1.

GENERAL DESCRIPTION OF PROJECT

Odisha Mining Corporation Limited (OMC) is a flagship Gold Category mining company of
Odisha which has been engaged in mining activities to explore and harness mineral wealth of
the State of Odisha and make value addition. Various minerals mined and sold to consumers by
OMC are Chrome Ore, Iron Ore and Manganese Ore which cater to the requirement of mineral
based industries such as Steel, Sponge Iron, Pig Iron, Ferro-Manganese, Ferro-Chrome, etc.

OMC had invited online Bids for Mine Development and Operation (MDO) for Kurmitar Iron Ore
Mine in Kurmitar Mines, near Barsuan, in Sundargarh dist. of Odisha, at an annual capacity of
around 9 MTPA.

Adani Enterprises Ltd. (AEL), a subsidiary company of Adani group, also involved in Mining
operations in India & abroad, had participated in the bidding process for this project and was
selected as preferred Mine Developer and Operator (MDO) for this mine.

Kurmitar Iron Ore Mining Private Limited (KIOMPL), a Group company of Adani Enterprises
Limited has been engaged by OMC for development of the Kurmitar Iron ore mine.

This tender document is for the series of Trough Belt conveyors, Downhill pipe conveyors,
Truck loading station, stockpile with skyline conveyor, Reclaim equipment and in motion Train
Loading station.

KIOMPL (Owner) intends to float this tender for design, engineering, supply, fabrication,
erection, installation, testing and commissioning of OHP infrastructure at Primary area, Dispatch
area 1 and Dispatch area 2. OHP includes belt conveyer systems, downhill pipe conveying
system, stacking and reclaiming of iron ore, ground bunker, truck loading systems and in motion
train loading systems. Crushing and screening unit is not part of this tender.

1.1. Site Location:

The proposed project access details as follows:

District and state Sundergarh and Orissa

Barsuan Railway Station about 20 Km north
Nearest Railway Station of the mine, on the Rourkela - Barsuan
section of South Eastern Railway.
Nearest Airport Jharsuguda & Bhubaneswar

Co-ordinates (Kurmitar iron ore lease): Survey of India topo sheet no.73 G/1& G/2,
Latitude 21°45' N to 21°51' N
Longitude 85°06' E to 85°10' E

1.2. Communication and Accessibility

The Project area of Kurmitar mine is located about 20 km South of Barsuan town (between
latitudes 21°45' N to 21°51' N and 85°06' E to 85°10' E) and appears on Survey of India Topo
Sheet Nos. 73 G1 SW and 73 G1 SE. Barsuan town is about 80 km South East of Rourkela
Steel City in Odisha. Barsuan, on the Rourkela - Barsuan section of South Eastern Railway, is
also the nearest railhead. Nearest airport Jharsuguda is at a distance of 165 km and
Bhubaneswar is at a distance of about 350 Km. Paradip Port is the nearest sea port at a
distance of about 375 Km. Barsuan town can be approached from Barkote on NH6, through
SH10A and then through Koida Road. From Barsuan a 16 Km long road leads to Khandadhar
mines camp area which is the camp area for Kurmitar mine.

1.3. Climate & Rainfall

The climate of the area is more or less similar to that of other tropical parts of India.

Temperature:

Sr.
No Description Project value Unit of measure
.

Ambient temperature
Mi 15 °C
1 n
M 42 °C
ax
Design ambient temperature for
2 equipment (maximum) 50 °C
Design ambient temperature for
3 equipment (minimum) 0 °C

The area lies in tropical region where climate is characterized by very hot summers and cool
winters. Summer is typically from March to June when monthly temperature ranges from a
maximum of 42°C during daytime to a minimum of 15°C at night. Winter is from November to
February when the maximum temperature during day goes up to 37°C and minimum
temperature at night becomes as low as 8°C.

The average annual rainfall of the area is 1269.1 mm. The Southwest monsoon lasts from mid-
June to mid-September and the area gets more than 80% of the annual rainfall during this
period.

2. RETURNABLE SCHEDULES:

The Contractor shall submit their tender in accordance with the requirements of the Returnable
Schedules contained as mentioned below. The format of these schedules should be maintained
to ensure owner to efficiently compare and evaluate the bidder’s submissions. The Returnable
Schedules are comprised of the following components as listed below:
 Sl.
Nos. Schedule Title

1 Schedule G List of Commissioning Spares

2 Schedule H List of 2 years Mandatory Spares

3 Schedule I List of 2 years Recommended Spares
4 Schedule N Major drive list with specific power consumption
5 Schedule Q Deviation List

DUST SUPPRESSION SYSTEM

GENERAL INFORMATION:

This detailed specification is intended to cover the scope of design, engineering, supply,
erection and commissioning of Plain Water Dust Suppression System for the proposed Material
Handling System for Adani Plant. The scope of services includes Design & Engineering
compatible to Indian codes and standards as well as applicable International Standards, Supply,
Erection, Testing and commissioning of Plain Water Dust Suppression System.

The dust control system to be furnished under this specification is required for control of fugitive
dust emissions from dust generation points such as transfer points etc. Dust control is achieved
by plain water dust suppression system for all material transfer.

Dust suppression spray nozzles discharging plain water in a fine spray to capture air borne dust
particles and direct them into the main material flow. Water shall be discharged via a pipe work
system through spray heads at the dust suppression zones.

For dust suppression, plain water sprinkling nozzles shall be provided at all loading / unloading
and material transfer points.

Solenoid valves shall be provided for open/close control of water line to each spray head. Spray
heads shall be provided at each material loading and receipt zone. Solenoid valves shall be
interlocked with the loading, unloading operations so that sprays will stop when material
handling stops.

Pressure at inlet to spray head shall not be less than 2.5 Kg/sq.cm (g).

Skirt height shall be selected considering dust suppression.

Each transfer tower shall be provided with pressure gauge and pressure switch.

Dust Suppression system shall be complete with water supply system, piping, sprays headers.

The entire water piping of dust suppression system shall be routed/supported on conveyor
galleries and concrete pedestal. Wherever the layout does not permit the pipes to be routed
over ground, the same shall be buried in conformity to the relevant standards & shall be
provided with necessary protective coating as per relevant standards and as specified
elsewhere in the specification.

Hangers and supports shall be capable of carrying the sum of all concurrently acting loads.
They shall be designed to provide the required supporting effects and allow pipe line
movements as necessary. All guides, anchors, braces, dampers, expansion joints and structural
steel to be attached to the building/structure, trenches etc. shall be provided.

All piping shall be capable of withstanding the maximum pressure in the corresponding line at
the relevant temperature.

Bidder to provide galvanized steel piping throughout, wherever possible with “Victaulic”
couplings and fittings, or any other approved method for pipe joint shall be adopted.

Piping supports shall be of coupling manufacturer’s recommendations as a minimum, but

supports shall be adequate to prevent pipe damage by maintenance personnel walking on
piping.

Piping shall be pitched to allow complete system drainage, if required. Provide adequate drain
points complete with valves. Sufficient vents shall be provided.

Bidder to provide adjustable pressure regulating valves for each dust suppression nozzle
header at each nozzle array. This shall be easily field-adjustable.

All valves shall be suitable for most stringent service conditions i.e. flow, temperature and
pressure under which they may be required to operate.

Gate/sluice valves shall be used for isolation of flow of pipe lines above 50NB and Globe valves
shall be used for regulating the flow.

In general pipe sizes 65 NB and larger are to be joined by butt welding and pipe work of size 50
NB and below by socket welding/screwed connections. Joints at valves or specialties shall be
flanged for sizes 65 NB or large and screwed for sizes 50 NB and below. All galvanized piping
shall be joined by screwed connections. Minimum pipe diameter selected for Water System
(along with branch pipes) shall be 32 NB.

Valves shall be provided with the following as necessary:

i. Hand wheel
ii. Position indicator
iii. Draining arrangement iv. By-pass valve and spur gear reduction units for larger
valves.

Globe valves shall be provided with contoured plug to have well controllability.

Non-return valves shall be swing check type. These valves will have a permanent ‘arrow’
inscription on its body to indicate direction of motion of the fluid.

All valves shall be provided with hand wheel, chain operated, extension spindle and floor stand
wherever required so that they can be easily operated either at a lower or higher elevation as
the case may be.
The dust suppression system shall be provided for all material transfer points.

A dust suppression system shall also be installed for the entire Stockpile (Lumps/CLO) by
providing a water pipe network fitted with nozzles/sprinklers, pumps & motors as required and
all other accessories.

TECHNICAL REQUIREMENTS
Dust Suppression System complete with Pumps (1 w + 1 s), spray nozzles, valves, solenoid
valves, pressure gauges, etc., including control panel, water storage tank, to make the system
complete in all respects using plain water. In Tippler House covering following dust generating
points:

 All Transfer Tower (TT-1 to TT-10) Refer TT dimensions’ sheet

 Primary Screening and Crushing Area
 Stockyard
 TT-4 (Ground Bunker with Truck Loading)
 Train and Truck Loadings

Water Tank with appropriate interlocks and level indicator shall be provided in the tippler house
for further distribution of water. The water tank shall have minimum 2 hrs. of storage capacity.

Motorised valves and controls for the DS System shall be provided and interlocked with the
unloading operations so that sprays will stop when material handling stops.

Hoppers: Spray nozzles shall be interspaced all around each hopper.

Nozzle’s capacity / pressure at tip: 4 LPM / 4 kg./sq.cm.

Belt Conveyor:

Wagons: Wetting of four leading wagons standing on in-haul track outside the tippler house

Pumps (1 w + 1 s): Horizontal centrifugal pumps of suitable capacity and pressure.

SPM concentration:

At hopper top: Train loading station and truck loading station can have 10 Mg/Nm3 at a distance
of 5 meter from source.

In other areas (below hopper outlet): ~2 mg/cu.m.

The scope of work shall include design, manufacture/ procurement, inspection, supply,
transportation to site, storage, testing, erection, painting, commissioning and performance
testing of Plain Water dust suppression facilities. Plain water dust suppression (DS) system
shall be provided for Wagon Tippler Complex. One set of pump (1w+1s) shall be provided for
DS system.

I. Water pipe line will be as per IS-1239 Part 1, MS, heavy grade, ERW.
II. Spray Nozzles/ Spray bar for DS systems shall be selected so as to ensure
complete coverage of the wagon tippler house.
III. Water line velocity shall be maintained less than 1.5 m/sec.
IV. Water pipe line shall be supported at regular interval.
V. Duplex strainer will be included at inlet to DS pumps.
VI. Ball valve will be provided in water line of size up to 65 NB. Butterfly valve will be
provided in water line of size 80 NB & above.
VII. Underground pipeline will have wrapping and coating as per IS – 10221
(wrapping coating will be preferably coal tar based). Hume pipe protection will be
laid at road crossing area.
The following minimum instruments shall be considered:
- High level and low level switch in water tank.
 - Spring loaded operated pressure release valve (adjustable) at pump
discharge line for by passing water line to tank to avoid shut-off condition.
- Pressure gauge at all pump discharge line 150 dia pressure gauge.
- At consumer application points following instruments will be provided.
- Independent pressure gauge & control valve (Ball valves) will be provided for
pressure regulation. This unit will be housed in a steel cabinet of IP-55
construction.
- Solenoid operated valves will be provided in water line for flow activation.
- Individual solenoid valve will have selection mode to run in Auto/ Manual
mode.

Equipment and system specification

Equipment-

The Equipment shall include Water Storage and Pumping Unit with Duplex Water Filter
and Associate Electrical Works, Water Piping, Enclosures, Necessary modification of
hoods and skirt Boards on Belt Conveyors / Equipment. Starter cum control panel shall
be provided at pumping station and local control panel shall be provided at different
application points.
Brief Specifications of various components of the System are given below: -

 Main Equipment comprises of following items:

i. Spray nozzles.
ii. Solenoid Box
iii. Piping
iv. Valves
v. MCC Panel
vi. Instruments
vii. Valves
viii. Duplex Strainer at Pump Inlet.
ix. Suction Bellow and Delivery Below.

Pipe work, Valves and Specials

Except where otherwise specified, all pipes shall be provided with butt welded
connections with flanged joints only at the connections with equipment, vessels and
valves. Ball valves shall be provided at water line of size up to 65 NB and above 65 NB
size butterfly valves may be provided. Either wafer type butterfly valves sand witched
between two flanges or double flanged butterfly valves shall be provided.
Butterfly valve

 Body: SG iron with nitrile rubber/ EPDM lining

 Disc: SG Iron with Teflon (PTFE) coating
 Stem: High tensile stainless steel
The valves will be provided with integrally moulded & bonded body liner to provide
perfect seating and complete isolation of body material from fluid. The body liner will
provide the seating to valve disc, primary seal to the stem & gasket joint with mating pipe
flanges. Valves will be provided with self-locking lever operation from open to fully
closed position with intermediate positions marked on the indicator plate mounted on the
top flange. The valves will conform to BS: 5155 / IS: 13095.
Ball Valve

 Body: Cast steel

 Body liner: Nitrile rubber/ EPDM
 Ball: ASTM A351 Gr CF8
Check valve

 Type: Single plate type

 Body: SG iron
 Body liner: Nitrile rubber/ EPDM
 Disc: ASTM A351 Gr CF8
The solenoid valves shall have heavy duty, double impregnated tropicalized coil and
shall be suitable for operating temperature and for operation continuously energised in
tropical climate. The solenoid valves shall be of bronze body with stainless steel trim.
The coil shall be suitable for continuous duty. The enclosure shall be water tight, dust
tight and the valve shall be suitable for mounting in any position. Flanged valves shall be
provided with flanged ends having raised face.
Valves of size NB 250 - 400 shall be of gear operated type.
All valves of air pipe line shall be of class 150 rating. The flanges shall be as per ANSI B
16.5, raised face, serrated. The trim material of all the valves shall be Stainless Steel. All
pipelines shall be provided with drain connections, generally at the lowest point for
removal of accumulated condensate or water and also for draining of the water after
hydro testing of the erected pipe work. Vents with valves shall be provided at highest
point of the pipe line. The drain piping shall have drain pocket followed by a connection
of drain pipe with isolation valve. Line shall be provided with slope towards the drain
point. MS Pipes of following specification shall be provided for industrial water and air
applications.

 NB 15 - 150: ERW, Black pipe having plain ends as per IS: 1239 Part-I – 1990,
thickness - medium for water service and heavy for air service.
 NB 150 above: ERW, Black pipe having plain ends as per IS: 3589-1991
 Pipe fittings conforming to IS: 1239 Part-II - 1992 shall be provided for pipes of
size up to NB 150. Fabricated fittings manufactured from the pipes shall be
provided for pipes of sizes NB 200 and above.
Complete pipe network after erection shall be hydraulically tested at a pressure of 1.5
times the maximum working pressure. The pipe network shall be subjected to the test
pressure for a minimum period of 4 hours.
All the over ground piping and equipment shall be painted.
Pipe supports comprising pipe shoes, saddles, base plate, clamps with nuts and
structural members like channels, angles etc. shall be supplied.
Centrifugal Pump

Horizontal back pull out pump shall be provided. Pump shall be coupled to motor with
flexible coupling. Spacer type coupling shall be provided. Pump shall conform to IS:
1520. Pump shall give satisfactory performance at any point on the H-Q curve over a
range of 40% of rated flow to 120% of the rated flow. The maximum efficiency shall
preferably be within ± 10% of the rated design flow. The total head -capacity curve shall
be continuous rising towards the shut off without any zone of instability and with a
minimum shut-off head of 15% more than the design head. Pumps shall have shaft seal
by gland packing. Pump shall be fitted with double wearing rings, one is fitted in the front
of the impeller on the casing and the other is fitted in the back of the impeller on the
impeller itself. Impeller shall be dynamically balanced. Pump impeller shall be non-
overloading type. Impeller shall be made in one piece & keyed to the shaft.
Material of construction-

 Casing - C.I
 Impeller - Bronze
 Bearing Bracket - C.I
 Shaft protection sleeve - Bronze
 Wearing ring - Bronze
 Shaft - EN-8
 Common base frame for pump & motor - M.S
The required NPSH at duty point shall be at least 1.0 m lesser than the available NPSH.
Common base plate for pump & motor shall be in one piece & made of welded steel
construction. Adequate space shall be provided between pump drain connection and
base plate for installation of minimum 15 mm drain piping. Pumps shall be supplied with
suitable drain pans or drain rim type base plates with tapped drain connections. Critical
speed of the shaft shall be at least 30 percent above the operating speed.
Pressure Gauge

 Manufacturing Standard: IS 3624

 Range: 0 – 6 Kg/ cm2 or 0-10 Kg/ cm2
 Range (at pump suction): (-)2 to (+)2 Kg/ cm2
 Dial Diameter: 100 mm
 Accuracy: + 1% of FSD
 Degree of protection: IP 65
 Sensing element: Bourdon tube
 Bourdon tube material: AISI SS316
 Connection: Screwed
 Connection size: ½ “BSP (M)
 Mounting: Direct with bottom entry
 Case: Die cast Al stove enamelled black finish
 Bezel (screwed): Die cast Al stove enamelled black finish
 Dial window: Shatter proof glass
 Pointer: Al anodized black
 Dial: Al white with black letters
 Movement assembly: AISI 304SS
 Shank: AISI 3166SS
 Adjustable pulsation damper: Yes
 Pressure gauges shall be provided with isolation valves (Ball valves)