DESIGN BASIS REPORT Alumina Unloading and

PROCESS & MECHANICAL Transportation System

DOC. NO. 14L08-000-DBR-M-001

DESIGN BASIS REPORT

FOR
ALUMINA UNLOADING AND TRANSPORTATION
SYSTEM

PROCESS & MECHANICAL

NATIONAL ALUMINIUM COMPANY LTD.

(A Govt. of India Enterprise)
Nalco Bhavan, P/1, Nayapalli
Bhubaneswar-751013, Odisha
Phone: 91-674- 2301988 to 2301999
Fax: 91-674-2300550/2300470/2300521/2300640

DOC. No. 14L08-000-DBR-M-0001

JULY 2015

DEVELOPMENT CONSULTANTS PRIVATE LIMITED

CONSULTING ENGINEERS
BLOCK DG-4, SECTOR II, SALT LAKE CITY ,KOLKATA – 700091, West Bengal, India
 DESIGN BASIS REPORT Alumina Unloading and
PROCESS & MECHANICAL Transportation System
DOC. NO. 14L08-000-DBR-M-001
 DESIGN BASIS REPORT Alumina Unloading and
PROCESS & MECHANICAL Transportation System
DOC. NO. 14L08-000-DBR-M-001

TABLE OF CONTENTS
CL. NO. DESCRIPTION PAGE NO
1. INTRODUCTION..................................................................................................................... 1
2. GENERAL INFORMATION: .................................................................................................. 1
3. DESIGN BASIS: ....................................................................................................................... 2
3.1 SITE DATA: ............................................................................................................................. 2
3.2 SITE LOCATION: ................................................................................................................... 2
3.3 MATERIAL CHARACTERISTICS: ....................................................................................... 2
4. SYSTEM REQUIREMENT ..................................................................................................... 4
4.1.0 GENERAL ................................................................................................................................ 5
5. EXISTING SYSTEM DESCRIPTION..................................................................................... 6
6. PROPOSED SYSTEM DESCRIPTION................................................................................... 7
7. MAJOR EQUIPMENTS........................................................................................................... 8
8. TECHNICAL FEATURES OF ALUMINA UNLOADING AND TRANSPORTATION
SYSTEM ..................................................................................................................................11
8.01 PIPE CONVEYORS ................................................................................................................11
8.02 AIR SLIDE...............................................................................................................................17
8.03 SCREW TYPE AIR COMPRESSOR .....................................................................................18
8.04 FAN ..........................................................................................................................................18
8.05 BEARING AND BEARING HOUSING..................................................................................19
8.06 DE-DUSTING UNITS / BAG FILTERS (JET PULSE TYPE)...............................................20
8.06.01 GENERAL ...............................................................................................................................20
8.06.02 BAGS........................................................................................................................................20
8.06.03 BAG MONITORING AND PROTECTION EQUIPMENT ...................................................20
8.06.04 DEDUSTING AIR VOLUME..................................................................................................20
8.06.05 VENTING DUCTS ..................................................................................................................21
8.06.06 HOPPER CONSTRUCTION ..................................................................................................21
8.07 AIRLOCKS..............................................................................................................................21
8.08 ROPE WINCH SYSTEM ........................................................................................................21
8.09 EQUIPMENT PARAMETERS AND OTHER SALIENT FEATURES: ...............................22
9. PERFORMANCE REQUIREMENT OF MAJOR EQUIPMENTS......................................24
10. UTILITY FOR ALUMINA UNLOADING AND TRANSPORTATION SYSTEM...............25
 DESIGN BASIS REPORT Alumina Unloading and
PROCESS & MECHANICAL Transportation System
DOC. NO. 14L08-000-DBR-M-001

11. ATTACHMENT

SL.
ENCLOSURES DRAWING NO
NO.
Proposed layout of Alumina
1) Unloading & Transportation System 14L08-DWG-M-PL-001, REV. I
in Smelter Plant

View Profile for Unloading &

2) 14L08-DWG-M-PL-002, REV. G
Conveying System

View Profile for Unloading &

3) 14L08-DWG-M-PL-003, REV. D
Conveying System

View Profile for Unloading &

4) 14L08-DWG-M-PL-004, REV. D
Conveying System

Process Flow Sheet for Wagon 14L08-DWG-PR-PFD-001 REV. A

5)
Unloading System (Sheet 1 of 2)

Process Flow Sheet for Unloading 14L08-DWG-PR-PFD-001 REV. C

6)
And Conveying to Silos System (Sheet 2 of 2)

Process And Instrumentation

14L08-DWG_PR-PID-001 REV. C
7) Diagram For Wagon Unloading
(Sheet 1 of 2)
System

Process & Instrumentation Diagram

14L08-DWG_PR-PID-001 REV. D
8) - Unloading & Conveying to Silos
(Sheet 2 of 2)
System
 DESIGN BASIS REPORT Alumina Unloading and
PROCESS & MECHANICAL Transportation System
DOC. NO. 14L08-000-DBR-M-001

1. INTRODUCTION
1.01 This document is to draw out design memorandum / technical features for Alumina Unloading and
Transportation at Smelter Plant, ANGUL of National Aluminium Company Limited (NALCO),
Odisha.
1.02 The scheme shall be in line with Process Flow Sheet, (Drg. No. 14L08-DWG-PR-PFD-001 REV.
A (2 Sheets) and Proposed layout Sectional Drawings of Alumina Unloading & Transportation
System in Smelter Plant (Drg. No. 14L08-DWG-M-PL-001,14L08-DWG-M-PL-002, 14L08-
DWG-M-PL-003 & 14L08-DWG-M-PL-004).
The new Alumina Unloading and Transportation system will commence from wagon unloading
and will terminate above the existing silos (silo no.6&5,2&1). From silo no.1&5 the incoming
alumina will be transported to silo no.3&4, 7&8 respectively through existing conveying /air
sliding path.
Alumina will be coming in the BTAP closed wagons in a rake. Wagon unloading system shall
include 2 nos. rope winch systems for hauling of 12 nos. BTAP wagons in each system and
positioning of wagons on the unloading platform, Pneumatic wagon unloading system followed by
air slides placed in an underground pit by gravity and through underground pipe conveyor to
transfer points located above the ground for further conveying by pipe conveyors to the alumina
silos. De-dusting, Ventilation & Air Conditioning system at appropriate locations shall be
provided.
1.03 The work for proposed system shall be carried out conforming to latest applicable Indian Standards
or other recognized international standards such as ASTM / CEMA / ASME / ISO/ DIN / JIS in the
absence of Indian standards.
1.04 Alumina Unloading and Transportation facility shall comply with applicable statutes, regulation
and safety codes related to design, construction & operation of the wagon unloading and
transportation system.
Sl. Type of Wagon Height Width Length over Gross Payload
No. (m) of coupling / Mass (tonne /
Tank overall (tonne) Volume)
(m) (m) Approx.

1. BTAP Wagon 4.29 3.200 9.78 /12.32 81.3 58 / 62m3

2. GENERAL INFORMATION:

PLANT HISTORY:
National Aluminum Co. Limited (NALCO) has set up a multi-location Bauxite alumina–
Aluminum Complex along with captive Power Plant in the state of Odisha. The implementation of
the project started in the year 1981 and all the segments of the project were commissioned by 1987
and are operating at rated capacity. As part of Phase-I expansion Pot line-3, pot room auxiliaries
and new carbon plant were installed at Angul to enhance total production of Primary aluminum to
345000TPY. As part of Phase-II expansion (Pot line-4), NALCO is further enhancing its total
production capacity of Primary aluminum to 4, 60,000TPY.

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DOC. NO. 14L08-000-DBR-M-001

3. DESIGN BASIS:

3.1 SITE DATA:

Aluminium smelter plant of NALCO is located at a site approximately 5 km. from the nearest town of
Angul in the state of Odisha. The site is connected by a link road to the existing highway NH-55,
linking NH-5 (Calcutta-Madras) and NH-6 (Calcutta- Bombay).

3.2 SITE LOCATION:

State where located Nearest important : Odisha

Town /distance Nearest Railway Station :
Angul/ 5 km.
For passenger traffic-Angul Railway
Station 7 km away with the opening of
Talcher-Sambalpur rail line from plant
site.

Goods in rakes and wagons:

Bhudhapank – NALCO siding (SCPM)
11 km from Smelter.

Goods in small Consignment:

Talcher, about 25 km. From Smelter.

Nearest port and distance : Paradeep Port – 190 km.

Nearest Airport and Distance : Bhubaneswar Airport – 140 km.
Nearest Highway Milestone : National Highway (NH-55) – 1km.distance

3.3 MATERIAL CHARACTERISTICS:

CHARACTERISTICS OF ALUMINA
Type : Sandy
Maximum density after Compression : 1.1 t/m3
under 4 bar

Angle of repose during reclaiming and : 35 degree & 23 degree respectively

during loading

Internal angle of friction : 27 degree to 36 degree

Angle of friction on steel : 25 degree

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DOC. NO. 14L08-000-DBR-M-001

Granulometry : + 125 micron max. 15%

- 45 micron max. 12%
Typical 10%
Hardness : 9 on Mohs’ Scale

SPECIFICATION OF ALUMINA

Item Unit Typical Limit (max)

SiO2 Wt % 0.01 0.025

Fe2O3 Wt % 0.01 0.015

TiO2 Wt % 0.003 0.004

Na2O Wt % 0.39 0.5

P2O5 Wt % 0.001 0.002

V2O5 Wt % 0.0015 0.002

CaO Wt % 0.025 0.06

Alpha Wt % <2.0 10.0

-45 micron Wt % 8.0 20 (Max corresponds to CA

15 grade Alumina)

+125 micron Wt % 10 - 12 15

LOI (300- 1000 Wt % 0.6 - 0.7 1.0

0
C

BET : 60-70 m2/g (Typical)

40 m2/g (Min) & 80 m2/g (max)
Bulk Density : 0.95 to 1 t/m3 Typical)

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DOC. NO. 14L08-000-DBR-M-001

UTILITIES AVAILABLE AT BATTERY LIMIT

Plant air cum instrument air

Oil Content in gm/Nm3 : Nil

4.5 kg/cm2 (g) min (line should be
Supply Pressure :
designed for 9 kg/cm2(g)
Temperature : 450C max

Dew point : +30C to + 50C at 7 kg/cm2(g)

4. SYSTEM REQUIREMENT
Requirement of Fresh Alumina for
: 900000 T per annum
the smelter plant (after expansion)

Days/Annum. : 365

No. of operation shift/week : 18 (max)

Total hours/shift : 8

Effective operating hours/day : 24

Rake capacity : 2700 ton

No. of wagons in a rake : 52

No. of track : Track 1, Track 2 + Engine Escape Line

No. of Wagon on each track : 26

Alumina unloading : 8 nos. simultaneously from Wagons

Rate of unloading for individual

: ≈ 2 T/min
wagon

Wagon unloading and conveying

: 1000 TPH
capacity to silo

The alumina handling plant is designed to operate 365 days in a year without interruption. The
proposed Alumina Unloading and transportation system shall be designed & installed in such a way so
that any one stream can be operated and if required both streams can be operated simultaneously.

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4.1.0 GENERAL
The following Design Criteria shall apply to all mechanical equipment.
4.01.01 The system shall be capable of operating continuously round the clock throughout the year. The
installation must be designed so that it can always be serviced without having a complete
shutdown.
4.01.02 Design of all facilities shall be in accordance with this specification and the respective
specification enclosed with the Purchase requisition.
4.01.03 Alumina unloading and transportation system shall be laid out and constructed for convenience
and safety of operation and maintenance. All equipment shall be oriented to permit servicing in
such a way as to require a minimum of dismantling. The specification indicates a minimum
standard of quality for the materials, fabrication and construction of the proposed plant.
4.01.04 All equipment and materials (mechanical, piping, electrical, instrumentation, controls, civil,
architectural etc) shall be sourced from manufacturers acceptable to DCPL and NALCO. For the
items not covered in the list, contractor shall submit the sub-vendor list along with the proven
track record of the proposed sub-vendors for review/approval of NALCO and DCPL before
placing orders for those items.
4.01.05 All electrical installations including the hoists in open area shall be provided with rain protection
hood.
4.01.06 Maintenance platforms/access walkways shall be provided at one end beam for each electric
monorail hoist.
4.01.07 All the equipment shall be field proven for such an operation taking into consideration normal
preventive and running maintenance of the unit and their auxiliaries. The spare part list along with
the drawings and part numbers shall be provided.
4.01.08 All equipment, controls and structure shall be designed for installation in carbon and alumina dust
charged atmosphere of aluminium smelter area and seismic condition of site.
4.01.09 All equipment shall be of proven design. Prototypes or extensive modifications of the basic
designs are unacceptable.
4.01.10 The installation shall be designed with adequate facilities for maintenance & operations.
4.01.11 The design, fabrication, painting, supplies and testing shall conform to relevant international
codes and standards, Indian codes and standards, wherever applicable, shall take precedence over
those of other nationalities. Only latest editions including addenda shall be referred to.
4.01.12 Design, fabrication & operation of the plant shall be based on the following:
A) Indian factory act
B) Indian explosive act
C) Petroleum & Carbide of calcium manual
D) Fire protection manual of fire sectional committee, Insurance association of India
E) Regulations laid down by explosive directorate and electrical inspectorate
F) Regulations of Director general of civil aviation for all stacks

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G) NFPA code of practice

H) Regulation of electrical equipment of buildings insurance association of India
I) Regulation of both Central and state pollution control boards of overall pollution
control for both surface and air
J) Indian electricity rules
4.01.13 An air cooled screw compressor (1w+1s) for pulse jet cleaning of de-dusting unit, cooling
chamber, dampers and actuators at wagon unloading area shall be provided. Contractor shall tap
the compressed air from the existing Plant compressed air line for pulse jet cleaning of three (3)
nos.de-dusting units, located at three (3nos.) transfer houses area. Fluidization air for air slide
shall be generated by blowers/centrifugal fans which will be supplied by contractor.
4.01.14 Compressed air and supply air facilities supplied by the contractor shall include all compressed air
piping, valves, regulators, pressure gauges and fittings as required.
4.01.15 All blowers and compressors generating process air supply for AUT shall be housed in a common
blower/compressor house, which shall provide weather protection as well as act as noise
enclosure common to all equipment inside the room. The noise level shall be maintained as per
requirement of environmental norms.
4.01.16 All equipment to be supplied shall be of robust design and manufacture and shall correspond to
state of the art of manufacturing technology. Selected equipment shall have a high degree of
availability, require minimum maintenance and operate with high efficiency. Electrical and
thermal energy consumption shall be low. Equipment shall be designed for heavy-duty industrial
application, capable of handling very abrasive materials in dusty environments. The equipment
shall be suitable for continuous operation at uniform maximum load without adverse effect on the
life or maintenance of the equipment under prevailing conditions. Furthermore it shall be suited to
all local climatic and operating conditions at the site.
4.01.17 The equipment shall be designed with sufficient safety margins from the mechanical design and
the process performance point of view. It shall be capable of re-starting after stopping due to
power failure or other process-related interruption (i.e. interlock).

5. EXISTING SYSTEM DESCRIPTION

The requirement of fresh alumina for the smelter plant after expansion will be approximately
9, 00,000TPY.The additional requirement of fresh alumina for the phase-2 expansion is approximately
2, 42,350 TPY.

In the existing NALCO Smelter Plant, requirement of alumina is being catered by transporting
alumina from Damanjodi to Angul in specially designed pneumatically operated wagons. These
wagons have a payload capacity of approx 55 T each. Total alumina payload in a rake comprising 48
to 52 wagons i.e. approximately 2700 T.

The residence time of rake is at present 8 hrs as maximum. The unloading time of one rake is
approximately 5 hrs. During unloading, a group of wagons are placed in position and each wagon is
connected to compressed air inlet. Flexible hoses are connected with one end to wagon evacuation

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DOC. NO. 14L08-000-DBR-M-001

points and other end to the fixed pipes leading to air slides. The rate of unloading for individual wagon
is 2 T/min. The extracted alumina is conveyed through air slide for feeding to intermediate bin (15 T
capacity). From the intermediate bin (having fluidized bottom) alumina comes to belt conveyor TR1
that conveys alumina to existing silos 1, 2, 3, 4, 5, 6, 7 & 8 through number of belt conveyors/air
slides at the rate of 1000TPH.

The main conveyor TR1 is integrated with weigh scale of the load cell type to meter the quantity of
alumina to be conveyed to the silos. In the existing unloading system an outlet has been provided from
the distribution box located over silo No. 1 to feed to air slide HA-AL-001. The air slide HA-AL-001
conveys alumina to the belt conveyor HC-BL-002.The belt conveyor transports alumina to pot line 3
areas for feeding to Silo No.5 (TI-AL-020) or to Silo No. 7 (TI-AL-021), through air slides and belt
conveyor HC-BL-012.

6. PROPOSED SYSTEM DESCRIPTION

The plant will have a yearly aluminium production capacity of 4,60,000 T after phase-2 expansion,
which approximately corresponds to a yearly requirement of 9,00,000 T of alumina. To achieve such
alumina requirement a new system with wagon unloading facility by gravity and alumina conveying to
the silo 5&6 and silo 1&2 (separately) have been envisaged.

From silo1 & silo 5 the alumina can be diverted to silo 3&4 and silo 7 &8 respectively through
existing conveying path (conveyor / air slides).Similar to existing system, alumina will arrive at the
plant in specially designed pneumatically operated wagons. Each rake is grouped in 52 wagons
corresponding to a service capacity of approx. 2700 ton. This new system has been envisaged to
facilitate to convey alumina to each silo @1000 TPH through pipe conveyors (for silos 1, 2&5, 6)
independently to all the silos during shut down of existing main conveyor TR1 & also conveyor (HC-
BL-002) which is conveying alumina from silo1 to silo 5. Afterwards alumina transportation facility
has been connected to existing belt conveyor TR2 & BL012 (both conveyors having 1400mm belt
width) for filling of silos 3, 4 & 7, 8 respectively.

Unloading of alumina from wagon for this new system shall be done in between proposed expansion
railway tracks1 &2 (12m apart), located at east side of Rolling Plant (RP). Suitable rope winch
systems (2nos.) for hauling 12 BTAP wagons has been envisaged. The unloading of 8 wagons shall be
done at a time (4 nos. wagon from each track).The drive units and automatic rope tensioning
arrangements of the winch systems shall be located in a common shed / house. 2 nos. Rope winch
system (reversible type) have been provided for wagon hauling, positioning for unloading and also
operate haulage winch to move the wagons from the unloading zone and again set for the position for
next 8 wagons. By adopting the suitable connecting / removing of hitch ropes / round link chain siling
to the near side rope / far side rope, the optimisation of unloading cycle are to be obtained.

A dedicated operator cabin shall be provided over the unloading area at the starting point to precisely
control the placement of rake in the unloading stations.

Unloading of alumina from each BTAP wagon is to be connected to compressed air inlet and also
flexible hoses to be connected with one end to wagon discharge points and other end to fixed pipes for

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gravity discharge (for quick unloading and lesser energy consumption) to the air slides placed in an
underground pit (i.e. in between two railway tracks). Unloaded alumina shall be conveyed by air slides
(3 nos.) to pipe conveyor PC-100 partly underground and partly over ground which in turn feed
alumina either to pipe conveyor PC-200 or another pipe conveyor PC-300 through 2-way chutes at
transfer point TP-1 located above ground. Underground tunnel shall have the sump with pumping (1w
+1s) facility to drain out water from the sump. The pipe conveyor (PC-100) shall be provided with
integrated Belt weigh scale of load cell type for metering amount of Alumina conveyed to the silos.
The pipe conveyors PC-200 & PC-300 shall carry same alumina from TP-1 to silo-1&2 and silo-5 &6
respectively through air slides (4 nos.). Two nos. transfer points (TP-2 & TP-3) shall be provided, one
near silo 1 &2 and other transfer point near to silo5 & 6 to convey alumina to silo1& 2 and silo5&6.

One rack and pinion type passenger cum goods lift of capacity 1Ton (16 passengers) with one side
collapsible gate shall be provided near the transfer point (TP-3) of silo 5&6.

Five nos. de-dusting units with measurement system of DP, Inlet pressure, outlet pressure and pulsing
pressure etc. one at unloading area, one at feeding area of pipe conveyor PC-100 from air slide (AS –
300) and three nos. at different transfer houses shall be installed. The dust emission level from the de-
dusting units shall be limited to 10 mg/Nm3.

One new control room, MCC room, Blower room & VVVF room shall be suitably installed. No
disturbance to the existing system while erection and commissioning will be allowed except during
hook-up. During construction and erection, proper care shall be taken for existing equipment at the
interface.
7. MAJOR EQUIPMENTS

Sl. Eqpt. Drawing

System / Item description Qty Brief specification
No. No No.
Rope winch system for wagon
1 2
hauling
Pneumatic Unloading System
from wagons to Air slides
2
(underground) through flexible
Hose connections:
KA100 Oil Free Screw Compressors 8w+1
2a
to 108 ( Air Cooled) s
BL100 /
2b 200 Fan type Blower for air slides 3
&300
FN 100 1w+1
2c Fan in Blower Room
& 200 s
AS 100
2d Air Slide 2 500 tph for each
& 200
SG-001,
2e Manual Operated Slide Gate 2
SG-

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Sl. Eqpt. Drawing

System / Item description Qty Brief specification
No. No No.
002

3 AS 300 Air Slide 1 1000 tph

Cap: 2 ton for
EH-1 & Electric Hoist with motorized Unloading Station &
4 2
EH-2 trolley 3 ton for Compressor
Room 14L08-
Goods cum passenger lift (Rack DWG-
5 EL 01 and Pinion type) near transfer 1 Capacity: 1000 kg PR-PID-
point (TP-2) of silo 5 &6 001
DE-1A De-dusting system complete (2 sheet)
6 & unit in unloading station & on 1+1
DE-1B pipe conveyor PC-100
DC 100
6a Dust Collector 1+1
A/B
EF 100
6b Dust Extraction Fan with motor 1+1
A/B
RV 100
6c Rotary air lock valve 1+1
A/B
Oil Free Screw Compressors
1w+1
6d (Air Cooled) For supplying
s
pulse air to Dedusting units
7 PC 100 Pipe Conveyor 1 Cap: 1000 tph
EH-3, Electric Hoist with motorized
Cap: 4 tons each for
8 EH-4& trolley for Pipe Conveyor drive 3
TP-1, TP-2& TP-3
EH-5 unit
Diverting gate (pneumatic
9 DG 01 1
Operated)
10 AS 400 Air Slide 1 Cap: 1000 tph
11 AS 401 Air Slide 1 Cap: 1000 tph
12 PC 200 Pipe Conveyor 1 Cap: 1000 tph
De-dusting system complete
13 DE-2 1
unit in Transfer Point (TP-1)
13
DC 200 Dust Collector 1
a
13
EF 200 Dust Extraction Fan with motor 1
b
13
RV 200 Rotary air lock valve 1
c
14 JB 001 Junction Box 1
PG 001
15 Pneumatic operated cut off gate 2
& 002

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Sl. Eqpt. Drawing

System / Item description Qty Brief specification
No. No No.
De-dusting system complete
16 DE-3 1
unit in Transfer Point (TP-2)
16
DC 300 Dust Collector 1
a
16
EF 300 Dust Extraction Fan with motor 1
b
16 14L08-
RV 300 Rotary air lock valve 1
c DWG-PR-
17 PC 300 Pipe Conveyor 1 Cap: 1000 tph PID-001 (2
18 AS 500 Air Slide 1 Cap: 1000 tph sheet)
19 AS 501 Air Slide 1 Cap: 1000 tph
De-dusting system complete
20 DE-4 1
unit in Transfer Point (TP-3)
20
DC 400 Dust Collector 1
a
20
EF 400 Dust Extraction Fan with motor 1
b
20
RV 400 Rotary air lock valve 1
c
21 BL 400 Fan type Blower for air slide 1
22 BL 401 Fan type Blower for air slide 1
23 BL 500 Fan type Blower for air slide 1
24 BL 501 Fan type Blower for air slide 1
Belt Weigh Scale on Pipe
25 BW-001 1
Conveyor (PC-100)
1w+1
26 P-1 &2 Sump Pump
s

The above is a list of major equipment only. Any other equipment required to make the system
complete in all respect for its successful and guaranteed operation which is acceptable to
NALCO and DCPL is also deemed to be included under bidder’s scope without any additional
cost to Owner.

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8. TECHNICAL FEATURES OF ALUMINA UNLOADING AND TRANSPORTATION

SYSTEM

The technical features of major equipment of alumina unloading and transportation system should
address all functional, safety and environmental requirement. All equipment foundation bolts shall
be high tensile (HT) bolts.

8.01 PIPE CONVEYORS

8.01.01 COMPONENTS OF THE PIPE CONVEYOR:

A. Mechanical

1. Conveyor Belt
2. Idler incl. Bracket
3. Pulleys
4. Plummer Block
5. Pulley Bearing
6. Discharge Hood
7. Discharge Chute & Liner
8. External Pre-Scrapper
9. External Main Scrapper
10. Int. V Plough Belt Cleaner
11. Drive Motors
12. Input Coupling
13. Gearbox
14. Output Coupling
15. Coupling Guards
16. Drive Base Frame
17. Pulley Frames
18. TU Arrangement
19. Disc Brake
20. Guide Frame
21. Take Up Cage
22. Stringer Frame & Post
23. Deck Plate
24. Skirt Board Assy.
25. Safety & Limit Switches.
26. Suitable no. of stairs, cross-over and platform from ground shall be provided
wherever access is required for regular inspection, Lubrication or operation of
machinery or equipment.
27. Clear walkway on one side of 1200 mm and other side of 600 mm minimum width
shall be provided along the length of pipe conveyor gallery.
28. In an underground tunnel, a clear walkway space of 1000 mm shall be provided
along the length of the conveyor on either side.
29. The pipe conveyor gallery structure shall be of box type with side sittings and also
top covered to avoid rainwater entry.
30. 1500 mm clearance shall be maintained all around drive system for maintenance
purpose.

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31. Maintenance platform & walkway for pipe conveyors shall be of chequered plate
construction

B. Electrics & Controls

Electrical drive motors for pipe conveyors shall be VVVF drive and for detail description of
VVVF drive, please refer relevant electrical DBR.

C. Structural Steelwork & Civil work

Please refer relevant civil & structural DBR.

8.01.02 CONVEYOR PARAMETERS

A. Design

Code & Standard - As per manufacturer’s standard

B. Belting ( Grade M24 FR)

Code & Standard - IS / DIN / BS / JIS

Duty - Continuous

Edge Construction - Moulded both edge capped.

Cover - Rubber

C. Pulley

Code & Standard - IS 8531

Shell - IS 2062

Disc - IS 2062

Hub - IS 2062

Construction - Welded

Shaft - 50C8 (IS 1570) / EN-9 (BS 970)

Connection - Keyed to Hub

Machining

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Tolerance - IS 919

Balancing - Statically Balanced

Lagging - Neoprene Rubber

Type - Drive Pulley : Grooved

- Non Drive Pulley : Plain

Shore Hardness - 55-60 Scale A

Plummer Blocks - Cast Iron Housing

Bearing - Double Row Self Aligning Spherical Roller

D. Idler

Code & Standard - IS 8598/Manufacturer’s standard

Construction - Grease Packed & Sealed for Life

Roll Tubes - ERW Black conforming to IS 9295

Shaft - 50C8 (IS 1570) / EN-9 (BS 970)

Machinging - IS 919
Tolerance

Bearing - Deep Groove Ball Bearing

Bearing Housing - Press Formed out of 3 mm DD Steel Sheet

Housing
Connection - Welded to Roll Tubes

Inner Seals - FRP

Labyrinth Seals - FRP

Inner Dust Seals - FRP

Outer Dust Seals - Press Formed out of 1 mm DD Steel Sheet

Out of Roundness - +/- 0.5 mm

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Mounting - Drop in Bracket Slot

Brackets - IS 2062 Fabricated

Carrying Idler - 3 Equal Roll – In Line/PSK Rollers

Return Idler - 2 Equal Roll – In Line/PSK Rollers

Impact Idler - 3 Roll with Rubber Disc. – In Line

Pipe Forming Idler - 12 (6+6) / 9 (6+3) Equal Roll – In Line

E. Skirt Board

Body - IS 2062 / 10 mm Plate

Liner - HARDOX 400 / 12 mm Plate

Sealing - Segmented Modular Rubber Blade

Cover - IS 2062 / 2 mm Sheet

Mounting - From Stringer Frame

F. Deck Plate

Material - IS 2062

Thickness - 3.15 mm

G. Chute Work

Discharge Hood - IS 2062 / 4 mm Sheet

Discharge Chutes - IS 2062 / 8 mm Plate

Liner - HARDOX 400 / 10 mm Plate

H. Technological Structure

Stringer &
Short Post - IS 2062 / Rolled Section

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Size - ISMC 150

Construction - Bolted

I. Gear Box

Type - Helical / Bevel Helical

Housing - Fabricated
Lubrication - Splash.
Mechanical Rating - Should be greater than equal to at least 1.25 times on Motor Rating
Or 1.5 times on Drive Pulley Shaft Power.
Thermal Rating - shall be at least equal to the motor rating.
Cooling Type - Natural Cooling.

Holdback - Integral with Gear Box

J. High Speed Input Coupling

Type - Resilient

Service Factor - 1.5 times on Motor Rating for Resilient Type

K. Low Speed Output Coupling

Type - Geared

Service Factor - 1.5 times on Motor Rating

L. Pull Cord Switch

Location - 30 m C/C (Walkway side)

Enclosure - Cast Aluminium

Protection - IP 65

Contact - 2 NO + 2 NC

Operating Positions- 1-0-1

Reset - Manual

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M. Belt Sway Switch ( Both Side )

Location - 50 m C/C

Enclosure - Cast Aluminium

Protection - IP 65

Contact - 2 NO + 2 NC

Reset - Manual

N. Speed Monitor

Function - Zero Speed Switch

Type - Inductive Proximity Switch

Location - Conveyor Pulley

Quantity - One (1)

Operating Distance- 15 mm

Probe Enclosure - Brass

Protection - IP 67

Accessories - Monitoring Unit

Type - Rotational Speed Controller

Contact Rating - 5A

O. Pull Cord Rope & Eye Hook

Cord Material - GI Rope

Diameter - 3 mm

Construction - 30 swg / 6x7

Protection - PVC Sheath

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Eye Hook
Diameter - 35 mm

Construction - 6 mm Rod
8.02 AIR SLIDE

8.02.01 TECHNICAL REQUIREMENT

Air slides unit shall be complete with:
a) Bottom casing, complete with flanged air inlet manifolds with dampers, stiffeners and
support brackets.
b) Top cover, complete with weather proof fixing arrangement, flanged feed spouts, bolted
inspection hatches and flanged air vent connection with damper.
c) Flanged discharge boxes and distribution boxes.
d) Air slide maintenance is limited to the replacement of fluidization cloth.
e) Total length of air slides shall be divided into suitable no of segments. Fabric, of required
size, preferably in single pieces for each air slide. Application of Silastic is must for
installation of air slide fabric. Fabric supporting wire mesh at feeding zones. The fluidization
cloth of air slides shall be of imported quality from reputed vendor.
f) Provision of balancing air in the air slide shall be kept. The control philosophy of balancing
and methodology shall be clearly mentioned.
g) Provision must be kept in the air slide chamber for fixing manometer and pressure gauge
with plug.
h) Flushing points shall be provided in all air chambers of air slides and vent pipe joints.
i) All air control valves of the air slides to be provided with butterfly valves only and suitable
platform shall be provided for maintenance of valves in all areas.
j) Air permeability of the fabric shall be approximately1.15 m3/m2/min at 600 mmWC.
Depending on bulk material characteristics, the air quantity may deviate from this figure.
k) Fan-Type Blowers
Guide values for air pressure (including reserve) are:
 Conveyor width ≤ 500 mm 60 mbar
 Conveyor width > 500 mm 80 mbar

Guide values for specific air volume are:

 Fine material 2 m3/m2 per minute
 Coarse material 3.5 m3/m2 per minute
l) Maximum speed: 3000 rpm for 50 Hz electrical supply.
m) Air filters shall be provided at fan inlets at man height.
n) Fans installed outdoors shall be protected against taking in of rain through the suction inlet.
o) Casing mounted fans are as well accepted.
p) All bolts, nuts, washers and loose fittings, as would be necessary for erection.

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8.03 SCREW TYPE AIR COMPRESSOR

Nine (9) nos. (8 working and 1 standby) lubricated air cooled Screw type air compressors, each
having suitable capacity free air delivery at 2 bar with suction filter fitted with electrical &
instrumentation, interconnecting cables etc. These compressors shall be controlled both from local
control panel view and from level 2 SCADA system. The piping design has to be done in such a
way that the stand by compressor shall be capable of substituting any blower as per requirement.

8.04 FAN
The fans shall be capable of withstanding the stresses which may be experienced during normal
operation and during over speed testing. All fans shall be suitable for outdoor installation.
All the fan units shall be reasonably noise and vibration free in operation and hence of reasonably
low speed. The noise level shall be limited to 80 db at 1.5M radius.
Operating pressure of fan shall not exceed 93% of Peak pressure of fan performance curve.
Fan static efficiency – min. 80%
Drive – Directly coupled and motor
Fan performance testing shall be as per BS : 848, Class ‘A’ latest revision.
Anti-vibration pads to be provided for fan installed above ground level
Inspection doors with fly nuts and gasket of suitable size shall be provided on the scroll for easy
access to fan internals for inspection, Cleaning and for in-situ rotor balancing.
Fan casing shall be provided with clean out doors and drain plugs, as required
Inlet Boxes are to be provided as required and casing shall be stiffened to resist vibrations and
distortions.
Motorised inlet damper has to be provided for fans with motor rating above 11 kW.
The fan and the drive motor shall be rated for continuous operation.
The starting torque characteristic of the motor shall be suitable for the duty desired.
All centrifugal fans may have adequate arrangement for vibration isolation of minimum 70%
efficiency as the case may be.
The centrifugal fans shall have flat backward inclined / backward curved blades. They shall be
single inlet and shall be of single width type. For design purpose outdoor temp. shall be taken as
50 deg.C.
The fans shall be of robust construction. The thickness of the casing and impeller shall be as given
below:
Casing – 8 mm.
Inlet box – 6 mm.
Blades – 8 mm (min.).

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Fan should be designed for adequate duty keeping a margin in approximately 15% on pressure
ratings. Operating speed of the centrifugal fan shall not preferably be more than 1500 rpm and
velocity of outlet shall not exceed 15 m/sec.

8.04.01 MATERIAL OF CONSTRUCTION

The following materials shall be used for the construction of various parts:

a) Fan scrawl : MS (IS 2062).

b) Supports, frames & : MS (IS 2062).
structures
c) Cone inlet for wall : CI or MS.
exhausters / supply fans
d) Dampers – louver type : MS (IS 2062).
and butterfly type
e) Flexible connections for : Rubber impregnated canvas with MS
fan inlet & outlet Flanges & Cleats. Split draw band
type made of spring steel for DE
System.
f) ‘V’ Pulleys : CI Multi-grooves (IS 210, Gr. 20).

g) ‘V’ Belt : Reinforced rubber of appropriate

section.
h) Slide Rails : CI or MS.

i) Connection Pieces : Galvanized iron according to

supplier’s design.
j) Bolts and Nuts : All foundation bolts and nuts shall be
HT and Others shall be MS unless
otherwise specified.
k) Rain protection cowls, : Casing & exhaust hoods will be hot
hoods and casing for dipped galvanized after fabrication
roof exhausters from MS IS 2062.

l) Vibration isolating pad, : Hard synthetic rubber of hardness 40

washers & bushes, if degree shore.
any

8.05 BEARING AND BEARING HOUSING

 Anti friction bearings, suitable for specified duty conditions shall be used for the fans,
conveyors, bucket elevators, etc. The bearings shall have a minimum life of 100,000 hours.

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 The bearing make shall be of SKF / FAG / TIMKEN. The supplier shall provide authenticity
certificate for genuineness of bearings. Spurious bearings shall be rejected.
 Bearings shall be provided with suitable lubrication system with adequate cooling
arrangement to maintain the bearing & lubricant temperature within permissible limits.
Grease lubrication system shall be preferred. For oil lubrication system, maximum
permissible oil temperature during operating condition shall be limited to 90 deg.C / 40 deg.C
above ambient temperature. Drain plug shall be provided in bearing housing.

8.06 DE-DUSTING UNITS / BAG FILTERS (JET PULSE TYPE)

8.06.01 GENERAL
 Not more than 8 dust sources shall be connected to a single dust filter.
 The maximum air to cloth ratio shall be 1.15:1 / air permeability shall be 1.15 m3/m2/min
for general de-dusting.
 Pulse jet type bag filter shall be provided with suitably reinforced bag/man-catcher screens.

8.06.02 BAGS
 Filter cloth for dry gas application up to 135 °C: Needle felt made of high quality Polyester
fibres (for air and alumina dust).
 For standardization of bags (e.g., diameter of 140/160 mm) most filters shall be matched in
such a way that only one size (i.e. diameter, length) and filter bag type is used for similar
applications.
 Maximum number of bags per row: 16 bags
 Bag cages shall be provided with longitudinal wires:
 To 12 for filter cloth diameter < 160 mm.
 Bag cages shall be of single piece design and shall be corrosion-resistant
(galvanized, stainless steel or epoxy coated), depending on application.

8.06.03 BAG MONITORING AND PROTECTION EQUIPMENT

 Bag cleaning shall be controlled by timer and differential pressure measurement across the
bag filter by DP gauge or transmitter.
Manual condensate drain, pressure gauge and regulator at the inlet of compressed air
receiver/manifold shall be provided.

8.06.04 DEDUSTING AIR VOLUME

 Air Slide : 125% of Air Blower capacity.
 Pneumatic Transport : 1.5 times of the expanded compressed air volume
 Small Bin (< 50 m3) : 1000 m3/h

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8.06.05 VENTING DUCTS

 Inclined vent ducts for up and downwards dust-laden air flow shall have an
inclination of at least 60 degrees measured from horizontal.
 A conveying velocity of 18-25 m/Sec shall be maintained at all points in the
ductwork between dust collection hood and dust collection plant to ensure flow of
air without settling of dust. Hinged cleaning hatches shall be provided on the
ducting near the bends & interconnection of ducts. Measuring ports shall be
provided on the ducting near each suction point and on ducting before & after the
centrifugal fan to measure the flow rate and pressure. Platform with ladder shall be
provided for approach to cleaning hatches & measuring ports.

 Horizontal ducts may be avoided.

 Minimum venting duct diameter shall be 133 mm (outside).
 Air velocity at venting hood entries shall not exceed 1.5 m/s
 Minimum duct and hood wall thickness shall be 3 mm
 All expansion / flexible joints shall have bolted flange-to-flange type connections
on both sides of expansion joint for removal of complete unit. Minimum flange
thickness shall be 6 mm.
Orifice plates with wear protection shall be used for balancing the de-dusting air volumes
from the various de-dusting points of a single filter if wear is predicted.

8.06.06 HOPPER CONSTRUCTION

Hopper valley angles shall not be less than 55 degrees (measured from horizontal) for dust from
general applications. For filters with the risk of operation below the water dew point, the casing
insulation shall be minimum 50 mm of rock wool.

8.07 AIRLOCKS
 RAL casing should be casting of IS 4896 Grade II.
 Spring loaded tips to be provided on rotor vanes for continuous sealing.
 Tip blade shall be of replaceable and adjustable type.
 RAL size : min. 300 x 300 mm
 RAL speed not more than 20 rpm.
 Motor shall be suitable for 100% filling of RAL at compact density. Minimum 1.1 kW /
1500 rpm motor to be considered.

8.08 ROPE WINCH SYSTEM

Rope winch system for wagon hauling shall be as per vendor’s standards.

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8.09 EQUIPMENT PARAMETERS AND OTHER SALIENT FEATURES:

 Stack height for Dust collector system shall be as per latest pollution control norms.
 Motor name plate rating at 50ºC shall have at least 15% margin over the input power
requirement of the driven equipment at duty point except for package type screw compressor
where service factor motor are used as per manufacturers standard.
 The system shall be capable of operating continuously round the clock throughout the
year. The installation must be designed so that it can always be serviced without having a
complete shutdown.
 Alumina unloading and transportation system shall be laid out and constructed for
convenience and safety of operation and maintenance. All equipment shall be oriented to
permit servicing in such a way as to require a minimum of dismantling.
 All equipment and materials (mechanical, piping, electrical, instrumentation, controls,
civil, architectural etc) shall be sourced from manufacturers acceptable to DCPL and
NALCO.
 All electrical installations including the hoists in open area shall be provided with rain
protection hood.
 Maintenance platforms/access walkways shall be provided at one end beam for each
electric monorail hoist.
 All the equipment shall be field proven for such an operation taking into consideration
normal preventive and running maintenance of the unit and their auxiliaries.
 All equipment, controls and structure shall be designed for installation in carbon and
alumina dust charged atmosphere of aluminium smelter area and seismic condition of
site.
 All equipment shall be proven design. Prototypes or extensive modifications of the basic
designs are unacceptable.
 The installation shall be designed with adequate facilities for maintenance & operations.
 The design, fabrication, painting, supplies and testing shall conform to relevant
international codes and standards, Indian codes and standards, wherever applicable, shall
take precedence over those of other nationalities. Only latest editions including addenda
shall be referred to.
 Design, fabrication & operation of the plant shall be based on the following:
a) Indian factory act
b) Indian explosive act
c) Petroleum & Carbide of calcium manual
d) Fire protection manual of fire sectional committee, Insurance Association Of India
e) Regulations laid down by explosive directorate and electrical inspectorate
f) Regulations of Director general of civil aviation for all stacks

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g) NFPA code of practice

h) Regulation of electrical equipment of buildings Insurance Association Of India
i) Regulation of both Central and state pollution control boards of overall pollution
j) control for both surface and air
k) Indian electricity rules
 Compressed air and supply air facilities supplied shall include all compressed air piping,
valves and fittings as required.
 All blowers and compressors generating process air supply for AUT shall be housed in a
common blower/compressor house, which shall provide weather protection as well as act
as noise enclosure common to all equipment inside the room. The noise level shall be
maintained as per requirement of environmental norms.
 All equipment to be supplied shall be of robust design and manufacture and shall
correspond to state of the art of manufacturing technology. Selected equipment shall have
a high degree of availability, require minimum maintenance and operate with high
efficiency. Electrical and thermal energy consumption shall be low. Equipment shall be
designed for heavy-duty industrial application, capable of handling very abrasive
materials in dusty environments. The equipment shall be suitable for continuous
operation at uniform maximum load without adverse effect on the life or maintenance of
the equipment under prevailing conditions. Furthermore it shall be suited to all local
climatic and operating conditions at the site.
 The equipment shall be designed with sufficient safety margins from the mechanical
design and the process performance point of view. It shall be capable of re-starting after
stopping due to power failure or other process-related interruption (i.e. interlock).
 The open space between the walkways on both sides of the air slides, conveyors to be
covered with plates for safety purpose.
 The pipe conveyor gallery shall be suitably designed to prevent ingress of rain water.
 Pipe conveyor belt shall be selected properly for smooth operation (namely pipe
formation, flexibility etc.). Pipe conveyor belt grade shall be fire resistance type.
 One Maintenance cum Sub-Store to be constructed near Blower room.
 All the alumina unloading area shall be under shed to protect Sun & Rain.
 Platforms (full length of the shed for both tracks) shall be constructed for two side access
to roof of BTAP wagons inside the shed for alumina unloading area.
 Flushing points to be provided in all air chambers of air slides and vent pipe joints.
 All air control valves of the air slides to be provided with butterfly valves only.
 Suitable platforms to be provided for maintenance of valves in all areas.
 All de-dusting chamber shall be protected from rainwater and in case of necessary,
sheds/canopy to be provided.
 In the control room, all the screens must be TFT to avoid heavy magnetic field.

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 The outdoor electrical /Instrumentation installations like local cabinet of motors and other
instruments shall be provided with rain protection shed.
 Total system lighting arrangement shall be preferably 70 Watts HPSV (High Pressure
Sodium Vapour) with glass fitting.
 Pull chord/Belt sway switches and other switches as mentioned in P&ID shall be
provided considering system tripping.
 In the control room there shall be Audible buzzer and Indication light during Alarm/Trip
of the any equipment /system.
 Elbow installed on alumina pipes must be designed to resist abrasion. The inside pipe
shall be lined with an abrasion proof medium. Elbow radius must not be less than 1
meter.
 The fluidization cloth for air slide shall be of fabric quality from reputed vendor.
 Pressurized ventilation system shall be provided in the blower room.

9. PERFORMANCE REQUIREMENT OF MAJOR EQUIPMENTS

Pipe conveyor
Equipment Number : PC-100/200/300
Capacity : 1000 TPH
Accuracy : ± 5%

Air slides
Equipment Number : AS-100/200
Average Capacity : 480 TPH
Design Capacity : 500 TPH
Air slides
Equipment Number : AS-300/400/401/500/501
Design Capacity : 1000 TPH

Dust Emission
Equipment Number : DC-100/200/300/400
Type : Bag Filter type
Location : As per site condition
Function : Filter the air loaded with alumina dust
before venting it to the atmosphere.
Dust Load : Approx. 25 gms/Nm³
Dust Emission to : 10 mg / Nm3 (desirable)
atmosphere

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10. UTILITY FOR ALUMINA UNLOADING AND TRANSPORTATION SYSTEM

One make up water line (existing 200-WT-35-2305-A34) will be tapped from existing line at
the Co-ordinate N= (-) 1153.28M, E = (-) 2581.83M
8” Fire Hydrant (U /G Line) shall be available from existing line at the co-ordinate
N= (-) 939.874M, E = (-) 2343.605M
8” / 12” compressed air line shall be tapped from the existing line at the co-ordinate
N= (-) 1258.68M, E = (-) 2581.83M
The compressed air line for bag filters near silo-6 and silo-2 shall be tapped from the nearest
existing compressed air line.
Drinking water supply line for proposed shall be tapped from existing system near RP area.

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