NMDC LIMITED MECON LIMITED § KUMARASWAMY IRON ORE PROJECT PACKAGE NO - IT VOLUME - IIT of V CHAPTER NO. D PAGE No. 4 of 12 Tail / drive house at tail end of down hill conveyor no. 723. vili) Conveyor no. 721 for conveying material from belt feeder no. 720 to tail end of down hill conveyor no. 723 along with metal detector and belt weigh scale. ix) Transfer House TH-2A at head end of conveyor no. 721. x) Parking / maintenance shed PS-1 for traveling trolley near tail end of down hill conveyor no. 723. xi) Down hill regenerative single flight long distance conveyor No. 723 having horizontal and vertical curvatures complete with the following: a. 2 nos. self propelled traveling maintenance trolleys ‘b. Triangular/ rectan r RCC / structural trestle da. State of art electrics with controlled starting & braking system Parking / maintenance shed PS-2 for traveling trolley near head end of down hill conveyor no. 723. xili) Transfer House TH-3 at head end of down hill conveyor no. 723 along with surge hopper, hydraulically operated gate and belt feeder no. 725 at bottom of surge hopper. Provision shall also be kept in the above Transfer House to convey material to the proposed new screening plant through a belt feeder and conveyor from the surge hopper in future. The opening at the bottom of the surge hopper feeding material to the proposed conveyor to new screening plant shall be closed. TENDERER shall ensure the adequacy of the storage capacity of the surge hopper considering the stopping time of the down hill conveyor at worst condition. xiv) Reversible conveyor no. 727 for conveying material from Transfer House TH-3 to the extended tail end of existing tripper conveyor no. 122 at Transfer House TH-4. The above conveyor shall also convey Iron Ore from Donimalai tripper MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 © 2010, MECON Limited. All rights reserved.NMDC LIMITED MECON LIMITED KUMARASWAMY IRON ORE PROJECT PACKAGE NO - IT VOLUME - III of V CHAPTER NO. D PAGE No. 6 of 12 xxv) Fire detection & suppression system for down hill conveyor no. 723. xxvi) HT/LT switchgear, LT Transformers and shop electrics. Control and power cables, signal cables, data cables, etc. Control panels, desks, PLC panel, VDU etc. Intra plant communication (PA System) xxvii) Field safety switches, Control, PLC based automation, instrumentation and SCADA. xxviii) Braking system for controlled starting, stopping of downhill conveyor under varying patterns of load and braking under No-power conditions. xxix) Braking system for reversible conveyor no. 727. xxx) Illumination of plant and area illumination. xxii) Approach road to TH-1, Silo area, Tail / drive house of Down Hill Conveyor, TH-2, TH-2A, PS-1 and Electrical, control cum office building from the approach road proposed for Secondary Crushing Plant under package-I. xxxill) Approach road to TH-3 from the kachcha road already developed by NMDC. xxiv) Approach road to take-up area of down hill conveyor no. 723 and PS-2 near head end of down hill conveyor. xxxv) Approach road to TH-4, TH-5 & TH-6 from the roads available already. xxxvi) Approach road to belt lay down area at two locations. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 © 2010, MECON Limited. All rights reserved.NMDC LIMITED MECON (ZQ\) Limited Kor KUMARASWAMY IRON ORE PROJECT PACKAGE NO - IT VOLUME - ITI of V CHAPTER NO. Qi PAGE No. 18 of 160 2.12.3 Take-up tower and maintenance platforms for VGTU & HGTU. Take up tower with maintenance platforms at every 3 m & suitable approach ladder shall be provided for VGTU. Unless otherwise indicated in the tender drawings, the VGTU shall be located inside 4-legged trestle of and maintenance Platforms and approach ladder for the same shall be Provided. HGTU counter weight tower shall be provided with vertical ladders for maintenance of sheaves. Monorail of adequate capacity shall be provided below the gallery for maintenance of vertical gravity take-up arrangement. 2.12.4 Screw take-up (wherever specified) For conveyor with screw take—up, the pulley shall be ‘supplied with stainless steel screw & nut for take-up travel. The pulley assembly arrangement shall be made such that the pulley will move back & forth due to rotation given to the nut. The take- up length for various conveyors with screw take-up shall be calculated as per IS—4776 (Part I) considering vulcanized Joint & 80% rated tension. 2.12.5 Cage, guides etc. for VGTU & HGTU Safety cage with door and sandpit shall'be provided for the Suspended counterweight. Sway movement of take up pulley and that of counter weights shall be controlled by adequate guides, supported on independent foundations. 2.13. PROTECTION SWITCHES 2.13.1 PULL CORD SWITCHES Pull ‘cord switches shall be provided on the wider walkway side for emergency stoppage of conveyor. The first switch shall be about 4 m away from the driving pulley and subsequently at not more than 30m intervals. The pull wires shall run along the entire length of each conveyor. All pull cord switches shall have individual local indicators to indicate when operated. The pull rope wire shall be standard galvanized steel wire with PVC cover and having overall diameter of minimum 6-mm. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 © 2010, MECON Limited. All rights reserved,NMDC LIMITED MECON LIMITED KUMARASWAMY IRON ORE PROJECT PACKAGE NO - IT VOLUME - IIT of V CHAPTER NO. Q1 PAGE No. 24 of 160 3.1.8 The conveyor will of elevated type with minimum 8.0m clearance from the ground to the bottom of the structure / travelling trolley of the conveyor at road crossings, above railway line crossing, over BMM plant, over Ranjitpura village and over proposed Pellet plant. In other locations, a minimum clearance of 6.0 m shall be ensured from the ground to the bottom of the structure / travelling trolley of the conveyor. An elevated truss is required to be provided over the first ravine and the conveyor is as much as 50 m above the bottom of the ravine. Also, the down hill conveyor will be passing over the ROM stock pile in BMM plant area and over the waste dump near BMM plant. The foundations for the conveyor trestles in the above areas shall be planned considering the height of the ROM stock pile and waste dump. Also, the location of the trestles in BMM plant area shall be planned considering the various existing facilities like weigh bridge, roads, etc, 3.1.9 Cutting and filling required along the alignment of the down hill conveyor to provide the trestles and also for maintaining the clearances as specified under Cl. No. 3.1.8 along the alignment shall be carried out by successful Tenderer, Wherever trestles are proposed along the slope of the hill, suitable protection shall be provided against soil slide, rolling of boulders from the higher elevation. Side slopes and its treatment shall conform to safe engineering practices, MEC/01/Q6DH/NMDC-KIOP/PKG-I1/TD Rev. 0 © 2010, MECON Limited. All rights reserved,NMDC LIMITED MECON LIMITED KUMARASWAMY IRON ORE PROJECT PACKAGE NO - II VOLUME - V of V CHAPTER NO. Q6 Page 2 of 194 ‘SECTION - I: GENERAL & SCOPE OF WORK 1.0 GENERAL aa The scope of this tender includes analysis, design, detailed engineering, preparation of construction drawings, bar bending schedules and submission of design calculations and construction drawings for approval of the Owner/ Consultant, supplying of all material, testing of all materials as per specifications/ BIS codes and labour and construction of the facilities as per the provisions of this specification, commissioning and handing over all facilities to the client. 2.0 ‘SCOPE OF WORK 21 The following / Buildings facilities are envisaged: Si. Description Remarks No. 1, | RCC trestle foundations 7 foundation for | See clause " short post_for Conveyor No: 718. No. 3.0 Transfer — House No:1 Column] Given 2, | foundations & with 200mm thick RCC| below for floors on steel beams. description 3, _| RCC trestle foundations 7 foundation for| _ of the ‘ short post for Conveyor No: 719. facility / 4, | RCC Storage Silo of 1000 t Capacity with | Building. ~_| structural roof. Tail/Drive house column foundations and 5. | foundation for drive platform with RCC floors. Transfer House No: 2 Column 6. | foundations & with 200mm thick RCC floors on steel beams. Transfer House No: 2A Column 7. | foundations & with 200mm thick RCC floors on steel beams. Parking/Maintenance station for 8. | traveling trolley (PS-1) Column foundations. 9, | RCC Trestle foundations for Conveyor = No: 721. MEC/01/Q6DH/NMDC-KIOP/PKG-11/TD Rev. 0 © 2010, MECON Limited. All rights reserved.NMDC LIMITED MECON UMITED © KUMARASWAMY IRON ORE PROJECT PACKAGE NO - IT VOLUME - V of V CHAPTER NO. Q6 10. } with RC a RCC Trestle foundations for Conveyor No: 727. a2) Parking/Maintenance station for traveling trolley (PS-2) Column foundations. 13. Transfer House No: 3 Column foundations & with 200mm thick RCC floors on steel beams. 14, Transfer House No: 4 Column foundations & with 200mm thick RCC floors on steel beams. 15. Transfer House No: 5 Column foundations & with 200mm thick RCC floors on steel beams. 16. Transfer Station Column foundations & with 200mm thick RCC floors on steel beams. 17. Transfer House No: 6 Column foundations & with 200mm thick RCC floors on steel beams. 18, RCC ‘Trestle foundations for Conveyor No: 727-1, 19, RCC ‘Trestle foundations for Conveyor No: 727-2. 20. Sub-station at tail end of down hill conveyor with Office room, VFD room, ‘Switchgear room, Pump house, Shift In charge room, Control room, Cable cellar, battery room, etc, 21, Sub-station near TH-5 with Office room, VFD room, Switchgear room, Cable cellar, battery room, etc. 22, Sub-station near TH-3 with VFD room for Belt Feeder and other panels as per Fequirement, Page 3 of 194 MEC/01/Q6DH/NMDC-KIOP/PKG-II/1D © 2010, MECON Limited. All rights reserved, Rev. 0NMDC LIMITED MECON LIMITED KUMARASWAMY IRON ORE PROJECT PACKAGE NO - IT VOLUME - V of V CHAPTER NO. Q6 Page 6 of 194 3.0 31 32 33 GENERAL DESCRIPTION OF BUILDINGS AND FACILITIES Foundations for trestle supports for conveyors: The foundations for structural trestle supports for all Conveyors shall be constructed in reinforced cement concrete duly taking into account wind loads, earthquake load, equipment loads, etc. The trestle foundations that are prone to undermining and erosion of topsoil due to rainwater shall be protected by appropriate methods like cut-off walls, catch drains and stone pitching. Locating the trestle foundations in the watercourses, rivulets and other water bodies shall be avoided. In cases where the trestle foundations are to be located on sloping hilly regions, the foundations shall. be Placed on stable and firm soil stratum. The trestle foundations shall be constructed on Suitable and adequate capacity piles in cases where such foundation system is to be adopted due te engineering properties of existing soil. n 723 shall be provided adequate slope to facilitate cleaning of accumulated mack Can eshing. Granolithic floor of sufficient thickness (min.200) with non-metallic floor hardener shall be provides RCC Storage Silo (1000t (effective storage) Capacity): A RCC Silo of 1000 t capacity (effective storage) is proposed MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 © 2010, MECON Limited. All rights reserved,NMDC LIMITED MECON UMITED KUMARASWAMY IRON ORE PROJECT PACKAGE NO - IT VOLUME - V of V CHAPTER NO. Q6 Page 13 of 194 a7 Ca 28 2.8.1 2.8.2 2.9 2.9.1 elements to aesthetics and these shall be designed judiciously. Building Type of structure and construction Transfer Houses RCC foundation, RCC floors on structural beams. Structural Steel Super structure with cl / Translucent Sheeting. Trestle foundations RCC. ‘Structural and construction elements eae Office building, Electric [RCC framed structure with room, MCC room. Masonry infill walls. ‘Service Road [10 wide formation; 1.5m Shoulder; [2 WBM carriage way with bitumen rpeting. Terrace Levels The terrace levels shall be fixed based @n the topography of the area and the filling/ cutting requirements as well as road gradients. In general terrace levels shall be 300mm below the road top level, In areas of rock outcrops/ cutting the surface shall be so chiselled so as to be aesthetically pleasing. Finished floor levels In general, finished floor levels of the building, sheds shall be determined with respect to top of approach road or pavement, Generally FFL shall be 600mm above terrace levels near the building or as indicated in the drawings, MEC/01/Q6DH/NMDC-KIOP/PKG-11/TD Rev. 0 © 2010, MECON Limited. All rights reserved.MECON Cer reD LIMITED ® KUMARASWAWY IRON ORE PROJECT PACKAGE NO - It VOLUME - Vof V CHAPTER NO. Q7 PAGE No. 17 of 84 2.4.8 Camber Wherever excessive deformation is likely to cause operational Problem or is aesthetically not agreeable, camber shall be Provided to neutralize the effect of deformation due to dead load plus 50 % of imposed loads. 24.9 Expansion joints @) Longitudinal and transverse expansion joints shall be Provided in buildings and structures in accordance with IS: 800-2007 (refer relevant clause) b) Expansion joints shall be formed by providing double rows of columns, with interconnecting gantry girders, secondary roof and wall framing being detailed to allow the maximum calculated movement for the specified temperature variation. ©) The above said expansion block 150 metres long shall: n ed by end ies ame ea a oa 2.4.10 Miscellaneous design requirements a) The minimum thickness of structural steel elements shall be in accordance with IS: 800-2007 and subject to the following minimum requirements: Gusset plate Base plate Stiffeners plates for Base plates Flange plates for plate girders Web plates for plate girders Stiffeners for webs of plate girders: 8mm Bracing member : 50 x 50 x 6 angle Hand Rail toe-guard : 100 x 4mm thk, MEC/01/Q6DH/NMDC-KIOP/PKG-11/TD Rev. 0 © 2010, MECON Limited. All rights reserved.MECON NMDC LIMITED LIMITED ® KUMARASWAMY IRON ORE PROJECT PACKAGE NO - IT VOLUME - Vof Vv CHAPTER NO. Q7 PAGE No. 18 of 84 Hand rail: Horizontal rails/Vertical posts Pipe 32 NB (Medium) dia maximum spacing of vertical posts - 1000 mm and minimum height of handrail shall be 1100mm. b) The diameter of structural bolts shall not be less than 16 mm except for those securing roof and. wall sheets, windows, doors and stitching of thin coverings. For bolted joints, at least two bolts per joint shall be provided, ©) The size of fillet welds shall not be less than 6 mm. 4) Main structural elements shall be welded continuously. Intermittent welding shall be used only on secondary members, which are not exposed to weather or other corrosive influence. ©) _ Field connection and splices shall be made as follows: i) By welding 1) By permanent bolts (for secondary members such as purlins, wall runners etc.) OF panera Design considerations 25 General 2.5.1 The dimensional parameters for conveyor galleries shall be in line with the dimension indicated in the tender drawings. The structure shall be designed so as to meet functional equirements and shall provide space for operation, maintenance and removal of machinery and give the workers good and safe environment. 2.5.2 Gallery floors shall be of Chequered plates / Gratings supported on steel beams as per the requirement MEC/01/Q6DH/NMDC-KIOP/PKG-11/TD Rev. 0 © 2010, MECON Limited. All rights reserved.al MECON NMDC LIMITED Me Lrvern LIMITED KUMARASWAMY IRON ORE PROJECT PACKAGE NO - IT VOLUME - Vof v CHAPTER NO. Q7 PAGE No. 20 of 84 2.5.10 isi 2.5.12 Seal plate of min. 3.15 mm thickness with adequate stiffeners shall be provided below the gallery at road / rail crossing, above nallahs, above buildings, in BMM plant area, pear Ranjitpura village and near proposed Pellet Plant to avoid falling of material, 2.5.13 The ‘effect of inclination of conveyors shall: be taken into account for design of structures. The inclination shall be as Per appropriate conveyor layout, 2.5.14 End portal of gallery (Vertically straight) shall be of ISMB Sections/Bullt-up 1 sections, designed to transfer sll vertical and lateral loads to supporting trestles / transfer houses, 2.5.15 Loads due to temperature effect, wind loads, effect of gravity take up, material loads, conveyor loads along with other load combinations, with appropriate dynamic coefficient, shall be considered for the design, 2.5.16 Conveyor galleries (Top & Bottom chord shall be ISMB Sections/Built-up T sections) and trestles shall be designed considering both the conveyors are working simultaneously in case of twin conveyor system, MEC/01/Q6DH/NMDC-KIOP/PKG-IT/TD Rev. 0 © 2010, MECON Limited. All rights reserved,MECON NMDC LIMITED LIMITED ® KUMARASWAMY IRON ORE PROJECT PACKAGE NO - IT VOLUME - Vof Vv CHAPTER NO. Q7 PAGE No. 23 of 84 was 8) Gallery for Down Hill Conveyor-723: Gallery for down hill conveyor no. 723 shall be suitable for 1050 mm belt width and shall be Open Type rectangular Gallery with R.C.C. pier supports (up to 12 metres height) and 4 legged steel structural supports for heights above 12 metres. Roofing and side sheeting shall not be provided for the above conveyor gallery. Walkway shall be provided on one side of the gallery. Gallery shall be designed considering the Movement of self-propelled maintenance trolleys along the entire length of the conveyor. b) Also please refer to the other clauses viz: 26 Components of structures 2.6.1 Gallery Trusses and Roof a) Gallery truss shall be of latticed type construction and shall support roof (for covered galleries) as well as floor deck supporting conveyor system. MEC/01/Q6DH/NMDC-KIOP/PKG-11/TD Rev. 0 © 2010, MECON Limited. All rights reserved.MECON NMDC LIMITED LIMITED ® KUMARASWAMY IRON ORE PROJECT PACKAGE NO - IIT VOLUME - Vof Vv CHAPTER NO. Q7 PAGE No. 24 of 84 b) The trusses shall be adequately braced at top and bottom chord level to transfer the horizontal wind forces to end portals, 2.6.2 Stringer beam These beams shall be suitably spaced to support the conveyor stringer post and shall deliver load to gallery trusses. Walkways on either side of the conveyor shall also be supported on these stringer beams & truss bottom chord member. 2.6.4 Transfer houses 2.6.4.1 a) Floors - Floor beam layout shall be arranged to suit equipment layout as well as equipment anchoring system. b) Columns - In addition to loads from floor and roof, columns shall be designed to transmit horizontal load due to belt tension/snapping of belts to the foundation 2.6.4.2 Transfer _houses/Towers shall be designed with structural steel framing. While peripheral framing will be designed as braced structure, intermediate framing may be designed as framed structures. 2.6.4.3 Chute loads on floors shall be evaluated duly considering the Chutes as fully plugged with material for its entire height. MEC/01/Q6DH/NMDC-KIOP/PKG-I1/TD Rev. 0 © 2010, MECON Limited. All rights reserved.