borne by the Bidder.

2.27.4. The cancellation of any document such as Power of Attorney, partnership Deed etc should be communicated by the Bidder to the Department in writing well in time, failing which Department shall have no responsibility or liability for any action taken by Bidder on the strength of the said documents. All the relevant papers shall be scanned and uploaded along with bid


P a g e |25 of 208

3. Documents Comprising the Bid

This is e-procurement tender. All the documents need to be

scanned and attached to the bid under “documents solicited from

Vendor” form.

Offers shall be sent online only using standard digital signature

certificate of class III with encryption / decryption. The tenders

authorized on or before the open authorization date only will be

considered as valid tenders even though the bids are submitted online.

The tenderer must authorize bid opening within the time stipulated in the schedule by SDSC SHAR. Otherwise the online bid submitted will not be considered for evaluation.

On-line bids shall consist of the following: -

3.1. Part – I Technical and Unpriced Commercial

Technical and un-priced commercial part shall comprise the following documents/information. All the documents shall be scanned and uploaded in the SDSC SHAR e-procurement portal.

3.1.1. Submission of bid letter along with one set of proposal document duly signed and stamped as token of acceptance. Scanned copy shall be uploaded in the ISRO e-procurement portal.

3.1.2. Power of attorney in favour of authorized signatory of the bid/ proposal documents.

3.1.3. Registration Number certificate of the Company.

3.1.4. Latest income tax clearance certificate (Last three FY).

3.1.5. Latest solvency certificate from a scheduled bank as detailed in bid qualification criteria. (Current FY)

3.1.6. List of projects in hand & completed during last five financial year indicating the name of client with contact details.

3.1.7. List and make of the bought-out components as well as imported items considered by bidder for this tender.

3.1.8. Organization chart for the proposed work with bio data of key personnel

3.1.9. Schedule Bar charts for realization of ovens.

3.1.10. Execution Plan. Any part of the work is planned to outsource, details of the same shall be provided along with bid documents.

3.1.11. Any other relevant document, bidder desires to submit.

3.1.12. Confirmation w.r.t bid qualification criteria as per Annexure-1.


P a g e |26 of 208

3.1.13. Compliance statement as per Annexure-2.

3.1.14. Quality Assurance Plan shall be as per Annexure-3. Detailed QAP shall be submitted by the party after placement of order based on the finalized manufacturing process plan.

3.1.15. Deviations, if any, w.r.t technical and commercial terms & conditions shall be clearly brought out under deviation list Annexure-4. If deviations are not listed separately, it will be presumed that party is adhering to all the specification and terms & conditions given in this document.

3.1.16. Party shall submit unpriced price bid format as per Annexure-5. Party shall only enter required tax percentages. In place of price columns, party shall mention “QUOTED”.

Note: All the above documents shall be uploaded in the ISRO e-procurement portal.

3.2. Part – II Priced Commercial Bid

Priced commercial bid shall contain schedule of prices and shall

be filled in ISRO e-procurement portal. No deviations, terms and

conditions, assumptions, discounts etc. shall be stipulated in price

bid. Department will not take cognizance of any such statement

and may at their discretion reject such bids.

3.3. Bid Submission

3.3.1. Bid shall be submitted in two parts

• Part -1 Techno-Commercial Part of the Bid

• Part-2 Price Part of the Bid

3.3.2. Offers should be submitted On-line using standard digital signature of class-3 with encryption/decryption options.

3.3.3. Prices shall be mentioned in the space/column provided for such purpose in the ISRO e-procurement portal.

3.3.4. Prices quoted should be on the basis of Delivery at Place (DAP), Sriharikota.

3.3.5. The purchaser will not pay separately for transit insurance and same shall be included in the cost quoted by the Bidder.

3.3.6. All risks in transit shall be exclusively borne by the contractor and the purchaser shall pay only for such items as are actually received in good condition in accordance with the purchase order.

3.3.7. Bids duly filled in by the Bidder should invariably be submitted as stipulated in the e-procurement portal.


P a g e |27 of 208

3.3.8. Department may open Part – I of the bid on the due date of opening at convenience. Price Bid (Part-II) of the bid of the technically and commercially acceptable bids will be opened at a later date.

3.3.9. Department reserves the right to reject any or all the Bids without assigning any reasons thereof.

3.4. Bid Evaluation

3.4.1. The bidder shall provide all the relevant data / details required for evaluating the bid technically and commercially in the specific formats enclosed with the tender. Apart from this, Bidder is free to add any other relevant information.

3.4.2. During evaluation, Department may request Bidder for any clarification on the bid/ additional documents/ information required. Bidder shall submit all clarifications/ additional documents/ information requested in original. If not submitted within the stipulated time department has right to reject such bids.

3.4.3. Techno-commercial discussion shall be arranged with Bidder, if needed. Bidder shall depute his authorized representatives for attending discussions.

3.4.4. The complete scope of work is defined in the Proposal document. Bidders, who undertake total responsibility for the complete scope of work as defined in the Proposal document will only be considered. As the items are interdependent, combined lowest cost shall only be considered to arrive at Lowest Offer.

3.4.5. In case Bid does not fully comply with the requirement of Proposal document and the bidder stipulates deviations to the clauses of the proposal, which are unacceptable to the Department, the Bid will be rejected.

3.4.6. Performance of Bidder on similar nature of works executed/ under execution shall be taken into consideration before selecting the Bidder for opening his price bid.

3.4.7. The time schedule for completion is given in the Proposal document. Bidder is required to confirm the completion period unconditionally.

3.4.8. Department shall not be obliged to furnish any information / clarification to unsuccessful bidder as regard non-acceptance of their Bids.


P a g e |28 of 208

S. No Annexure Reference

1. Bid Qualification Criteria Annexure-1

2. Compliance Statement Annexure-2

3. QAP Annexure-3

4. Deviations Annexure-4

5. Unpriced Price Bid Format Annexure-5

6. Main Oven & AGNI Oven - Drawings Annexure-6A

7. Water Circulation System Annexure-6B

8. Instrumentation & Control System -

Details Annexure-6C

9. Electrical System - Details Annexure-6D

10. Layout & Location – Drawings Annexure-7A

11. Above Ground Curing Facility –

Civil Drawings Annexure-7B

12. Agni Curing facility – Civil Drawings Annexure-7C

3.5. Determination of Responsiveness

3.5.1. SDSC SHAR will scrutinize bids to determine whether the bid is substantially responsive to the requirements of the tender documents. For the purpose of this clause, a substantially


P a g e |29 of 208

responsive bid is one which inter-alia conforms to all the terms and conditions of the entire Tender document without any deviations and reservations. The decision of Department shall be final in this regard.


P a g e |30 of 208

Main Oven with Motorized trolley & Internal Mandrel Water Circulation System

Agni Oven

Electrical Systems

Instrumentation & Control System


P a g e |31 of 208

4. Scope of Works:

4.1. Main Oven with motorized trolley & Internal Mandrel water

circulation system

4.1.1 The scope of work under this purchase order covers design of

oven with Motorized trolley, Internal Mandrel water circulation system, preparation of drawings, supply, manufacture, fabrication, inspection and testing at vendor’s / sub-vendor’s works, packing, transportation to site, unloading (Material handling equipment’s for erection will be provided by us on chargeable basis subject to availability) and storage at site, transportation to place of erection, site fabrication, erection inside the building, testing, cleaning and commissioning including trial run necessary to qualify all the systems.

4.2. Agni Oven

4.2.1 The scope of work under this purchase order covers design of

Agni oven preparation of drawings, supply, manufacture, fabrication, inspection and testing at vendor’s / sub-vendor’s works, packing transportation to site, unloading (Material handling equipment’s for erection will be provided by us on chargeable basis subject to availability) and storage at site, transportation to place of erection, site fabrication, erection inside the building, testing, cleaning and commissioning including trail run necessary to qualify all the systems.

4.3. Instrumentation and Control Systems

4.3.1. The scope of work covers Design, Supply, Erection and Commissioning of Instrumentation and Control System (ICS) for Main Oven, Internal Mandrel water circulation system and Agni Oven including support for trial run towards qualification of all the systems. The details of work are covered in ICS Chapter.

4.4. Electrical Systems

4.4.1. The scope of work covers Design, Supply, Erection and

Commissioning of two nos. of Intelligent Motor Control Centers

(i-MCC) one i-MCC for Main Oven & Internal mandrel water

circulation system and one for Agni Oven including necessary

interfacing with Blower, Heater battery, trolley, Fire damper

motor, control panel and SCADA system with support for trial


P a g e |32 of 208

run as per details covered in electrical systems chapter.

4.5. Inspection & Testing

4.5.1. For Scope of Work defined above, arrangements shall be made

by the supplier for the inspection and testing during different

stages of its manufacture starting from the raw materials till

the completion of works, as declared by SDSC SHAR.

4.6. General Description

4.6.1. SDSC SHAR is planning to realize Ovens Systems along with

Sub systems.

4.6.2. As the ovens are used for heating rocket propellants, indirect

heating shall be employed using air as medium. The blower and

heaters shall be placed in service room and the oven shall be

located in oven bay. The oven and blower –heater system shall

be connected through ducts. The abstract specifications of the

Ovens are below

Table 1. Specifications of the Ovens

Description Main Oven Agni Oven

Clear internal dimensions

(L x W x H)- meters 4.6 x 4.6 x 6.75 7.0 x 5.5 x 3

Mass of heating (excluding of oven structures+ ducts)

30 tons structural steel + 35 tons propellant.

12 tons structural steel +

3 tons Propellant.

No. of blowers Required

1 working + 1 standby (2nos.)

1 working + 1 standby (2nos.)

No. of heater banks 03

On/Off - One bank Thyristor controlled – 02 Banks

03 On/Off - One bank

Thyristor controlled – 02 Banks

Operating temp. 50 to 600C 50 to 600C

Ramp up time from ambient

temperature 30 min for 600C 30 min for 600C

Oven performance Set temp +/-20C Set temp +/-20C


P a g e |33 of 208

Description Main Oven Agni Oven

Spatial variation 1.5 0C or better 1.5 0C or better

Doors/base structures

Shall have double leaf manually operated steel doors and motorized trolley

Shall have manually operated double leaf swing doors.

No. of RTDs

Oven Data logging and monitoring-600mm Length:12nos.

On/Off & Thyristor control for Three Banks-600mm Length: 03 nos.

Hot Water Circulation System-800 mm Length: 03nos.

Oven heater box compartment (400 mm length)- 2nos

Fire dampers(400 mm length)- 2nos

Room temparature (400 mm length)- 1no

Blower duct Inlet & outlet(400 mm length)- 2no

Hot water Line Inlet & outlet(300 mm length)- 2no

(Total: 27) Ref: ICS Section

Data logging and monitoring-600mm Length :8nos

On/Off & Thyristor control for Three Banks-600mm Length: 02 nos.

Oven heater box compartment (400 mm length)- 2nos

Fire dampers(400 mm length)- 3nos

Room temparature (400 mm length)- 1no

(Total: 14) Ref: ICS Section

Controllers 03 nos. 03 nos.

4.6.3. The operator console consisting of SCADA Station and PLC as

detailed in I&C section shall be common for both the new ovens

and shall be located in a remote control room at a distance of

250 m from the main oven and 300 meters from the Agni oven.

4.6.4. The Intelligent Motor Control Centre (IMCC) shall be two nos.

For the Main Oven & Mandrel Jacket water circulation

For the AGNI Oven.

4.6.5. All the necessary cables between the control room and the

ovens are to be laid below (trench) the ground with few road

crossings in an approved manner with cable markers, cable


P a g e |34 of 208

trenches and Hume pipes will be provided by the department at

road crossings. Push button station, indication lamps,

annunciation panel temperature controller (only space) to

indicate alarms like blower off, air fail, over temperature, door

open etc., are already provided in common control and console

located in control room. These elements in common control and

console to be interfaced with iMCC systems. The details are

furnished in I & C chapter. Control console consisting of MMI

for SCADA based control and monitoring for all ovens and

water circulation systems shall be provided as I&C chapter.

4.7. Equipment & Services to be provided by the Supplier

4.7.1. Design, Supply, erection and commissioning of the following systems

Main Oven with motorized trolley & Internal Mandrel water circulation system.

Agni Oven.

Electrical Systems.

Instrumentation & Control Systems.

4.7.2. Hot air oven structures for Main and AGNI oven including doors

4.7.3. AGNI oven bottom structure

4.7.4. Hot air re-circulation Blowers 2no.s (one working & one stand by) for Main oven & 2nos (one working & one stand by) for AGNI oven, complete with base frame and anti-vibration pads, heater banks for Main & AGNI, hot air distribution system, thermal insulation of Blowers & ducts.

4.7.5. Internal Mandrel water circulation system complete with hot water tank with heaters, water re-circulation pumps 2nos. (one working & one standby) interconnection piping complete with valves and specialties and their thermal insulation, spray pond piping ring header with nozzles as shown in the schematic diagrams. The civil works related to spray pond is not in the scope of the contractor.

4.7.6. Motorized trolley for main oven.

4.7.7. Electrical works and Instrumentation works required for the successful operation of hot air ovens.

4.7.8. The details / designs and drawings given in the tender for various systems / equipment are of minimum requirement and are for guidance only. Contractor is free to modify / improve /


P a g e |35 of 208

redress the design if required to meet the guaranteed performance of the systems / equipment being supplied. However, any modification / improvement shall be carried out after approval from the Department.

4.7.9. Quality assurance plan for manufacturing, fabrication and testing w.r.t sub-systems as well as complete system

4.7.10. Quality records, history dockets, as built drawings and all documentation related to manufacturing, inspection, testing and erection.

4.7.11. Painting of oven structures, all piping, equipment, doors & approach platform-ladders.

4.7.12. All anchor /foundation bolts, nuts, washers and inserts to be embedded in concrete for the equipment, piping and ducting.

4.7.13. First fill of oil, grease, lubricants as required during start-up and commissioning,

4.7.14. Temporary equipment’s like piping with fittings, flanges, strainers, supports, tanks, pumps, compressors and any other necessary equipment required for testing, cleaning and flushing of the system.

4.7.15. Auxiliary steel/ structural steel supports for supporting the equipment, ducting, piping and cabling.

4.7.16. Engineering and construction of foundation for equipment.

4.7.17. Drawings for review and approval.

4.7.18. Shop inspection and tests as per specifications shall be arranged by the contractor / sub vendor to enable Department to inspect. Wherever not specified, the shop inspection tests shall be as per recent codes applicable.

4.7.19. Operation and maintenance manuals of all components and systems. Hard Copy: 02 nos., and soft copy – 01 no.

4.7.20. Training of persons for the operation and maintenance in the Electrical (soft starter, VFD, Thyristor controllers & MMS) and instrumentation system (PLC/SCADA) from M/s Siemens /Schneider/AEI /Allen Bradley to be provided as specified in Electrical & I&C chapter.

4.7.21. The ovens and their instrumentation systems shall be

calibrated by a Govt. approved testing centre / agency to meet

the technical specifications and requirements.

4.7.22. Delivery period is essence of the contract. Bidder shall comply

with the delivery schedule of 12 months.


P a g e |36 of 208

4.7.23. The CONTRACTOR shall perform tests on the total system at

the end of commissioning. All the subsystems shall be offered

for stage inspection prior to delivery.

4.7.24. Testing and Evaluation of equipment shall be carried out by the

CONTRACTOR to meet the functional requirements of each

individual equipment and systems.

4.7.25. After ensuring that the testing and evaluation of all individual

sub systems are completed in the facility, each equipment /

system shall be operated for endurance trial of min.15 days to

ensure that design specifications are met by the CONTRACTOR.

4.7.26. The party shall depute its team of competent personnel to

assist the Department staff in carrying out the process trials

during a specified period (for a min. of 15 days), after

completion of commissioning and endurance trials.

4.7.27. It is not the intent to specify completely herein all details of

design, supply, manufacture and construction of ‘equipment /

work’. However, the equipment, materials and services shall

conform in all respects to approved standards of engineering

design, workmanship and be capable of performing in

continuous commercial operation in a manner acceptable to the

DEPARTMENT who will interpret the meaning of drawings and

specifications and shall have the power to reject any

‘work/equipment’ or material which in its judgment is not in

full accordance therewith.

4.7.28. All the structural and door drawings are to indicate the

minimum requirement that the party shall meet. The party may

be asked to modify the systems if required to meet the actual

site conditions. The party shall carefully study all the interface

and dimensional details of the systems with the building

dimensions and shall ensure that the fabricated items meet the

functional requirements and to suit site conditions. The party

shall study the adequacy of all item from functional as well as

fabrication point of view and may come out with better

alternatives also if any which may be implemented after

obtaining approval from us.

4.7.29. The party shall carefully go through the civil drawings of the


P a g e |37 of 208

buildings where the ovens will be installed and design the

ovens and its ducts accordingly. The ovens shall be fabricated

in parts and shall be assembled at our site.

4.7.30. Steel shim plates required to level the Equipment during installation.

4.7.31. All hardware e.g. Fasteners, flanges, O-rings, gaskets etc. is in the Party’s scope. No separate claim shall be entertained, in this respect. At least 10% extra hardware shall be provided for any installation/fixing work to ensure ready availability of hardware in case of damage of some hardware during installation. Party shall also arrange the necessary hardware required to carry-out hydro test and functional test.

4.7.32. Slings, ropes, D-shackles etc., required for handling of equipment at SDSC SHAR shall be provided by the party.

4.7.33. The details shown in the drawing shall be verified with actual site conditions and minor changes if any required shall be incorporated. It is advised to visit the site to understand the interfaces and take essential dimensions wherever equipment is having interface with civil structure/equipment realized by others.

4.7.34. Minor changes, if any required to meet the functional requirement shall be incorporated at no extra cost.

4.7.35. Drawings for review and approval as mentioned in this proposal

4.7.36. For standard bought out components whose details were furnished in the tender either in the form of catalogue/data sheet, the contractor shall strictly adhere to the respective makes only.

4.7.37. In case Bidder suggests any changes in the Make/vendor, same shall be supported with complete technical details including need for such changes proposed. Alternate make suggested by the Party shall be better than the make suggested in this tender document. Department has the right to accept or reject the changes in the suggested make/vendors list.

4.7.38. Any changes envisaged by the party shall be mentioned in the deviation sheet along with the bid.

4.7.39. The Party’s scope of work shall also include erection, testing, start up, commissioning, operational trials covered in this specification.

4.7.40. Supplier is wholly responsible for getting necessary approvals from the concerned departments/ authorities to transport the


P a g e |38 of 208

Equipment from party’s site to SDSC SHAR.

4.7.41. All bolts/studs shall be of class 8.8 or higher and shall be of Unbrako/DFL/TVS make only. Each fastener shall be supplied with two flat washers.

4.7.42. Bidder shall mobilize following minimum equipment of adequate quantity for carrying out fabrication work at our site. These items can be taken back by the party after completion of work.

• Welding equipment & TIG welding

• Gas cutting machine

• Drilling machine with magnetic base

• Grinding machine, Cutting machine & Buffing machine

• Grouting machines for drilling in concrete.

• Consumables, cleaning agents.

• Manila ropes

• Ladders, stools, to approach different heights etc.

• Other equipment/tools required for erection

4.7.43. Any other system not indicated herein, but required to make the system complete shall be included and provided by the bidder at no extra cost unless otherwise specifically excluded as indicated. Such of these items considered by the supplier shall be identified and listed separately.

4.7.44. All equipment supplied shall have capacities not less than those specified in the offer and necessary test certificates shall be furnished in this regard.

4.7.45. The motor rating indicated in the bid shall be minimum and bidder is free to select higher capacity if found essential to meet the requirements specified in the tender.

4.7.46. Structures of ovens need to be fabricated in modules in such a way that the modules can be brought inside the room/building and assembled. Bidder shall note the clear dimensions of the openings provided in the building for handling each module and accordingly the oven shall be split into minimum number of modules.

4.7.47. Party shall offer for stage and final inspection prior to dispatch at the party / sub vendor’s premises of the following items. Blowers, Heater battery, Pumps, Hot water tanks, structural modules, doors, Motor control centres, Control panel, Instrumentation & Data Acquisition system and other items if any decided during execution.

4.7.48. Party shall submit physical & chemical properties with respect


P a g e |39 of 208

to materials used in construction of ovens & sub systems.

4.7.49. Party shall submit material and performance test certificates for all items.

4.7.50. Party shall submit the programming code of SCADA and iMCC software programming code which can be edited to convert or augment the features at a later date.

4.7.51. A detailed manufacturing / fabrication drawing is to be submitted and the fabrication is to be started only after Department’s approval.

4.7.52. Users shall have access for stage inspection during the various stages of fabrication. Any minor modifications that become necessary during the manufacturing period or during erection shall be done free of cost.

4.7.53. The supply of cables and termination is also in the scope of the party.

4.7.54. All the structural steels used for oven fabrication shall be of reputed make like TATA steel, SAIL, RINL and Jindal

4.7.55. All pre-polished SS sheets and plates shall be Salem Steel / Jindal/SAIL steel only. SS sheets shall be polished / buffed to have mirror finish.

4.7.56. Non-standard make / re-rolled steels/ old stock etc., are not acceptable

4.8. Instructions during Fabrication

The following instructions shall be followed during /after carrying out the fabrications of equipment by the Party

4.8.1. Mill certified plates only shall be used for fabrication.

4.8.2. 100% DP test for root and final weld pass.

4.8.3. 100% Ultra sonic test for plates of 20 mm thick or above

4.8.4. 100% Radiography test for all butt welds of plates of 20 mm thick or above

4.8.5. All welds shall be ground and free of burrs and undulations.

4.8.6. The entire fabrication activity shall be performed in a planned/sequential manner to achieve desired dimensional/geometrical tolerance specified in the drawing or functional requirement mentioned in this document.

4.8.7. Dimensions shown in the drawing are final acceptance dimensions. Allowances for machining and thinning due to fabrication process shall be added to arrive at material sizes.


P a g e |40 of 208

4.8.8. Dimensional tolerance wherever not specified shall follow the standard open dimension tolerances provided in the drawing.

4.8.9. The effective throat thickness of a fillet weld shall be shortest distance from the root to face of the diagrammatic weld.

4.8.10. Wherever welded attachments are used to facilitate fabrication, same shall be removed carefully by cutting or chipping and surface of material shall be finished smooth by grinding. As far as possible, hammering shall be avoided.

4.8.11. Edge preparation shall be carried out for all joints as mentioned in the drawing or as per standard fabrication procedure.

4.9. Codes and Standards

4.9.1. All equipment, systems and works covered under this specification shall comply with all currently applicable statutes, regulations, standards and safety codes in the locality where the equipment will be installed.

4.9.2. In particular, the latest editions of the following standards are applicable.

Table 2. Codes and Standards

(i) Steel for general structural purposes

IS 2062

(ii) Rolled sections and special sections IS:808, IS:1161, IS:1173, IS:1252, IS:1730, IS:1731, IS:1732, IS:1863, IS:1864, IS:2314,

4.9.3. Other national standards established to be equivalent or superior to the codes and standards specified are also acceptable.

4.9.4. In the event of any conflict between the codes and standards referred to in the specification and the requirements of this specification, the more stringent of these requirements shall govern.

4.9.5. Unless indicated otherwise, all codes and standards referred to in this enquiry specification shall be understood to be the latest version on the date of offer made by the bidder.

4.10. Safety

4.10.1. It is the Party’s responsibility to see the safety of workmen and protection of surrounding equipment at the work zone.


P a g e |41 of 208

4.10.2. All the safety equipment required for carrying out the work such as face shields, welding goggles, helmets, safety belts etc. shall be supplied by the Party at his own cost.

4.10.3. Party shall give an under taking to observe all safety norms put forth by department from time to time, until completion of the work.

4.11. Painting

4.11.1. Spray Painting of Agni oven, main oven, water circulation system,supporting structures of oven, ducts, supports, platforms and equipment’s shall be as follows:

4.11.2. Surface Preparation: Cleaning by wire brush or power tools to remove any loose dirt or mill scales from the surface.

4.11.3. Primer: One coat of zinc rich primer with red oxide and zinc phosphate pigments to achieve total DFT of 70 to 75 micron.

4.11.4. Final Coat: Two coats of Aluminium heat resistant paint of total 100-micron DFT.

4.11.5. Total DFT shall be 175 microns (min.)

4.11.6. Oven shall be painted with Al heat resistant paint and all other items shall be painted with PU paint of 2 coats of ASIAN/BERGER/NEROLAC make of approved shade.

4.11.7. The grade of paint (heat resistant paint) shall be chosen such that it will withstand the maximum temperatures to which the painted components will be subjected. Epoxy paint selected shall meet this requirement.

4.11.8. Any intermediate cleaning required between successive coats of paint shall also be carried out as per paint manufacturer’s standard.

4.12. Summary of Data to be furnished by Party

4.12.1. Bar chart for supply & erection schedule indicating the date of

completion of various activities so as to complete the execution

of the tender within the time frame stipulated in the tender

specification.

4.12.2. Quality Assurance Plan based on the proposed manufacturing

process.

4.12.3. Proposed Project execution plan and fabrication process plan.

4.12.4. P&ID & Layout for Service Equipment

4.12.5. Party shall submit all fabrication drawings.


P a g e |42 of 208

4.12.6. Party shall send copies of instruction manuals along with the

dispatch of equipment. Instruction manual shall contain full

details, as-build drawings of all equipment, erection procedure,

testing procedure, operation & maintenance procedure of the

equipment. If after commissioning and initial operation of the

equipment, the instruction manuals require any modifications

/ additions the same shall be incorporated and the updated

instruction manuals shall be submitted by the Party to

Purchaser.

4.12.7. Unpriced Purchase orders for bought out components

4.12.8. Test Certificates (physical and chemical) for all raw materials.

4.12.9. Procedures for Welding, Qualifications of Welders, Painting and

Finishing

4.12.10. Transportation Plan

4.12.11. Erection and Commissioning Plan

4.12.12. Inspection and Testing Plan

4.12.13. Dimensional inspection reports generated during entire

fabrication process, erection and commissioning.

4.12.14. All the reports generated during fabrication including material

test certificates and other NDT tests.

4.12.15. Final as built drawings, 2 sets hard copy and one set soft copy

in *.dwg format.


P a g e |43 of 208

General Specifications & Mechanical Systems

for Main Oven with Motorized trolley and

Internal Mandrel water circulation system.


P a g e |44 of 208

5. Main Oven with Motorized trolley and internal water circulation system

5.1. Basis of Design & System Description

5.1.1. Curing is carried out after the propellant casting of segments (Head end, Middle and Nozzle end segments) in the casting facility. The assembled segment with propellant is transported from casting facility in vertical position by means of trailer. The segment shall be lifted by EOT crane and positioned on the motorized trolley. This trolley shall be bottom portion of the oven and shall be movable from the motor receiving bay to the oven. The oven shall be provided with double leaf swing doors. The segment placed inside the hot air oven is subjected to curing operation to achieve required mechanical properties for the case bonded propellant grain.

5.1.2. The oven shall be provided with suitable spring loaded pressure relief arrangement. This pressure relief arrangement shall be operated at 1 Ksc of pressure and size of vent/ disc shall be of 300mm diameter.

5.1.3. Curing operation is carried out over a period of 200 hours continuously, of which, the first 85 hours shall be heating phase and remaining 115 hours shall be cooling phase.

5.1.4. The oven shall be operated between 500C to 600C based on the process requirement. The design temp of the oven shall be 750C. The oven operating temp shall reach 600C within 30 minutes.

5.1.5. The oven internals are cooled to ambient conditions during the cooling phase. No temperature control is required during the cooling phase of curing cycle.

5.1.6. The hot air re-circulation system for oven comprises of the following:

2 Nos. (1 Working +1 Standby) hot air re-circulation

blowers

Supply & return air ducting with dampers

Supply and return air grills.

5.1.7. The dampers for blower selection shall be operated manually and shall be provided with end limit switches (proximity type).

5.1.8. Black heat type (Each heater element shall not become red hot when in operation with the blower running) electric heater for heating of air. Heater watt density to be designed accordingly.

5.1.9. The entire heater battery shall be divided in to three banks.


P a g e |45 of 208

Two of the heater banks shall be controlled by PID controller with Thyristor power controller and the remaining one heater bank shall be controlled by On / Off mode with power contactors. The oven shall be capable of maintaining the operating temp., either with one on / off bank or one heater bank with Thyristor power controller INDEPENDENTLY. Heater elements pertaining to each heater banks shall be uniformly distributed along the cross section heater battery to have uniform heating.

5.1.10. Blower and heater battery shall be located in the service room.

5.1.11. Insulated oven chamber, complete with concealed supply & return GI ducts, SS grills for uniform air distribution in X & Y axes, sheet metal cladding and its support structure.

5.1.12. The oven shall be maintained at a positive pressure, so that outside cool air does not enter the ovens.

5.1.13. The oven shall be airtight and thermally leak proof such that the fall of oven temp., by 50C from an operating temperature of 600C shall not occur earlier than 20 minutes.

5.1.14. Hot air shall be supplied from both sides of the oven. Return air shall be collected at the bottom, close to the oven floor refer the drawing no. MCO/SD & DD/01

5.1.15. The total live mass of steel to be considered inside the oven shall be 30 tons which includes mass of support stool, end rings, segment case, and mandrel. Party shall consider the actual mass of oven structural that may get heated up when the oven is under operation for finalizing the heater banks, blower capacities to maintain temp. within specified limits and to attain the operating temperature with in stipulated time

5.1.16. The mass of propellant need not be considered in sizing the heater and the blower since the thermal conductivity of propellant is very low.

5.1.17. Spatial variation when measured inside the oven shall not exceed 1.5 0C.

5.1.18. Total No. of RTDs required including spare– 54 nos.

5.1.19. The heater shall have minimum 20% margin over design values.

5.1.20. The Blowers shall be sized for additional 20% capacity over the design capacity.

5.1.21. Blowers capacity shall be arrived by considering the following


P a g e |46 of 208

The discharge pressure drop across ducts, dampers,

heater banks, grills etc.

Attaining the operating temp within stipulated period.

No. of air changes required to maintain uniform

temperature (spatial variation: 1.50 C or better)

To maintain a positive pressure inside the oven so that

the cool air from outside shall not enter the oven. The

blowers shall develop minimum static pressure of 120

mm WC.

Blowers’ frame size shall be selected considering the

space available in the service room and the door entry

dimensions.

5.2. Outside Atmospheric Conditions

Parameter Summer Monsoon Winter

Dry bulb temperature 0C 42.2 28.3 18.3

Wet bulb temperature 0C 28.3 26.7 13.9

Relative humidity % 35.0 >90 60.0

5.3. Oven Parameters

Table 3. Ovens Parameters

Description Specifications

Operating principle Hot air re-circulation

Hot air oven dimensions

(Clear internal dimensions.)

4600mm(L) x 4600mm(W) x

6750mm(H)

Blower capacity Min 40000 cfm

Static pressure Min 120 mm of water column

Heater bank capacity Min 300 kW

No of heater banks

03nos each 100KW

01nos. On/Off

02 nos. Thyristor power controlled

Operating temperature for

hot air oven 50 - 60 0C

Design temperature 750C


P a g e |47 of 208


Outer skin temperature of

oven

Not to exceed 5 0C over the ambient

for 600C

Time to reach operating

temp., from ambient

temperature of 30 0-C

30 minutes for 600C operating temp.

RH controls Not required

5.4. Oven Construction

5.4.1. The oven structure shall be of free standing type.

5.4.2. Oven shall be fabricated in double wall construction. The outer wall shall be of 5 mm thick carbon steel plate. The inner side of the oven shall be covered with 2mm thick SS 304 pre-polished sheet/panels, suitably stiffened. Material certificate shall be produced for SS sheets/panels.

5.4.3. TIG welding shall only be used for welding of all SS fabrication works.

5.4.4. The annular gap between the outer wall and inner wall shall be filled with Rock wool mattress which shall be used for insulating the oven walls so that outer skin temperature is limited as specified. Studs shall be provided to retain the mattress in the position without collapsing.

5.4.5. Insulation mattress shall be sandwiched between SS sheet (oven side) and MS sheet on the rear side (Oven outer wall side). 10 mm dia. studs shall be welded on MS sheets to retain the insulation mattress in position.

5.4.6. All internal SS sheets used for door and grills shall be buffed at welded regions and polished to have mirror like finish. Enough care shall be taken to purchase only plastic cover protected pre-polished SS sheets and the plastic cover shall be removed after erection at site.

5.4.7. The oven outer walls shall be provided with ladders and working platforms as decided at site for accessing the individual sensors for repair / other maintenance works and also to reach top of oven roof.

5.4.8. The oven shall be provided with a bogie/trolley with double flanged wheels’ movable on rails.

5.4.9. The oven shall be provided with two front openable doors operating on heavy hinges with a provision for locking. The


P a g e |48 of 208

doors shall have hinges with antifriction bearings. Special care shall be taken that the door bearings can be replaced without dismantling the entire door. The doors shall have manual locking arrangement.

5.4.10. Intrinsic safe proximity sensors shall be provided for doors to meet fully closed, fully opened and for door locked conditions

5.4.11. Sealing between the doors, trolley and oven walls shall be ensured so that no leak of air is present.

5.4.12. Oven structural design shall be approved by the Department before fabrication.

5.4.13. Oven structures shall support water & air lines of fire-fighting deluge system (not in the scope of the party). However necessary support brackets for installing these lines inside the oven are in the scope of this contract.

5.5. Air Distribution System

5.5.1. Blowers: Oven shall be provided with 2 Nos of centrifugal blowers of same capacity for hot air circulation out of which one blower shall be a standby blower connected in parallel to the heater battery with suitable isolation dampers. Dampers shall be provided to select the blowers.

5.5.2. The blowers shall be suitably interlocked such that the blowers can be switched on only when the concerned dampers are kept open and dampers of other blower are kept in closed condition and oven door shall be kept in closed condition. Hence dampers shall be provided with limit switches to sense whether they are in open or in closed condition and this status shall be available in the data acquisition system. The blower shall also be interlocked with fire damper motor.

5.5.3. The blowers shall be of approved make and blowing sufficient capacity of air at 750C and static pressure of 120mm of water gauge. The blowers and drive system shall be rated for continuous operation. The motor shall be of S1 duty and energy efficiency IE2 or better. The motor current shall not Exceed 80% of rated current of motor. Each blower shall be connected by V- belts to a separate electrical motor of sufficient capacity for continuous running.

5.5.4. Blowers shall be located in the service room adjacent to the hot air oven bay. The blowers are sized to provide sufficient number of air changes inside the oven to limit the spatial variation inside the oven to 1.50 C.

5.5.5. Two nos., of blowers (1 working & 1 standby) shall be provided.


P a g e |49 of 208

The blowers shall be mirror image of each other. The area available in the service room and the door entry at the service room shall be taken into account while selecting the blowers.

5.5.6. The blowers shall be sized to suit the requirement such that the operating temperature is reached within 30 min for 600C.

5.5.7. Blowers shall be thermally insulated and designed to handle hot air at 750C. Blowers shall have butterfly dampers, vibration isolators, inlet and outlet with duct interfacing arrangements.

5.5.8. Blower performance shall be inspected before dispatch at party site.

5.5.9. Blower pedestal requirement as blower mounting frame size, load condition (static & dynamic) shall be provided prior to dispatch.

5.5.10. Each independent blower performance & run test shall be performed in our presence. However, the material test certificates for the critical components and ultrasonic testing for shaft, DP test for all weld joints shall be submitted. Dynamic balance report for impeller shall be submitted.

5.5.11. Blower motor shall be selected such that blower should draw a maximum current of 80% of rated current at a rated delivery and static head.

5.5.12. Blower motor shall be provided with space heater to avoid low IR values during prolonged idle period.

5.5.13. Blower and all other brought out component details drawings shall be submitted for approval before procurement.

5.5.14. The location of the blowers w.r.t. ovens is indicated in building and equipment lay out dwg. no. MEC/10JN/11/11/35D/0016

5.5.15. Supply and return air to / from the oven shall be through rectangular galvanized iron (GI) ducts.

5.5.16. Ducts shall be of double wall construction made of 2 mm thick GI sheets. Rockwool insulation (min 150mm) shall be chicken mesh sandwiched between the walls. The rock wool insulation shall be kept in position by chicken mesh.

5.5.17. Ducts shall be made in segments with flanged joints. Joints shall be provided with asbestos /millboard gaskets of thickness not less than 5 mm.

5.5.18. Ducts shall be air tight & smoke test for ducts and duct assemblies where ever possible for ensuring the air tightness.

5.5.19. Ducts shall be suitably reinforced with stiffeners. Overhanging ducts shall be supported with ISMC members.


P a g e |50 of 208

5.5.20. The heater battery shall be of same size of oven ducts to avoid convergent and divergent arrangement of ducts.

5.5.21. Heater battery shall be mounted inside the discharge ducts.

5.5.22. The Heater battery compartment shall be provided with air-tight doors for accessing heating coils for maintenance.

5.5.23. SS grills with volume control dampers shall be provided to ensure uniform air distribution in the oven.

5.5.24. Motorized Fire dampers shall be provided both for suction and discharge ducts of the ovens. Each fire dampers shall have a RTD (2nos one for Temperature Controller and one for PLC logic) for and dedicated Temp controller with motorised damper closing provision. The damper motor to be interlocked with temp controller to operate and close the damper when the temperature of Hot air is equal /above the set value. In case damper closes blower also shall be switched off. The RTD details are mentioned in ICS chapter

5.5.25. Provision shall be made available in the ducts to install air flow switch. The air flow switch shall be interlocked with blower. The supply and installation of Air flow switch minimum two nos (one for Hardwired logic and one for PLC logic) also in the scope of the party.

5.5.26. All ducts shall be fully insulating and covered with GI sheets.

5.5.27. The ducts discharge and suction grills inside the oven shall be of SS material.

5.5.28. Duct end flanges shall be 5mm thick MS and duct joints shall be at intermediate locations as decided during detailed engineering, for easy dismantling in case of any repair. All bolts shall be galvanized and of 8.8 class. All ducts shall be rectangular cross section & only blower interface/ connecting duct shall be matching with blower duct / delivery ports.

5.5.29. The blower manufacturer shall specify bearings greasing quality and requirements.

5.5.30. Bearings shall be easily dismantling type whenever required.

5.5.31. Rotating parts shall be provided with guard like belts, extended shafts etc.

5.5.32. The party shall supply 5 sets of V belts as spare for main oven and Agni oven.

5.6. Heating System

5.6.1. The heater shall be fitted with withdrawal type, sheathed,


P a g e |51 of 208

tubular heating element. The entire heater battery should be mounted inside a double walled mild Steel casing having rock wool insulation of not less than 150 mm thickness between walls in order to prevent heat losses. The heater terminals must be brought to one side so as to facilitate connection and replacement easily. They shall be terminated in a terminal box.

5.6.2. The heater shall be suitable for mounting on air duct. Heaters battery shall have flanges for connecting the heater and ducts. Heater battery shall be sized same as that of the duct size preferably.

5.6.3. Heaters shall be encased in tubes to avoid ingress of hot air and to enable replacement of heating elements during operation suitable provision is to be made.

5.6.4. Heaters shall be black heat type. The heaters shall not become red hot when air flow exists.

5.6.5. Heating elements shall be of nickel-chrome resistance wire. The elements shall be packed with magnesium oxide powder and compressed by swaging to ensure rapid heat transfer.

5.6.6. The heating coil shall be supported at sufficient intervals, but not more than 600mm.

5.6.7. All the electrical terminations shall be airtight. The termination shall be carried out using heat resistant Teflon wire or better arrangement. The heater body shall be air tight to prevent any leakage of hot air / gases.

5.6.8. The heater assembly shall be complete with all accessories (Mechanical, Electrical & Instrumentation connection accessories, controllers, control panels, sensors, and wiring accessories).

5.6.9. The design & arrangement shall be suitable for standard cabling into the terminal enclosure without the need for an intermediate junction box and high temperature cables. If this requirement is not met by the product, then necessary high temperature cables & junction box shall be provided by the contractor / party.

5.6.10. Elements/banks shall be arranged/ connected in such a way, that failure of few elements does not affect the uniformity of heat drastically.

5.6.11. Heaters shall be protected against over temperature and shall be provided with auto power cut-off.

5.6.12. It shall be possible to dismantle & replace / repair components & heating elements at site.


P a g e |52 of 208

5.6.13. Silicone seal shall be applied to the lead exit and between lid and terminal box to improve ingress protection. This shall be supplied in adequate quantity along with the equipment.

5.6.14. Watt densities of heating elements shall be limited to a suitable value to prevent red hot (black heat operation).

5.6.15. Heater battery shall be painted with heat resistant paint.

5.6.16. Heater element specifications shall be:

Tube: INCOLOY

Sheath: SA240 Gr. 304

Heating element: Nichrome wire (Nickel- chrome

resistance wire)

Replaceable.

Individual heater capacity: Limited to prevent red hot.

(black heat operation)

Heater body: Carbon steel.

Mounting arrangement: Suitable for mounting on duct.

5.6.17. Heater battery design and construction.

Maximum pressure drop across the battery should be:

15mm WC.

Heater battery shall have flanges for connecting the

heater and ducts.

All the electrical terminations shall be airtight.

Heater battery shall be painted with heat resistant

paint.

Each heater shall be with 1.1kW rating.

5.7. Power Supply

5.7.1. The oven shall be designed for operating on 415V, 3ph, 50Hz AC, 4 wire systems. All motors shall be operated with 415V, 3ph, and 50Hz supply. Power supply will be available at the Power control centre of the facility. The supply and laying of incoming cables for MCC (supplied by the party) from PCC and from IMCC to all systems and to control room are in the scope of the party.

5.8. Temperature Uniformity

5.8.1. The maximum temperature difference between any two points inside the oven should be maintained within 1.5 0C of the set temperature. The oven should be sufficiently insulated so as to limit the oven skin temp within 5.00C above the ambient


P a g e |53 of 208

temperature when the oven is working at maximum design temperature.

5.9. Interlocks

5.9.1. Blower shall not be switched ON unless the doors are closed, their respective suction and delivery dampers and fire dampers are in open condition

5.9.2. When one blower is ON, the other blower shall not get on.

5.9.3. Heater banks shall get ON only when blower is ON and availability of air flow.

5.9.4. Fire dampers and oven heater banks shall be interlocked with temperature sensors provided at fire damper inlet & outlet and heater battery duct through dedicated temperature controller fixed at iMCC panel and these temperature controllers in turn is to be interlocked with PLC PID controller for oven temperature control purpose.

5.9.5. All the heater banks shall get off if the Temp Controller installed in the ducts operate in addition to the control from the temperature controllers installed in the Control panel.

5.9.6. Alarm shall be provided for following conditions: Main Oven: Blower 1 off, Blower 2 off, Air fail, Air low temp., Air over temp., Water pump 1 off, water pump 2 off, water level low, water flow not ok, water temp high etc. AGNI Oven: Blower 1 off, Blower 2 off, Air fail, Air low temp., Air over temp, Fire damper motor operated.

5.10. Motorized Trolley

5.10.1. The movement of the trolley shall be achieved by means of flameproof electrical motor of suitable capacity through reduction gear box. The bogie design shall be such that the motor, gear box drive shaft, Plummer blocks etc are not in the hot zone. The bogie with drive system shall be designed to a safe working load of 60 tons.

5.10.2. An electro mechanically operated trolley of 60 tons shall be provided.

5.10.3. The top and sides of the bogie platform shall be covered with 20mm thick MS sheet cladded with 2mm thick SS 304 pre-polished sheets. Trolley shall be designed such that the load can be positioned anywhere with an offset of 200 mm on both X and Y axis.

5.10.4. This trolley shall move in and out through a set of guide rails. Rails shall be laid above ground. Supply and erection of


P a g e |54 of 208

suitable rails are also in the scope of the party. The length of travel of this trolley shall be approximately 20m.

5.10.5. Anti-friction bearings shall be provided at wheels. Wheel stoppers shall be provided to limit over travel of the trolley in addition to the limit switches.

5.10.6. Drive motor shall be flame proof suitable for Gas group IIA, IIB and temp class T4 (1350C) with ‘F’ insulation class but temp rise limited to class B (Flame proof receptacle shall be provided for connecting the power cable). Thermistor shall be provided for winding protection. The motor shall be compatible for operation with VFD. Motor shall be inverter duty compatible for VFD and certificate indicating suitability shall be furnished.

5.10.7. The trolley shall be designed with suitable gear mounted motor. The geared motor shall be located on the outer side of the wheel module. The trolley can have motor, gear box and chain drive system.

5.10.8. The power cables to the trolley drive system shall be through cable drag chains.

5.10.9. The department shall approve the drive mechanism before fabrication.

5.10.10. It shall be possible to dismantle the wheel module for easy maintenance.

5.10.11. Party shall demonstrate trolley movement at their site. Load testing of the trolley shall be carried out at our site.

5.10.12. The trolley shall be moved at two levels of speed I. 2.5 m/min II. 0.50 m/min using local push button station with suitable intrinsically safe barrier interfacing. The control & power wiring shall be interfaced with VFD in iMCC. The trolley shall be interlocked with proxy sensors for bogie in and bogie out positions. Shall also interlocked with door open/close status.

5.10.13. The power & control cable to the trolley shall be through cable drag chain. The party shall submit control drawing for approval. The operation for Bogie shall be from Pendent with for/rev/stop push buttons and indication lamps. The pendent push buttons/ indication lamps shall be intrinsically safe and be interfaced with Intrinsic safe barriers of P & F make and barriers shall be placed in i-MCC.

5.10.14. The drive system specifications given below are indicative. The party shall design and submit the design details for approval.


P a g e |55 of 208

Fig. 1. Motorized Trolley

Table 4. Drive System Specifications

Sl.

No Item Description Qty

1. Gear box

Make: M/s Shanthi / PBL

Parallel shaft double helical gear box

HQN-320

Gear ratio 630:1

Type: Bi- direction

Foot mounted

Double extended output shaft

01


P a g e |56 of 208

2. Motor

Make: Crompton/ PBL/ Bharat Bijilee

/CEMP/ SEW Kirloskar

FLP brake motor 5.5kW

No. of poles: 6, Ex-d

Gas group: IIA/ IIB Temp. Class T4

Electrical motor frame size: 132 M

IP 55

415 ± 10 %, 50 Hz ± 5 %

Duty S4

Speed: 960 rpm

Insulation Class F or better with

temp. rise limited to Class B.

“Or”

The flame proof motor shall be provided

with integrated flameproof Disc brake of

M/s PETHE make or Brake with

Department Approval with necessary

shaft extension arrangement.

Motor shall be compatible for inverter

duty addressing bearing currents/better

insulation requirements/ voltage rise

time.

Motor shall be provided with Thermistor

in the winding with tripping arrangement

using external Thermistor trip relay.

It shall be suitable for VFD.

01

3. Plummer

block Heavy duty 8

4. Couplings Flanged couplings 4

5. Circlips 4 mm thick dia matching

6. Bogie wheel Ø500mm Dia single flanged wheel, 100

thk forged steel C-55 (EN9) 4

7. Rail 120 Lbs – STD 50m

8. Shaft

Material: EN-24U

Diameter: 125 mm

Length:2800 mm

02

9. Top plate 20 mm


P a g e |57 of 208

10. Cladding

plate 3 mm thick

11. Chain 1.25 “pitch, Duplex chain

Length: 5000 mm (approximate) 03

12. Driven chain

wheel

(sprocket)

Pitch 1.25”

Teeth 27

Suitable for 1.25”, Duplex chain

04

13. Idler

sprocket

Pitch 1.25”

Suitable for 1.25”, Duplex chain 02

14. Cable drag

chain

Make: IGUS

Length: 25 m

Plastic closed type

Width: 50mm (appx.)

With guide brackets.

01

15. Power Cable

Make: IGUS

1C X 4 sq.m, Copper

(Suitable for IGUS cable drag chain

trailing application)

Length: 30m.

With suitable flame proof glands -

2Nos for end termination.

01

16. Cable glands

12 pair, 0.5 sq.mm control cable.

Suitable gland 2 Nos. for end

termination.

01

17.

Push button

station

Panel: 2 mm thick pre-polished

SS sheet, Power coated with the

following components.

Emergency: Key operated, lockable,

Make: Siemens, Qty: 1 No.

Indication lamps: Intrinsically safe,

Type: BA 390 Make: BEKA, Qty: 4Nos.

Push buttons: Make: Siemens, Qty:

2Nos.

01

18. Cable tray

with covers

Perforated, GI, Size: 100 mm, Each

2.5 m length.

With supporting brackets, clamps and

grounding bolts.

100

mtrs.


P a g e |58 of 208

19. Keys

20 x 20 -155 long coupling end – 8 nos

80 long wheels - 8nos 75 long sprockets -06 nos

22

20. Fasteners Make: Unbrako /TVS

21. Power Cable

Make: Finolex / RR Kabel / National /

Lapp / CCI / Universal /Asian/

Polycab / Incab / Havell / Torrent

Armoured, 4 C X 4 sq.mm, Copper,

XLPE insulation, 1.1 kV, confirming

to IS:7098.

Length: 100 m.

With suitable flame proof gland-1 No.

and Non-flame proof- 1 No. for end

termination.

01

22. Cable

control

Make: Finolex / RR Kabel / National /

Lapp/ CCI / NICCO / Universal /

Asian / Polycab / Incab / Havell /

Torrent

Armoured, 16 C X 1.5 sq.mm, Copper

XLPE insulation, 1.1 kV.

Length: 200 m

With suitable flame proof gland- 1No.

and Non-flame proof -1No. for end

termination.

01

23. Power

supply unit

Make: Semens

24VDC, 5A 01

24. 2- Channel

isolated

barrier

KFD2-SR2- Ex.2 for Proximity

sensors. 04

25. 2- Channel

Solenoid /

LED driver

KFD2-SL2- Ex.2 for indication lamps. 04

26. Switch gears Make: Siemens

MCCB (63 A, 50KA, Qty: 1No) 01

27. VFD Make: Siemens / ABB

28. Thermal

relay Make: Siemens / Any reputed make


P a g e |59 of 208

5.11. Wiring

5.11.1. The oven shall be wired through an intelligent motor control centre (i-MCC) located in the service room as marked in the drawing and a common control and monitoring console is located in the control room from service room. All data cables, RTD sensors, power cables, control cables are to be supplied, laid and terminated by the party. The details of Motor control centre are given in electrical system chapter.

5.12. Internal Mandrel Water Circulation System

5.12.1. This system provides water circulation in the mandrel jacket of the segment during curing cycle. During heating phase, hot water is circulated in the mandrel jacket.

5.12.2. During cooling phase cold water is circulated in the mandrel jacket.

5.12.3. The system comprises of the following:

Hot water circulation system comprising of a hot water

tank with heating elements, hot water circulation

pumps, piping, valves, controllers (at CCMC), Flow

switch, pressure gauge, level switch, RTDs, etc.

Cold water circulation system comprising of

interconnecting piping for circulating the mandrel

jacket water during cooling phase.

5.12.4. Hot Water Tank

Clear Internal dimensions:1130mm (L) x 1130mm (W) x

1200mm (H)

Material of Construction: SS 304L

Bottom plate shall be of 10mm thick SS 304L material

Inner wall shall be of 5 mm thick SS 304L material

Outer wall shall be of 3 mm thick SS304L material

Tank shall be suitably reinforced by structural steel.

Rock wool insulation mattress shall be provided

between the walls so that the tank outside wall

temperature is same as the ambient temperature.

Thickness of insulation shall be 75 mm minimum.

Suitable provisions shall be made to mount the RTDs,

level switch etc.

The tank shall have visual level indicators; inspection

covers as per standard industrial practice.


P a g e |60 of 208

The tank shall have arrangement to know the water

level without opening the cover.

The hot water tank shall be fitted with electrical heating

elements to raise the water temperature to a maximum

of 800C within 1 hour.

5.12.5. Hot Water Heaters

Total no. of heaters shall be divided into two banks.

Bank 1 shall be controlled in on/off mode and Bank 2

controlled by an analog input. Bank 2 shall be powered

through a Thyristor power controller whereas Bank 1

shall be powered through power contactor. In both

modes PLC PID controllers will control contactor &

Thyristor controller.

1. Supply of immersion type water heaters as per the specifications given below.

2. Capacity of each heater is 6.0KW (Each heater shall be consisting of three elements of 2.0KW each suitable to connect in Star 4 wire refer Electrical chapter).

Temperature controllers (2 nos.) shall be provided at

CCMC control room for controlling the water

temperature in hardwired control mode.

Each heater shall be provided with MCB

Each bank feeder shall be provided with ELMCB

The heater shall be fitted withdraw type, sheathed,

immersion type tubular heating elements. The heater

shall be fitted to the body of the hot water tank by

flanged connections with PTFE gasket to enable easy

installation.

Heating elements shall be of nickel- chrome resistance

wire. The element shall be covered by magnesium oxide

powder and compressed by swaging to ensure rapid

heat transfer. All the electrical terminations shall be

water tight.

Individual heater capacity shall not exceed 6 kW. 230 V

AC. All the heaters shall be equally distributed among

the phases.

Heater sheath shall be out of SS 316 L, suitable for raw

water quality


P a g e |61 of 208

The tubular heating elements shall be supported if

required.

All the electrical terminations shall be watertight.

The Distribution box consisting of ELMCB and MCB for

two heater banks shall be mounted on Tank with

suitable Gland plate for terminating Incomer cables

from i-MCC. The outgoing wires shall be taken to

individual heaters.

Elements/banks shall be arranged/ connected in such

a way that failure of few elements does not affect the

uniformity of heat drastically.

Heaters shall be protected against dry run and over

temperature and shall be provided with auto cut-off for

the dry/exposed bank.

Heaters shall get ON only when sufficient water is

available in the tank. One no of level transmitter to

display the water level in the tank to the operator at

control room.

There shall be one level transmitter and level switch to

be provided and interlocked with water pump as

detailed in Electrical and I & C sections.

The unheated length of elements shall be sufficient to

allow only the heated section to be immersed in water.

All the heaters shall be of equal rating & capacity.

Silicone seal shall be applied to the lead exit and

between lid and terminal box to improve ingress

protection.

Heater terminals and cable entries shall be protected

from dripping, condensation and spill over. Heater

terminal box shall be dust and vermin proof with

hinged doors having locking arrangement.

Teflon insulated wires shall be used near the heaters.

The capacity of the heaters shall be 20% more than the

actual heaters’ capacity required

Schematic sketch shown is only indicative.

Location of ports shall be finalized based on the piping

layout.

5.12.6. Circulating Pumps & Circulation System


P a g e |62 of 208

Two (2) nos. (1w+1s) centrifugal pumps, with flooded

suction shall be provided for hot / cold water re-

circulation.

The pump shall be capable of circulating the water at a

pressure of 3.0 kg/cm2; the other details are as follows

Table 5. Pump Specifications

Total Head 35 m Flow rate 3lps

Suction/ Delivery 50 / 32 mm Motor : 3phase induction

Motor & pump

make Kirloskar Duty S1

Pump model DB32/16

Orientation Suction inside,

,Delivery at top

Motor &

pump

Coupled through

love joy flexible

coupling

Electric motor

power rating

Pumps shall have mechanical seal with SS body.

Suitable three phase electrical motor shall be provided

for the above pump.

The hot water lines shall be thermally insulated with

pre-formed insulation material of suitable thickness.

Aluminium cladding shall be provided over the

insulation.

All the valves shall be L & T make, 3-piece construction,

flanged end ball valves except at the pump delivery

where it shall be a globe valve.

A bypass line shall be provided for flow control.

Piping shall be common for both hot and cold-water

circulation systems and hot water circulation lines shall

be thermally insulated.

Connections between the mandrel and water lines

provided on the wall of the oven shall be established

manually by a flexible hose prior to commencement of

curing operation. Supply of flexible hose of 5 m length

(2no.) with flanges at both ends is also in the scope of

party.


P a g e |63 of 208

Hot/cold water circulation lines are to be terminated

inside the oven at a convenient height and location

shall be provided with valves as shown in the

Schematic diagram.

Pipe lines shall have flanged joints at intermediate

locations as decided during detailed engineering for

easy dismantling of piping in case of any repair.

The piping shall be suitable for the pump, flow

requirement, pressure requirement etc.

Suction filter shall be of 300-micron rating.

All piping (piping and fittings) shall be of SS304 L

Seamless pipes. All flanges used shall be of SORF

flanges. All pipe fittings shall be butt welded except

SORF flanges.

The entire hot water system shall be located in the

service room of the curing facility.

The party shall weld the pipe joints using TIG welding.

The party shall provide pipe supports for every 2.0 m

either from the wall or from the floor as per the

requirement. The party shall use SS clamps, Structural

steel of Jindal / SAIL/ TATA and Hilti make anchor

fasteners for providing supports.

Entire piping system shall be hydro pressure tested at 5

ksc.

Die penetration (DP) test shall be carried out before and

after hydro test and test certificate shall be provided by

the party.

The following list of materials is required for water

circulation system. The listed material /quantity shall

be supplied.

Table 6. List of Items for Water Circulation System

S No Item Qty

1. 1 ½” SS304 L seamless pipe Sch 40 in m 90

2. 2” SS304 L seamless pipe Sch 40 in m 45

3. 2” 900 elbow ASTM A 403 WP 304L ANSI B 16.9 BW

OF Sch40 OF butt weld type 25

4. 1 1/2” 900 elbow ASTM A 403 WP 304L ANSI B 16.9

BW OF Sch40 OF butt weld type 10


P a g e |64 of 208

S No Item Qty

5. 2” Equal TEE ASTM A 403 WP 304L ANSI B 16.9

BW OF Sch40 OF butt weld type 10

6. 1 1/2” Equal TEE ASTM A 403 WP 304L ANSI B

16.9 BW OF Sch40 OF butt weld type 15

7. 1 ½” – 1” Unequal TEE ASTM A 403 WP 304L ANSI

B 16.9 BW OF Sch40 OF butt weld type 6

8. 1 ½” – 1/2” Unequal TEE ASTM A 403 WP 304L

ANSI B 16.9 BW OF Sch40 OF butt weld type 15

9. 2” SORF forged flange of ASTM A 182 F304L ANSI

B16.5 of 150lb standard OF SS304L 26

10. 1” SORF forged flange of ASTM A 182 F304L ANSI

B16.5 of 150lb standard OF SS304L 16

11. 1 1/2” SORF forged flange of ASTM A 182 F304L

ANSI B16.5 of 150lb standard OFSS304L standard 60

12. 2” SORF blind forged flange of ASTM A 182 F304L

ANSI B16.5 of 150lb standard OF SS304L 10

13. 1 1/2” SORF blind forged flange of ASTM A 182

F304L ANSI B16.5 of 150lb standard OF SS304L 10

14. 1” SORF blind forged flange of ASTM A 182 F304L

ANSI B16.5 of 150lb standard OF SS304L 6

15. 1½” Barrel nipple of BSPT 100mm long of ASTM A

403 WP 304L ANSI B 16.9 of Sch40 20

16. 2” Barrel nipple of BSPT 100mm long of ASTM A

403 WP 304L ANSI B 16.9 of Sch40 12

17. ½” Barrel nipple of BSPT 100mm long of ASTM A

403 WP 304L ANSI B 16.9 of Sch40 20

18. 2” –1 ½” concentric reducer of ASTM A 403 WP

304L ANSI B 16.9 BW OF Sch40 OF butt weld type 5

19.

1½” 2 piece carbon steel ball valve with flanged

ends of L &T make, Body: ASTM A 216 Gr. WCB

Ball & stem: SS304, Seat: Glass filled PTFE (with

backup metal seat), Bolts: ASTM A 193 Gr. B7/

ASTM A 194 Gr. 2H, Operation: 4-inch lever

25

20. 2” 2 piece carbon steel ball valve with flanged ends

of L &T make 8

21. ½” 2 piece carbon steel ball valve with BSP threaded

ends 15


P a g e |65 of 208

S No Item Qty

22.

½” port pressure gauge with a dial size of 100mm,

range: 0-7 ksc with resolution of 0.1 ksc of H Guru/

Wika / Atlas make

10

23.

2” Y type strainer

• Body & cover: Carbon steel fabricated IS 2062 Gr A

• Screen basket: CAF, IS 2712 GR.0/2

• SS mesh of 300 microns

• Ends; Flanged ends, SORF, B16.5, 150#

4

24.

1 ½” non-return valve

• Dual plate, spring loaded

• Ends: wafer to suit 150#

• Valves shall be suitable for mounting between

• Slip on flanges of 150 # as per ANSI B16.

• Body; ASTM A216 GR. WCB

• Plate: 13% Cr steel

• Seal: EPDM

• Hinge pin & stop pin: SS304

• Spring: Spring steel.

5

25. Foot valve with strainer 2

26. 1" Rubber braided steam hose of 5m length of 10

bar rating 6

27. 6 kW immersion heater 25

28. Kirloskar water pumps 3

29. Mechanical seals for water pumps - spare 6

30. Neoprene gaskets of 3 mm thk for 1 1/2" size

flange 100

31. 2" Neoprene gaskets of 3 mm thk for 2" size flange 75

32. 1"Neoprene gasket of 3 mm thk for 1” size flange 50

33. M12 X 60 long with 2 washers of UNBRAKO/TVS

make of 8.8 class as required 500

34. M12 X 75 long with 2 washers UNBRAKO/TVS

make of 8.8 class 500





37. Al cladding of water line in m 100


P a g e |66 of 208

5.12.7. Cold Water Circulation System

The cooling phase shall be for a period of 115 hours.

During this phase water from the cold water circulation

system is to be circulated through the mandrel jacket.

10000 litters sump shall be provided by the

department.

After completion of heating cycle water from the

mandrel at 60 0C with a flow rate of 3 lps will come to

the cold water circulation system.

Pumps which are used for hot water circulation will

also be used for cold water circulation. Piping shall be

planned such that the pumps can used for both the Hot

and cold water. Refer P &ID

Electrical Instrumentation and Control System for

Water Circulation System (Details are covered in

Electrical & ICS Chapters)

The pumps shall have provisions to start /stop locally

from i-MCC and also from control room from SCADA

console/CCMC.

All interlocks for pumps and heaters shall be provided

in the PLC system in the control room. All alarms shall

also be provided in the SCADA console.

Temperature sensors shall be provided at the inlet and

outlet lines and tank.

Flow switch ( two nos.) shall be provided in the return

line.

Hot water temperature in the hot water tank, inlet and

outlet of mandrel shall be monitored continuously and

heater banks shall be controlled based on the same.

The water temperature shall be maintained by

monitoring the tank temperatures 6 nos including

spare. (01 for monitoring & 02 for controlling). RTD

(800 mm length) shall be provided in the tank and 2

nos of RTD (300 mm length) in inlet and outlet.

Heaters shall get on only when sufficient water is

available in the tank. One no of Level transmitter to be

provided to display the water level in the tank to the


P a g e |67 of 208

operator at control room. Alarm and Status shall be

provided in SCADA

Pressure transmitter shall be provided in water line

8nos of valves to be provided with Limit switch /

proximity sensors for valve open / close interlocking /

proximity requirements. These valves are to be

interlocked with pumps. The pumps status, valve

status & alarm shall be provided at SCADA.

5.12.8. Tests and Certificates

Party shall submit hydro & pneumatic test certificates

for ball valves.

Party shall submit pump performance test certificates.

Party shall carry out DP test for all weld joints before

and after hydro test.

Party shall carry out hydro test to a pressure of 5.0 ksc

and provide test certificate.

Party shall provide pump guarantee certificate.

Pressure transmitter, RTDs, pressure gauge calibration

certificates shall be submitted.

Rock wool insulation & pre formed insulation material

& test certificates shall be submitted.

Routine test certificate for blower motor, pump motor

and bogie motor.

Flameproof test certificate for bogie motor shall be

submitted.


P a g e |68 of 208

General Specifications and Mechanical

systems for AGNI Oven


P a g e |69 of 208

6. AGNI Oven

6.1. Basis of Design & System Description

6.1.1. Curing is carried out after the casting of AGNI grains & cartons samples in the Agni casting/SPF facilities. The samples /AGNI grains will be transported in explosive van/forklift / tractor & trolley with proper latching arrangement from the Agni casting/SPF facilities. The oven shall be provided with double leaf steel swing door in the front. The samples /AGNI grains placed inside the hot air oven are subjected to curing operation to achieve required mechanical properties.

6.1.2. The oven shall be provided with suitable spring loaded pressure relief arrangement. This pressure relief arrangement shall be operated at 1 ksc pressure and shall be of size 300 mm.

6.1.3. Curing operation is carried out over a period of 120 hours continuously.

6.1.4. The oven will be operated from 500C to 600C. The design temp shall be 750C. The oven temperature shall be raised to 600C within the first 30 minutes. The temperature of the oven shall be maintained thereon until curing operation is completed.

6.1.5. The hot air re-circulation system for oven comprises of the following:

Two Nos. (1W+1S) hot air re-circulation fans,

supply & return air ducting with dampers,

supply and return air grills.

6.1.6. The dampers for blower selection shall be operated manually and shall be provided with proximity sensors.

6.1.7. The entire heater battery shall be divided in to three banks and controlled using PLC PID controllers. Two of the heater banks shall be controlled using analog command to Thyristor power controller and the remaining one heater bank shall be controlled in On/Off mode (digital) commanding heater bank power contactor. The oven shall be capable of maintaining the operating temp., either with the on / off controller or with the PID controllers independently.

6.1.8. Blower and heater battery shall be located in the service room.

6.1.9. Insulated oven chamber, complete with concealed supply & return GI ducts, SS grills for uniform air distribution in X & Y axes, sheet metal cladding and its support structure.

6.1.10. The oven shall be maintained at a positive pressure so that the


P a g e |70 of 208

outside cool air does not enter the oven.

6.1.11. The oven shall be airtight and leakage through the oven doors, SS sheet cladding shall be avoided. The oven shall be airtight and thermally leakage proof such that the fall of oven temp. by 50C from an operating temperature of 600C shall not occur earlier than 20 minutes.

6.1.12. Hot air shall be supplied from the roof of the oven. Return air shall be collected at the bottom sides, close to the oven floor refer the drawing.

6.1.13. The total mass of steel to be considered inside the oven shall be 12 tons, which includes mass of AGNI &Carton crates, AGNI &Carton moulds. Party shall consider the mass of oven structures that may get heated up to finalize the heater banks, blower capacities to maintain temp. within specified limits and to attain the operating temperature with in stipulated time.

6.1.14. The mass of propellant need not be considered in sizing the heater and the blower since the thermal conductivity of propellant is very low.

6.1.15. Spatial variation when measured inside the oven shall not exceed 1.50C.

6.1.16. Heater elements shall be of black heat operation type – i.e., the heaters shall not become red hot during normal operation (when air flow exists) of the oven.

6.1.17. The heater shall have minimum 20% margin over design values.

6.1.18. The Blowers shall be sized for additional 20 % capacity over the design capacity.

6.1.19. Blowers capacity shall be arrived by considering

The discharge pressure drop across ducts, dampers, heater banks, grills etc.

Attaining the operating temp within stipulated period.

No. of air changes required to maintain uniform temperature (Spatial variation: 1.5o C or better)

To maintain a positive pressure inside the oven so that the cool air from outside shall not enter the oven

The blowers shall develop a static pressure of 120 mm WC

Blowers’ frame size shall be selected considering the space available in the service room and the door entry dimensions


P a g e |71 of 208

6.2. Specification of AGNI Oven

Table 7. Specification of AGNI Oven

DESCRIPTION Specification

Oven clear internal

dimensions

(LXWXH)- meters

7.0X5.5X3.0

Base structures

Bottom base structure of size -

5.5mX7.0mDept will provide fire brick & MS

grid (1.0 x 1.0 mt) arrangement for oven

area of 5.5m X 7.0m to withstand oven

temp of 75 Deg Cel.

Oven doors Manually operated double leaf swing doors

No. of blowers

1 working + 1 standby

(Total: 2nos.)

Fan capacity Minimum 40,000 CMH (23543 CFM)

Fan static pressure Minimum 120mm WC

No. of heater banks Total: 3 Nos. (distributed in equal capacity)

Heater bank capacity Minimum 150 kW

ON/OFF controlled

banks 1 Nos.

Thyristor controlled

bank 02 No.

Operating temp. 50 0C to 60 0C

Design temperature 75 0C

Ramp up time from

ambient temperature

30 min for 60 0C

30 min for 60 0C

∆T – Outer skin

temperature of the

oven & amb.

Temperature

5 for 60 0C

Spatial variation 1.5 0C or better

Oven performance –

controllability Set temp. ± 20C

6.3. Interlocks

Table 8. Interlocks of AGNI Oven

Sl. No Activity Interlocks

1. Blower on 1. Stand by blower should be in off mode


P a g e |72 of 208

2. Oven doors are closed

3. Blower dampers open.

4. CCMC emergency released

5. Fire damper.

2. Air heater

on

1. Blower is on

2. Air flow switch is on

3. Duct based RTD should be normal.

4. fire damper open

5. Blower RPM- 80%

6. Not in Local mode

7. Temperature inside oven is below set point

6.3.1. Blower shall not be switched on unless the doors are closed, their respective suction and delivery dampers and fire dampers are in open condition

6.3.2. When one blower is ON the other blower shall not get ON.

6.3.3. Heater banks shall get ON only when blower is ON and availability of air flow.

6.3.4. Fire dampers and oven heater banks shall be interlocked with temperature sensors provided at fire damper inlet & outlet and heater battery duct through dedicated temperature controller fixed at iMCC panel and these temperature controllers in turn is to be interlocked with PLC PID controller for oven temperature control purpose.

6.3.5. All the heater banks shall get off if the Temp Controller installed in the ducts operate in addition to the control from the temperature controllers installed in the Control panel.

6.3.6. Alarm shall be provided for following conditions: AGNI Oven: Blower 1 off, Blower 2 off, Air fail, Air low temp., Air over temp, Fire damper motor operated.

6.4. Atmospheric Conditions

Parameter Summer Monsoon Winter

Dry bulb temperature 0C

42.2 28.3 18.3

Wet bulb temperature 0C

28.3 26.7 13.9

Relative humidity % 35.0 >90 60.0


P a g e |73 of 208

6.5. Oven Parameters

Description Specification

Operating principle Hot air re-circulation

Hot air oven dimensions

(Clear internal

dimensions.)

7000mm(L) x 5500mm(W) x

3000mm(H)

Operating temperature

for hot air 50 - 60 0C

Design temperature 750C

Outer skin temperature

of oven

Not to exceed 50C from the ambient for

600C

Time to reach operating

temp., from ambient of

30 0-C

30 minutes for 600C operating temp.

Rh controls Not required

No. of temperature

sensors required 32 nos (Including spare)

6.6. Oven Construction

6.6.1. The oven structure shall be of free standing type. Refer drawing in this regard.

6.6.2. Oven shall be fabricated in double wall construction. The outer wall shall be of 5 mm thick carbon steel plate. The inner side of the oven shall cover with 2mm thick SS 304 sheets/panels, suitably stiffened. Material certificate shall be produced for SS sheets/panels. The oven base structure area 7000mm X 5500mm shall be provided with fire bricks with MS grid of 1.0 m X 1.0 m size to withstand oven temp of 75 degree C. SS cladding (3.0 mm thk) shall be done by the oven supplier. Fire brick and MS grid work is in the scope of department.

6.6.3. The drawing is only indicative and the supplier may work on 6 mm thk MS plate out any other alternate method but shall be implemented with the approval of the Department.

6.6.4. TIG welding shall be used for welding of all SS fabrication works.

6.6.5. Rock wool mattress of at least 150 mm thickness shall be used for insulating the oven walls such that the outer skin temperature is limited as mentioned earlier. Spikes shall be provided to retain the mattress in the position without


P a g e |74 of 208

collapsing.

6.6.6. Insulation mattress is sandwiched between SS304 sheet (oven side) and MS sheet on the rear side (Oven outer wall side).10 mm dia. studs shall be welded in MS sheets to retain the insulation mattress in position.

6.6.7. All internal SS304 pre-polished sheets, shall be buffed after welding and merge it properly. Doors and grills shall be buffed and polished to have mirror like finish. Enough care shall be taken to purchase only plastic coated SS304 sheets and the plastic cover shall be removed after erection at site.

6.6.8. The oven outer walls shall be provided with ladders for accessing the individual sensors for repair / other maintenance works and also to reach top of oven roof.

6.6.9. Manually operated double leaf swing door at the front shall be provided.

6.6.10. Intrinsic safe proximity switches shall be provided for Doors locked condition.

6.6.11. Use only silicon gaskets for sealing between the doors and oven walls so that no leakage of air exists.

6.7. Air Distribution System

6.7.1. The blowers shall be located in the service room adjacent to the hot air oven. The blowers are sized to provide sufficient number of air changes inside the oven to limit the spatial variation inside the oven to 1.50 C.

6.7.2. Two nos., of blowers (1 working & 1 standby) shall be provided. The blowers shall be mirror image of each other. The area available in the service room and the door entry at the service room shall be taken into account while selecting the blowers.

6.7.3. The blowers shall be sized to suit the requirement such that the operating temperature is reached within 30 minutes.

6.7.4. Blowers shall be thermally insulated. Impellers shall be designed to handle hot air at 75oC. Blowers shall have butterfly dampers, vibration isolators, inlet and outlet with flexible bellows with flame retardant material.

6.7.5. The blower location w.r.t. ovens are indicated in building and equipment lay out drawing.

6.7.6. Ducting requirements for the hot air distribution system shall be as follows:


P a g e |75 of 208

Supply and return air to / from the oven shall be

through rectangular galvanized iron (GI) ducts.

Ducts shall be of double wall construction made of 2 mm

thick GI sheets. Rockwool insulation (150mm) shall be

sandwiched between the walls. The rock wool insulation

shall be kept in position by chicken mesh.

Ducts shall be made in parts with flanged joints. The

joints shall be provided with asbestos /millboard gaskets

and ensure leak tight.

Ducts shall be air tight and shall be tested as per

standard procedure.

Ducts shall be reinforced with suitable stiffeners.

6.7.7. The heater battery shall be of same size as that of oven ducts or proper divergent & convergent portions are to be provided.

6.7.8. Heating coils shall be mounted inside the discharge ducts.

6.7.9. The Heater battery compartment shall be provided with air-tight doors for accessing the heating coils during maintenance.

6.7.10. SS grills with volume control dampers shall be provided to ensure uniform air distribution in the oven.

6.7.11. All ducts shall be fully insulated, and covered with GI sheet.

6.7.12. Motorized Fire dampers shall be provided both at the suction and discharge ducts of the ovens. The fire dampers shall be controlled through Temp Controller which closes the damper if the temperatures of Hot air are equal/above the set value.

6.7.13. Hot air supply shall be from both sides of the oven and return air duct shall be routed from top/roof to the oven.

6.7.14. Provision shall be made available in the ducts to install air flow switch.

6.7.15. Oven structures shall support fire hydrant lines and air lines of deluge system. Necessary support brackets shall be made available for installing these lines inside the oven.

6.8. Heaters & Heater Battery

6.8.1. The heater shall be fitted with withdraw type, sheathed, tubular heating element. The entire heater battery should be mounted inside a double walled mild Steel casing having rock wool insulation of not less than 150 mm thickness in between in order to prevent heat losses. The inside sheets of heater


P a g e |76 of 208

battery should be with G.I. The heater terminals must be brought to one side so as to facilitate connection and replacement easily. They shall be terminated in a terminal box.

6.8.2. The heater shall be suitable for mounting on air duct. Heater battery shall have flanges for connecting the heater and ducts. Heater battery shall be sized based on the duct size preferably.

6.8.3. Heaters shall be encased in tubes to avoid egress of hot air and to enable replacement of heating elements during operation suitable provision is to be made.

6.8.4. Heaters shall be black heat type. The heaters shall not become red hot with air flow.

6.8.5. Heating elements shall be with of nickel-chrome resistance wire. The elements shall be covered by magnesium oxide powder and compressed by swaging to ensure rapid heat transfer.

6.8.6. The heaters shall be encapsulated in hollow tubes.

6.8.7. The heating elements shall be supported at sufficient intervals, but not more than 600 mm.

6.8.8. All the electrical terminations shall be airtight.

6.8.9. The heater body shall be air tight to prevent any leakage of hot air / gases.

6.8.10. Elements/banks shall be arranged/ connected in such a way that failure of few elements does not affect the uniformity of heat drastically.

6.8.11. Heaters shall be protected against over temperature and shall be provided with auto cut-off.

6.8.12. It shall be possible to dismantle & replace/repair heating elements at site.

6.8.13. Silicone seal shall be applied to the lead exit and between lid and terminal box to improve ingress protection.

6.8.14. Watt densities of heating elements shall be selected properly to prevent carbonisation.

6.8.15. Heater battery shall be painted with Aluminium heat resistant paint.

6.9. Electrical Requirements

6.9.1. The enclosure shall be provided with removable gland plates for cable entries

6.9.2. All elements shall be of equal wattage & voltage.


P a g e |77 of 208

6.9.3. The heater capacity shall have a margin of +20 % (i.e. more by 20 % than the design value)

6.9.4. The heater battery terminal box shall have hinged doors with a standard cupboard like locking arrangement.


P a g e |78 of 208

Electrical Systems


P a g e |79 of 208

7. Electrical Systems

7.1. Scope of Work – Electrical Systems

7.1.1. Design, Fabrication and supply of intelligent Motor Control Centres (i-MCC) – 2 No’s.

i-MCC 1 for Hot Air Recirculated type Main oven and Mandrel Jacket water circulation system.

i-MCC 2 for Hot Air Recirculated type Agni Oven.

7.1.2. Testing and commissioning of above intelligent Motor Control Centres (i-MCC – 1 & 2))

7.1.3. Erection of the intelligent Motor Control Centres (i-MCC – 1 & 2) and interconnecting of field equipment’s along with Power & Control wiring etc. to the above panels.

7.1.4. Supply of Electric motors, Heater Banks, VFD drive, Thyrister controllers and other items and their erection and testing as per detailed specification. (Some of the items are part of iMCC itself)

7.1.5. Supply and laying of power and control cables, earth strips etc as per related specification mentioned in the following tender document.

7.2. General Terms

7.2.1. Party shall realize Intelligent Motor Control Centre (iMCC) as per detailed specifications furnished below.

7.2.2. The iMCC shall be fabricated and Integrated by an Authorized panel manufacturer.

7.2.3. Party shall engage panel manufacturer, obtain and submit GA Drawing, power and control circuit drawings, including selection of switch gear ratings, control drawing, Motor management scheme, Bill of material for Dept. Approval prior to start of fabrication.

7.2.4. The panel shall undergo functional checks, HV test, Dielectric strength checks, Dimensional checks and other qualification tests as per standards at panel manufacturer works in the presence of the Department.

7.2.5. The i-MCC panel shall be designed for operation in high

ambient temperature up to 50°C, high relative humidity up to 95 % and tropical atmospheric condition.

7.2.6. Instruction, Operation and maintenance manuals of items like MMS, Thyristor controller, VFD, switch gears etc. shall be


P a g e |80 of 208

submitted along with dispatch document.

7.2.7. Rubber mats of 2mx1m, 33 kV grade shall be provided for the complete length of all the panels (the panels which are in the scope of supplier) both in front and back side such that persons stand on rubber mats during maintenance.

7.2.8. The vendor shall supply documents consisting of as built drawings (iMCC power & control drawings, cable schedule), catalogue of all bought out electrical items, VFD parameterization Details & motor management system manual, Motor management coding.

7.2.9. The supplier shall provide three complete sets of all the drawings, operation and maintenance manuals and test certificates for the operation and maintenance purpose of the department.

7.2.10. i-MCC Panel cubical keys, Handles, interlock keys, are to be

handed over to department during supply.

7.2.11. Party shall submit the following for approval before fabrication

7.2.12. Detailed Schematics of the i-MCC Panel

7.2.13. General arrangement drawings with complete bill of materials, Bus bar layout, installation details etc.

7.2.14. Control wiring drawings.

7.2.15. Switchgear/Cable Ratings

7.2.16. The party should incorporate all changes / modifications / rectifications suggested by Department after verifying Drawings and bill of materials.

7.2.17. Any specification deviations required on technical grounds or non-availability of specified items have to be brought to the department notice in the deviation table in the Annexure and changes in these regards shall only be acceptable with the approval of the department.

7.2.18. Any item not specified but required for satisfactory functioning and integration of the total system to be considered and included by the party and demonstrating the total functionality of the system as specified is the responsibility of the party.

7.2.19. Trouble shooting and Maintenance documents to be prepared and submitted for electrical systems.

7.3. Intelligent Motor Control Centre (i-MCC)

7.3.1. Party shall carryout supply, Testing & Commissioning of front operated indoor cubicle type free standing and Compartment


P a g e |81 of 208

arrangement intelligent Motor Control Centre suitable for operation on 3-Phase, 4 wire 415V ± 10%, 50Hz ± 3% AC supply.

7.3.2. The panel should be designed, manufactured and tested in accordance with IS 8623(Pt1), IS 13947(Pt4/Sec1) and as per the specifications issued by us.

7.3.3. Enclosure symmetrical frame construction (16-fold profile) of rolled hollow sections made up from 1.5mm Thickness sheet with holes on a 25mm DIN pitch pattern.

7.3.4. Static load bearing capacity of the enclosure shall be around 1400 kg.

7.3.5. It shall have Horizontal sections, Vertical sections with fixing levels for space saving interiors installation.

7.3.6. Doors shall be fitted with concealed hinge to ensure 130 deg opening.

7.3.7. Lock shall be of 7 mm Triangular Bit Lock insert with key.

7.3.8. Panel lighting shall be provided in the cable chamber and it shall be LED lamps only. The same needs to be controlled with panel door open / close limit switch.

7.3.9. Removable Type Rear, side panel and Roof plate made of 1.5mm sheet steel, with foamed in seal (PU Foam gasket mixture of polyol and isocyanate).

7.3.10. Ingress protection: Should comply to IP54. Partial doors, Covers are PU Foamed (mixture of polyol and isocyanate) integrated to ensure I54 of Ingress Protection.

7.3.11. The panels shall be of modular design with a horizontal bus bar compartment running at the top and the cable entry shall be from the bottom for MCC unless it is specified.

7.3.12. The outgoing feeders shall be arranged in multi – tier mode. The panel front shall contain individually enclosed switchgear modules. All of the electrical accessories shall be mounted on the front side of the panels with facility to remove /refit form the front side.

7.3.13. Completely enclosed vertical bus bars shall be provided for feeding to the feeder modules.

7.3.14. The corners shall be rounded and no rough or sharp edges shall be left.

7.3.15. The dimensions of the panel shall be designed liberally allowing suitable access for using the maintenance tools in all cubicles / alleys.


P a g e |82 of 208

7.3.16. The panel can be limited to maximum height of 2100 mm excluding ISMC base of 100 mm, Overall height of the panel is 2200 mm.

7.3.17. Liberal clearances shall be maintained in all panel cubicles, bus bar chambers and cable alleys by considering the maintenance point of view.

7.3.18. All contacts / terminals of the switchgear components shall be wired to the terminal block.

7.3.19. MCCB add-on blocks, intelligent modules terminals are to be wired with single wire only. No multiplication is allowed in the above said terminals.

7.3.20. The structure shall be mounted on a rigid base frame of ISMC 100 channel. The design shall ensure that the weight of the components is adequately supported without deformation or loss of alignment during transit or during operation.

7.3.21. The ISMC channel shall be provided with adequate no. of holes at bottom in order to ensure installation convenience at site.

7.3.22. i-MCC panel shall have provision to access from the back side of the panel and also all the feeders shall have provision for entry of cable from the back side bottom of the panel except marshalling chamber.

7.3.23. Marshalling chamber shall be provided for both front side bottom as well as back side bottom.

7.3.24. Detachable, split gland plates of 3mm thick sheet steel shall be provided for panels both in the top and bottom.

7.3.25. Multiplication if any can be done only in the terminal blocks using shorting link between the terminals.

7.3.26. Complete metallic partition sheets shall be provided between any two adjacent vertical panels or horizontal feeders.

7.3.27. For the bus bar chamber, the doors shall be of bolted type. Suitable cable core clamping arrangement shall be provided in the cable alley/chamber.

7.3.28. Cable alley/chamber should have a minimum width of 400mm.

7.3.29. Cable alley /chamber should be provided with removable bottom plate to have cut outs for cable entry.

7.3.30. Each feeder compartment shall be provided with suitable nameplate showing feeder name with rating as given in the bill of quantities table. Name plates should be made of aluminum black enamel painted and names should be engraved and screw fixing type. Inscription shall also be provided for indication


P a g e |83 of 208

lamps, meters, operating handles and panel opening lock.

7.3.31. All live parts shall be shrouded with non – deteriorating insulating barrier to prevent against accidental contact.

7.3.32. All the feeders shall be properly extended up to the rear side of the panel for cable termination with suitable connecters and insulating barriers.

7.3.33. Suitable cable chamber housing the cable end connections, power and control cable terminations shall be provided in the backside of the individual compartment.

7.3.34. Marshalling chamber can be planned preferably in the middle of the i-MCC. All the feeders control terminals shall be brought

to this chamber. Control cables and communication cables from the field are to be entering through this chamber only.

7.3.35. Suitable provision can be made for routing the control cable and communication cable separately inside the entire length of i-MCC panel. Nowhere, it shall get linked.

7.3.36. Mounting of the switchgear components inside the i-MCC panel also to be arranged in such a way that the control and communication cables shall not get crossed anywhere.

7.3.37. The design shall ensure generous availability of space for ease of installation and maintenance of cabling and adequate safety for working in one vertical section without coming into accidental contact with live parts in the adjacent section.

7.3.38. The i-MCC should have necessary compartment cubicles of electrical switch gear as mentioned in the document below.

7.3.39. Provision shall be made for lifting and handling of panel by eyebolts.

7.3.40. Fire retardant DMC / SMC fillings for openings around bus bars near the sectional barriers shall be provided. Also adequate fire barriers are to be provided appropriate locations in all feeder compartments in such a way that products of combustion if any shall not spread to other compartments of the panel.

7.3.41. The panel shall have high mechanical and dielectric strength.

7.3.42. The panel shall be suitable for horizontal expansion in future on both sides. Hence necessary provisions like providing full length bus bars in the main bus chamber, providing holes in the main bus bar ends for connecting fish plates and providing separate end covers in the bus bar ends for chamber shall be made.


P a g e |84 of 208

7.3.43. Bus bar support conductors shall be FRP type firmly fitted to the frame work of the panel.

7.3.44. Safety

• All electrical panels shall have finger touch protection, for human safety viz. working on one component shall not cause shock to the personnel due to any other live component in the panel. Also, the terminal live parts shall not be accessible by fingers (finger cannot come in contact with live parts of the terminals).

• The apparatus and circuits in the i-MCC panel shall be so arranged as to facilitate their operation and maintenance and at the same time to ensure the necessary degree of safety.

• Apparatus forming part of i-MCC panel shall have the following minimum clearances as per the standards

a. Between Phases

b. Between Phase and Neutral

c. Between Phase and Earth

d. Between Neutral and Earth

• All the live parts to be covered properly (no live parts to be visible after opening the door) in order to avoid the possibility of in advent touching of the same during operation and maintenance.

• Mounting of both measuring as well as protection CBCTs should be taken care properly.

• Routing of all the control cables planned such a way that it should not cross any live parts.

• Routing of all the communication cables planned such a way that it should not cross any live parts.

• All the insulated materials used in the construction of the panel shall be non-hygroscopic, duly treated to withstand the effect of high humidity, high temperature and tropical ambient service conditions.

• Door interlocking facility and defeat interlock facility is to be provided for all MCCB handle mechanisms on the front door of the cubicle.

• All the feeders shall be provided with double Earthing.

• All the feeders shall be provided with LOTO (Lock out Tag out) devices. Necessary locks are to be supplied from the standard manufacturer of LOTO products. The same will be approved by department during drawing approval.

7.3.45. Bus bars


P a g e |85 of 208

• The bus bar arrangement shall confirm to IS 11353:1985

• Copper bus bars made of high conductivity electrolytic grade

copper confirming to IS 613:1984 of suitable capacity shall

be provided.

• The bus bars shall be sleeved (heat shrinkable sleeve) air

insulated and made of high conductivity, high strength

Electrolytic copper complying with the requirements of IS

5082.

• The bus bar shall be suitably braced with non-hygroscopic

supports to provide a through fault withstand capacity as

specified earlier.

• MS Bolt / nuts are to be used for Busbar coupling and

Stainless steel bolts / nuts to be used for busbar chamber

covers, Panel coupling bolts and for Earth busbar

connections.

• Suitable Bus bar support to be planned.

• The neutral as well as the earth bus shall be capable of

withstanding the fault level as mentioned above. However,

earth bus shall not be less than 50 x 6 mm CU.

• Fire retardant SMC/DMC fillings for openings around the

bus bar in the feeder compartments near the sectional

barriers shall be provided.

• Large clearance and creepage distances shall be provided on

the bus bar system to minimize the possibility of a fault.

• High tensile bolts, nuts and spring washers shall be

provided at all bus bar joints. Additional lock nut (i.e. double

nut) has to be provided in all the bus bar tappings.

• The short circuit strength of bus bars shall be 50kA rms

(minimum), one second and 105 kA peaks.

• They shall be of uniform cross section thought out the panel

with a current density of 80Amps per square centimetre or

better.

• Suitable colour – coded heat shrinking sleeves shall be

provided for the bus bar conductors with colour – coding.

• Cadmium plated high – tension bolts and nuts shall be used

for the joints. Spring washers will be used for sustaining the

contact pressure.

• All joints / tapping points of the buses shall be suitably

shrouded to prevent accidental contact.


P a g e |86 of 208

• Panels shall have bus bars with respective phase colour

coded heat shrinkable PVC sleeve. All joints shall be

shrouded. No live terminal shall be directly accessible, but

shall be properly shrouded.

• Proper shrouding arrangement shall be provided between

the auxiliary bus bars and the main bus bars.

• Minimum clearances shall be maintained as per the latest IS

code.

• All the live bus bars shall be covered with transparent

acrylic sheets / FRP, Sheet.

• Main bus-bar shall be rated for minimum of 120% more

than the selected switchgear rating of main incomer.

7.3.46. Earthing

• Earth copper bus bars of minimum 300 Sq. mm size shall be provided throughout the length of the panel.

• Within the panel board all the switch gear bodies shall be duty connected to the earth bus bars.

• Provision for connection to the plant earth grid shall be provided at both the ends of the panel.

• All hinged doors with electrical accessories shall be provided with flexible copper earth connections.

7.3.47. Power Wiring

• Power wiring shall be carried out with minimum 4.0 Sq. mm size of 660/1100V grade multi strand single core copper flexible wires. While selecting individual feeder cable size, current rating one step above the feeder rating is to be considered.

• Panel Control wiring shall be carried out with minimum 1.5 Sq. mm sizes of 660/ 1100V grade multi strand single core copper flexible wires.

• Transducer outputs and control/signal wires from all cubicles should be wired with shielded cables and terminated in terminal blocks housed in control compartment.

• Inter connections in the DOL starter and MCCB feeders shall be carried out with suitable rated wires.

• All the power wires shall be wired up to the clip on type terminals mounted on the edge of the feeder base sheet in the cable alley for facilitating easy cable termination.

• All the control wires shall be wired up to the Control terminals of Nylon Unbreakable type “PHONIX” or any other


P a g e |87 of 208

reputed make mounted on the edge of the feeder base sheet in the cable alley for facilitating easy cable termination.

• Tube Insulated copper lugs shall be used for terminating the control wires.

• All the wires at the terminal block shall be identified properly by providing suitable number / letter ferrules.

• All Switchgear shall be of AC 23 Duty.

7.4. Feeders for Intelligent Motor Control Centre (i-MCC)

7.4.1. The i-MCC should be provided with following feeders with compartmentalized cubicles separated from each other, with bus bars on top and bottom cable entry

Table 9. Feeders for i-MCC – Main Oven

Feeder Description

Capacity (KW)

Specification

Incomer To be

arrived by Vendor

ACB with adjustable short circuit, earth fault and overload. Electrically operated.

Multi-Function meter with Profinet/ Ethernet connectivity for local display and remote data logging.

Shall have RYB indication lamps, on, off, trip status and Suitable Current CTs to be provided for current measurement and display at Multi-Function meter.

Outgoing Feeders

ON/OFF Heater Bank – 1

(Air) 100

Switchgear: MCCB, Contactor

(There shall be two contactors connected in series to avoid heater getting on in case of contact welding.)

Earth Leakage protection with MMS

Measurement & Monitoring with MMS

Thyristor Heater Bank – 2

(Air) 100


Thyristor controller (Detailed specification for Thyristor Controller is given in data sheets)

Conventional Earth Leakage Relay

Measurement & Monitoring with Thyristor Controller


(Air) 100


P a g e |88 of 208

Blower - 1 55

Semiconductor Fuse as incomer to soft starter

Soft Starter – 2 no’s (Main & Redundant for Blower-1)

Soft Starter- 1 no’s (For Blower-2)


Measurement & Monitoring with Soft Starter

Local Push Buttons

Note for Blower-1 Soft starter:

a. Provide interlocking between Soft starter (Main & Redundant) such that only one Soft starter shall be ON at a time.

b. This feeder is with Main & Redundant Soft starter and changeover shall be possible from both starters.

c. The selection between Main & Redundant Soft starter to be effected by operation of a key operated selector switch and the power & control connection changes to be effected by operation of Power & Auxiliary contactors.

Blower - 2 55

Fire Damper Motor - 1 2 Switchgear: MPCB, Contactor



Fire Damper Motor – 2 2

Hot Water Pump - 1 3.7

Switchgear: MPCB, Contactor Earth Leakage protection with MMS Measurement & Monitoring with

MMS Local Push Buttons

Hot Water Pump – 2 3.7

ON/OFF Bank – 1 (Water) 18






P a g e |89 of 208

Thyristor Controlled Bank –

2 (Water) 18




Measurement & Monitoring with thyristor Controller

Bogie Motor 5.5

MCCB/Semiconductor fuse

VFD Refer Data Sheets


Note:

a. AOP (Advanced operator panel) of drive should be mounted on cubicle door of panel. The ON /OFF, forward, reverse & emergency OFF are to be provided in a push button station located in Bay.

b. VFD shall be interfaced from PBS for forward &reverse operations of Bogie.

c. VFD need not to be interfaced with PLC/SCADA.

Table 10. Feeders for i-MCC – AGNI Oven

Feeder Description

Capacity (KW)

Specification

Incomer To be

arrived by Vendor

MCCB with adjustable short circuit, earth fault and overload. Electrically operated.

Multi-Function meter with Profinet/ Ethernet connectivity for local display and remote data logging.

Shall have RYB indication lamps, on, off, trip status and Suitable Current CTs to be provided for current measurement and display at Multi-Function meter.


P a g e |90 of 208

Outgoing Feeders

ON/OFF Heater Bank – 1

(Air) 50






(Air) 50




Measurement & Monitoring with Thyristor Controller


(Air) 50

Blower - 1 30

Switchgear: MPCB, Star Delta Starter



Local Push Buttons

Blower - 2 55

Fire Damper Motor - 1 2

Switchgear: MPCB, Contactor



Fire Damper Motor – 2 2

7.4.2. Feeders shall have the following features as per the above specifications

Switch Gear • MCCB: MCCB with adjustable short circuit, earth fault

and overload protection with necessary arrangements. Electrically operated. Specifications as per the Data sheets

• MPCB: MPCB with adjustable short circuit, and earth

fault with necessary arrangements. Electrically operated. Specifications as per the Data sheets

• Contactor: DOL starter with contactors of suitable

rating. 4 NO + 4 NC contacts shall be provided in contactor for on/off status etc. Specifications as per the Data sheets


P a g e |91 of 208

Earth Leakage protection • Earth Leakage protection shall be provided through MMS

with External CBCT. In case the selected MMS brand is not offering an integrated/add on Earth leakage module (documentary proof from OEM to be submitted) microprocessor based ELR of PROK DVS can be used and interfaced through MMS digital input.

Conventional Earth Leakage protection • Earth Leakage protection shall be provided with

microprocessor based Earth leakage relay with adjustable current/time and display of earth leakage current. ELR of Prok DVS make shall be provided.


• Motor Management System

Measurement & Monitoring with Soft Starter • Soft starter shall be interfaced with SCADA/PLC System

meeting communication Interfacing/Protocol Requirements.

Measurement & Monitoring with Thyristor Controller • Thyristor Unit shall have Communication Compatibility

with PLC/SCADA to display Current / Voltage / Power / Healthy Status etc.,

Local Push Buttons: • Illuminated Push buttons for ON / OFF & Indications

Lamps shall be provided on Feeder compartment hinged Door for local mode operation.

7.4.3. Ethernet switches required quantity shall be arrived by vendor (Refer Instrumentation and control section for details) and shall be located in the i-MCC itself as a separate compartment.

7.4.4. Necessary power supply unit, power supply online monitoring systems needs to be introduced and located in the same compartment.

7.4.5. Network switch compartment shall have a glass door for easy monitoring.

7.4.6. All the feeders shall have sufficient no. of aux. contacts (NO & NC) in power contactor apart from the power contactors to use with Digital inputs of PLC and SCADA depending on the requirement (No add-on block for the contact multiplication is acceptable).

7.4.7. For all design purposes, ambient temperature shall be considered as 50°C. Temperature rise shall be as per IS-8623


P a g e |92 of 208

7.4.8. All the feeders shall be compartmentalized.

7.4.9. The Control and data acquisition is through PLC & SCADA. The PLC envisaged for this automation is dual redundant with criss-cross configuration. The i-MCC should use PROFINET/MODBUS TCP/ETHERNET communication Protocol and all feeder elements should be configured suitable to this dual redundant configuration. All feeder currents, VFD currents,on/off/trip status, On/Off commands status, run status, feeder protection (EL, SC, OC, winding temp) should be communicated through communication cable.

7.4.10. i-MCC communication cable (main & redundant -2 runs) should be laid from i-MCC to control room with sufficient extra length.

7.4.11. The HMI/operator panels MMS (door display unit) are to be mounted on the front door of each compartment.

7.4.12. All the above listed feeders should have iMCC/MMS modules for remote ON/OFF status, current monitoring etc

7.4.13. The Intelligent motor management system shall consist of necessary modules and add-ons for control and status monitoring, current/voltage measurement, operator panel with display unit for each motor feeder, ground fault monitoring, winding temp. monitoring etc.

7.4.14. Panel shall have the 3-phase indication lamps in the metering cubicle controlled by 3-pole MCB.

7.4.15. Voltage input to the Multifunction meter shall be routed through 3-pole MCB.

7.4.16. Resin cast Current transformer shall be planned and secondary to be routed through terminal dis-connector.

7.4.17. The incomer panel shall consist of MCCB with safety lock and key with suitable rating, which will be used to switch off power supply during EMERGENCY OFF.

7.4.18. Control transformer can be planned for the control supply. Incoming and Outgoing MCBs shall also be planned for the same.

7.4.19. Control transformer can be mounted on the front side / backside of the panel in any of the compartment with suitable ventilating arrangement.

7.4.20. Sizing of the control transformer to be submitted for review and clearance before proceeding for the fabrication.

7.4.21. All the feeders control supply to be routed through the suitable


P a g e |93 of 208

/adequate rating MCB having the provision of acquiring ON, OFF and TRIP Status.

7.4.22. All the MCBs shall have the provision for ON, OFF and Alarm contact provisions. The same shall be wired for the control logics and SCADA information as per the requirement.

7.4.23. Local/Remote Selection Switch: Blowers and water pumps be provided with Local/Remote Selector Switch to facilitate Local/Remote Operation Selection. The status of Local / Remote Switch shall be taken as one of the input to respective Remote DI Module. The Push Button also shall be taken as DI to PLC input module. The PLC DO shall issue command after fulfilling all interlocking requirements.

7.5. Motor Management System (MMS)

7.5.1. Motor Management System means Electronic Modules capable of Monitoring, protecting, controlling motor feeders and as the nomenclature of the system is different among different makes term “MMS” will be used to represent the system. MMS shall provide protection, metering, control, monitoring, and historical logging for 3ɸ AC induction motors and Heater Bank currents up to 200A (min) using integral current transformers (CTs) or external CTs as applicable.

7.5.2. The make of the motor management system should be of Siemens/ Schneider/Allen Bradley make MMS and the make shall be same as that of PLC selected.

7.5.3. Protections: MMS shall provide all current and voltage based

protections mentioned below:

Thermal overload

Current phase imbalance

Current phase loss

Current phase reversal

Long start

Jam (locked rotor during run)

Undercurrent

Over current

Ground Fault protection (internal)

Motor temperature sensor

Voltage phase imbalance

Voltage phase loss

Voltage phase reversal

Under / Over voltage


P a g e |94 of 208

Any other additional protection feature as applicable.

7.5.4. Monitoring:

It shall provide monitoring of all 3ph currents, ground

current, avg. current, voltages, power, PF, active and

reactive and energy, it shall have fault recording with all the

current, voltage values for the last minimum 5 faults.

Ground fault protection & leakage protection shall be

possible & it shall also have the provision to connect the

(external) CBCT to MMS.

MMS shall have provision to directly connect to the

temperature sensor, with or without expansion module

MMS shall monitor, display and communicate the

temperature value (when connected with PT100 sensor)

7.5.5. Communication

Device should have integrated communication port for the

communicating through Modbus TCP, Ethernet IP, Profinet,

communication suitable for SCADA/PLC system with media

redundancy

7.5.6. Control Voltage: 24VDC or 100-240V AC, 50 Hz

7.5.7. The MMS Module shall have integral or through add on/Expansion modules

Digital inputs

Programmable relay outputs

Temperature sensor input

CBCT input terminal.

7.5.8. Configuration / Programming:

MMS shall be programmable from HMI / PC.

MMS shall have prebuilt configuration modes for motor

starters (DOL / star-delta)

MMS shall be configurable to operate as an overload relay

Custom logic for programming DI/DO shall be possible and

the software shall have the provision for programming on

structured text / Function block.

Digital outputs shall be potential free. Each output shall be

capable to be connectable to different field voltages

7.5.9. User Interface:


P a g e |95 of 208

HMI or Memory plug shall have the capability to upload /

download parameters to MMS

The address & other communication parameters shall be

configurable from HMI or through address module.

HMI shall have the simple text display in English

7.5.10. Earthing of intelligent modules to be connected to the

Instrumentation earth (Earth strip available within 25 mtrs). Insulated copper of 2R x 1C x 10 sq.mm at both the ends of the i-MCC panel.

7.5.11. Minimum 20% spare with respect to NO & NC terminals shall be provided in all compartments.

7.6. Measuring & Monitoring Requirements

7.6.1. Panel shall be provided with Multifunction meter with Add-on DI / DO modules and PROFINET/ETHERNET module as applicable to motor management system selected.

7.6.2. Motor management system modules, Thyristor Controller, PAC Meter etc., in all feeders shall be suitable for communication protocol and dual redundant criss-cross configuration used in PLC & SCADA system.

7.6.3. Parameters from iMCC both digital and analog are listed in following table. The list is indicative and exact list is to be finalized along with iMCC GA drawing and BOM approval.

Table 11. Parameters – Digital & Analog

Feeder type Digital data Analog data

Incomer feeder

MCCB ON/OFF

Aux Contactor

Control Trfr off (supply to

control Trfr cut off)

MCCB ON status

ELR trip status

MCB (Primary of Control

transformer) ON/OFF Status

MCB (secondary of Control

transformer) ON/OFF Status

Emergency OFF Status

-


P a g e |96 of 208

Feeder type Digital data Analog data

Outgoing feeder with MPCB

Permanent local mode MCB ON status (shunt trip

coil supply) MCB ON status (Control

supply) MPCB ON status MPCB trip status MCB trip status (control

supply) Panel start (P/B) stop(P/B) Power contactor ON/OFF

status

Three phase currents

Voltage(average) Time for tripping

OL Last trip current Restarting time

after trip Motor / feeder

operating hours (In addition to above for Thyristor Heater bank, Power)

Outgoing feeder with MCCB

MCB ON status (Shunt coil supply)

MCB ON status (Tr supply) MCB ON status 24V DC

supply MCCB ON status ELR trip status.

Outgoing feeder with Thyristor Controller

MCCB ON status MCB ON status (Shunt coil

supply) Load circuit (Overcurrent,

under current) Mains voltage Thyristor unit health

Multi-function Meter Incomer Feeder

-

Voltage L-L, L-N, Current Per phase, Neutral conductor

current Active power Per

phase and total Power factor Per

phase and total Frequency THD voltage Per

phase THD current Per

phase


P a g e |97 of 208

7.7. Operation Modes

Operating modes shall be provided as per the following.

7.7.1. MODE - 1:

SCADA PLC iMCC CONTACTOR MOTOR/HEATER BANK

(iMCC only for Monitoring & Data logging purpose)

In this mode, operations are carried out from operator console at control room using SCADA Station, The SCADA Station is interfaced with PLC configured in Main & redundant mode in criss-cross configuration.

Remote I/O’s are provided both in control room and service room are to be linked by communication cable running from control room to service room.

The PLC DO in service room will be driving Soft Starter to switch on blower and DOL starter for water pumps fire damper Motor using PLC. Contactors are provided in iMCC for powering heater bank in ON/OFF mode PID control.

Thyristor controlled heater banks shall be commanded (Analog) from PLC. Motor management system (MMS) consists of Current/Voltage measurement module, Basic module etc., are to be provided in iMCC and to be interfaced with PLC for monitoring of voltage, current, protection features, ON/OFF status. MMS shall not be used for control purpose. All control shall be through PLC remote DI/DO’s.

7.7.2. MODE - 2: Console Push Button Station

CCMC Panel PB’s CONTACTOR MOTOR/HEATER BANK

MODE 2: Redundant mode using CCMC Push Button Station @ control room (Remote)

This mode will be chosen in case of failure in SCADA/PLC.

In this mode push button from CCMC at control room are hardwired with soft starter, water pump DOL starter and Fire damper motor contactor etc., using control cable to be laid between control room and service room.

ON/OFF command for heater banks to be hardwired from temperature controller provided at control room panel and Analog voltage from PID controller provided at control room panel.

The push buttons and indication lamps are already provided


P a g e |98 of 208

in a control cum monitoring console and mounting place for temperature controller. Similar provision is there for Agni Grain Ovens also. Please refer to I & CS section for further information.

7.7.3. MODE - 3: Maintenance Mode

LOCAL PBS IN SERVICE ROOM PLC CONTACTOR BLOWER /

WATER PUMPS

MODE-3: Control from iMCC in Local mode.

This mode is only for switching on Blowers, Water pumps for maintenance purpose from service room.

Illuminated pushbutton for Blower/Water pumps are provided in respective compartments at iMCC for interfacing Soft starter /contactor (DOL). This PBs shall be taken as Digital Inputs to PLC.

Local/Remote switching modes are enabled through PLC selection.

7.8. i-MCC Configuration for Operating Modes

7.8.1. Power Wiring:

i-MCC shall accommodate all the conventional Switchgears like MCCB/MPCB, Power Contactor, ELRs, Soft Starters, Thyristor Banks etc.,of each individual feeder Motors/Heater banks.

For Selecting norms of Switchgears vendor shall refer Switchgear Selection Chapter. In addition to this MMS shall be introduced in the panel for the purpose of monitoring and Data Acquisition (through current & voltage module) only not for Controlling. Please refer Drawings

7.8.2. Control Scheme:

iMCC panel shall be realized in such a way serving for the both operation modes Main Mode & PLC/SCADA fail safe Mode.

7.8.3. Scheme Illustration:

iMCC shall be interfaced with:

a. PLC/SCADA: Control Station for Mode-1 (Through Soft linking)

b. CCMC Panel: Control Station for Mode-2 (Through Hardwiring)


P a g e |99 of 208

All Functional Interlocks like Proxy sensors of Bogie In/Out, Oven Doors Open/Close, Dampers Open/Close, Air Flow switch etc.,are to be interfaced with Intrinsic safe single input dual output isolators, the two Outputs obtained shall be utilized for following purpose:

a. As input to Another Intrinsic safe single input dual output isolator (PLC mode purpose – Mode-I)

b. As Input to Aux. Contactor(4NO/4NC as per Hard wired Interlocking requirements – Mode – II purpose).

Further the two Outputs of Intrinsic safe single input dual output isolator shall be utilized for Following Purposes:

a. Output-1: As input to PLC Main b. Output-2: As input to PLC Redundant.

The Aux. Contactor Outputs can be utilized for achieving the conventional Hardwired interlocks and status monitoring.

These Intrinsic safe single input dual output isolators along with Auxiliary contactors, power Supply etc., for Hardwiring and interlocking to be accommodated in a cubicle.

Control panel shall be envisaged with PID controllers for Hot Air, Hot Water (On & OFF banks) & Fire damper. These PID controllers are dedicated for hard wire control interlocks in case of PLC/SCADA failure. The specs are defined in instrumentation Chapter.

7.9. Terminal Blocks and Labels

7.9.1. Terminal blocks shall be of 500 Volts grade of the stud type and shrouded.

7.9.2. Insulating barriers shall be provided between adjacent terminals.

7.9.3. Provisions shall be made for label inscriptions for the easy identification of terminal blocks (by means of numbering)

7.9.4. Group TBs can be planned with respect to the cleared control scheme. Group TBs are to be named clearly.

7.9.5. All the power terminals are to be selected for connecting the ring type lugs (in both panel and FLP junction boxes if required)

7.9.6. All the power terminals and live parts are to be covered with proper terminal covers.

7.9.7. Group terminal markers to be used for the clear identification.

7.9.8. All the power and control terminals are to be provided with suitable terminal numbers.


P a g e |100 of 208

7.9.9. Power terminal blocks shall be separated from each by means of replaceable insulated spacers.

7.9.10. The nomenclature shall mention the feeder rating in Amps and details of feeder.

7.9.11. The nomenclature feeder details for the label plates shall be furnished by Department during detailed engineering.

7.9.12. Equipment tag plate inside the i-MCC panel and compartment

nameplates shall be of acrylic engraved sheets only and same to be fixed by screws/rivets and shall not be pasted.

7.9.13. All the compartment needs to be provided with ON / OFF / TRIP indication lamps. The self-illuminated push button planned for ON / OFF operation may be used for ON / OFF indication lamps. However, a separate TRIP indication lamps needs to be considered.

7.9.14. ON/OFF/TRIP inscriptions shall be clearly marked over the individual compartment with clear marking of direction of the operation of handle apart from the standard marking provided by the switchgear manufacturer.

7.9.15. ON/OFF inscriptions shall be clearly marked over the individual feeder cubicles with clear marking of direction of the operation of handle apart from the standard marking provided by the switchgear manufacturer.

7.9.16. Enamel Danger plates of size and descriptions as recommended in the relevant IS, shall be provided on the MV Panel inscribed in Telugu, Hindi and English languages mainly. The same to be indicated the G.A after getting the order and before proceeding for fabrication.

7.10. Power & Control Cables

7.10.1. Party shall supply Power cables, control cables, cable trays as per the specifications in the data sheets and shall also carryout cable laying on wall /trench /cable tray as applicable. All the miscellaneous items like cable glands, lugs, ties, fixers shall also be supplied by the party.

7.10.2. Power wiring with suitable rated armoured cables as per load requirements shall be provided. The cable make shall be as per specifications (datasheets).

7.10.3. The power wiring shall be carried out for the following

PCC to Both iMCCs (Incomer)

I-MCCs to other loads (Motors, Hot water Pumps, Blowers,

heater Banks etc.)


P a g e |101 of 208

7.10.4. The cables shall comply with LT voltage level 1100V, Armoured with XLPE insulation as per IS:7098. The minimum size of cable shall be 4 sq. mm copper conductor for all power wiring. All feeders shall be with copper conductor cables. The power wiring shall be carried out with necessary saddles, clamps, cable tags, glands, etc.

7.10.5. In case of FLP Bay, FLP Items shall be used.

7.10.6. Necessary cable glands and suitable lugs with respect to the feeder requirement and field equipment’s are in the scope of supplier.

7.10.7. All the power and control cables which are routed from i-MCC

panel are to be routed through SS cable tray with proper cover inside the cable trench as per the direction given by the department.

7.10.8. Wiring shall be neatly bunched, adequately supported and properly routed through cable alley (duct) to allow easy access and maintenance.

7.10.9. The ferrules shall be of the ring type and of non-deteriorating material.

7.10.10. They shall be firmly located on each wires so as to prevent free movement.

7.11. Cable Termination

7.11.1. Wherever copper to aluminum Interconnections are made, necessary bimetallic washers shall be used.

7.11.2. In case of control cables all cores shall be identified at both ends by their terminal numbers by means of PVC ferrules for core size. Wire numbers shall be as per schematic wiring/inter-connection diagram. All unused spare cores of control cables shall be nearly bunched and ferruled with cable tag at both ends, for future use.

7.11.3. Contractor shall drill holes for fixing glands wherever necessary. Gland plate shall be wherever more number of cables are terminated. All unused cable entries on equipment/panels shall be plugged or sealed.

7.11.4. The cable shall be terminated at electrical equipment/switchboard through glands of proper size.

7.11.5. Before energizing, the insulation resistance of every circuit shall be measured from phase to phase, phase to neutral and from phase/neutral to earth. The approximate cable length requirements are listed in below mentioned table.


P a g e |102 of 208

7.12. Control Wiring

7.12.1. The control wiring shall be armoured with minimum copper conductor size of 2.5 sq. mm of XLPE/PVC insulation, voltage grade 660V/1100V as per IS: 1554/7098. The control wiring shall consist of following:

7.12.2. Master Emergency OFF at Control room shall be hardwired with i-MCC panel incomer MCCB trip circuit.

7.12.3. i-MCC panel to Control room

7.13. Cable Trays

7.13.1. Cable trays shall be provided for cables that are laid both inside and outside the facility. Power cables, control cables and communication cables shall be laid separately in different cable trays.

7.13.2. The cable tray shall be wire mesh cable tray of CABLOFIL (LEGRAND) or suitable cable tray/make with Dept approval.

7.13.3. Supply and installation of Cable tray is in the scope of the party. Civil cable trenches shall be provided by the department.

7.14. List of Cables

7.14.1. The quantity of Power & control cables required to meet various interfacing field elements is specified below. The details are indicative and party shall meet extra cable requirements in case of requirement.

7.14.2. The size of the cable should be decided based on the expected highest load in the cable adding 50% cushion. Calculations arriving the cable sizing should be submitted for approval. Any other cable not listed below but required for completion of the system/proper working of the system shall be provided by the party without any additional cost.

Table 12. Power Cables – Quantity – Main Oven

Cable Description Capacity (tentative)

Length (metre)

Cable from i-MCC Three Air Heater banks-100KW-

Aluminium 150Sq.mm X 4C 100

Cable from i-MCC to Blower motors-Cu

35 Sq.mm X 3C 50

Cable from i-MCC Air damper Motors-Cu

4 Sq.mm X 3C 60


P a g e |103 of 208

Cable Description Capacity

(tentative)

Length

(metre)

Cable from i-MCC to Hot water Pumps-Cu

4 sqmm X 3C 60

Cable from i-MCC to Water Heater Banks-Cu

6 sq.mm X 4C 90

Cable from i-MCC to Bogie Motor-Cu

6 sq.mm X 3C 75

Cable from PCC to i-MCC - Aluminium

400 Sqmm X 4C 30

Control Cable From iMCC to CMCC Panel

37 Core X 2.5 sqmm 350

Control Cable From iMCC to CMCC Panel

30 Core X 2.5 sqmm 350

Table 13. Power Cables – Quantity – AGNI Oven

Cable Description Capacity (tentative)

Length (metre)

Cable from i-MCC Air Heater bank - 50KW - Cu

25Sq.mm X 4C 90

Cable from i-MCC to Blower motors- Cu

16 Sq.mm X 3C 60

Cable from i-MCC Air damper Motors - Cu

4 Sq.mm X 3C 60

Control Cable from i-MCC 2.5 Sq.mm X 24C 600

Power cable PCC to i-MCC 95 Sq.mm X 4C 30

7.15. Inspection – FAT & SAT

7.15.1. FAT:

The i-MCC panels shall be completely assembled, wired, and

tested for operation under stimulated conditions to ensure correctness of wiring and interlocking and proper functioning of all components.

HV & IR checks as per standard procedure shall be conducted.

The above tests shall be successfully carried out at factory with the presence of Department Engineers and necessary


P a g e |104 of 208

test certificates shall be enclosed along with dispatch of panels in triplicate.

Any modification and rectification suggested by inspection team should be incorporated /attended before dispatch.

Subject to the clearance from Department after the satisfactory completion of tests at factory / works panel can be dispatched.

Any transit damage should be rectified at site

Routine test certificates shall be provided for all motors. FLP test certificates shall be provided for all FLP motors

Test certificates, data sheets and manuals of Switchgears, CTs, ELRs, Transducers, Motor management system and Power electronic controller shall be produced.

7.15.2. SAT

During commissioning / energisation of the MV panel, the supplier shall depute their supervisor and perform the following tests on the feeders at site prior to commissioning.

Insulation resistance between the phases and individual phases and earth.

Earth continuity checks.

All the protective relays and tripping mechanism shall be checked for their proper operation and setting / grading shall be done as per the directions by department.

All metering functions shall be checked to ensure proper operation / indication.

Operation and functionality tests of the switch gear and interlocks

All i-MCC functionality to be demonstrated at site.

7.16. Erection & Commissioning

7.16.1. The party has to erect i-MCC over the designated trench, with channels L angles and fasters as required.

7.16.2. Power connection to the i-MCC including incomer connections from PCC to be completed.

7.16.3. Erection of all electrical systems is in the scope of party and shall be under the supervision of an engineer deputed by the party.


P a g e |105 of 208

7.16.4. All control interfaces & control wiring from i-MCC to PLC and other elements to be carried out.

7.16.5. Soft copy of drive parameters in CD/DVD shall be provided.

7.16.6. The Integration of i-MCC with PLC & SCADA shall be carried out at SDSC, SHAR. A team of Authorized Engineers (M/S Schneider / Siemens / Allen Bradley) who has expertise in MMS shall be deployed @ SDSC, SHAR for integration, commissioning and testing of i-MCC with PLC/SCADA and shall be made available till completion of first live trial. They should demonstrate all functional and protective features.

7.16.7. Party shall employ (BS Techno LTD Chennai or AE) authorised person for commissioning of Thyristor Controller.

7.16.8. All cable laying and suitable termination, loop checking, interfacing and trial runs is in scope of supplier. Necessary works like clamping, crimping, ferruling etc. is in party’s scope.

7.17. Training

7.17.1. Training shall be provided from the Original Equipment

Manufacturer at their training centre for 2 persons deputed by

Department on the following

• Maintenance, configuration & troubleshooting of Motor Management system by Siemens / Schneider / Allen Bradley

• Maintenance, configuration & troubleshooting of Thyristor Controller by AEG

• Maintenance, configuration & troubleshooting of VFD by Siemens / ABB

• Training is to be arranged before the start of erection by the supplier at our site.

7.17.2. The quoted price shall be inclusive of the cost of training

7.18. Standards

7.18.1. The Electrical systems shall conform to respective IS/IEC

specification with latest amendments.

7.18.2. An indicative list is given below

Table 14. List of Standards

S No Description of the Item Standard

1 FLP/INTRINIC SAFE ITEMS IEC60079 / IS 2148

IS 5571 / 5572

2 Motors IEC 60034 / IS 325

3 PVC Cables IS 1554


P a g e |106 of 208

S No Description of the Item Standard

4 XLPE Cables IS 7098

5 LV switch gear and control gear IEC 13947

6 General requirements for switch gear and control gear for voltages not exceeding 1000 V

IS 4237

7 Current Transformers IS 2705

8

MV Panel – Factory built assemblies of switch gear and control gear for voltages up to and including 1000 V AC and 1200 V DC.

IS 8623

7.19. Spares

7.19.1. Party shall supply the following spares as per the specifications

(data sheets)

Table 15. List of Spares – Main Oven

S No Item Description Rating Qty

1. Thyristor(Hot Water Heater) 1

2. VFD Drive for Bogie Motor 1

3. MCCB for Hot air Heater ON/Off &

Thyristor Bank 250 A 2

4. MCCB for Hot Water Heater Thyristor

Bank 63 A 2

5. MPCB for Hot Water Heater Pumps 8A 1

6. Contactor Kit & Coils for Hot air

Heater Bank ON/OFF & Thyristor Bank

205 A 2

7. Contactor Kit & Coils for Hot air

Heater ON/OFF & Thyristor Bank 205A 2

8. Contactor for Hot Water Heater Bank

ON&OFF 32A 1

9. Contactor Kit & Coils for Hot Water

Heater Bank ON&OFF 32A 2

10. Contactor Spare for Hot Water Pump 9A 2

Table 16. List of Spares – AGNI Oven

S No Item Description Rating Qty

1. MCCB for Hot air Heater Bank ON &

OFF 160A 1

2. MPCB for Blowers 63 A 1


P a g e |107 of 208

3. Contact for Hot Air Heater Banks 75A 1

4. Contact Kit & Coil Spares for Hot Air

Heater Banks 75 A 1

5. Contact Kit & Coil Spares for Blowers 63A 1

7.20. Technical Specifications (Data Sheets)

Party shall supply the items as per the following specifications.

Table 17. Specifications of Switch Gear - ACB

Description Essential Specification

Maximum rated current (In max)

Standard Rating higher than 150% of the calculated maximum current

Rated short circuit breaking capacity Ics(=Icu)

85kA or higher

Rated insulation voltage Ui 1000V

Rated operational voltage Ue 690V

Rated Impulse withstand voltage Uimp

12kV

Standard IEC 60947-2

Over current release features

Overload protection (L-tripping), Short time delay short circuit protection(S-tripping), Instantaneous short-circuit protection (i-tripping), Neutral conductor protection (N-tripping), Earth fault tripping.

Load monitoring, short circuit protection and overload protection switchable to I2t. Changeable parameter set. Graphical display.

Communication via Ethernet / Profibus, parameterization by communication

Motor operating mechanism Working on 208 - 240 V AC

Auxiliary releases Shunt trip, closing coil, Signaling switch, Capacitor energy storage unit for shunt releases

Indicators and operating elements

Locking set, Make-break operation counter, Electrical on pushbutton, Emergency off pushbutton

Model Latest series meeting the above specification

Make M/s Siemens / L&T / Schneider


P a g e |108 of 208

Table 18. Specifications of Switch Gear - MCCB



Standard Rating

• Incomer Feeder- 150% Rated Current

• Motor Loads-150% Rated Current

• Other loads-125% Rated Current


55kA for incomers and main feeder switches,35kA for sub feeders

Rated insulation voltage Ui 1000V


Standard

Circuit breakers shall comply with the following standards:

• IEC 60947-2

• IEC 60947-1

• Isolating features in accordance

with IEC 60947-3

Over current release features

Overload protection (L-tripping), Short time delay short circuit protection(S-tripping), Instantaneous short-circuit protection (i-tripping), Neutral conductor protection (N-tripping), Earth fault tripping.

Load monitoring, short circuit protection and overload protection switchable to I2t.

Communication via Ethernet / Profibus, parameterization by communication

Auxiliary releases Shunt trip, closing coil, Signaling switch



Table 19. Specifications of Switch Gear - MPCB



Standard rating higher than 120% of the motor name plate current.


35kA or higher

Standard IEC60947-2, IEC60947-4-1


P a g e |109 of 208


Releases Relay Function

Aux Contacts 1NO + 1NC

Add ons Additional 1NO+1NC, short circuit

signaler with 1NO+1NC (Preferable)

Model Latest series meeting the above


Table 20. Specifications of Switch Gear - MCB



Standard rating higher than 120% of the calculated maximum current.


10kA or better


Standard IEC 60898-1 or IS 8828

Curve C Curve for highly inductive loads


Make M/s Siemens / L&T / Schneider / Legrand

Table 21. Specifications of Switch Gear - Contactor



Standard rating higher than 200% of the calculated maximum current.

AC3 current rating at 415V to be considered.

AC4 for inching operatonal requirements

AC1 for resistive loads


50Ka or better


Control Coil Voltage 230V AC

Standard IEC 60947, IS13947

Aux Contacts Required 2NO + 2NC (minimum)


Make M/s Siemens


P a g e |110 of 208

Table 22. Specifications of Switch Gear – Aux Contactor


Control Coil Voltage 230V AC


Aux Contacts Required 4NO + 4NC


Make M/s Siemens

Table 23. Specifications of Switch Gear - OLR


Trip Class 10


Aux Contacts Required 1NO + 1NC (minimum)


Make M/s Siemens

Table 24. Specifications of Earth Leakage Relay


Detail Microprocessor based Earth Leakage

Relay with CBCT of Resin Cast

Model MPEL-02

Current Range 30 mA – 3000 mA

Current Range Setting 18 steps

Tripping time 0 – 5 sec

Auxiliary Voltage 85 – 275 V AC

CBCT Type and Size Resincast Circular

Contact rating 8A, 250V AC / 8A 30V DC 2 C/O

Contacts

Mounting Flush

Dimensions 96 mm x 96 m x 70 mm (W x H x D)

Make Prok DVs

Table 25. Specifications of Power & Control Cables


Type Armoured Copper Conductor

Size Power cable – 4 sq mm. (minimum) Control cable – 1.5 sq. mm. (minimum) Profinet/Ethernet cable-As per standard

Make – 1.1 KV LT Power Cable

CCI / Universal / Finolex / Polycab / IGUS / Gloster / Lapp / KEI / Havells


P a g e |111 of 208


Make – 1.1 KV LT PVC Control Cable

Finolex / RR Kabel / Gloster / Lapp / KEI / Havells / Polycab / IGUS

1.1 KV Panel Wire

Finolex / RR Kabel / Lapp / Havells

Table 26. Specifications of Soft Starter


Quantity 2 +1

Make Siemens

Rated operating voltage

200-460 V , 3 Phase

Duty Heavy duty

Output rating One size higher in standard Soft starter rating of selected motor full load rating

Features required

Soft start, Soft stop, Adjustable current limit. Ramp up minimum up to 120 Sec

Bypass contactor

Integrated

Programmable inputs

4 Nos (minimum)

Programmable outputs

3 Nos (minimum)

Protection Integrated microprocessor based relay with adjustable trip class 5/10/15/20/30 (Overload relay should remain active when drive is in bypass mode also)

Motor winding temp protection

Thermistor protection through PTC

Communication Profibus/Profinet/Modbus/Ethernet TP communication module to be provided.

Parameterisation Through PC interface(Necessary software and connector and cable for PC interface to be provided)

Operator panel External display and operating module to be provided

Control voltage 230V AC

Fault/Error signals required

Missing voltage, Wrong direction of rotation, wrong starting condition, phase failure, missing load, current unbalance, thermal overloading of thyristors, undercurrent and over current limit exceeded, ground fault, Maximum number of starts exceeded.


P a g e |112 of 208

Table 27. Specifications of VFD for BOGIE MOTOR


Quantity 1 Nos

Make Siemens / ABB

Main voltage 380-480 V , 3 Phase

Input Frequency

48-63 Hz

Output rating One size higher standard Drive rating of selected motor full load rating

Control requirement

The drive should start & stop in slow speed and in between higher than start speed .The start, stop and acceleration should not cause any considerable jerk.

Overload capacity

150 % for 60 sec

Digital inputs 6 Nos programmable (minimum)

Analog inputs 2 Nos programmable (0-10 V, 0-20 mA, and -10 to +10 V) (minimum)

Relay outputs 3 Nos programmable (minimum)

Analog outputs 2 Nos programmable (0-20 mA) (minimum)

Safety guidelines

IEC 61800

Ambient Temperature

50 Deg C

Choke or filter Choke/Filter of suitable rating to limit THD as per IEEE519

Operator panel Advanced Operator panel (AOP)mounted on panel cubicle door

Table 28. Specifications of Electric Motors – Blowers & Pumps

BLOWER - MAIN OVEN BLOWER - AGNI OVEN HOT WATER PUMPS


Make Make: Kirloskar /Crompton Greaves/Bharat Bijili /CEMP /Marathon / Siemens

RPM 1500RPM (SYN)

Motor capacity

The motor capacity should be selected such that motor shall draw only 80% of rated current at full load. Design calculations to be submitted towards arrival of motor power rating and approval to be obtained.

Motor type Induction motor


P a g e |113 of 208

Operating Voltage

415 V ± 10 %, 3 Phase

Operating Frequency

50 Hz ± 3 %

Duty class Continuous

Protection IP 54 or better

Insulation class

F and temperature rise limited to class B

Efficiency IE 2 or Better

Thermistor Embedded in windings to monitor winding temperature and trip system upon high winding temperature.

Standard Motors shall comply IS:325 or Equivalent IEC standard

Table 29. Specifications of Electric Motors – Bogie Motor


Make Kirloskar / Crompton Greaves / Bharat Bijili / CEMP / Marathon / SEW / PBL

RPM 1000RPM(SYN)

Motor capacity

The motor capacity should be selected such that motor shall draw only 80% of rated current at full load. Design calculations to be submitted towards arrival of motor power rating and approval to be obtained.

Motor type Flameproof induction motor Ex-d

Operating Voltage

415 V ± 10 %, 3 Phase

Operating Frequency

50 Hz ± 3 %

Hazardous zone operation

Zone I, Group IIA, Group IIB compatible

Duty class Inverter Duty

Protection IP 55 or better

Winding Protection

Minimum Two no’s of Thermistor to be provided for winding protection and interfaced with thermistor relay.

Temperature classification

T4 (135) or better

Insulation class

F and Temperature rise limited to class B

Connector Armoured copper conductor cable terminated using double compression flameproof gland


P a g e |114 of 208

Hazardous zone certification

Flame proof certificate to be issued by CMRI, Dhanbad, ERDL or any other approved body shall provide along with motor.

Standard Motors shall comply IS: 325 or Equivalent IEC standard and provided with Anti Friction Bearings. Motor shall be compatible for operating with VFD addressing issues like Voltage Rise time, Better Insulation Class, bearing currents & documentary proof towards this should be furnished.

Table 30. Specifications of Thyristor Controller


Quantity

Heater Bank - Hot Air (Main Oven – 100kW)- 2No’s Heater Bank - Hot Air (Agni oven – 50kW) )-2No’s Heater Bank - Hot Water (18kW) - 2No’s

Make AE

Model ThyroPX-

Main voltage 380-480 V, 3 Phase

Input Frequency

47-63 Hz

Load type 3phase resistive connected in star configuration

Controller type 3Legged, Digital Processor, 32 Bit or Higher

Firing mode TAKT (Burst Firing), VAR (Phase Angle) and SSSD (Soft Start & Soft Down )

LED Indication LED indications 4 Green, 3 Red LEDs (Freely Configurable Type)

Control mode option required

Vrms, V2, Irms, I2, P or OPEN LOOP selectable with Highest accuracy of 0.5% in V & I Control & 1.0% in P Control

Display Unit Local Display and Monitoring unit for Configuration and Parameterisation with COPY & SAVE function

Removable type display: The Local Display shall be equipped with a graphic touch display and SD card. Process data recorder feature shall be available as standard. Display shall also have following option

Line chart (6 values Min) Operation display (6 values, Min) Bar chart (4 values, Min) Data logger Multi-colour Line / Bar chart


P a g e |115 of 208

Communication Features: Communication Feature – Required for digital data transfer with Motor Management System (MMS)

ProfiNET-V3 / Ethernet IP Communication shall be a Plug & play card type (Communication to be selected based on PLC/MMS Communication Protocol selected) with following key features: - Minimum of 3 free digital Inputs (Configurable for Local / Remote Setpoint change, etc.) - The ProfiNET / Ethernet plug-in card shall have two RJ45 ports which are equipped with a switch functionality which allows a line topology to be constructed - Bumpless Setpoint Transfer shall be a key feature

Digital Load synchronisation

Automatic Synchronisation of Multiple power controller for load optimisation shall be available as standard

Digital inputs 6 No’s programmable (minimum)

Analog inputs 3 No’s programmable (0-10 V, 0-20 mA, and -10 to +10 V) (minimum)

Relay outputs 3 No’s programmable (minimum)

Analog outputs 3 No’s programmable (0-10V / 0-20 mA) (minimum) Configurable

Ambient Temperature

45Deg C

Choke or filter Choke/Filter of suitable rating to limit THD as per IEEE519, if required

Configuration method

PC software or Through Local Display

Short circuit test Compliance

Shall have 100KA Short circuit test certificate from any International Test Lab

Table 31. Specifications of Heater Banks – Hot Water Tank


Bank Capacity No of heating elements

ON/Off Heater Bank –I : 18 kw and Thyristor Controller Heater Bank II :18 Kw No of elements : Bank I-Three No’s Bank-II Three Nos, Each element 6kW (standard immersion heater working on 240V AC)

Heater control ON/OFF control for Bank 1, and Thyristor control for bank 2

Water level Automatic water level controller using level


P a g e |116 of 208

control sensor

Connection

There shall be a local power distribution board mounted on Tank outer wall consisting of six numbers of MCB (one for each heater) & two ELCB one for each bank with Bus bar arrangement in star 4 wire configurations for both heater banks. There will be one heater in each phase and Neutral in each bank.

Teflon wires or suitable heat resistance wires shall be used for terminating heaters from Bus bar in local DB Size of the wire is 200% with respect to the heater drawing current.

Teflon wires or suitable heat resistance wires shall be used for terminating heaters from Bus bar in local DB.

Size of the wire is 200% with respect to the heater drawing current.

Capacity 36 Kw

No of Banks 2Nos

Supply Voltage 415V+/-10% 3phase, 4 wire

Connection 3Phase Star Configuration

Individual Heating Element Voltage

1 Phase, 240V AC

Heater tube material

INCONEL

Heater Material Nichrome 80/20

Insulation Material

Magnesium oxide

Table 32. Specifications of Heater Banks – Main Curing Hot Air


Capacity ON/Off Control Heater Bank 100Kw- 1No Thyristor Controller Heater Bank 100 Kw – 2Nos Total Capacity: 300 KW

Supply Voltage

3phase, 4 Wire, 415V+/-10%


1 Phase, 240V AC


P a g e |117 of 208



INCONEL

Heater Material

Nichrome 80/20

Insulation Material

Magnesium oxide

Heater box housing

The entire heater battery should be mounted inside a double walled mild Steel casing having rock wool insulation of not less than 100 mm thickness between walls in order to prevent heat losses. The heater terminals must be brought to one side so as to facilitate connection and replacement easily. They shall be terminated in a terminal box. The heater shall be fitted with withdrawal type, sheathed, tubular heating element Heaters battery shall have flanges for

connecting the heater and ducts. Heater battery

shall be sized same as that of the duct size

preferably.

The design & arrangement shall be suitable for

standard cabling into the terminal enclosure

without the need for an intermediate junction

box and high temperature cables. If this

requirement is not met by the product, then

necessary high temperature cables & junction

box shall be provided by the contractor / party.

Silicone seal shall be applied to the lead exit

and between lid and terminal box to improve

ingress protection. This shall be supplied in

adequate quantity along with the equipment.

Black heat operations

Heaters shall be black heat type. The heaters shall not become red hot with air flow. Watt densities of heating elements shall be limited to a suitable value to prevent red hot.

Table 33. Specifications of Heater Banks – AGNI Curing Hot Air


Capacity ON/Off Control Heater Bank 50 KW- 1No Thyristor Controller Heater Bank 50 KW – 2Nos Total Capacity: 150 KW


P a g e |118 of 208

No of Banks 3 Nos

Supply Voltage 3phase, 4 Wire, 415V+/-10%


1 Phase, 240V AC



INCONEL

Heater Material Nichrome 80/20

Insulation Material

Magnesium oxide

Heater box housing

The entire heater battery should be mounted inside a double walled mild Steel casing having rock wool insulation of not less than 100 mm thickness between walls in order to prevent heat losses. The heater terminals must be brought to one side so as to facilitate connection and replacement easily. They shall be terminated in a terminal box. The heater shall be fitted with withdrawal type, sheathed, tubular heating element Heaters battery shall have flanges for connecting the heater and ducts. Heater battery shall be sized same as that of the duct size preferably.

The design & arrangement shall be suitable for standard cabling into the terminal enclosure without the need for an intermediate junction box and high temperature cables. If this requirement is not met by the product, then necessary high temperature cables & junction box shall be provided by the contractor / party.

Silicone seal shall be applied to the lead exit and between lid and terminal box to improve ingress protection. This shall be supplied in adequate quantity along with the equipment.

Black heat operations

Heaters shall be black heat type. The heaters

shall not become red hot with air flow. Watt

densities of heating elements shall be limited

to a suitable value to prevent red hot.


P a g e |119 of 208

Instrumentation & Control Systems


P a g e |120 of 208

8. Instrumentation & Control Systems

8.1. Scope of Work

8.1.1. Design, procurement, integration, factory testing, supply, packing, forwarding, unloading at site, erection, testing & commissioning of total instrumentation & control system for the operation of Segment & AGNI Curing Oven

8.2. Equipment & Services to be supplied by the Party

Party shall carryout Supply, installation and commissioning of Instrumentation and Control System (ICS) and related accessories for Curing Facilities as detailed in this document.

8.2.1. The details of the systems, equipment & services from the party

are listed below

S. No Description Details

1. The PLC System

As per enclosed specifications &

Annexures 6C-1 to 6C-8

2. The SCADA System

3. Data Acquisition & Control System

(DACS)

4. Power Supply Systems

5. Panels & Field Instruments

6. Cables

7. Miscellaneous Items

8.2.2. Preparation of P&ID and detailed engineering drawings.

8.2.3. Design of data acquisition and control system for curing

process as per technical specification, Procurement of items as

per technical specifications.

8.2.4. Panel wiring, assembly, factory acceptance testing, packing

forwarding and delivery at site.

8.2.5. PLC & SCADA environment and application programme

development.

8.2.6. Installation, interfacing PLC & SCADA with associated sub-

systems with field instruments, electrical systems (i-MCC) etc.,

8.2.7. Ferruling, wiring terminations at junction boxes and laying of

cables to the PLC panel


P a g e |121 of 208

8.2.8. PLC logic implementation as per User Requirement Documents,

which will be given after the award of contract.

8.2.9. All software development works shall be carried out at

purchaser’s site.

8.2.10. Site acceptance test, commissioning & handing over of systems

for automated operations.

8.2.11. Factory Acceptance Test (FAT) procedures (verification of BOM,

functional checks, compliance to specifications, load test of

power supplies, environment software testing, diagnostics data,

alarms and report generation check etc.,) shall be submitted to

department for approval.

8.2.12. Quality Audit Plan (QAP) assurance plan containing the

detailed test and evaluation plan for instrumentation and

control system with identified stages shall be submitted.

8.3. General Instructions to the Party

Party shall comply with the following general instructions to realise the Instrumentation and Control System (ICS) and related accessories as detailed in this document.

8.3.1. The party should select the control system components with the preferred makes mentioned in the technical specification section.

8.3.2. The details of the control system configuration, PLC and

SCADA systems, I/O’s and sensor specifications are mentioned

in the below sections.

8.3.3. Party shall inform to purchaser at identified stages to carry out

inspection and the copies of such reports after inspection shall

be forwarded to Purchaser.

8.3.4. The original copies of test certificates shall be submitted along

with other documents at the time of site acceptance testing.

8.3.5. The commissioned instrumentation, control system and its

subsystems are to be subjected to Test and Evaluation by the

Purchaser Committee. This is to ensure that the integrated

system is meeting all its intended requirements as per the given

specifications. Any deviations observed shall be resolved by the

supplier at no extra cost

8.3.6. In addition to Instrumentation & Control System, the supply

and interfacing of auxiliary systems like Operator consoles,

Panels / Junction Boxes, UPS Distribution Panels along with


P a g e |122 of 208

SPDs, Cables etc. are also in the scope of the supplier

8.3.7. The Oven manufacturer shall employ an authorized system

integrator of M/s Schneider / M/s Siemens/ M/s Allen Bradley

to execute the Instrumentation and SCADA Systems.

Authorization certificate shall be produced along with tender

document

8.3.8. IMCC shall be similar make of PLC/PAC only

8.3.9. The quantity mentioned in the specifications/ data sheets is

the minimum quantity to be supplied.

8.3.10. Party shall submit P&ID, detailed panel engineering and I/O

wiring schemes to obtain clearance (from SHAR) prior to the

commencement of erection and commissioning activities.

8.3.11. Party shall obtain clearance for panel engineering drawings,

P&ID Diagrams, I/O wiring schemes, Marshalling chamber

termination schemes and Technical specifications of all the

items from Department prior to the supply, erection and

commissioning activities. Any other make/Model/ Dimensions

require prior approval from department

8.3.12. Party shall be OEM or employ an authorized & reputed system

integrator of OEM (Siemens/ Schneider/Allen Bradley), in case

of outsourcing DACS works. This system integrator shall be

approved by department & shall have minimum 5 Years of

experience in the field of Control systems proposed make along

with proof.

8.3.13. Much care has been taken in arriving the list of equipment and

quantities, however if any equipment or components which is

not mentioned explicitly but essentially required for the

completion of system is in the scope of the Party.

8.3.14. The configuration of major bought out items like PLC, SCADA

etc., shall be reviewed and wetted by original equipment

manufacturer (OEM). If any of the item supplied as part of this

contract is not meeting the system requirement or any

compatibility/ interface issues with other systems are found at

any stage of the project, same shall be replaced with suitable

items without any additional cost.

8.3.15. The party should interface the control system with all field

elements which are brought to the instrumentation junction

box. The supply of isolators / signal conditioners / signal


P a g e |123 of 208

converters required to interface the field elements are in the

scope of the party. Specifications of the isolators are as per the

datasheet

8.3.16. The party should interface Drives and iMCC through suitable

interfaces as mentioned in the technical specification section

and also data to SCADA from existing PACs also.

8.3.17. The User Requirement Document for PLC/SCADA program

development will be handed over to the party after the award of

contract.

8.3.18. Detailed schedule of execution is mentioned in earlier part of

this document

8.3.19. The party shall necessarily fill the compliance statement and

may visit site before bidding for discussion.

8.3.20. For the warranty period, Party shall deploy team to carry out the updations, if any required in SCADA or PLC program after commissioning. They shall also carry out fine tuning/ carry out modifications in DACS and train the operators. The team should have thorough knowledge on PLC & SCADA systems and worked for this project.

8.3.21. During the warrantee period, party has to arrange for periodical maintenance once in every three months and unlimited breakdown calls and replacement of failed/ malfunctioning components without any additional cost.

8.3.22. Party shall provide PLC/SCADA Project backup.

8.3.23. The configuration of major bought out items like PLC, SCADA

etc., shall be reviewed and vetted by original equipment

manufacturer (OEM)

8.3.24. List of documents to be submitted (one set of soft & 2 set of printed copy);

• Full set of as built drawings (system configuration, GA, as built wiring, cable layout, instrument layout etc.).

• Software design documents – SRS, SDD, PLC/SCADA – Configuration & Program, test case documents, contingency procedures and operational check lists. PLC program shall be provided as hard copy also.

• Final BOM with make & model number.

• All technical catalogues and datasheets of all items.

• All test results (Internal tests by vendor, FAT, software test results, SAT etc.).

• Warranty certificates.


P a g e |124 of 208

• Passwords/ Licenses/ Operating keys etc.,

• Any other relevant document not listed above.

8.4. Design & Reviews

Party shall carryout the design of the systems and submit the documents as a part of design review of the systems.

8.4.1. Proposed control room layout indicating of operator consoles,

SCADA Server, SCADA Historian/ Ethernet Accessories/ UPS

Distribution panel etc.

8.4.2. GA drawing of the I/O panel in field and PLC panel in the

Control room.

8.4.3. Cable routing schemes indicating the cable trenches, junction

boxes and terminations etc.

8.4.4. PLC and SCADA configuration indicating the Field elements,

I/O modules, network switches, Ethernet to fibre converters,

Operator work stations, SCADA Servers, SCADA Historian,

SCADA Clients, etc.

8.4.5. Wiring diagram for DI, DO, AI and AO.

8.4.6. Tentative I/O list

8.4.7. Details of interfacing with Drives, i-MCCs, Pumps,

Compressors, weighing scales, CCTV systems etc.

8.4.8. Final BOM of all the systems.

8.5. Inspection – FAT & SAT

8.5.1. Purchaser reserves the right to inspect all phases of Supplier’s

operations. Therefore, it is the responsibility of the supplier to

provide the necessary support for the inspection agency and

get the works inspected at all stages of work as identified in

Quality Assurance Plan. The Supplier shall carry out required

supervision and inspection as per Quality Assurance Plan and

furnish all assistance required by the Purchaser in carrying

out inspection work during this phase.

8.5.2. Supplier shall inform the Department the readiness for

Instrumentation & Control Systems pre-delivery inspection at

least 10 days in advance. All necessary test results /

inspection reports / certificates as per the QAP and any other

test results mutually agreed by Department and supplier shall

be made available to the Purchaser after conducting tests as


P a g e |125 of 208

mentioned above in pre-dispatch inspection for obtaining the

dispatch clearance.

8.5.3. The following items will be inspected by department at factory

before dispatch (FAT), necessary test set up and test

equipment shall be arranged by supplier,

• Field Elements

• 24V DC power supply modules.

• PLC & SCADA systems assembled as per system configuration with environment software.

• Simulation of Digital and Analog Signals

• All IO panels, control consoles and UPS Distribution Panel.

• All types of cables

8.5.4. After delivery of items to site, the installation works shall be taken up after obtaining clearance from department.

8.5.5. Site Acceptance Test (SAT) procedures for the following tests shall be submitted for approval prior to inspection.

• BOM verification.

• Functional checks, compliance to specifications, load test and burn-in test of all items.

• I/O loop End to End checks, line calibration and environment software validation.

• Application software testing including failure modes, validation of diagnostics data, event & alarms log view, data logging, report generation etc.

• Trial runs with nominal & off-nominal cases.

8.5.6. After completion of installations, testing and commissioning, Site Acceptance Test at SDSC SHAR will be carried out.

8.6. Training

8.6.1. Training shall be provided from the Original Equipment

Manufacturer at their training centre for 2 persons deputed by

Department on the following

• Hot Standby PLC configuration and programming

• SCADA configuration, programming, trend and alarm generation and data backup

8.6.2. The training shall be for a minimum duration of 1 week on each

topic. Training is to be arranged before the start of PLC

program development by the supplier.


P a g e |126 of 208

8.7. The PLC system

8.7.1. Supply, installation, testing and commissioning of PLC/PAC components like CPU, communication modules, power supply modules, I/O modules, 3rd party interface devices, I-MCC interface modules and associated PLC accessories as per the enclosed technical datasheets. IMCC for curing operation is only for monitoring.

8.7.2. PLC/PAC shall be provided with suitable communication ports to interface with intelligent motor control center (I-MCC) of similar make as PLC for monitoring of their electrical health parameters as described in Electrical section of this tender document.

8.7.3. A common hot standby PLC shall be planned for both Ovens and shall be located in control room Control console and Remote IOs shall be located in respective oven service room IO Panel.

8.7.4. Hot standby PLC/PACs with Ethernet IP Port & with Criss-Cross configuration & with communication ring shall be provided. Service rooms are away from the control room. The distance between Main oven service room and AGNI oven service room from the CCMC located at control room are about 250 and 300m respectively. IO rack shall have dedicated panel attached Air conditioner for IO Modules. Panel Air conditioner rating shall be selected according to instruments/ modules positioned in IO rack.

8.7.5. All communication speed between IO/PAC/PLC/IOs/SCADA stations shall be of 100 Mbps or better.

8.7.6. The System shall be designed with three modes of operation.

PLC/PAC Mode Operation – Command from SCADA - Remote

operation from control room operator station.

Console Mode – Command from console to iMCC - Soft

starter/VFD/Thyristor controller/Aux & Main contactors/

DOL/SD housed in iMCC without Motor Management

System(MMS) like CVMM/Basic module etc.,) - Remote operation

from control room.

MCC Mode - Local operation from service room only for blower & hot water pumps

8.7.7. In PLC/PAC Mode, all controls of the Electrical sub systems


P a g e |127 of 208

shall be controlled & Commanded by PLC & it’s DO and AO Modules. PLC to be linked with MMS for acquiring current, voltage, ON/OFF status etc., only for monitoring and recording wherever necessary and not for control purpose.

8.7.8. In Console Mode, All sub systems will be operated from Console, PID Controller Relays & AO Output will be connected directly to MCC (Soft starter/VFD/Thyristor controller/Aux & Main contactors/ DOL/SD housed in iMCC without MMS like CVMM/Basic module etc.,) for operation. The command from Console & PLC DO o/p shall be interfaced with Diode TBs. The Push buttons shall be interfaced to a solid state relay with latch / release mechanism in control room console and potential free point of solid state relay shall be interface with P&F 2 In 2 Out Relay in IO Panel (Blowers, Pumps & Heater Banks). The DO command from PLC & potential free point of P&F relay of PBs shall be interfaced with single solid state relay to command the sub system with Diode TBs. Analog Output from PID controller shall be interfaced to Thyristor through Diode TBs along with AO command from PLC in IO Panel.

8.7.9. In MCC mode, all systems shall be controlled from push buttons in MCC. Heaters shall be controlled from Single loop Controller in Control Console. The control for blowers & pumps shall be separated from IO rack for MCC operation.

8.7.10. The mode selection in MCC panel shall be local/ remote and in control room (Remote) shall be SCADA/ Console.

8.7.11. In PLC Mode or Console Mode, the final command from IO panel shall be one to MCC. Both PLC & Console commands shall be parallel with proper protection.

8.7.12. The Annunciator provided in the Control Console in control room shall show the status of the systems independent of mode selection. The status will be finalized at the time of commissioning. Annunciator is not in the scope of the party.

8.7.13. All Discrete/Manual mode operation contactor status shall be acquired in PLC/PAC.

8.7.14. Only one output shall leave from IO panel to MCC for operation in SCADA/ PB mode. Local/ remote isolation shall be provided in MCC.

8.7.15. All 1 in 2 out IS relays for Proximity sensors status & contactor status shall be placed in MCC panel. The dual output status from IS relays in MCC shall be interfaced to PLC DI module in IO panel.

8.7.16. PLC/PAC shall acquire all analog & digital parameters


P a g e |128 of 208

irrespective of Mode selection and logging of parameters in SCADA also independent of Mode selection.

8.7.17. Suitable interface converters shall be provided with redundancy to interface iMCC.

8.7.18. Three number of PID Controller in Main Oven MCC & Agni Oven MCC for hardwire tripping of over temperature in Inlet & Outlet damper and Heater bank area. The transmitters shall be placed in IO rack and signal shall sent to Controllers in MCC Panel.

8.7.19. Two numbers of Duplex RTDs shall be planned at Inlet fire damper, Outlet fire damper & in Heater bank location. Out of which One output of one of duplex sensor in each location shall be interfaced to Temperature Transmitter, shall be located in IO Panel, & to ABB Controller in MCC. The two outputs of Second Duplex RTD shall be interfaced directly to Main & Redundant PLC RTD Input module. Two runs of 24 core FOC shall be laid for each oven. All cores shall be spliced in both ends.

8.7.20. Two runs of 16 Pair, 1 sq.mm Data cable shall be laid from IO rack to control Console from each oven and shall be terminated in both ends. One run for console signals to MCC and Second run for Transmitter signals & Annunciator signals. One run of 16 pair cable from deluge system Junction box to IO rack is in the scope of the party.

8.7.21. Two numbers of 230VAC/ 10A double pole MCBs shall be provided for safety system in IO rack. One MCB shall be provided for safety deluge System and another MCB for smoke detection System in IO panel. The safety system shall be operated independent of control system PLC. The transmitters & related Isolators and other elements functioning shall be possible to use without control system. A dedicated Dual power supply shall be provided for safety deluge systems and DIN rail mounted recorder, with Modbus TCP interface, for logging safety parameters (5 AI & 5 DI) shall be provided in IO rack and recorder also shall be linked to SCADA.

8.7.22. 2 sets of DC power supplies with diode ORing Module along with Voltage & Current monitoring shall be used in both ovens. One set for acquisition/control chain, second for safety systems.

8.7.23. A dedicated memory card (4GB SD Card or more) shall be available in PLC/PAC as an option to log the data continuously in defined log intervals irrespective of communication with SCADA Station to avoid data loss.


P a g e |129 of 208

8.7.24. For Interlocks/Proximity Sensors P&F 1 in 2 Out dual Power rail Modules shall be used instead of Relay boards.

8.7.25. All Proximity sensors & Contactor status IS relays shall be placed in MCC Panel.

8.7.26. All the spare digital and analog inputs shall be wired up to Marshalling chamber.

8.7.27. All PID controller data shall be interfaced to SCADA via Ethernet interface available in controller.

8.7.28. Safety related status shall be brought directly through 16 pair data cable planned to annunciator and Oven related system status to annunciator via DO card or through 16 Pair cable in Control room.

8.7.29. A dedicated IO Rack shall be provided to house IO Modules, Network Accessories, CCTV Accessories with Panel AC. It shall be separated from MCC Panels. CCTV accessories & smoke detection system is not in the scope of supplier.

8.7.30. Another separate MCB shall be provided for CCTV Systems powering and to be terminated in TB. Space shall be provided for mounting two number of 12VDC power supply with Diode oring module and Infinova Video to fiber converter in IO rack.

8.7.31. A dedicated Instrumentation Marshalling chamber with screw/ Spring gage type terminal blocks shall be provided to terminate all Signals for ease troubleshooting and shall be positioned adjacent to Instrumentation Rack. Panel shall have proper earthing & isolation system.

8.7.32. General Features for PLC / PAC & IO Modules

The controller shall be supplied with the CPU, input/output scanner, inputs, outputs, memory, power supply, and all power and interface cables necessary to function as a complete and operable Programmable Automation Controller system.

Modules are defined herein as devices that can be removed individually from its position for replacement and are keyed to allow installation in only one direction. The design must prohibit upside down insertion of the modules.

The Programmable Automation Controller shall have downward compatibility, whereby all new module designs can be interchanged with all similar modules, in an effort to reduce obsolescence.

The Programmable Automation Controller shall have the


P a g e |130 of 208

ability to support TCP/IP data communication link like Ethernet/IP and other third-party networks.

In a single chassis system, all system and signal power to the Programmable Automation Controller and support modules shall be distributed on a single backplane. No interconnecting wiring between these modules via plug-terminated jumpers shall be acceptable.

All system modules, including the Programmable Automation Controller, may be removed from the chassis or inserted into the chassis while power is being supplied to the chassis without faulting the controller or damaging the modules (removal and insertion under power (RIUP)).

The Programmable Automation Controller shall include an integrated Real Time Clock (RTC). This clock value shall be in the form of a predefined tag and shall be accessible via logic or remotely.

The Programmable Automation Controller shall have the capability of providing proportional, integral, and derivative (PID) control in real time, preferably with pre-emptive priority multitasking.

The Programmable Automation Controller shall support Auto-Tuning functionality without additional software and it should be the in-built functionality

A controller, or I/O card, shall be capable of being inserted under power, without upsetting the process being controlled by other controllers.

Controller shall have the ability to monitor and override I/O.

IO module shall have status lights for each input and output module.

The Programmable Automation Controller shall be configurable to accept only firmware updates from authorized users.

The Programmable Automation Controller project files shall be configurable to allow modification only by authorized users.

8.7.33. General Features for Network

The system should utilize the standard TCP/IP Network to move data seamlessly throughout the system. Multiple physical networks, including the plant, supervisory, control, and device networks should appear as a single network


P a g e |131 of 208

making communications efficient.

The Onboard Communication port in Programmable Automation Controllers should be used only for Programming not for HMI or I/O Communication. Dedicated communication card shall be provided for IO Communication & SCADA Server communication.

The Ethernet TCP/IP interface shall support bridging between Ethernet TCP/IP networks within a Programmable Automation Controller chassis.

The Programmable Automation Controller shall be capable of direct communication with standard commercial Ethernet products, without the use of software or hardware gateways.

Supervisory Network: The open technologies of Ethernet and TCP/IP shall be utilized for communication between the control system server and the operator stations. The control system server and its associated operator stations must be capable of connecting to two fully independent Ethernets run in parallel. No repeater or bridge connection between the Ethernet is acceptable as a means of achieving this function. This Network shall be used for connection of Servers, Workstations and OWSs to the controllers.

Control Network: The process control network/remote I/O network is used to connect the controller to field (Remote) I/O and shall be an open, flexible, high performance network.

Control Network Redundancy: To ensure maximum reliability, communications shall be redundant. The communications system shall be capable of sustaining loss of one media channel without loss of data or performance and Loss of communications shall not cause loss of control at the local subsystems. Also, loss of a local subsystem (either a single node or both of a redundant pair) shall not cause the loss of network communication.

8.7.34. General Features for Redundancy

The Programmable Automation Controller system shall be true hot back up i.e., redundant with separate chassis, power supply, controller and communication modules

The Programmable Automation Controller Enhanced Redundancy System shall provide higher system availability. This shall be realized by switching control to a secondary controller chassis if anything in the primary controller chassis fails.


P a g e |132 of 208

The Programmable Automation Controller Redundancy System should be able to operate without any local I/O, and having all I/O configured as remote I/O

The Programmable Automation Controller Enhanced Redundancy System shall be realized by using standard revisions of hardware, including chassis, power supplies, Programmable Automation Controllers, and communication adapters.

The Programmable Automation Controller/ PLC Redundancy System shall use fiber-optic media to connect the primary and the secondary control system.

It shall be possible to implement the Programmable Automation Controller Redundancy System without additional programming.

The redundancy system shall take over the program and data from the main controller instantaneously in case of failure of main controller.

Runtime modification done in Main controller should automatically get updated in stand-by controller without any exporting and importing of logic, it should be a true Hot Back-up system.

8.8. The SCADA system

8.8.1. Two numbers of SCADA Server in Hot standby mode with full configuration SCADA license, One Nos of SCADA Historian Server dedicated for all 8 ovens and 1 Nos operator client HMI work station shall be provided for communicating with the above PLC for Data Acquisition & Control along with acquisition from Existing Ovens PLCs.

8.8.2. All the communication between SCADA Station, Historian/Alarm Server and Operator station shall be provided with redundant Ethernet port.

8.8.3. SCADA server license for Two Servers with 5000 Tags of full development version with four numbers of HMI client license (one for operator station & 3 for Thin Client units) and 2 Nos of web space clients and One No’s of Historian Licences with 1500 Tags & with 10 multiple HMI user access and 10 web user access shall be supplied. One SCADA license for programming station shall be provided by the supplier. SCADA license shall be of floating (USB Dongle) license type which shall be positioned inside the Server/ Operator Station Cabinet and also two nos of PLC programming software shall be supplied.


P a g e |133 of 208

8.8.4. Sub-system wise mimic screens to monitor the process status and real time operations.

8.8.5. MMI-PLC-IO network configuration screens with critical diagnostic information and messages shall be designed.

8.8.6. Diagnostics screen for PLC hardware components, 3rd party devices, transmitters and valves etc., with faceplates for each device shall be designed.

8.8.7. Event & Alarms screen (Sub-system wise filtering to be provided).

8.8.8. Trends screen & any other screens as per the user requirement

8.8.9. Statistical tool shall be provided for report generation and SCADA software should support this tool.

8.8.10. Suitable interface module/ converters & switches shall be used for effective communication between CPU rack to I/O rack & CPU to MMI. Design of redundant SCADA System shall be free from any single point failure.

8.8.11. SCADA System shall acquire (via Ethernet communication) the data from the existing ovens PLC system also. Necessary details of the existing ovens DAS will be provided by the department. All existing Ovens PLCs are with Ethernet/IP with MODBUS TCP protocol.

8.8.12. Party shall interface existing Ovens PLC to the SCADA for new ovens along with suitable MIMIC/ Data logging/ Alarms/ etc. All Servers, Operator console shall display and log all oven data. An L3 switch shall be provided to interface the system to centralised location through existing LAN. The failure of L3 Switch shall not affect the SCADA Network.

8.8.13. All internal switches shall be of L2 Managed Switch with ring features.

8.8.14. Operator Console: Operator SCADA Station, CCTV Keyboard, Wireless Base station and Intercom shall be housed in a single modular furniture of unique design and of high quality as per the details given subsequent chapters along with furniture and control room partition shall be executed.

8.8.15. A network Server rack shall be provided to house SCADA / Historian Servers, Fiber Optic Converters, another server rack with all Optical fibre Splice racks and an Operator station shall be mounted in Modular console.

8.8.16. Common Control and Monitoring Console - CCMC with provision to mount Temperature controllers and PLCs will be


P a g e |134 of 208

provided by the department. Party shall interface the system with this CCMC for operations.

8.8.17. Features of SCADA / HMI

It shall be scalable from small systems to very large systems.

Screen update times will be one second or less.

Security will be an integral part of the system.

The HMI shall be designed for use in latest Microsoft Operating System. It shall use ODBC, OPC, and ActiveX technologies for optimal performance and integration with other software systems.

SCADA Server shall have thin manager support. i.e. All client HMI can be managed with thin clients instead of computer/ work station.

The system will be able to browse all tags in the controller.

There will be a factory library for standard face plates and controller instructions that will be maintained and supported by the vendor

Data servers shall be configurable to run on both a primary computer and a backup computer. The system should automatically switch to a backup computer if communication with the primary computer fails.

The servers should handle failure detection and failovers automatically for all components (OWSs) of the system.

The HMI editor should allow for simultaneous collaboration by multiple developers.

The HMI shall provide a tool to show the status of installed product patch file versions currently installed on a computer.

The HMI shall support data servers as a means to communicate with any OPC server.

The HMI shall log all data in files in an ODBC database for easy retrieval in other programs such as Microsoft Excel

The HMI Server/Client should support Thin Client/ Terminal Services Architecture

The HMI clients shall be able to view tag data from any HMI server or data server in the application as well as displays.

The HMI shall support remote editing

The alarm system shall have the ability to monitor any


P a g e |135 of 208

analog or digital tag for alarms.

The alarm system shall have the ability to define up to 4 different severity classes to visually distinguish alarms.

In the alarm summary display, a user can acknowledge an alarm. The alarm will then appear as acknowledged to all OWSs in the application.

Custom alarm summary objects shall be able to be embedded on any display

The alarm system shall allow online export of an alarm log file to ODBC format databases.

The alarm system shall allow the operator to write a custom message to the alarm history.

Alarms can either be polled or sent by exception from the controller

The system shall ensure Operator WorkStation security by authenticating users against a set of defined user accounts and access privileges.

The available security service should protect against unauthorized use but still allow authorized users to use the system efficiently.

8.8.18. Features of Historian Servers

Data collection nodes (SCADA Server) will feed the historian

Historian trends can be inserted into the HMI graphics and browse for tags in the controller

The Plant Historian shall be an integrated software package for collection of plant floor process data and running information / reporting applications

The Historian shall support a variety of client platform technologies with primary focus on thin client access to data and reports from a web browser.

The Historian shall utilize an optimized time series database for optimal performance in both collection and storing data and for accessing data for displays, dashboards, trends and reports.

The Historian shall support redundant architectures for both redundant data interface nodes on redundant data servers.

The Historian shall support store and forward capability between the Historian and the data collector interfaces, such


P a g e |136 of 208

that data is stored at the interfaces if the Historian is un-available, and then forwarded to the Historian when it is available, ultimately minimizing data loss.

The Historian shall be capable of accepting data from multiple sources of inputs.

Primarily signals from Programmable Logic Controllers, Programmable Automation Controllers, Distributed Control Systems and Human Machine Interfaces shall be used for data input

All standard configurations changes shall be “on-line” without the need to stop & re-start the Historian server. Only exception to that would be licensing changes to add or remove capabilities on the server.

The Historian shall store data in time limited archive files, so only the current archive file is updated with new data, and prior archives are updated by exception only.

System must provide for the automatic creation of archive files and the ability to automatically overwrite the oldest archive for unattended operation.

The Historian shall provide a method for backing up all on-line archives on-line without the need to stop the archive system

The interface shall allow for Historian data to be trended in the native HMI trend.

The Historian shall have real-time and historical trending capabilities. It shall also have the ability to display both real-time and historical data at the same time on the same trend

8.9. Data Acquisition & Control System (DACS) programming

DACS (PLC & SCADA) programming shall be developed as per IEEE 12207 standard. User requirements document (URD) will be provided after award of the contract.

8.9.1. Environment Software

a. Environment software comprising of PLC hardware configuration, I/O acquisition, simulation tags for all I/O’s, main or redundant signal override function, scaling function etc., shall be developed.

b. The acquired I/O’s of main, redundant and triplicate are to be validated by taking into account of concerned channel diagnostics data, channel discrepancy and simulated value etc.


P a g e |137 of 208

c. Design of environment software shall be submitted for approval. After development, the same will be thoroughly reviewed & tested during pre-delivery inspection (Factory Acceptance Test-FAT) by department.

8.9.2. Application Software

a. The application software design shall be carried out based on URD and shall be submitted for review & approval from the department.

b. The application software shall be developed covering the following general requirements

• Automatic sequence of operation

• Initial conditions, running interlocks, surveillance checks etc.

• Failure cases, contingency conditions etc.

• Discrete mode of operation (Individual components/ overall all sub-system)

• User friendly messages and pop-up windows for guiding the operator on steps of operation, warning, alarm & trip conditions etc.

8.9.3. The PLC/PAC & SCADA software development shall be carried at Party’s Site for Functional Checks only and remaining development shall be carried at our site (SHAR).

8.9.4. Bidder shall deploy minimum 2 persons at site to carry out above software development works immediately after system configuration is approved by department. Both should have thorough knowledge on PLC/PAC & SCADA systems with minimum 5 years’ experience in PLC/PAC & SCADA programming of PLC Brand offered for the system.

8.9.5. After successful testing & commissioning, the source code should be handed over to department.

8.9.6. Steps in DACS Software Development, Review & Testing;

a. Submission of environment software design document for approval from department.

b. Development of environment software by Party at site.

c. Review & testing of environment software by Party & department.

d. Based on review, modify/update environment software, documents and submit for approval.

e. URD document for application software design will be given by department, if any modifications are required, same shall


P a g e |138 of 208

be carried out by Party.

f. Submission of application software design documents (SRS, SDD and SCADA design documents) shall be submitted for approval

g. Application software development & testing by Party.

h. Submission of test case (black & white box with nominal & off-nominal test cases) documents for department review & approval.

i. Review & testing of application software by Party & department.

j. Modify/update application software, documents (including URD) and submit for approval.

k. Carry out trial runs of individual sub-systems, simulation and dry runs of integrated system by Party and department.

l. Modify/update environment and application software for fine tuning and update documents, then submit for approval.

8.9.7. The DACS Application Program

a. It shall be developed for the operation, control, monitoring and data logging of following sub-systems

• Main Oven Sub Systems

• Agni Oven Sub Systems

• Hot Water Circulation System for Main Oven

• Safety System

• UPS System

b. Control room operation shall have discrete and manual mode of operation.

8.10. Power Supply Systems

8.10.1. Uninterruptible Power Supply (UPS)

3 Phase UPS AC power distribution panel (2 Nos.)

with suitable surge protection devices (SPD) shall be

provided as per datasheet and drawing.

Three phase DUAL UPS supply will be provided to

party. Party has to supply the Elegant UPS

distribution panel with SPDs at Input & Output and

take care of distributing load to all system. All Main

Power supply shall be powered from Main UPS Line &

redundant power supply from redundant line. UPS is

not in the scope of the contractor


P a g e |139 of 208

8.10.2. 24V DC power supply

Supply, installation and commissioning of diode OR-

ed redundant 24V DC power supplies in each PLC

rack (M/ R/ T) with SPD for Measurement and

Command chain and 24V DC power distribution

panels (3 Nos.) shall be provided as per the datasheet

and drawing.

One set of diode ORed redundant 24V DC power

supply shall be provided for Safety System.

All dual 24VDC power equipment’s shall be powered

on both supply terminals.

Status monitoring for the following shall be provided

and wired to DACS.

• ON/OFF status of UPS input/ output MCCB/ MCB / SPD.

• ON/OFF status of critical MCBs (25 Nos.) in AC & DC PDB.

• UPS output load current & voltage.

• Each DCPS Diode OR-ed Output Load Current & Voltage shall be monitored.

A dedicated single IO chain shall be planned to

acquire all power supply related parameters.

8.11. Safety Systems

8.11.1. The safety deluge system shall be interfaced from Field JB in Deluge Room to IO Rack with a 16 pair armoured cable is in the scope of the party.

8.11.2. Interfacing Smoke Detection System with SCADA system is in the scope of the supplier. Suitable interface converter to interface Smoke detection system with SCADA is in the scope of the party. The interface converter will be decided at the time award of contract.

8.11.3. Party shall provide separate dual pole UPS MCB for Deluge & Smoke detection System separately.

8.11.4. The Deluge transmitter signal shall be splitted to two using P&F Signal isolator – one for dedicate DIN Rail recorder with Modbus TCP Interface & other to PLC Main & Redundant system via 1 in 2 out P&F Isolator is in the scope of the


P a g e |140 of 208

supplier.

8.11.5. Party shall interface Pressure Transmitters, Pressure switches and 24VDC solenoid valves in deluge system with SCADA System

8.11.6. The solenoid valve shall be operated through hardwired Manual Call Point Key to release system, which shall be located at the entrance of control room. Provision shall be provided to interface via PLC with Diode protection TBs at Field JB. The Manual Call point button shall be hardwired to carry 24 VDC to solenoid valve. Deluge System field JB is not in the scope of the supplier. Supplier has to lay 12 Pair cable from Deluge Room to PLC Rack.

8.11.7. All status of Switches and solenoid valves shall be acquired by the recorder and PLC.

8.11.8. Recorder shall be provided with 2 GB Memory card.

8.11.9. Supply, Installation of deluge system & Smoke detection systems is not in the scope of the supply. These systems will be installed by third party. However as explained above necessary data monitoring, recording and Interlocks shall be provided.

8.12. Cables

8.12.1. Supply, laying, termination & testing of Fiber optic, Ethernet, RS 485 cables, Power, Control and Signal cables are in the scope of the contractor.

8.12.2. All the miscellaneous items like instrument fittings, Junction box (Weather Proof & Ex. Proof), cable glands, lugs, terminal blocks & internal wirings required for realizing the above scope of works are in the scope of Bidder. Bidder shall obtain approval prior to procurement of the above items for its make & model (refer datasheet & list of approved vendors)

8.12.3. The cables within the buildings shall be laid over perforated type, modular SS/ GI cable trays with SS/GI cover. Bends/ reducers/Tees shall be used as per actual requirement.

8.12.4. The cables shall be laid in trenches outside the buildings (from service rooms to control rooms). Necessary Galvanised Steel cable trays shall be used inside the buildings

8.13. Earthing

8.13.1. Separate Instrumentation earth pits are provided near to control room, main oven service room & Agni oven service room. These earth pits are not in the scope of the contractor and will be provided by SHAR.


P a g e |141 of 208

8.13.2. Supply, laying & termination at both ends of instrumentation Earthing cable from respective areas to pit are in the scope of the contractor.

8.13.3. Earth strips from power earth pit are provided by SHAR inside control room & service rooms. Contractor may use these strips for connecting system to power earth.

8.14. Equipment or Services not in the scope of the contract

8.14.1. Instrumentation & power (Panel) earth pits.

8.14.2. Fire detection and alarm system (FDAS), fire-fighting system (FFS), telephones and wireless sets.

8.14.3. Deluge & Smoke detection System

8.14.4. CCTV Cameras

8.15. IO Details – Main Oven

8.15.1. Analog Inputs

Table 34. Analog Inputs – RTD Inputs

S.No Details Main Red

Range Qty. Qty

1

Main oven RTD (For Monitoring) –

4 wire Duplex type of 600 mm

length

12 12 0 - 100 °C

2

Main oven RTD (For ON/OFF &

Thyristor Control) - 4 wire Duplex

type of 600 mm length

3 3 0 - 100 °C

3 Suction Fire Damper RTD – 4 wire

duplex of 400 mm Length to PLC 1 1 0 - 100 °C

4 Delivery Fire Damper RTD – 4 wire

duplex of 400 mm Length 1 1 0 - 100 °C

5 Heater Bank RTD - 4 wire duplex

of 400 mm Length 1 1 0 - 100 °C

6 Oven Room Temperature 1 1 0 - 100 °C

7

Hot water tank RTD (For

Monitoring) – 4 wire Duplex type of

800 mm Length

1 1 0 - 100 °C

8

Hot water tank RTD (For ON/OFF

& Thyristor Control) – 4 wire

Duplex type of 800 mm Length

2 2 0 - 100 °C


P a g e |142 of 208

9

Hot Water inlet (For Monitoring) –


Length

1 1 0 - 100 °C

10

Hot water outlet (For Monitoring) –


Length

1 1 0 - 100 °C

Total RTD Channels 24 24

20% Spare Channels 5 5

Total Channels 29 29

Total Number of 8 Channel RTD

Input Modules 4 4

Table 35. Analog Inputs – RTD Inputs for Hardwire

S.No Details Qty Range

1

Suction Fire Damper RTD – 4 wire

duplex of 400 mm Length to Discrete

Controller

1 0 - 100 °C

2

Delivery Fire Damper RTD – 4 wire


Controller

1 0 - 100 °C

3

Heater Bank RTD – 4 wire duplex of

400 mm Length to Discrete

Controller

1 0 - 100 °C

Table 36. Analog Inputs – IO Panel

Analog Inputs (1-5 V or 4-20 mA) - In IO Panel

S.

No Details

Ma

in Red

Range

Duplic

ation

by

Isolat

or

Qty

req

Qt

y. Qty

1 Water Level Transmitter 1 1 0 -1000

mm WC Isolator 1

2 Hot Water Line Pressure

with Dual O/p Isolator 1 1

0 -10

KSc Isolator 1

3 Cold Water Line Pressure


0 -10

KSc Isolator 1

4 Temperature Transmitter


0 -100

°C Isolator 8


P a g e |143 of 208

S.

No Details

Ma

in Red

Range

Duplic

ation

by

Isolat

or

Qty

req

Qt

y. Qty

5

24VDC Diode Ored

Output – Single O/p

Split in to Two using P&F

Isolator

1 1 0 -24

VDC Isolator 1

6

24VDC Load Current

from Diode ORed Module

Output – Single O/p


Isolator

1 1 0 -20 A Isolator 1

7

UPS 230 VAC Supply to

PLC Rack– Single O/p


Isolator

2 2 0 -300

VAC Isolator 1

8

UPS Load to IO Rack–

Single O/p Split in to

Two using P&F Isolator

2 2 0 - 20 A Isolator 1

9

Raw 230 VAC to IO

Rack– Single O/p Split in

to Two using P&F

Isolator

1 1 0 -300

VAC Isolator 1

10

Raw 230 VAC Load

Current to IO Rack–

Single O/p Split in to

Two using P&F Isolator

1 1 0 - 20 A Isolator 1

11 Deluge Air Pressure with

Dual O/p Isolator 1 1

0 -10

KSc Isolator 1

12 Set Water Pressure with


0 -10

KSc Isolator 1

13 Line Water Pressure with


0 -10

KSc Isolator 1

14 AI Isolators - Hardwire

Damper/HB RTDs 2 2

0 -

100°C Isolator 3

15 24VDC V&I - Electrical

Panel 2 2 -- Isolator 2

Total AI Channels 26 26


P a g e |144 of 208



Total Number of 8

Channel Analog Input

Modules

5 5

Note: 4th Module for safety System

8.15.2. Digital Inputs

Table 37. Digital Inputs

Digital Inputs (1-5 V or 4-20 mA)

S.No DETAILS Main Red

Range Duplication

by Isolator Qty req Qty. Qty

1 Blower 1 Suction Damper OPEN Proximity Sensor

1 1 0 - 1 Isolator 2

2 Blower 1 Suction Damper CLOSE Proximity Sensor


3

Blower 1 Delivery Damper OPEN Proximity Sensor


4

Blower 1 Delivery Damper CLOSE Proximity Sensor


5 Blower 2 Suction Damper OPEN Proximity Sensor


6 Blower 2 Suction Damper CLOSE Proximity Sensor


7

Blower 2 Delivery Damper OPEN Proximity Sensor


8

Blower 2 Delivery Damper CLOSE Proximity Sensor



P a g e |145 of 208



Range Duplication


9 Fire Damper At Suction OPEN Proximity Sensor


10 Fire Damper At Suction CLOSE Proximity Sensor


11 Fire Damper At Delivery OPEN Proximity Sensor


12 Fire Damper At Delivery CLOSE Proximity Sensor


13 Front Left Door OPEN Proximity Sensor


14 Front Left Door CLOSE Proximity Sensor


15 Front Right Door OPEN Proximity Sensor


16 Front Right Door CLOSE Proximity Sensor


17 Door CLOSE Proximity Sensor


18 Bogie In 1 1 0 - 1 Isolator 2

19 Bogie Out 1 1 0 - 1 Isolator 2

20 Mainoven Air Flow Switch Status


21 Hot Water Flow Switch Status


22 Cold Water Level Switch Status


23 Main Line Water Flow Switch Status


24 Hot Water Line Outlet Flow Switch Status



P a g e |146 of 208



Range Duplication


25 Cold Water Line Outlet Flow Switch Status


26 Water Level Switch Status


27 HWCS Emergency Stop PB Status

1 1 0 - 1 Contactor 1

28 All Water Line Ball Valve Open Status


29 All Water Line Ball Valve Close Status


30 Mcc MCCB On Status


31 Mcc Emergency Off Status


32 Local Operation Selector Switch Status


33

Remote Operation Selector Switch Status


34 Local/ Remote Contactor Mode


35 24VDC Main Ps Status - Elec Panel


36

24VDC Redundant Status - Elec Panel


37

Power Fed Module-1 of DI Isolator Status-Chain-1- Elec



P a g e |147 of 208



Range Duplication


38

Power Fed Module-2 Of DI Isolator Status- Chain-1- Elec


39



40



41

Power Fed Module-1 Of AI Isolator Status- Chain-3- Elec


42



42 Pump-1 On/Off Status

From iMcc

0 - 1

From iMcc

43 Pump-2 On/Off Status

0 - 1

44 Pump-1 Trip Status

0 - 1

45 Pump-2 Trip Status

0 - 1

46 Main oven Blower-1 On/Off Status

0 - 1

47 Main oven Blower-1 Trip Status

0 - 1

48 Main oven Blower-2 On/Off Status

0 - 1

49 Main oven Blower-2 Trip Status

0 - 1


P a g e |148 of 208



Range Duplication


50 Main oven Emergency Stop Pb Status

0 - 1

51 Air Heater Bank-1 On/Off Status- Main Oven

0 - 1

52 Air Heater Bank-1 Trip Status

0 - 1

53 Air Heater Bank-2 On/Off Status-Main Oven

0 - 1

54 Air Heater Bank-2 Trip Status

0 - 1

55 Air Thyristor On/Off Status-Main Oven

0 - 1

56 Air Thyristor Trip Status-Main Oven

0 - 1

57 Water Heater Bank-1 On/Off Status- HWCS

0 - 1

58 Water Heater Bank-1 Trip Status- HWCS

0 - 1

59 Water Heater Bank-2 On/Off Status-HWCS

0 - 1

60 Water Heater Bank-2 Trip Status- HWCS

0 - 1

61 Water Thyristor On/Off Status-HWCS

0 - 1

62 Water Thyristor Trip Status-HWCS

0 - 1

63 24VDC Main Ps Status- Inst Chain



P a g e |149 of 208



Range Duplication


64

24VDC Redundant Status- InstChain


65 24VDC Main Ps Status- Safety Chain


66

24VDC Redundant Status - Safety Chain


67 Panel AC On Status


68 Main Foc Fault Status


69 Redundant Foc Fault Status


70 Power Fed Module-1 Of AI Isolator Status


71 Power Fed Module-2 Of AI Isolator Status


72 Power Fed Module-1 Of DI Isolator Status


73 Power Fed Module-2 Of DI Isolator Status


74 SCADA Mode selection Relay Status


75 SPD Status 1 1 0 - 1 Isolator 1

76 Low Air PS (Safety)


77 Deluge Open PS (Safety)


78 MCP Activation (Safety)


79 Solenoid Valve Status (Safety)

1 1 0-1 Isolator 2


P a g e |150 of 208



Range Duplication


80 Power fed Module (Safety)

2 2 0 -1 Isolator 2

81 SPD Status 2 2 0-1 Isolator 2

Total DI Channels

72 72

94

20% Spare Channels

13 13


Total Number of 32 Channel Digital Input Modules

4 4

Note: 8th Module for safety System

8.15.3. Digital Outputs

Table 38. Digital Outputs

S No DETAILS Main Red

Range Qty. Qty.

1 Blower-1 On 1 1 0 - 1

2 Blower-2 On 1 1 0 - 1

3 Pump-1 On 1 1 0 - 1

4 Pump-2 On 1 1 0 - 1

5 Air Heater Bank

Initiation Command 1 1 0 - 1

6 Air Heater Bank-1 On 1 1 0 - 1



9 Water Heater Bank

Initiation Command 1 1 0 - 1

10 Water Heater Bank-1

On 1 1 0 - 1

11 Water Heater Bank-2 1 1 0 - 1


P a g e |151 of 208

On

12 Emergency Stop

SCADA 1 1 0 - 1

13 Over Temperature

Alarm 1 1 0 - 1

Total DO Channels 13 13



Total Number of 32

Channel Digital

Output Modules

1 1

8.15.4. Analog Outputs

Table 39. Analog Outputs

S No DETAILS Main Red

Range Qty. Qty

1 Main Oven Air HB-2 Thyristor 1 1 4- 20

mA

2 Main Oven Air HB-3 Thyristor 1 1 4- 20

mA

3 Main Oven Water HB-2

Thyristor 1 1

4- 20

mA

Total 3 3


Total Channels 4 4

Total Number of 8 Channel

Analog Output Modules 1 1

8.16. IO Details – AGNI Oven


Table 40. Analog Inputs – RTD Inputs


Range Qty. Qty


P a g e |152 of 208

1 Agni oven RTD (For Monitoring) – 4

wire Duplex type of 600 mm length 8 8

0 - 100

°C

2

Agni oven RTD (For ON/OFF &

Thyristor Control) – 4 wire Duplex

type of 600 mm length

2 2 0 - 100

°C

3 Fire Damper RTD – 4 wire duplex of

400 mm length 3 3

0 - 100

°C

4 Oven Room Temperature 1 1 0 - 100

°C

Total RTD Channels 14 14



Total Number of 8 Channel RTD

Input Modules 3 3

Table 41. Analog Inputs – RTD Inputs for Hardwire

S.No Details Main

Range Qty.

1

Suction Fire Damper RTD – 4 wire


Controller

1 0 - 100 °C

2

Delivery Fire Damper RTD – 4 wire


Controller

1 0 - 100 °C

3 Heater Bank RTD – 4 wire duplex of

400 mm Length to Discrete Controller 1 0 - 100 °C

Table 42. Analog Inputs – IO Panel

Analog Inputs (1-5 V or 4-20 mA)


Range Duplication


1

Deluge Air Pressure with Dual O/p Isolator

1 1 0 -10 KSc

Isolator 2

2

Temperature Transmitter with Dual O/p Isolator

6 6 0 -100 °C Isolator 6


P a g e |153 of 208

3

24VDC Diode Ored Output – Single O/p Split in to Two using P&F Isolator for Process, Electrical & safety

3 3 0 -24 VDC

Isolator 3

4

24VDC Load Current from Diode ORed Module Output – Single O/p Split in to Two using P&F Isolator for Process, Electrical & safety

3 3 0 -20 A Isolator 3

5

UPS 230 VAC Supply to PLC Rack– Single O/p Split in to Two using P&F Isolator

2 2 0 -300 VAC

Isolator 2

6

UPS Load to IO Rack– Single O/p Split in to Two using P&F Isolator

2 2 0 - 20 A Isolator 2

7

Raw 230 VAC to IO Rack– Single O/p Split in to Two using P&F Isolator

1 1 0 -300 VAC

Isolator 1

8

Raw 230 VAC Load Current to IO Rack– Single O/p Split in to Two using P&F Isolator

1 1 0 - 20 A Isolator 1

9 24VDC V&I - 2 2 -- Isolator 2


P a g e |154 of 208

Electrical Panel

Total AI Channels

21 21

23

20% Spare Channels

5 5

Total Channels

27 27

Total Number of 8 Channel Analog Input Modules

4 4


Table 43. Digital Inputs


Range Duplication


1

Blower 1 Suction damper OPEN proximity sensor


2

Blower 1 Suction damper CLOSE proximity sensor


3

Blower 1 Delivery damper OPEN proximity sensor


4

Blower 1 Delivery damper CLOSE proximity sensor


5 Blower 2 Suction



P a g e |155 of 208

damper OPEN proximity sensor

6

Blower 2 Suction damper CLOSE proximity sensor


7

Blower 2 Delivery damper OPEN proximity sensor


8

Blower 2 Delivery damper CLOSE proximity sensor


9

Fire damper at Suction OPEN proximity sensor


10

Fire damper at Suction CLOSE proximity sensor


11

Fire damper at Delivery OPEN proximity sensor


12

Fire Damper At Delivery CLOSE Proximity Sensor


13

Front Left Door OPEN Proximity Sensor


14 Front Left Door CLOSE



P a g e |156 of 208

Proximity Sensor

15

Front Right Door OPEN Proximity Sensor


16

Front Right Door CLOSE Proximity Sensor


17 Door Close Proximity Sensor


18 Air Flow Switch


19 MCC MCCB ON Status


20 MCC Emergency Off Status


21

Local Operation Selector Switch Status


22

Remote Operation Selector Switch Status


23 Local/ Remote Contactor Mode


24 24VDC Main Ps Status - Elec Panel


25

24VDC Redundant Status - Elec Panel


26

Power Fed Module-1 of DI Isolator Status-Chain-1- Elec


27 Power Fed Module-2 Of



P a g e |157 of 208

DI Isolator Status- Chain-1- Elec

28



29



30



31


1 1 0 - 1 Isolator

1

32 Agni Oven Blower-1 On/Off Status

From IMcc

0 - 1

IMCC

33 Agni Oven Blower-1 Trip Status

0 - 1

34 Agni Oven Blower-2 On/Off Status

0 - 1

35 Agni Oven Blower-2 Trip Status

0 - 1

36 Agni Oven Heater Bank-1 On/Off Status

0 - 1

37 Agni Oven Heater Bank-1 Trip

0 - 1

38 Agni Oven Heater Bank-2 On/Off Status

0 - 1


P a g e |158 of 208

39 Agni Oven Heater Bank-2 Trip

0 - 1

40 Agni Oven Thyristor On/Off Status

0 - 1

41 Agni Oven Thyristor Trip Status

0 - 1

42 24VDC Main Ps Status- Meas Chain


43

24VDC Redundant Status- Meas Chain


44

24VDC Main Ps Status- Command Chain


45

24VDC Redundant Status - Command Chain


46 Panel AC On Status


47 Main FOC Fault Status


48 Redundant FOC Fault Status


49

Power Fed Module-1 Of AI Isolator Status


50

Power Fed Module-2 Of AI Isolator Status


51

Power Fed Module-1 Of DI Isolator Status


52 Power Fed 1 1 0 - 1 Isolator 1


P a g e |159 of 208

Module-2 Of DI Isolator Status

53 SCADA Mode slection Relay Status


54 SPD Status 2 2 0 - 1 Isolator 2

Total DI Channels

45 45

63

20% Spare Channels

10 10

Total Channels

65 65


3 3

8.16.3. G197


Table 44. Digital Outputs


Qty. Qty

1 Blower-1 On 1 1

2 Blower-2 On 1 1

3 Air Heater Bank Initiation Command 1 1

4 Air Heater Bank-1 On 1 1



7 Emergency Stop SCADA 1 1

8 Over Temperature Alarm 1 1

Total DO Channels 8 8



Total Number of 16 Channel Digital

Output Modules 1 1


P a g e |160 of 208

8.16.5. Analog Outputs

Table 45. Analog Outputs

S.No DETAILS Main -

Qty. Red - Qty

1 Agni Oven Air HB-3 Thyristor 1 1

Total 1 1


Total Channels 2 2

Total Number of 8 Channel Analog

Output Modules 1 1

8.17. IO Details – Control Room


Table 46. Analog Inputs – Control Room

S.No Details

Main Rang

e Duplication by

Isolator

Qty req

Qty.

1 24VDC Diode Ored Output – For FOC

1 0 -24

VDC Isolator (2 In 2 Out)

1

2 24VDC Load Current from Diode ORed Module Output – For FOC

1 0 -

20 A

3 24VDC Diode Ored Output – For Isolator

1 0 -24


1

4 24VDC Load Current from Diode ORed Module Output – For Isolator

1 0 -

20 A

5 24VDC Diode Ored Output – For PLC

1 0 -24


1

6 24VDC Load Current from Diode ORed Module Output – For PLC

1 0 -

20 A

7 UPS 230 VAC Supply to Control Console

1 0 -300 VAC

Isolator (2 In 2 Out)

1

8 UPS Load to Control Console 1 0-80

A

9 UPS 3 Ph Supply to Curing ICS 3 Isolator (2 In 2

2 10 UPS 3 Ph Load to Curing ICS 3


P a g e |161 of 208

Out)

11 Raw 230 VAC to Control Console 1 0 -300 VAC


1

12 Raw 230 VAC Load Current to Control Console

1 0-80

A

13 PID Controller Analog Output Current via dual o/p isolator

10 4-20 mA


3

Total AI Channels 26

10

20% Spare Channels 6

Total Channels 32

Total Number of 8 Channel Analog Input Modules

5


Table 47. Digital Inputs – Control Room

S.No DETAILS Main

Range Duplication

by Isolator Qty req Qty.

1 24VDC Main PS Status – FOC 1 0 - 1 Isolator (2 In 2 Out)

1 2 24VDC Redundant Status –FOC 1 0 - 1

3 Main FOC Fault Status 1 0 - 1 Isolator (2 In 2 Out)

1 4 Redundant FOC Fault Status 1 0 - 1

5 24VDC Main PS Status – Isolators 1 0 - 1 Isolator (2 In 2 Out)

1 6 24VDC Redundant Status –Isolators 1 0 - 1

7 24VDC Main PS Status – PLC 1 0 - 1 Isolator (2 In 2 Out)

1 8 24VDC Redundant Status –PLC 1 0 - 1

9 Power Fed Module-1 Of Isolator Status

1 0 - 1 Isolator

(2 In 2 Out) 1

10 Power Fed Module-2 Of Isolator Status

1 0 - 1

11 PLC Mode Selector Switch Status of Main Oven

1 0 - 1 Isolator

(2 In 2 Out) 1

12 Push Button Mode Selector Switch Status of Main Oven

1 0 - 1

13 PLC Mode Selector Switch Status of Agni Oven

1 0 - 1 Isolator

(2 In 2 Out) 1

14 Push Button Mode Selector Switch Status of Agni Oven

1 0 - 1

15 Emergency Off Status of Main Oven 1 0 - 1 Isolator (2 In 2 Out)

1 16 Emergency Off Status of Agni Oven 1 0 - 1

17 All UPS & MCB Status 20 0 – 1 Isolator 10


P a g e |162 of 208

(2 In 2 Out)

18 All SPD Status 8 0 – 1 Isolator

(2 In 2 Out) 4

Total DI Channels 44

22


Total Channels 54


2


Table 48. Digital Outputs – Control Room

S.No DETAILS

Main Range

Qty.

1 PLC Mode Selection to Annunciator of Main Oven

1 0 - 1

2 Manual Mode Selection to Annunciator of Main Oven

1 0 - 1

3 Local Mode Selection to Annunciator of Main Oven

1 0 - 1

4 Remote Mode Selection to Annunciator of Main Oven

1 0 - 1

5 PLC Mode Selection to Annunciator of Agni Oven

1 0 - 1

6 Manual Mode Selection to Annunciator of Agni Oven

1 0 - 1

7 Local Mode Selection to Annunciator of Agni Oven

1 0 - 1

8 Remote Mode Selection to Annunciator of Agni Oven

1 0 - 1

Total DO Channels 8


Total Channels 10

Total Number of 32 Channel Digital Output Modules

1

8.18. IO Channel / Module Summary

8.18.1. Main Oven

S.No Input/ System No. of Main

No. of Red.

No. of Main

No. of Red.

Total Module


P a g e |163 of 208

Ch. Ch. Module Module

1 8 Ch. RTD Module

29 29 4 4 8

2 8 Ch AI Module 32 32 5 5 10

3 32 Ch DI Module 85 85 4 4 8

4 32 Ch DO Module

16 16 1 1 2

5 8 Ch AO Module 4 4 1 1 2

Total IO Channels 166 166

8.18.2. AGNI Oven

S.No Input/ System No. of Main Ch.

No. of Red. Ch.

No. of Main

Module

No. of Red.

Module

Total Module

1 8 Ch. RTD Module

17 17 3 3 6

2 8 Ch AI Module 21 21 4 4 8

3 32 Ch DI Module 65 65 3 3 6

4 32 Ch DO Module

10 10 1 1 2

5 8 Ch AO Module 2 2 1 1 2

Total IO Channels 115 115

8.18.3. Control Room

S.No Input/ System No. of

Channels No. of Module

1 8 Ch AI Module 32 5

2 32 Ch DI Module 54 2

3 32 Ch DO Module 10 1

4 PLC / Accessories -- 2


P a g e |164 of 208

Total IO Channels 106

3rd Party Interfaces 535

Total IO Count for New Ovens 668

Existing Ovens IO Counts including 3rd Party

Devices

500

Total Counts for all Ovens 1703

8.19. Instrumentation Items

Table 49. Instrumentation Items – List

S.No Item Make Qty Req

Spare Req

Ref Tble no:

1 Duplex RTD of 600 mm Length – Main Oven

Baumer/ Nagman/ Tempsens/ Exotherm/ Rosemount

15 15 50



3 3 50

3 Duplex RTD of 600 mm Length – Agni Oven


10 10 50



7 7 50



2 2 50



7 7 50

7 Temperature Rosemount/ Siemens 21 0 51


P a g e |165 of 208

Transmitters

8 Pressure Transmitter

Rosemount 3051 (0 to 55 Bar)/ Siemens

6 1 52

9 Single Loop Controller

ABB CM10 14 0 53

10 Level Switch P&F 1 1 54

11 Level Transmitter P&F / Rosemount/IFM

2 1 55

12 Proximity sensors

P&F 36 4 56

13 Isolators (I/I or I/V) – 1 In 2 Out

P&F 52 0 57


P&F 10 0 57

15 Relay – 1 In 2 Out

P&F 157 10 57

16 Relay – 2 In 2 Out

P&F 22 0 57

17 Power fed Module and Power rail

P&F 22 2 57

18 Power Rail P&F 15 0 57

19 Low Air pressure Switch

Switzer/ IFM 2 2 58

20 Water flow switch

Switzer / IFM 1 1 59

21 DC Voltage transducer

Rishab/ LEM/ AE/ M- Systems/ NK Technologies

9 0 60

22 DC Current transducer

Rishab/ LEM/ AE/ M- Systems

9 0 61

23

UPS Voltage Monitoring (1 Phase) Transducer


6 0 62

24

UPS Current Monitoring ( 1 Phase) transducer


6 0 63

25

UPS Voltage Monitoring (3 Phase) Transducer


2 0 62

26 UPS Current Monitoring ( 3

Rishab/ LEM/ AE/ M- Systems/ NK

2 0 63


P a g e |166 of 208

Phase) transducer

Technologies

27

Raw Voltage Monitoring (1 Phase) Transducer in Main & Agni Oven


2 0 62

28

Raw Current Monitoring (1 Phase) Transducer in Main & Agni Oven


2 0 63

29

24 V DC/20 A power supply with Diode Oring Module

Phoenix/ Siemens/ Aplab

6 0 64

30



8 0 64

31



4 0 64

32 IO Rack Rittal 2 0 65

33 Hot Standby PLC/PAC

Siemens/ Schneider/ Allen Bradley

2 1 66

34 PLC Programming Full License


2 0 66

35 16/32 Channel Digital Input Module


30 / 15 2 67

36 16/32 Channel Digital Output Module


8/ 4 2 68

37 8 Channel RTD Input Module


16 2 69

38 8 Channel Analog Input Module


21 2 70

39 4/8 channel Analog Output


4 2 71


P a g e |167 of 208

Module

40 SCADA Server License (For Hot stand By Server)

Siemens/ Schneider/ Allen Bradley (Unlimited Run-time + Configuration Supply of for HSBY server– 5000 Tags

2 0 72

41 SCADA Historian License

Siemens/ Schneider/ Allen Bradley (1500 tags for historian server with 10 HMI User access & 2 Web user access

1 0 73

42 SCADA Client License (HMI Clients)


4 0 73

43 SCADA (Web Clients)

Siemens/ Schneider/ Allen Bradley (Web space clients)

2 0 73

44 SCADA Historian Server

HP/Dell 1 0 73

45 SCADA Server HP/Dell 2 0 73

46 Operator Station HP/Dell 1 0 74

47 Thin Client Unit HP/Dell 3 0 75

48 PG Station (Laptop)

HP Pavilion/ Dell 1 0 76

49 A3/A4 Color Inkjet Printer

HP 1 No Each

0 --

50 A4 Color Laser Printer

HP 1 0 --

51 A4 Scanner HP 1 0 --

52

Digital camera

Compact Camera with 20x Optical Zoom or

better Model:

DSC-WX350 or better, Black

Mega Pixel: 18MP,

SONY 01


P a g e |168 of 208

Optical Zoom: 20X or better

Battery Charger + Extra Battery

32GB Memory or better

Camera Pouch

53 Ethernet Switch- L2 (Field)

Extreme/ Antaira / Moxa/Schneider/ Siemens

8 0 77

54 Ethernet Switch- L2 (Control room)


2 0 78

55 Ethernet Switch- L3 (Control Room)

Extreme/ Moxa /

Cisco / Allied

Telesys/Planet

/ HP

1 0 79

56 Surge Suppressor – 1 Phase

Phoenix/ Dhen/ Citel 12 1 80

57 Surge Suppressor – 3 Phase

Phoenix/ Dhen/ Citel 2 0 80

58 Operator Console Pyrotech 1 0 81

59 Server Rack APC/Rittal/ Valrack 2 0 82

60 43 Inch LED TV LG/ Panasonic/ Samsung/ Sony/ Toshiba

3 0 83

61 16 Pair Armored Signal Cables

Uniflex /

Thermocables /

Thermocabs /Delton

/ Delta / Lapp /

Paramount cables /

Polycab

/ RPG /CMI

2000 Mtrs

0 84

62 1 Pair Armored Uniflex / 1000 -- 85


P a g e |169 of 208

Cable Thermocables / Thermocabs /Delton / Delta / Lapp / Paramount cables / Polycab

Mtrs

63 3 Pair Armored Cable

Uniflex / Thermocables / Thermocabs /Delton / Delta / Lapp / Paramount cables / Polycab

1000 Mtrs

-- 85

64 Heat Resistant Cables

Uniflex /

Thermocables /

Thermocabs /Delton

/ Delta / Lapp /

Paramount cables /

Polycab / / RPG

/CMI

5000 Mtrs

-- 86

65 Optic Fibre Cables

HFCL/3C/ Schneider/ Tyco/ RPG

4000 Mtrs

-- 87

66 Cat 6 /7 cable Belden/ Schneider 1000 Mtrs

-- --

67 Double compression Glands

Baliga/ Comet As

Reqd -- --

68 Terminals/ Stoppers/ Fuse TB

DIN Rail Wago/ Phoenix/ Weidmuller, Fuse TB with Fuse Break LED

As reqd -- --

69 Flameproof Junction Boxes

P & F/ Baliga As reqd -- --

70 Non Flame proof Junction Boxes

P & F/ Baliga / Rittal / Adarsha

As reqd -- --

71 Relay Phoenix Solid state relay module to drive contactors.

For All DOs

4 --

72 48 port OFC Splice box (Wall Mount)

3M/ FCI 2 1 --

73 19” Rack Mount 48 Port OFC

3M/ FCI 2 1 --


P a g e |170 of 208

Splice Tray (Rack)

74 Push Buttons, Emergency Stop Buttons

Siemens As reqd -- --

75 Chairs Godrej PCH 7003 10 -- --



78 Table Godrej ENZ0, Color: Beige, Dim: 1500 x 750 x 750

2

79

Modular partition with glass door in control room

6.0m x 6.0 m x 3.5m modular partition with transparent glass

As required

8.20. Technical Specifications (Data sheets)

Party shall supply the full quantities of the items mentioned in the below data sheets. Required quantities shall be issued to the party during erection.

Table 50. RTD Sensors


Type of sensor Pt100, 4 – wire, Duplex Type

Accuracy Class-A

Termination Head Type Ex. Proof Head IIA/ IIB

No of Conduit Entry /

Entries

Double Entry

Cable Gland 1/2” NPT

Head Extension Type Adjustable connection

Process Connection M20 x 1.5 (M)

Glands Double compression cable gland in Nickel

plated Brass - FLP

Tip Length 60 mm

Tip Diameter 4.5 mm

Sheath Diameter 6 mm

Sheath Material SS316

Termination Style Nut with Knurling’s

Temperature

Coefficient:

0.00385 Ohms/ 0C

Temperature Range: 0 to 1200C


P a g e |171 of 208


Sensor wire PTFE insulated, Nickel coated copper

stranded wire.

Calibration certificate Required and traceable to NIST - 40 °C, 50

°C, 60 °C, 70 °C, 80 °C, 90 °C, 100 °C,

110°C & 120 °C

Tag Plate Shall be provided with sensor details

Sensor Immersion

Length

Main Oven – 600 mm, Agni Oven – 600

mm, Hot water tank – 800 mm, Hot water

Inlet & Outlet-300mm, Dampers – 400 mm

Quantity As per the IO Count given in previous

chapter

Table 51. Temperature Transmitter


Make Rosemount/ Siemens

Input 4 wire RTD

Output Two wire 4-20 mA HART

Approvals No Approval

Mounting To Clip onto top-hat DIN rail

Alarm High Alarm configuration feature shall be

available

Power Supply 24 VDC

Failure Mode User selectable Up or Down scale Indication

Accuracy +/- 0.2 deg C of span for RTD

Line voltage filter 50 Hz

Update time <= 0.5 sec or better

Terminals Screw terminals

Display Dual-line LC display with additional display

elements (option)

Inputs 4 wire RTD

Table 52. Pressure Transmitter


Make Rosemount 3051/ Siemens

Operating Principle Capacitance


P a g e |172 of 208

Integral display LCD display

Range 0 to 55 Bar

Output Linearized

Accuracy 0.075% of span

Electro Magnetic

Compatibility

(EMC)

As per EN 61326 or equivalent.

Calibration

certificate Required and traceable to NIST/ NABL.

Power supply 24 VDC

Output signal 4- 20 mA.

Span / Zero

adjustment Required.

Transmitter

diagnostics

Standard & all advanced diagnostics are

required.

Protection IP 65

Over range

protection Required. 150 % of maximum pressure.

Application of

measurement Water Line & Deluge Pressure

Process connection ½” NPT (F)

Cable Entry ½” NPT Female with double compression cable

gland.

Area Intrinsically safe: Zone 1, Gas group IIA, IIB &

T4

2-valve manifold SS316 and shall be suitable to pressure

ratings.

Model ROSEMOUNT 3051TA 3 A 2B 2 1 A B4 K5

Q4 D4 M4/ Siemens

Table 53. Single Loop Controllers (SLC)


Make ABB

Model CM-10

IP Rating IP20

Display Type Dual 4 Digit LED

Supply Voltage 230Vac/ 24Vdc

Input Types 4-20mA, 1-5V, Pt100RTD


P a g e |173 of 208

PV Accuracy 0.2% of reading ±1LSD

Control Types On/Off, PID

Output Types Logic, relay, triac, DC,4-20 mA Analog

Output

No of Alarms 4

Set-point Programmer required

Min Analogue

IO

Input 2 (4-20mA)

Output 2 (4-20mA)

Min Digital IO Input 4

Output 4

Communication interface Ethernet

Table 54. Level Switch


Make P&F

Aux. Supply 24VDC

Output contact 3 CO

Mounting

location

On top of the hot water tank

Input sensors 3 sensors

Sensitivity 1 k ohm to 200 k ohm adjustable

Trip time delay Less than 1 sec

Protection IP 65 , Intrinsically safe certified or better

Range: 1200 mm

Fittings Required


gland

Body material,

sensing element,

fittings

Suitable for corrosive environment

Table 55. Level Transmitter


Make P&F / Rosemount / Vega / IFM

Aux. Supply 24VDC

Output contact 4 – 20 mA

Mounting location On top of the hot water tank


P a g e |174 of 208


Range: 1200 mm

Fittings Required


gland

Body material,

sensing element,

fittings

Suitable for corrosive environment

Capacitive continuous level measurement.

Display Local Indication shall be available

Table 56. Proximity Sensors


Make P&F

Type of proximity

sensor

Inductive NAMUR type

Mounting location Hazardous area

Type of mounting Threaded cylindrical type with check nuts

Enclosure Protection IP 67, Intrinsically safe certified to Zone 1,

GR-IIA, IIB & T4.

Length of integral cable

with sensor

As required to interface with IS Isolators

in IO Rack

Terminal box for

termination of integral

cable

IP 65

Table 57. Isolators & IS Relays

S. No Type of isolator Make & Model Location

1 Analog input

( 1 In 2 Out)

KFD2-STC4-EX1.2O or

KFD2-STV4-Ex1.2O-1

Main & Agni

oven

2 Analog input

( 2 In 2 Out)

KFD2-STC4-EX2 or

KFD2-STV4-Ex2-1

Main & Agni

oven

3 Digital input

(1 In 2 Out) KFD2-SR2- EX 1.W.LB

Main & Agni

oven

4 Digital input

(2 In 2 Out) KFD2-SR2- EX2.W

Main & Agni

oven


P a g e |175 of 208

5 Power Fed Module P&F – KFD2-EB2-

R4A.B

Main & Agni

oven

6 Universal Power

Rail P&F – UPR-03

Main & Agni

oven

Note: - Suitable power isolator modules, power rails & other

accessories shall be provided to mount the isolator.

Table 58. Low Air Pressure Switch


Make Switzer / IFM

Medium Hot air 120 0C

No of contacts 2 NO + 2 NC 5 A rated at 250 V A.C

Mounting location In the air delivery ducts


Range: 0- 100 mm WC

Cable Entry ½ “ NPT 2 nos.,

Table 59. Water Flow Switch


Make Switzer/ IFM

Sensing element Vane

Type Vane / paddle

Mounting location Pipe line

Switch type Micro switch

Accuracy ± 2% of span

Switch contacts DPDT

Contact rating 10A resistive load , 3 A inductive load at 250 V

AC

Switch setting Tamper proof and external adjustment

Over range

protection

1.5 times of Max. flow

Protection IP 67

Intrinsically safe certified.


gland.

Body material Brass

Vane / Paddle SS 304 four vane combination – vane length


P a g e |176 of 208

material shall be adjustable and shall be compatible

with water pump flow rate

Temperature of

water

1000C

Note: - The dimensions of sensing element shall be suitable for the

mounting location.

Table 60. DC Voltage Transducer

Make AE / LEM/ Rishab/ M- System

Rated Input Voltage 50 VDC for 24VDC Measurement & 400

VDC for Battery Volt Measurement

Output signal 4 -20 mA

Power supply 24 VDC

Measuring accuracy +/- 0.5 % or better

Isolation available between Input, Output and Power

supply

Input Resistance > 1 Mega Ohms or better

Load Resistance >2 Kiloohms or better for Voltage output

&<=250 Ohms or better for current output

Isolation withstanding

voltage

> 2.5 KV (Min for 1 Min)

Response time 400 ms or better

Mounting DIN Rail

Table 61. DC Current Transducer


Make AE / LEM/ Rishab/ M- System/ NK

Technologies

Use 24 VDC DideoORed Output Monitoring

in CCMC, in each IO Rack

Operating principle Scale down, rectification & conversion

Auxiliary power supply 24 VDC

Input parameter (I in Amp) As per load

Output 4-20 mA

No. of signal outputs Dual

Output ripple (Accuracy

class)

0.2 % of span or better


P a g e |177 of 208


Input / output Isolation Galvanic or optical

Mount DIN Rail

Table 62. UPS Voltage Transducer


Make Rishabh/ LEM/ M- Systems

Rated Input Voltage (

Measurement voltage)

300 VAC or Nearby range (It shall be greater

than 280VAC)

(IO Panel & Control Room) & 500 VAC -3

Phase for UPS Incoming & Outgoing

Frequency of Input

Voltage

50 Hz

Output Signal 4 -20 mA

Power Supply 24 VDC

Measuring Accuracy +/- 0.5 % or better

Isolation available between Input, Output and Power

supply

Input Resistance > 1 Kilo Ohms or better

Load Resistance >2 Kilo ohms or better for Voltage output

&<=250 Ohms or better foe current output

Isolation

withstanding voltage

> 2.5 KV (Min for 1 Min)

Response time 300 ms or better

Mounting DIN Rail

Table 63. UPS Current Transducer


Make AE / LEM/ Rishab/ M- System/ NK

Technologies

Use UPS Output Load Monitoring at CCMC

& in Each IO Rack Load (Single Phase

& 3 Phase)

Operating principle Scale down, rectification & conversion

Mounting location MCC panel, DIN rail mounted

Auxiliary power supply 24 VDC

Input parameter (I in Amp) As per load


P a g e |178 of 208


Output 4-20 mA

No. of signal outputs Dual

Output ripple (Accuracy

class)

0.2 % of span or better

Input / output Isolation Galvanic or optical

Response < 500 ms or better

Insulation resistance > 100 MΩ @ 500V DC or better

Impulse withstand voltage Peak Voltage of 5kV, Standardized

impulsed waveform of 1.2 / 50µsec or

better

Enclosure type IP 40

Mount DIN Rail

Table 64. 24 V DC Power Supply


Make Pheonix/ Siemens / Aplab

Input voltage 230 V AC ± 10%, 50 Hz

Output voltage 24 V DC

Output current 20 A / 10A /5A

Overload & short circuit

protection type

Required

Over voltage protection Required

Load As required.

Ripple 50 mV peak – peak or better

Mounting DIN rail mounted/ panel mounted.

Coating Protective Coating Shall be available

Operating temperature Ambient to 50 Deg C

Oring Pheonix Quint Diode Oring Module

with protective coating .

Table 65. IO Rack


Manufacturer Rittal of required dimension & to be spacious

for future addition of modules


P a g e |179 of 208

Service Housing PLC, I/O modules, DCPS, P&F

Isolators, P&F IS Relays, FOC, Video to Fiber

Converters, etc

Location Service rooms

Type Free standing

Cable entry Bottom entry. Base Mounting Height shall be of

Minimum 300 mm for free entry of cables.

Door Required

Front & rear door : Double leaf lockable

Concealed type hinges & a 180 degree swing.

Temperature Ambient to 50 Deg C

Painting Inner: Glossy white colour

Outer: Siemens grey colour (RAL7032)

Shield bus Through screw connection

Mounting and

wiring

• Double compression SS glands (FCG,

Baliga or equivalent)

• Separate Fuse TBs/ TB for analog, digital

and different voltage level signals (Phoenix or

WAGO) of Screw/gage terminal type

Dimensions Min 1800 mm(H) x 600 mm (D) x 2400 mm

(W) or more based on requirement

Material 1) Sheet material thickness: CRCA-COLD

rolled 2mm

2) Gland plates thickness : 3mm

3) Gasket for door & cover: neoprene

4) Plugs for spare cable entries: required

Channels Shall provide with bolt & nut

Anti-vibration pads 15 mm thickness

Panel AC Required. It is to be panel attached.

Light Fluorescent lamp

Lifting Eye-bolts

Plugs For incoming & outgoing

Metal tag name

plate

Required

Clamps Required

Fixtures Required

Bolts, nuts &

gaskets

Required

Earthing Power Earth & Instrumentation Earth shall be


P a g e |180 of 208

separated.

Pocket Plastic pocket shall beb provided to keep

manuals/ wiring diagrams

Lock & key Required

Spares • 20 % spare entries to be provided for

incoming & outgoing cables.

• 20 % spare for terminal blocks.

• 20 % spare space for future requirement.

Table 66. Programmable Logic Controller


Manufacturer Siemens/ Schneider/ Allen Bradley

Location Common PLC in Control Room

CPU rack power

supply

Hot Stand by Redundancy Required. Power:

24VDC

Self-diagnostics

features

Required for each and every module available

in the PLC (i.e. CPU, PS, I/O modules, other

communication interface modules etc). and

access through Web without any software

development

Integrated

Connection

Ethernet/ Profinet HSBY Port – 1 Nos, ,

Ethernet /Profinet device network – 2 Nos,

Ethernet Ports for SCADA Network

Memory

Integrated RAM: 16 MB Program and Data or

more

External Flash: 4 GB for local Data storage or

more,

Minimum LED

Status

LED Status for Run, Error, IO Fault, Memory

card fault, HSBY Status or more.

Synchronization

between CPUs

FO communication/ Ethernet between CPUs

shall be provided.

Redundancy Media Redundancy shall be available.

Programming and

downloading to PLC

2 Nos. of Licensed latest version shall be

provided for programming. Floating type

license is preferable. Any other necessary

License required to configure PLCs

communication shall be provided.

Standards

compliance CSA, EN/EIC, UL


P a g e |181 of 208

Interface for

communication

between PLC and

I/O modules

1) Required – EtherNet/IP

2) PLC to SCADA Communication shall be

EtherNet IP.

3) Suitable Interface converter shall be

provided to link field devices to PLC.

4) The system shall be integrated with

existing ovens & to centralized DAS and

suitable converters shall be supplied.

Table 67. DI Modules



Number of Channels 16

Input type Current sink (logic positive)

Discrete input voltage 24 V DC positive

Input compatibility Potential free Contacts

Sensor power supply 24 VDC

Insulation resistance > 10 M Ohm 500 V DC or better

Protection type Reverse polarity protection

Status LED Required for all channels

Isolation Galvanic/ Optical

Operating Temperature 0 to 50 Deg C

Relative humidity 20 - 80 % without condensation

Table 68. DO Modules




Discrete output type Solid state

Discrete output logic Positive

Discrete output voltage 24VDC

Discrete output current 0.5 A or better

Protection type Reverse polarity protection

Overvoltage protection

Overload protection


P a g e |182 of 208


External short-circuit protection

Status LED Required for each channel

Isolation Galvanic/ Optical


Relative humidity 20 - 80 % without condensation

Table 69. Temperature Input Modules




Analogue input type Thermocouple: S, R,K,T,K,E,L,J,U,N,B

Temperature probe: Ni 1000, Ni 100, Pt

1000 IEC, Pt 100 IEC, Pt 1000 UL/JIS, Pt

100 UL/JIS, Cu 10

Resistor: 4000 Ohm: 4 wires, 3 wires, 2

wires

Resistor 400 Ohm: 4 wires, 3 wires, 2 wires

Analogue input

resolution

16 Bits

Input impedance 10 Mega ohm or better

Common mode

rejection

70 dB or better

Measurement error 0.2% of Full scale

Status LED/ Self

Diagnostics

Required for each channel


Relative humidity 20...80 % without condensation

Table 70. Analog Input Modules




Analog input type Voltage: 1...5 V,

Current: 4...20 mA

Analogue input 16


P a g e |183 of 208


resolution

Input impedance 10 Mohms or better

Measurement error 0.2% of full scale

Common mode between

channels

> 75 dB or better

Isolation voltage Galvanic/ Optical

Status LED/

Diagnostics

Required for each channel



Quantity As required + 2 Spare modules

Table 71. Analog Output Modules




Measurement error 0.25 % of full scale

Common mode between

channels

>= 70 dB or better

Isolation voltage Galvanic/ Optical

Analogue output type Current: 4...20 mA and 0...20 mA

Analogue output

resolution

16

Status LED Required for each channel



Table 72. Supervisory Control and Data Acquisition system


SCADA package Siemens/ Schneider/ Allen Bradley

Type Data acquisition & Process monitoring.

Operating system Win 8.1/ Windows 10 Ultimate or latest

Graphical user

interface

Man Machine Interface


P a g e |184 of 208

Essential Features:-

1. Dynamically configurable Mimics,

2. Real time & Historical data trends,

3. Data logging & Report generation in user prescribed format,

4. Tags (PLC & Third party tags).

5. Alarms & Events Logging.

6. Access security management

7. OPC Support shall be available to pool data to another

historian

8. Modbus TCP Protocol Support

Mimics 8.1. MMI-PLC-IO network configuration screen

with critical diagnostic information and messages.

8.2. Sub-system wise screens to monitor the

process status.

8.3. Sub-system wise I/O screen.

8.4. Alarms screen.

8.5. Trends screen.

8.6. Any other screen as per the user

requirement.

Trends 8.7. Real time & historical trends.

8.8. X- axis & Y- axis ranges shall be user

selectable.

8.9. Trend configuration shall be user-friendly &

shall be available during Run-time.

8.10. Trends data export to MS Excel (.xls) format

shall be provided.

8.11. Print option for trend chart shall be provided.

8.12. Trend analysis tool shall be provided as per

the user requirement.

Data logging Time based (with minimum 1sec interval) & Event

based data logging for all analog inputs shall be

provided. Data logging shall be in SQL Database.

Alarms &

Events Logging

Alarms & Events shall be logged separately.

Sub-system wise filtration option.

Logging shall be as per user defined format,

Report

Generation

8.13. Reports shall be generated for logged data,

alarms & events as per the user defined formats.

8.14. From- & To- date and time shall be user

selectable.


P a g e |185 of 208

8.15. Time interval shall be user selectable.

8.16. Options to export data in MS Excel, MS

Access, SQL formats.

8.17. Print report option shall be provided.

License 8.18. As per previous chapter

Table 73. Server for SCADA / Historian


Make & Model HP/ Dell

Processor 2 x Intel twelve core Xeon processor or

better.

Memory 64 GB ECC DDR4 memories @ 2133 MHz

or more.

Drive bays 6 or more SATA/ SAS hot pluggable drive

bays.

Drive controller Integrated or add-on SATA/SAS controller.

Hard drives 4X2 TB SATA/ SAS HDD for RAID 5 or

RAID 1 configuration.

RAID controller On board or add-on RAID controller to

configure the above RAID.

Optical drive DVD-RW

HBA Dual port 8 Gbps SAN host bus adapter.

Expansion slots 2 slots or more after configuring the

requirements.

Graphics Integrated graphics controller.

Network interface

cards

• 6 x 100/1000 Mbps Ethernet ports

(Excluding management Ethernet ports

bundled for redundant and load balancing).

• Add-on cards for redundant

communication management between PLC

to SCADA Stations as recommended by

OEM.

I/O ports &

connectors 4 USB

Input device USB keyboard and mouse

Monitor 23/24” LED Monitor( OEM) + 42"/43” LED

monitor (LG)

Power supply 2 x hot plug power supply (230V AC @50

Hz) unit. Indian power cords to be supplied.


P a g e |186 of 208

Form factor Rack mountable.

Warranty 3-3-3 years

Hard Disk Drive (HDD) Minimum. 4 Nos. of HDD with each Min.

2TB capacity

RAM 32GB

Operating system (OS) Windows server latest edition and

compatible with the latest SCADA version.

Software with license

• System management software to

monitor the system health at local console

& over network.

• Redundant connection (red connect)

management license for CPU to SCADA

Stations with associated interface card.

• SNMP OPC server.

• Any other relevant software as

required.

DVDs to be included. Server Hardware drivers, OS and associated

software.

Location

Server shall be mounted in server rack with

monitor and located in Instrumentation

panel room.

Table 74. Operator Workstation

S.No Functionality/

Description Specification

1 Make HP/Dell

2 Type

19” Rack Mount in Server Rack is

preferable or with Support tray in Server

rack.

3 Processor Intel i7, 6th Generation Processor or latest ,

3.4GHz or better / Intel Xeon processor E3

4 Memory 2 x 8 GB DDR4

5 Hard Disk 2 TB GB Hard Disk Drive

6 BIOS 8 MB Flash memory for system BIOS or

better

7 I/O Expansion

slots

2 PCIe & 1 PCI empty shall be available for

future use

8 Optical drives 16X DVD+/-RW Super Multi drive with

dual layer facility


P a g e |187 of 208

9 Key board &

Mouse

OEM make standard USB Key board &

optical scrolled Mouse

10 Network

Interface

1. 10/100/1000 GBPS or better with

RJ45 Connection Port

2. Add On NIC for additional LAN Port

11 IO Ports

Front: 2 USB 3.0, 1 USB 2.0, 1 Headphone,

1 Microphone, 1 IEEE 1394a; One serial

Port

Rear: 2 USB 3.0; 4 USB 2.0, 2 x RJ-45(one

must be integrated) Gigabit LAN, 2 PS/2, 1

Audio Line-In, 1 Audio Line-Out, 1

Microphone, VGA, DVI and HDMI port.

12 Colour Monitor

• OEM

• 23/24” wide screen LED Color

Display

• Resolution – 1920 X 1200

13 Graphics

1. On-board Intel HD Graphics Card

2. Dedicated Graphics NVDIA Card with

4GB RAM PCIe Card

14 Power supply 220 ±10% VAC, 50 Hz

15 System

Management

Integrated management controller for

monitoring the health of system with

OEM’s management software

16 System Fans

Shall be provided as per system

requirement for better operation: Fans

shall be along with power supply

17 Accessories

Complete with all interconnecting cables,

cords, connectors, peripherals, adaptors

& display mounting accessories, keyboard,

mouse and external speaker (OEM make)

with microphone & mouse pads etc.

18 Documentation All Standard Documentation and Driver

CDROMs with required licenses in Original

19 Operating

System

Microsoft Windows 8.1/10 Professional

Edition 32 / 64 bit OS or latest with latest

Service Pack and original media

20 MS Office (Latest version) Licensed MS-Office with

latest service pack with original media

21 Security Power on password; administers password;


P a g e |188 of 208

Features and other necessary security related

features for workstations

22 Original

Software

• Recovery DVD

• Drivers & Utilities DVD

• CD/DVD Writing Software’s

• Restore CDs, smart start CDs,

Operating system CDs to install the

operating system in case of system crash

shall be in Original.

23 Warranty 3 Years 24x7 support and certificate for 3

years from OEM

25 Printer

A3 Inkjet Color Printer – 1 Nos, A4 Inkjet

color printer -1 No, A4 Color Laser Printer

– 1 Nos. and A4 Scanner - 1 Nos

Printers/Scanner shall be of HP make

Table 75. Thin Client Unit


Operating system Windows Win 10 IoT/ Embedded Win 7/8

CPU AMD G-Series (1.4 GHz, Dual Core, 1 MB,

AMD Radeon HD Graphics Card) or latest

Flash/ SSD 16 GB Flash or better

RAM 4 GB RAM DDR3 or latest

I/O peripheral

support

1. 1 x Display Port

2. 1 x One DVI-I port with DVI-I to VGA

Adaptor

3. Min 2 x USB 2.0 ports (one front, one

rear)

Networking 1. 10/100/1000 Gigabit Ethernet

2. Dual band 802.11 a/b/g/n wireless

Resolution

1. Display Port: 2560x1600@ 32bpp

2. DVI-I: 1920x1200@ 32bpp or with

better features

Monitor 21” or equivalent size LED HD Resolution

Monitor with VGA & DVI Ports of OEM make

Audio 1/8-inch mini jack

Mountings

Vertical feet standard

VESA mounting bracket for mounting to flat

surfaces, such as walls shall be supplied


P a g e |189 of 208


Security 1. Security protocols shall be available for

network connectivity

Accessories USB Keyboard and Optical Mouse

Browser IE 11 or latest

Software

MS Office Viewer

Device Manager Software & other related

software

Others Support to install IPSAN driver to access

mass storage ,

Power 240 VAC, 50 Hz. With Energy Star

certification

Temperature range Operating: 10° to 40° C

Certifications Energy Star , UL & RoHS complaint shall be

available

Make HP/Dell

Table 76. Programming Station (Laptop)


Manufacturer HP / Dell

Processor INTEL CORE i7 latest generation

Hard disk capacity 1 TB

Motherboard INTEL original (Suitable for the

configuration)

DDR RAM (DDR4) 8 GB (2 x 4GB)

Network cards Ethernet card:1 Nos. (100Mbps/1Gbps)

Optical Drive DVD RW

Ports (other than those

required for connecting

monitor, keyboard and

mouse)

Ethernet ports: 1 Nos.

RS232 port: 1 Nos.

USB: Minimum 3 Nos. (with at-least one

USB 3.0)

Power supply Suitable 230V AC Adapter with Indian

Pin

Operating system Microsoft Windows 8.1/10 Professional

Edition 32 / 64 bit OS or latest with

latest Service Pack and original media

Software to be supplied

and loaded on system.

Licensed MS Office Professional Latest

version

Monitor Screen 14”, supported resolution 1280x1024 and


P a g e |190 of 208

above.

Optical Mouse

(additional)

Standard USB Mouse with scroll.

CD’s for all software &

drivers

Required.

Quantity 02 Nos

Table 77. Ethernet Switch – L2 (Field)


Ethernet Port Min 6 x 10/100TX/1000 TX (UTP/ SFP) or more

Fibre Port Min 2 x FX (FX/ SFP) or more

Fiber Type Single Mode

Fiber Distance 30 Km or better

Wavelength 1310 nm

IEEE IEEE 802.3, IEEE 802.3u, IEEE 802.3x,

IEEE 802.1d, IEEE 802.1w, IEEE 802.1p,

IEEE 802.1Q

Backplane

communication

2 GBPS

MAC Address Table 2K

Buffer Size 1 Mbit

VLAN Available

IGMP V1

SNTP trap Available

Quality of service IPV4

Management Web Interface and SNMP

Ring redundancy

features

Available

Spanning Tree STP, RSTP

Power input Power input – Dual Power

Mounting DIN Rail

Operating Temperature 0 to 50 Deg C or better (Industrial Grade)

EMI compatibility FCC Class A, CE

Safety certification UL, cUL certification

Model As per previous chapter

Table 78. Ethernet Switch – L2 (Control Room)

Description Essential Specifications


P a g e |191 of 208

Type Manageable, Layer-2 Fast Ethernet

switches.

Make & Model As per previous chapter

Physical Ports • Minimum 8 UTP RJ45 Port.

• Minimum 12 Nos of SFP Port

SNMP management feature Required

Power 230 V AC/ 24VDC with Dual power

input

Diagnostics LEDs for power, duplex mode

indication, etc shall be available

IEEE

IEEE 802.3, 802.3u, 802.3ab, 802.3z,

802.3x, 802.3ad, 802.3d STP/ IEEE

8020.1w, 802.1s, 802.1p, 802.Q,

802.1ab

Protocol

IGMP v1/v2, GVRP, SNMP v1/v2/v3,

DHCP Server/Client, SNTP, RMON,

HTTP, Telnet, Syslog, LLDP, IPV6,

LACP

MAC Address Table 8 K or better

System Configuration Web console, Telnet, CLI Console

Network Redundancy STP, RSTP, MSTP, Ring Redundancy

Recovery <20 ms or better

IGMP Snooping/ GMRP IGMP V1, V2, V3 up to 256 Multicast

groups & Query

Reverse polarity protection It Shall be available in case of 24 VDC

Relay Alarm Contact 1A @ DC24V

Security Port security

Quality of service Required

Spanning tree protocol Required

Associated software Required of the same make as the

Ethernet switch

Virtual LAN capability Required

Mounting 19 “ Rack Mount

Table 79. Ethernet Switch – L3 (Control Room)


Type Manageable, Layer-3 Fast Ethernet switches.

Make & Model Extreme, Moxa, Cisco, Allied Telesys, Planet

Number of copper 24


P a g e |192 of 208


ports

Number of fibre

ports

4 and shall be supplied with 2 Nos. of 1G

single-mode fibre SFP of 1310 nm fibre up to 40

km &2 Nos. of 10 G single-mode fibre SFP of

1310 nm fibre up to 40 km

Forwarding rate 90 Mpps or better

Performance

a. 512 MB DDR SDRAM or more

b. 64 MB Flash memory or more

c. Packet Buffer memory: 2 MB or more

Diagnostic Tools

a. Active Fiber Monitoring detects tampering

on optical links

b. Built-In Self-Test (BIST)

c. Cable fault locator (TDR)

d. Optical Digital Diagnostics Monitoring

(DDM)

e. Ping polling for IPv4 and IPv6

f. Port mirroring

IP features

a. IPv4 static & Unicast & Multicast routing

b. Route Distribution (RIP & OSPF)

c. Policy based routing

d. DHCPv6 client

e. Device management over IPv6 networks

with SNMPv6

f. NTPv6 client and server

Management

a. Centralized management and zero-touch

device installation and recovery

b. Console management port on the front

panel for ease of access

c. Web-based Graphical User Interface (GUI)

d. Industry-standard CLI with context-

sensitive help

e. Comprehensive SNMP MIB support for

standards based device management

f. Front panel display for status & fault

information

Quality of Service

(QoS)

a. 8priority queues

b. Policy-based storm protection

c. Tail drop for queue congestion control


P a g e |193 of 208


d. Strict priority, weighted round robin or

mixed scheduling

e. IP precedence and Diff Serv marking

based on layer 2, 3 and 4 headers

Resiliency

a. Stacking ports shall be configured as 10G

Ethernet ports

b. Control Plane Prioritization (CPP) ensures

the CPU always has sufficient bandwidth to

process network control traffic

c. Dynamic link failover (host attach)

d. EPS Ring (Ethernet Protection Switched

Rings) with enhanced recovery for extra

resiliency

e. Loop protection: loop detection and

thrash limiting

f. STP root guard

Security

a. Access Control Lists (ACLs) based on

layer 3 and 4 headers, per VLAN or port

b. Configurable ACLs for management traffic

c. Authentication, Authorization and

Accounting (AAA)

d. Boot loader can be password protected for

device security

e. DHCP snooping

f. Dynamic VLAN assignment

g. MAC address filtering and MAC address

lock-down

h. Network Access and Control (NAC)

features manage endpoint security

i. Port-based learn limits (intrusion

detection)

j. Private VLANs provide security and port

isolation for multiple customers using the same

VLAN

k. Strong password security and encryption

l. Tri-authentication: MAC-based, web-

based and IEEE 802.1x


P a g e |194 of 208


Environmental

specifications

a. Operating temperature range: 0°C to 50°C

b. Operating relative humidity range: 5% to

90% non-condensing

Protocols

All standard protocols/ Algorithms such as

cryptographic algorithm, Ethernet standards,

IPV4/ IPV6, Network Management support/

Multicast protocol support/ VLAN/ Voice Over

IP, etc shall support by the switch

Power supply 230 VAC +/- 10% or better

Routing

- VRRP (Virtual Routing Redundancy

Protocol) feature shall be available

- Routing: Layer 3 switch routing

- Routing protocols: RIP v1/2, OSPF &

Static routing

Standards &

Compliance

- Safety: UL508/CSA C22.2/14 (pending);

EN60950-1, CE

- Others: RoHS, WEEE and REACH

compliant

Mounting 19 “ Rack Mount

Table 80. Surge Suppressor


Make Phoenix/ Dhen/ Citel

Location UPS Output & IO Rack Input (Lightning & Surge

Protection for power supplies)

Use SPD between UPS Output in Control Room & IO rack

in Service room

Type Type 1/2/3

Mounting Pluggable SPDs between LN, LE , DIN Rail Mounting

Table 81. Control Consoles


Manufacturer Pyrotech electronics private limited/ Adarsha/

Evans/ Winstud

Dimension Drawings given in the annexure

Service Housing MMIs, Telephones & wireless sets etc.,

Location Curing Control room

General • The consoles shall be fully modular in


P a g e |195 of 208


design and construction.

• Consoles shall be ergonomically designed

for operator comforts and suitable for housing

One Operator station, Telephones & wireless sets

etc.,

• Console system shall have option of being

one or two tiers high.

Construction

features

• Cabinet shall be made of high quality wood

ASS with very good finish. The top layer of the

surface shall be capable of withstanding day to

day usage of the work surface (Free usage)

without losing the high quality finish. The surface

should be made of tough material that withstands

mild abrasions without losing finish.

• Shall have Ball bearing pull out CPU trays,

height adjustable & pull out key board trays,

mouse wire holes, Solid floor panels with cable

entries, movable equipment shelves, rails for DIN

mounting equipment’s.

• Structure: Powder Coated Aluminium

Sturdy Structure and extreme side Aesthetic Legs.

• It shall Hold one PC with 23 Inch Monitors,

Infinova V2117X Keyboard, Motorola Wireless

Base station, Phone and related Accessories

Door Front & rear hinged ASS wood doors.

Monitor tiers

• Heavy duty pipes have swivel head. The

monitor angle can be adjusted

up/down/left/right and also vertical height can

be adjusted as desired.

• Flexible telephone tray.

• Extreme ends with aesthetic elements.

Quantity Operator console - 1Nos.

Work surface

Made up of 12mm Acrylic solid surface (ASS) and

25mm of MDF wood. Desired colour shade

matching with control room interiors will be

decided by user.

Electrical • The Console System should provide a

concealed cable routing system.


P a g e |196 of 208


• The separation necessary between network

and power cabling shall be taken care off. All

trays should be easily accessible during

installation and maintenance. The horizontal

cable tray should have arrangement to

accommodate plug connectors and sockets of

varying sizes.

• Power distribution for console equipments

with 5/15-amp surge protector, 3 pin sockets,

MCBs & TBs.

• RJ-11 (2 Nos.), RJ-45 (4 Nos). Earthing kit.

Light Required. LED lamp

Chairs/ Tables Godrej (Refer Table 49, S. Nos 72, 73, 74 & 75

Dimensions Approximate Dimensions provided below

Min 1.5mts

Fig. 2. Control Consoles

Table 82. Server Rack


Make Valrack/ APC/ Rittal

Location Control Room

Size 24U

Mount Rack Mounting for Servers

Doors Transparent Glass doors shall be provided at both

PC Monitor


P a g e |197 of 208


front and Rear side.

Fans Shall be provided

Castor Castors with brake shall be provided

Cable

Manager

Shall be provided to meet system requirement

Power

manager

Shall be provided to meet system requirement

Trays Cantilever Trays & Server positioning trays shall be

provided to meet system requirement.

Earth strip Shall be provided

Tube light Fitting shall be provided

Side panels Side panels shall be provided with cam lock or Lock&

Key

Table 83. 43 Inch LED TV


Screen Size 43 Inch or better

Resolution 1920 x 1080

Panel IPS panel

Analog Video PAL/ SECAM/ NTSC

Smart Energy Smart energy saving feature shall be available

Video

a. Triple XD Engine shall be available

b. Active noise reduction feature shall be

available

c. Dynamic clear white feature shall be available

d. Dynamic colour enhance feature shall be

available

e. Picture modes: Minimum 3 Modes (Vivid,

Standard, Cinema)

f. Aspect Ratio: 16:9, 4:3, 14:9, Zoom, Cinema

zoom

Audio

a. Dolby Decoder shall be available

b. 2 Channel speakers shall be available

c. Audio output: 10 watts or better

Features Smart with WebOS3.0 with Magic remote

USB a. DivX HD feature shall be available

b. JPEG Picture support shall be available


P a g e |198 of 208

c. Audio Codec: AC3, EAC3, AAC, Mpeg, MP3,

PCM supports shall be available

Connections

a. Minimum 1 USB port shall be available at side

b. RF In: 1

c. Composite Input: 2

d. Component Input: 1

e. HDMI: 2,

f. Headphone out: 1

g. VGA IN: 1

Power supply 230 VAC

Model As per previous chapter

Table 84. 16 Pair Signal Cables


Code used BS-5308

Conductor 1.0 Sq.mm annealed tinned copper conductor of 7

strands.

No. of Cores 16 Pair

Primary

insulation

XLPE insulated core.

No. of

twists/meter

Minimum 20 twists/meter

Core

identification

By colour

Voltage grade 1100 V

Cable

identification

Running length of the cable shall be printed at

least at every 5 meter interval.

Pair

identification

With numbers at interval of not more than 250

mm as per vendors standards.

Shielding Individual + Overall:

Aluminium Mylar tape & ATC drain wire with PTP

tape.

Drain wire size 0.5 Sq.mm or better

Drain wire Multi-stranded bare tinned annealed copper in


P a g e |199 of 208


material continuous contact with aluminium side of the

shield.

Drain wire

resistance

Drain wire resistance including shield shall not

exceed 40Ω/km

% coverage /

overlap

100% / 25%

Inner sheath Extruded Black FRLS PVC type ST-2.

Armouring Galvanized steel round wire.

Outer sheath Extruded flame retardant 90 °C PVC to IS-5831

type ST-2/IEC 502. Color light blue.

a) PVC oxygen index: over 30%

b) PVC temperature index: over 250 °C

c) Fire retardant: yes, as per IEC-332 part3,

CAT A

Electrical

properties @ 20

°C

1) Conductor resistance: maximum 30Ω/km

or better

2) Insulation resistance: minimum 5000M Ω.

3) Mutual capacitance: maximum 75pF.

4) L/R ratio: maximum 40µH/ Ω or Better

5) Test voltage: Conductor to conductor: 1000

V for 1 minute.

6) Conductor to shield & Armour: 1000 V for 1

minute.

Tests All the tests shall be conducted as the part of pre-

delivery inspection.

Location From Control Room to Each Oven IO Rack

Table 85. 1 Pair / 3 Pair Signal Cables


Code used BS-5308

Conductor 0.5 Sq.mm annealed tinned copper conductor of 7


P a g e |200 of 208


strands.

No. of Cores 1 Pair/ 3 Pair

Primary

insulation

XLPE insulated core.

No. of

twists/meter

Minimum 20 twists/meter

Core

identification

By colour

Voltage grade 1100 V

Cable

identification

Running length of the cable shall be printed at

least at every 5 meter interval.

Shielding Individual + Overall:

Aluminium Mylar tape & ATC drain wire with PTP

tape.

Drain wire size 0.5 Sq.mm or better

Drain wire

material

Multi-stranded bare tinned annealed copper in

continuous contact with aluminum side of the

shield.

Drain wire

resistance

Drain wire resistance including shield shall not

exceed 40Ω/km

% coverage /

overlap

100% / 25%

Inner sheath Extruded Black FRLS PVC type ST-2.

Armouring Galvanized steel round wire.

Outer sheath Extruded flame retardant 90 °C PVC to IS-5831

type ST-2/IEC 502. Color light blue.

a) PVC oxygen index: over 30%

b) PVC temperature index: over 250 °C

c) Fire retardant: yes, as per IEC-332 part3,

CAT A

Electrical

properties @ 20

°C

1. Conductor resistance: maximum 40Ω/km

or better

2. Insulation resistance: minimum 5000M Ω.

3. Mutual capacitance: maximum 75pF or

Better

4. L/R ratio: maximum 25µH/ Ω or Better

5. Test voltage: Conductor to conductor: 1000

V for 1 minute.


P a g e |201 of 208


6. Conductor to shield & Armour: 1000 V for 1

minute.

Tests All the tests shall be conducted as the part of pre-

delivery inspection.

Location From Control Room to Each Oven IO Rack

Shielding Cores shall have common shield of 0.25mm Dia

annealed, tinned copper conductor braid with

85% min coverage

Overall

sheathing

0.5mm PTFE insulation or appropriate as

mentioned above

Temperature The cable should withstand temperature of

minimum 80 to 150 deg C

Location From Each RTD Sensor to IO Rack

Table 86. Heat Resistant Cables


Make Thermocab, Thermocables, Delton, Lapp, Polycab,

Paramount

Conductor 7/0.32 Dia stranded, annealed, tinned copper

conductor to have effective cross sectional area of

0.5 sq.mm as per IS 8130

Insulation 0.4 mm PTFE insulation or appropriate to

withstand ambient temperature of Max 150 deg C

Type Flexible cable

No. of cores 8

Color-coding Suitable distinctive color-coding with polyester

taping shall be provided over the cores

Shielding Cores shall have common shield of 0.25mm Dia

annealed, tinned copper conductor braid with

85% min coverage

Overall

sheathing

0.5mm PTFE insulation or appropriate as

mentioned above


P a g e |202 of 208


Temperature The cable should withstand temperature of

minimum 80 to 150 deg C

Location From Each RTD Sensor to IO Rack

Table 87. Optic Fiber Cables

Make HFCL, Polycab, Schneider, RPG

Fiber type Single Mode

Fiber Count 24

No of loose Tubes 6 nos. (4 fibers per tube)

Colour of fibers Blue, Orange, green and natural

Attenuation at 1300 nm less than 0.5 db/km

Fiber coating diameter 245 +/- 10 microns

MFD 9.3 +/- 0.5 microns

Clad diameter 125 +/- 1 microns

Diameter of cable 15 mm nominal

Inner sheath thickness Black PE 1.0 mm

Outer sheath thickness Black HDPE> 0.5 mm

Armor Corrugated ECCS tape

Moisture barrier Water swells able tape or poly tape

Tensile strength > 2000 N

Crush resistance > 2000 N

Impact resistance 25 Nm – 10 impacts

Minimum bend radius 20 D

Repeated pending 30 times

Torsion resistance 10 cycles

9. Suggested Vendors

9.1. Main Oven, AGNI Oven & Sub Systems – Mechanical

Table 88. Suggested Vendors - Mechanical

Description Make

Centrifugal Fans

ABB Limited / Nadi Airtechnics Pvt.

Limited / CB doctor, Ahmedabad /

Patel Air temp India Limited, Mumbai

Centrifugal Pumps Kirloskar Brothers Limited

Bearings SKF

Fire Dampers Carrier / Bhupathi Associates / Belino


P a g e |203 of 208

Description Make

/ Juventa

Ball Valves L & T / Audco

Insulation

Lloyds Insulation (India) Limited,

Mumbai / Navbharat Insulation &

Engineering Company, Mumbai / U P

Twiga Fibre Glass Limited, New Delhi

/ Newkem Engineers Private Limited,

Mumbai

SS pipes Ratnamani / REMI

SS pipe fittings Rajamani / Aravind

Pressure gauges Wika / Atlas/ H Guru/FIEBIG

Fasteners UNBRAKO / TVS

9.2. Electrical Systems

Table 89. Suggested Vendors – Electrical Systems

Sl. No.

Item Description Suggested Vendor

1. ACB Siemens / L&T

2. MCB Siemens / Schneider / Legrand

3. MCCB Siemens / Schneider / L&T

4. MPCB/CONTACTOR/OLR/Aux Contactor

Siemens

5. Timer Siemens / L&T

6. Line / Power Monitoring Relay

Siemens

7. Limit Switches Siemens / L&T

8. CT Kappa / AE

9. CT Current Transducer / Voltage Transducer

Rishab / M-System /AE

10. Current Transducer LEM

11. Earth Leakage Relay PROK DVS

12. FLP Items Baliga / FCG / STAHL

13. Intrinsic Safe Items P&F

14. Power Cable Havells / Finolex / CCI / Universal / Polycab / IGUS / Gloster / Lapp /KEI

15. Control Cable Havells / Finolex / Polycab / IGUS / Gloster / Lapp / KEI / RR Kabel

16. Panel Wiring Cable Havells / Finolex / Lapp / RR Kabel


P a g e |204 of 208

Sl. No.

Item Description Suggested Vendor

17. Motor Management System (MMS)

Siemens / Schneider / Allen Bradley

18. Soft Starter Siemens

19. Thyristor Power Controller AEI

20. Digital Panel Meter AE / RISHAB / Schneider / L&T / ABB / MCIH / PMA / Conzerve

21. Multi-function Meter Siemens

22. Push Buttons Siemens

23. Indication lamps Siemens / L&T

24. IS Indication Lamps BEKA

25. iMCC Integrator

M/s SIEMENS LTD M/s ALLEN BRADLEY LTD M/s ADARSHA CONTROL &

AUTOMATION PVT. LTD, Chennai

M/s AUTOSYS ENGINEERING PVT LTD

M/s KASA ANLAGEN PVT LTD, Chennai

M/s CHEMIN CONTROLS PVT LTD , Pondicherry

M/s RSP CONTROLS LTD, Chennai

M/s FORMOPLASTIC CONTROLS (P) LTD

26. For any other make, approval to be obtained from department before placement of order.

9.3. Instrumentation & Control Systems

Table 90. Suggested Vendors – Instrumentation & Control

Systems

S.No Item Make










P a g e |205 of 208

5 Duplex RTD of 400 mm Length – Hot Water Tank


6 Duplex RTD of 300 mm Length – Hot water Inlet & Outlet


7 Temperature Transmitters Rosemount/ Siemens

8 Pressure Transmitter Rosemount 3051 (0 to 55 Bar)/ Siemens

9 Single Loop Controller ABB CM10

10 Level Switch P&F

11 Level Transmitter P&F / Rosemount/IFM

12 Proximity sensors P&F


P&F


P&F

15 Relay – 1 In 2 Out P&F

16 Relay – 2 In 2 Out P&F

17 Power fed Module and Power rail

P&F

18 Power Rail P&F

19 Low Air pressure Switch Switzer/ IFM

20 Water flow switch Switzer / IFM

21 DC Current transducer Rishab/ LEM/ AE/ M- Systems/ NK Technologies

22 DC Voltage transducer Rishab/ LEM/ AE/ M- Systems

23 UPS Voltage Monitoring Transducer


24 UPS Current Monitoring transducer


25 UPS Voltage Monitoring (3 Phase) Transducer


26 UPS Current Monitoring ( 3 Phase) transducer


27 Raw Voltage Monitoring (1 Phase) Transducer in Main & Agni Oven


28 Raw Current Monitoring (1 Phase) Transducer in Main & Agni Oven


29 24 V DC/20 A power supply with Diode O ring Module


30 24 V DC/10 A power supply with Diode O ring Module


31 24 V DC/5 A power supply Phoenix/ Siemens/ Aplab


P a g e |206 of 208

with Diode O ring Module

32 IO Rack Rittal

33 Hot Standby PLC/PAC Siemens/ Schneider/ Allen Bradley

34 PLC Programming Full License


35 16/32 Channel Digital Input Module


36 16/32 Channel Digital Output Module


37 8 Channel RTD Input Module Siemens/ Schneider/ Allen Bradley

38 8 Channel Analog Input Module


39 4/8 channel Analog Output Module


40 SCADA Server License (For Hot stand By Server)

Siemens/ Schneider/ Allen Bradley (Unlimited Run-time + Configuration Supply of for HSBY server– 5000 Tags

41 SCADA Historian License

Siemens/ Schneider/ Allen Bradley (1500 tags for historian server with 10 HMI User access & 2 Web user access

42 SCADA Client License (HMI Clients)


43 SCADA (Web Clients) Siemens/ Schneider/ Allen Bradley (Web space clients)

44 SCADA Historian Server HP/Dell

45 SCADA Server HP/Dell

46 Operator Station HP/Dell

47 Thin Client Unit HP/Dell

48 PG Station (Laptop) HP Pavilion/ Dell

49 A3/A4 Color Inkjet Printer HP

50 A4 Color Laser Printer HP

51 A4 Scanner HP

52 Digital camera SONY

53 Ethernet Switch- L2 (PLC N/w)


54 Ethernet Switch- L2 (SCADA N/w)


55 Ethernet Switch- L3 (Control Room)

Extreme/ Moxa / Cisco / Allied

Telesys/Planet

/ HP


P a g e |207 of 208

56 Surge Suppressor – 1 Phase Phoenix/ Dhen/ Citel

57 Surge Suppressor – 3 Phase Phoenix/ Dhen/ Citel

58 Operator Console Pyrotech

59 Server Rack APC/Rittal/ Valrack

60 43 Inch LED TV LG/ Panasonic/ Samsung/ Sony/ Toshiba

61 16 Pair Armored Signal Cables

Uniflex / Thermocables /

Thermocabs /Delton / Delta /

Lapp / Paramount cables /

Polycab

/ RPG /CMI





64 Heat Resistant Cables

Uniflex / Thermocables /

Thermocabs /Delton / Delta /

Lapp / Paramount cables /

Polycab / / RPG /CMI

65 Optic Fibre Cables HFCL/3C/ Schneider/ Tyco/ RPG

66 Cat 6 /7 cable Belden/ Schneider

67 Double compression Glands Baliga/ Comet

68 Terminals/ Stoppers/ Fuse TB

DIN Rail Wago/ Phoenix/ Weidmuller, Fuse TB with Fuse Break LED

69 Flameproof Junction Boxes P & F/ Baliga

70 Non Flame proof Junction Boxes

P & F/ Baliga / Rittal / Adarsha

71 Relay Phoenix Solid state relay module to drive contactors.

72 48 port OFC Splice box (Wall Mount)

3M/ FCI

73 19” Rack Mount 48 Port OFC Splice Tray (Rack)

3M/ FCI

74 Push Buttons, Emergency Stop Buttons

Siemens

75 Chairs Godrej PCH 7001


P a g e |208 of 208



78 Table Godrej ENZ0, Color: Beige, Dim: 1500 x 750 x 750