Professional Documents
Culture Documents
Table of Contents
1. INTRODUCTION...................................................................................................................... 2
2. BATTERY LIMITS.................................................................................................................... 3
4. OBLIGATIONS OF EC......................................................................................................... 10
6. EXCLUSION........................................................................................................................... 12
ANNEXURE-1 Page 1 of 30
ENGINEERING CONSULTANT SCOPE
1. INTRODUCTION:
JSPL proposes to install second DRI plant (DR 2) adjacent to the upcoming first DRI plant
(DR 1) in the upcoming Steel Complex at Angul.
This scope has been proposed by JSPL for the engineering consultant (EC) to submit their
techno commercial offer for DR 2 proposed to be of 2.5 MTPA capacity, to produce Hot DRI
& Cold DRI simultaneously; with ENERGYIRON technology, using synthesis gas (to be
produced from upcoming LURGI design Coal Gasification plant) and COG (Coke-oven gas a
byproduct from Coke Oven Batteries in the proposed Steel Complex) for Jindal Steel &
Power Ltd (JSPL) at our Angul location.
The DR 2 will also include COG gas cleaning system and pressure boosting, CO2 removal
system, Process gas Heater, DR Furnace, process gas, cooling gas and HYTEMP transport
compressors, material handling system, utilities, Fire protection system and turbo expander
system. Syn Gas from Coal Gasification plant shall be made available at Battery Limit (BL)
of DR Plant., whereas BL for COG is proposed to be at source of COG to include scope of
cleaning and pressure boosting & transportation to DR 2.
The scope of work which includes following major heads and a detailed scope spilt are
provided in “Engineering Scope of Work” part,
Process License : by JSPL
Statutory Licenses : by JSPL
Basic Information and Basic Engineering : by JSPL from Licenser and to be
issued to EC as per scope matrix
Detail engineering incl. procurement support by EC as per scope matrix
Erection support : Support as per man day basis
Commissioning support : Support as per man day basis
a. Battery limits for the Project will start from ore receipt at the junction house DRJ 4 from
yard conveyor, and will end at belt discharge of product conveyor feeding to SMP
feeding conveyor or belt discharge of Export conveyor – at DRJ 4 junction house.
b. Review of RMHS from Oxide Day bin to Common conveyor related to DR2 plant and
Review of Common product conveyor related to DR2 plant. Product storage design is
excluded from Present scope.
Redcution Gas:
c. Syn Gas: Battery limits for the Syn gas will start from tap-off point from DR-1 syn gas
line.
d. Coke Oven Gas: Battery limits for the Coke oven gas will start from tap-off point from
COG network within 2km from DR 2 Plant boundary.
e. Make-up water, process water, Fire water, drinking water, steam, Oxygen, Nitrogen
shall be provided at DR plant battery limit by JSPL at required temperature, pressure
and flow.
f. BOF Gas: gas line for BOF gas from tap off point within 2km from DR plant boundary
to be used as fuel.
Power:
g. Battery for electric power will be at the control room building at 33KV level.
Slurry:
h. Slurry discharge in sludge pond within DR 2 plant boundary and return water back to
clarifier by EC.
From the furnace discharge up to the discharge point of surge bins at Melt Shop Area. This
excludes the support and civil engineering and structural support of bins within the Melt
Shop area.
The scope covers review & suggestions for possible improvements of Basic
information documents received from Licenser within Battery Limit (BL) of DR plant in
terms of completeness to carryout basic engineering and complete basic information
will be provided by EC for its scope of activities as specified in scope matrix. In general
the basic information documents shall include: the sketches and design basis
necessary for the development of basic engineering, which are:
Main Process data
Description of the main features of the machine, main technical data and list of
the main components.
Feed materials and Finished Products main data.
Main Process Parameters and Conceptual process scheme.
Preliminary overall material balance.
Power calculation of the Production Line. Indications related to the basic
operating conditions
utility consumption figures and fluid characteristics
Specification, main description and general data.
The scope covers review of Basic Engineering documents and suggests possible
improvements if any, received from Licenser for BL of DR plant in terms of
completeness to carryout detail engineering and complete basic engineering will be
provided by EC for its scope of activities as specified in scope matrix. In general the
basic engineering documents shall include:
Mass and energy balance
Process flow diagrams
The detail engineering scope covers EC scope of work materials and shall not
include the Licenser supplied equipments within BL of DR plant as specified in
scope matrix. The detail engineering documents shall include following including
Technical specifications of respective areas as applicable:
Process Engineering
Utility balance
P&ID’s including vendor information
Logic diagram including vendor information
Preparing technical bid/tender document
Technical evaluation of Vendor offers up to five(5) vendors
Vendor drawing/document approvals
Interface engineering with vendor information within BL.
Hazop study for non - core area as applicable; and participate for integration
with the core area Hazop and preparation of combined report thereof, within BL
of DR 2 plant.
General Layout Engineering: (BL of DR Plant)
Layout with DR plant & auxiliary units- and also with roads and drains within the
BL of Layout.
Integration up to HDRI bins at SMS feeding tower, however Integration with
Steel Melting Shop (SMS) is not in scope.
Interface engineering with vendor information within BL.
Material Handling
Raw Material Handling System (RMHS):
Review of RMHS from Oxide day bin to common conveyors related to DR2
plant.
Detail engineering of RMHS from material receipt from DRJ 4 JH conveyor to
DR2 furnace feeding
Dedusting System:
Dedusting of RMHS within BL.
Dedusting of DRI within BL.
Material handling bins, chutes and conveyor arrangement drawings with in BL
Tender documents for material handling equipments like belt, conveyor belt,
pulleys, idlers, screw take-up, drive assembles, screens, feeder, etc
Preparing technical bid/tender document
Technical evaluation of Vendor offers up to five(5) vendors
Vendor drawing/document approvals
Vendor Quality control plan approvals
Interface engineering with vendor information within BL.
Incorporation of vendor details in detail engineering
EOT or similar hoists needed at different locations.
Structural Engineering
Fabrication drawing preparation for reactor tower and technological structure
using detail engineering drawings provided by Danieli/HYL
Detailed engineering for following buildings/facilities and Racks
a. Material handling- Junction house and conveyor galleries
b. Non technological pipe racks between auxiliary facilities and to core
plant battery limit
c. CO2 Removal system ( on package basis)
d. Heater (on package basis)
e. Syn gas Turbo expander building
f. Syn gas station for receiving & metering
g. Compressed air plant building
h. MCC & Control room building for DR plant
i. Cable Racks
j. Oxide and product handling Junction Houses & Conveyor Galleries
Preparing technical bid/tender document
Technical evaluation of Vendor offers up to five(5) vendors
Vendor drawing/document approvals
Vendor Quality control plan approvals
Interface engineering with vendor information within BL.
Civil Engineering
Pile design and piling layout, if required
Detail engineering for civil foundation for all equipments and structures of BL
which includes the following Buildings :
a. Civil work for areas specified in above structural detail engineering part
b. Sludge Pond
c. Water sumps
d. Clarifier
Instrumentation Engineering
Technical specifications and typical hook ups for field instruments, analyzers,
and DCS
Final Control system Logic Diagrams for non core area & integration with core
area
Final Control system for packages -Process Gas Heater, CO2 Removal system,
Turbo Expander, PG&CG compressors will be supplied by Package Vendor
DCS Screen Layouts support with Supplier/Vendor
Process Automation Design support with Supplier/Vendor
Cable scheduling and routing
Preparing technical bid/tender document
Technical evaluation of Vendor offers up to five(5) vendors
Vendor drawing/document approvals
Vendor Quality control plan approvals
Interface engineering with vendor information within BL.
CO and Explosive monitoring system
Electrical Engineering
Single Line Diagrams (SLD)
Cable scheduling and routing
Substation layout at control room building
MCC room layout
Transformers
Lighting
Earthing
Preparing technical bid/tender document
Review of all Basic Information, Basic Design, Detail Design documents submitted by
Licenser, Vendor for completeness to carryout procurement and/or construction.
4. OBLIGATIONS OF EC
e. Provide all its engineering data/documents/ drawings in AUTO CAD format in English
language through “fnps portal” method or it’s “edocs” a document sharing portal.
f. Provide the project sequence for execution of DR-2 plant activities within the battery
limit and review the execution schedule for integration with other units.
5. OBLIGATIONS OF JSPL
a. Furnish to EC, all the information regarding equipment procured from LICENSER /
other party.
c. Provide all basic engineering data/documents/ drawings including mass, material &
utility balance sheets, PFDs, P&IDs, Logic Diagrams, Data sheets for equipments,
instruments, & Piping, electrical load data, equipment list to EC.
d. Furnish plant location details, climatic conditions, Site survey maps and soil
investigation study.
f. Organize all the discussions / meetings with technological / process consultant/ local
authorities as and when required in connection with engineering of the plant.
6. EXCLUSIONS:
BI-BASIC INFORMATION, BD- BASIC DESIGN, DD- DETAIL DESIGN, RE- REVIEW
ES- ERECTION SUPPORT, CS- COMMISIONING SUPPORT.
CORE PLANT AREA
QT BI BD DD RE ES CS
Y
1. REACTOR CHARGING
5. MECHANICAL EQUIPMENT –
HYTEMP
5.1 Pneumatic Transport to Meltshop
5.1.1 Manual Plug Valve RE 218-L 1 H H -- EC
6.1 Water Treatment Plant (WTP) which 1 Set D EC E C EC EC E C
includes Clarifier, Cooling Towers,
and Pumping facilities.
6.1.1 DM Plant & Boiler 1 set D E C EC EC EC EC
6.2 Compressed Air Plant EC
6.2.1 Compressed Air Plant for Instrument 1 Set D D EC EC EC EC
and Service Air
6.3 Seal Gas System EC
6.3.1 Seal Gas Storage Tanks UT 431-F1h- 4 D D D EC EC EC
F4
6.4 Material Handling
6.4.1 Iron Oxide Handling 1 Set D D EC EC EC EC
6.4.2 Coating Station Complete (excluding 1 H H -- EC EC EC
1.3 )
6.4.3 Bin, Piping & Structures for 1 H H H EC EC EC
Coating Station
6.4.4 Cold DRI Handling 1 Set D D EC EC EC EC
6.4.5 Bins with in Battery Limit 1 Set D EC EC EC EC EC
6.4.6 Dedusting within BL 1 Set D D EC EC EC EC
6.5 Syn Gas Turbo Expander
6.5.1 Syn Gas Turbo Expander; 1 D D EC/ EC EC EC
Note: This will be handled as a V
package system. Detail engineering
for this will be done by the Vendor
except civil which will be done by EC.
Integration of this with main plant will
be done by EC
6.5.2 Structure, Piping & Ducting, E&I, 1 V V V EC V V
insulation, within the package by
Vendor.
6.5.3 Automation logic diagram will be in the 1 V V V EC V/EC V/EC
7. DRP – GENERAL
7.1 Steel Structures
7.1.1 Reactor Technological Tower Steel 1 D D D EC EC EC
Structure Set
7.1.2 Main Technological Pipe Rack inside 1 D D D EC EC EC
Technological Area Set
7.1.3 Heater Supporting Steel structures 1 D D EC EC EC EC
Set
7.2 Piping & Ducting
7.2.1 Yard Piping (Type 1 Piping) 1 Set D D EC EC EC EC
7.2.2 Technological Rack Piping (Type 2 1 Set D D D EC EC EC
Piping)
7.2.3 On Field Piping Type 3 Piping 1 Set D D D EC EC EC
7.2.4 Packages Piping Type 4 Piping 1 Set D D EC EC EC EC
7.2.5 Technological Tower Piping Type 5 1 Set D D D EC EC EC
Piping
7.2.6 Process Ducts 1 Set D D D EC EC EC
7.3 Instrumentation
7.3.1 Measuring Instrumentation for Core & 1 Set D D D EC EC EC
Non core area
7.3.2 Mass spectrometer 1 Set D D EC EC EC EC
7.4 Refractory & Insulation
10. AUTOMATION
QTY BI BD DD RE ES CS
10.1.5 Application Software for PLC for fired 1set V V V EC V/E V/EC
Heater (Package) C