Down Hill Conveyor System-Mecon

NMDC LIMITED
HYDERABAD
KUMARASWAMY IRON ORE PROJECT

BELLARY DIST - KARNATAKA
TENDER DOCUMENT
FOR
PACKAGE - II
DOWNHILL CONVEYOR SYSTEM
VOLUME – III OF V
MECON LIMITED
BANGALORE
MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD REV. 0 JANUARY 2010

NMDC LIMITED MECON
LIMITED

PACKAGE NO – II DOWN HILL CONVEYOR SYSTEM
CONTENTS
VOLUME – I of V
Chapter
Description
No
1. Check list
2. Notice Inviting Tender (NIT)
3. Instructions to Tenderers (ITT)
4. General Conditions of Contract (GCC)
5. Special Conditions of Contract (SCC)
6. Erection Conditions Of Contract (ECC)
VOLUME – II of V
Preamble, Summary of Prices, Price for exemptions / variations

1.
and Price Format
VOLUME – III of V
Chapter
Description
No
A Brief on the Project and Intent Of Tender
B General technical conditions
C General site information
D Scope of work and battery limit
E Performance guarantee and warranty
F Surface preparation and painting
G Quality assurance, inspection and testing
H Construction, erection, testing and commissioning
I Engineering services
J Project management services
K Site services
L List of Tender Drawings
M Part/1 - Documents/ drawings to be submitted along with the
tender
Part/2 – Questionnaire and design data sheets to be filled and
submitted along with the tender
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PACKAGE NO – II DOWN HILL CONVEYOR SYSTEM
N Documents /drawings to be submitted by successful Tenderer

O Spares, Special tools & Tackles
P List of Preferred makes of equipment
Q1 Technical specification – Mechanical
Q2 Technical specification – Environmental
Enclosures: -
1. Tender drawings as per the list under chapter-L

2. Specimen QAP format for Structural & Mechanical equipment
3. Specimen QAP format for Electrical equipment
4. Specimen Inspection call format.
VOLUME – IV of V
Chapter
Description
No
Q3 Technical specification – Electrical
Q4 Technical specification – Automation and Control
Q5 Technical specification – Plant Communication System
VOLUME – V of V
Chapter
Description
No
Q6 Technical specification – Civil
Q7 Technical specification – Structural
Q8 Technical specification – Hydro Engineering
Q9 Technical specification –Fire Detection and Suppression
System for Down Hill Conveyor
Q10 Technical specification – General Layout, Roads and Fire
Fighting
Enclosures:- One Compact disc containing soft copy of the following:
1. Soft copy of Questionnaire and design data sheet – Chapter-M (Part-2 of 2)

2. Soil investigation report (for reference only)
3. Waste Dump Location - Sketch dated 14.09.07
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PACKAGE NO - II VOLUME - III of V
CHAPTER NO. A PAGE No. 1 of 5
CHAPTER - A
BRIEF ON THE PROJECT AND INTENT OF

TENDER
1.0 BRIEF ON THE PROJECT
1.1 NMDC Limited, a premier iron ore producer in the public

sector and export house for high grade iron ore lumps & fines
is presently engaged in mining at Donimalai in the district of
Bellary, Karnataka State.
1.2 Now, NMDC proposes to develop Kumaraswamy Iron Ore

Mines for an ROM capacity of 7 Million Tonnes per annum to
produce Calibrated Lump Ore (- 30mm to + 10 mm) and
Fines (-10mm). At Kumaraswamy, facilities required for
crushing ROM ore to the required size is being created. The
crushed ore will be conveyed to the existing screening plant /
proposed new screening plant at Donimalai, which is approx
5.20 km away from the proposed location of the crushing
plant through a down hill conveying system.
1.3 Brief Description of the System under Package-II
1.3.1 Iron ore (-) 100 mm size received from the scalping screen
and cone crusher will be conveyed to RCC silo of 1000 T
(effective) storage capacity through conveyor nos. 718 and
conveyor no. 719. Belt feeder no. 720 provided at the bottom
of the silo will convey the material to conveyor no. 721.
Conveyor no. 721 will feed the material to the tail end of
single flight down hill conveyor no. 723. A tail / drive house
will be provided at tail end of down hill conveyor for
accommodating the drives & tail pulley of down hill conveyor.
Down hill conveyor no. 723 will convey Iron Ore through a
hilly terrain over a distance of about 4900 m and discharge
the material to a surge hopper at transfer house TH-3. Belt
feeder no. 725 mounted at the bottom of the surge hopper
will convey the material to a reversible conveyor no. 727
passing through a deep valley. Provision will also be kept in
TH-3 for conveying material from the surge hopper to a
future conveyor conveying material to new screening plant.
MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0
© 2010, MECON Limited. All rights reserved.
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Reversible conveyor no. 727 will feed the material at the

extended tail end portion of the existing tripper conveyor
no. 122 at transfer house TH-4. Two self propelled travelling
maintenance trolleys are envisaged for maintenance of down
hill conveyor no. 723.
1.3.2 Iron Ore from the existing Donimalai tripper conveyor

no. 122 will also be tapped (by extending the existing tripper
travel towards the tail end of the conveyor no. 122) and
conveyed to the reversible conveyor no. 727 through
conveyor nos. 727-1 and 727-2. Reversible conveyor no. 727
will convey this material in reverse direction to a future
conveyor in TH-3 for further conveying to the proposed new
screening plant.
2.0 IMPLEMENTATION METHOD
2.1 MECON Limited has been appointed as CONSULTANT for

engineering, contract procurement services, project
management & construction management services for the
Kumaraswamy Iron Ore Project.
MECON has associated with Conveyor Dynamics, Inc. USA for

rendering their services for Package-II: Downhill Conveyor
System.
2.2 NMDC is proposing to implement the Kumaraswamy Iron Ore

project through six(6) numbers of turnkey packages.
2.3 The details of these six packages are as follows:
2.3.1 Package – I: CRUSHING PLANT
Major facilities / units included under this package are:
• Primary crushing Plant

• Conveyor No.708
• Secondary crushing plant
• Mines office & PCH office building
• ROM Stockpile area, Dumper platform
• Mine Road from battery limit to ROM Stockpile and further
up to dumper platform
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• Service road from PWD Road to PCH and SCH office

complex area up to switch yard
• Approach road to various levels of Primary and Secondary
Crushing Plant
Package shall also include associated technological

equipment, civil works, structural works, water supply works,
electrical, automation & control system, etc., pertaining to
the Primary crushing plant and secondary crushing plant.
Package shall further include earth cutting & leveling of the

area covering hill top facilities and crushing plant.
2.3.2 Package – II: DOWNHILL CONVEYOR SYSTEM
• Conveyor No. 718

• RCC silo of 1000 T (effective storage)
• Belt Feeder No. 720 below RCC silo
• Down hill Conveyor No. 723 complete with 2 nos. self
propelled traveling maintenance trolleys
• Surge Hopper with Belt Feeder No. 725 at Transfer House
TH-3
• Reversible Conveyor No. 727
• Conveyor No. 727-1
• Conveyor No. 727-2
• Extension of existing tripper conveyor No.122
• Extension of travel of existing tripper on conveyor No. 122
• Tail / drive house for Down hill conveyor no. 723
• Transfer Houses TH-1, TH-2, TH-2A, TH-3, TH-4, TH-5
and TH-6
• Transfer station at tail end of conveyor no. 727-1
• Parking / maintenance stations PS-1 (near tail end of
down hill conveyor) & PS-2 (near head end of down hill
conveyor) for self propelled traveling maintenance trolleys
on down hill conveyor no. 723
• Handling facilities at the tail / drive house of down hill
conveyor, transfer houses, parking / maintenance stations
for traveling trolley, etc.
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• Electrical, control cum office buildings

• Plant communication system
• 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.
• Approach road to PS-2 and take-up area of down hill
conveyor
• Approach road to TH-3 from the kachha road already
developed by NMDC
• Approach road to TH-4, TH-5 & TH-6 from the roads
available already.
• Approach road to belt lay down area at two locations
Package shall also include associated technological

equipment, civil works, structural works, electrical,
automation & control system, fire detection & suppression
system for down hill conveyor no. 723, air-conditioning &
ventilation system, dust suppression system, fire fighting
system (fire extinghishers), etc. The Package shall also
include modification to the structure of existing tripper
conveyor no. 122 and transfer tower at tail end of conveyor
no. 122.
Package shall further include earth cutting & leveling of the

area for various units / approach roads planned under
package-II .
2.3.3 Package – III: ELECTRICAL WORKS
• Mains receiving sub-station

• Power distribution including Overhead lines
• Illumination system of the Mines area
Package shall also include earth cutting & leveling, civil

works, structural works, etc.
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2.3.4 Package – IV: TELECOMMUNICATION WORKS
• Telecommunication facilities between various units of

Crushing plant, Downhill conveyor system, hill top
facilities and Donimalai units.
• Wireless communication system including interface with
existing screening plant
Package shall also include civil works, structural works, etc.

related to the subject package.
2.3.5 Package – V: HILL TOP FACILITIES
• Package V-A : Civil, structural Works & Water Supply

facilities
• Package V-B : Electrics & Illumination
• Package V-C : EOT Cranes
The above packages shall include earth cutting & leveling,

civil works, structural works, etc.
2.3.6 Package – VI: ROADS
Widening and asphalting of the following roads:
• Kacha road developed by NMDC from Ranjitpura village to

Kumaraswamy Hill top
• Kacha road from bottom of the hill to top of the hill (near
proposed Transfer House TH-3 at the head end of down
hill conveyor)
3.0 INTENT OF TENDER
The intent of this Tender document is to enable the Tenderer

to submit a detailed comprehensive offer matching the
requirements specified in this document for Package-II, on
lump sum turnkey (LSTK) basis.
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CHAPTER NO. B PAGE No. 1 of 11
CHAPTER-B
GENERAL TECHNICAL CONDITIONS

1.0 GENERAL
1.1 This part covers technical conditions pursuant to the Contract

and will form an integral part of the Contract. The following
provisions shall supplement all the detailed technical
specifications and requirements brought out in the
accompanying Technical Specifications. The Tenderer’s
proposal shall be based on the use of equipment and materials
complying fully with the requirements, specified herein. It is
recognised that the Tenderer may have standardised on the
use of certain components, materials, processes or procedures
different than those specified herein. Alternate proposals
offering similar equipment based on the manufacturer's
standard practice will also be considered provided such
proposals meet the specified designs, standards and
performance requirements and are acceptable to the
Owner/Consultant.
1.2 The Tenderer shall carefully go through the entire tender

document and understand the scope of work and plant
requirements before the execution of work.
1.3 The Bidder shall be deemed to have exhaustively examined the

tender documents, have obtained all the information and
clarifications on all matters and must have satisfied himself as
to the adequacy of the bid. He is deemed to have understood
the scope, nature and magnitude of work to complete the
erection and commissioning of the plant including performance
guarantees as mentioned in the tender document. Any flow
sheet, details, data furnished in the tender document does not
absolve the Tenderer of his responsibility to verify and satisfy
himself whether it is adequate for the guarantees given in the
tender.
1.4 The Bidder should ascertain himself, by a visit to the site at his
own cost to assess the actual site conditions, local factors, etc.
before submission of the bid. The Contractor shall bear full
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responsibility for deductions and conclusions as to the nature

and conditions under which the work is to be executed,
including effect of climate, rainfall etc. Failure to do so will not
absolve the Contractor of his responsibilities about the proper
execution of the job. No claims for extra payments due to any
special site conditions and ignorance of site conditions will be
considered after the acceptance of his quotation.
2.0 LIMIT OF CONTRACT
2.1 Equipment furnished shall be complete in every respect with all

mountings, fittings, fixtures and standard accessories normally
provided with such equipment and/or needed for erection,
completion and safe operation of the equipment as required by
applicable codes though they may not have been specifically
detailed in the Technical Specification, unless included in the
list of exclusions. All similar standard components/parts of
similar standard equipment provided shall be interchangeable
with one another.
2.2 All the equipment offered shall also conform to the statutory
requirements of Government of India / DGMS / State
Government of Karnataka / IEC / Indian Electricity Rules.
3.0 EQUIPMENT PERFORMANCE GUARANTEE
3.1 The performance guarantees of the equipment / system under

the scope of the Contract are detailed separately in this
document. These guarantees shall supplement the general
performance guarantee provision covered under GCC in Clause
title "Guarantee".
4.0 PROJECT ENGINEERING
4.1 MECON Ltd who are the Project Consultants, have associated
with M/s. Conveyor Dynamics Inc., USA for engineering the
downhill conveyor in the tendering as well as in the Project
execution stage. They will be involved in the tender appraisal,
discussion with the tenderers and also in approval of drawings
/ calculations furnished by the successful tenderer. They will
also be involved at erection and commissioning stage of the
project.
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5.0 ENGINEERING DATA
5.1 The furnishing of engineering data by the Tenderer shall be

in accordance with the schedule as specified in the Technical
Specifications. The review of these data by the
Owner/Consultant will cover only general conformance of the
data to the specifications and documents interfaces with the
equipment provided under the specifications, external
connections and of the dimensions, which might affect plant
layout. This review and/or approval by the Owner/Consultant
for the details of the equipment, material, any devices or items
indicated or the accuracy of the information submitted shall
not be constrained by the Tenderer, as limiting any of his
responsibilities and liabilities for mistakes and deviations from
the requirements, specified under these specifications and
documents.
5.2 All engineering data submitted by the Tenderer after final

process including review and approval by the Owner/
Consultant shall form part of the Contract Documents and
the entire works covered under these specifications shall be
performed in strict conformity, unless otherwise expressly
stated by the Engineer in writing.
6.0 DRAWINGS
6.1 All drawings submitted by the Tenderer including those

submitted at the time of bid shall be of sufficient detail to
indicate the type, size, arrangement, weight of each
component break-up for packing and shipment, the external
connections, fixing arrangements required, the dimensions
required for installation and interconnections with other
equipment and materials, clearances and spaces required
between various portions of equipment and any other
information specifically requested in the specification.
6.2 Each drawing submitted by the Tenderer shall be clearly

marked with the name of Owner, Consultant, the unit
designation, the specifications title, the specification number
and the name of the project. If standard catalogue pages are
submitted the applicable items shall be indicated therein. All
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titles, noting, marking and writings on the drawing shall be in

English. All dimensions shall be in metric units.
6.3 Copies of drawings returned to the Tenderer will be in the form

of a print with the Consultant’s marking.
6.4 The drawing submitted by the Tenderer shall be reviewed by

the Owner/Consultant as far as practicable within three (3)
weeks of receipt and shall be modified by the Tenderer if any
modifications and/or corrections are required by the
Owner/Consultant. The Tenderer shall incorporate such
modifications and/or correction and submit the final drawings
for approval. Any delays arising out of failure by the Tenderer
to rectify the drawings in good time shall not alter the contract
completion date.
6.5 The drawings sent for approval to the Consultant shall be in

ten (10) copies. One print of such drawings will be returned to
the Tenderer by the Owner/Consultant marked APPROVED /
NOT APPROVED or APPROVED AS NOTED. The Tenderer shall
thereupon furnish the Owner/Consultant with ten prints and
one reproducible of the original of the drawings after
incorporation of all corrections.
6.6 Further work by the Tenderer shall be in strict accordance with

these drawings and no deviation shall be permitted without the
written approval of the Owner/Consultant.
6.7 The Tenderer may make changes in the design, which are
necessary to make the equipment conform to the provisions
and intent of the Contract, but such changes will again be
subject to approval by the Owner/Consultant. Approval of
Tenderer’s drawings or work by the Owner/Consultant shall not
relieve the Tenderer of any of his responsibilities and liabilities
under the Contract and the Tenderer shall remain wholly
responsible for any error in his drawings and documents,
approved or otherwise.
6.8 Drawings shall include all installation and detailed piping

drawings wherever applicable.
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6.9 Finalised layout and GA drawings with sections and certified

foundation outline drawings including dimensional
anchor/foundation bolt location plans and loading drawings
with drawings for foundation if any anchor bolts and inserts/
embedment shall be furnished by the Tenderer to the
Owner/Consultant
7.0 FIRST FILL OF CONSUMABLES, OILS AND LUBRICANTS
7.1 All the first fill of consumable such as oils, lubricants and
essential chemicals for pickling etc, which will be required to
put in the equipment covered under the scope of the
specifications up to successful commissioning shall be
furnished by the Tenderer. Equipment shall be lubricated by
systems designed for continuous operation. Lubricant level
indicators shall be furnished and marked to indicate proper
levels under both stand-still and operating conditions. The first
fill of oils, lubricant, fuel etc. to be supplied shall include at
least 10% extra quantities to cover the wastages/breakage
during transportation, storage, handling, erection etc.
8.0 MANUFACTURING SCHEDULE
8.1 The Tenderer shall submit to the Owner / Consultant, his

delivery schedule for all equipment within 15 days from the
date of the Letter of Intent. Such schedules shall be reviewed,
updated and submitted to the Engineer, once every month
thereafter by the Tenderer. Materials and equipment proposed
to be purchased from outside suppliers shall be separately
identified and schedules thereof shall also be submitted.
9.0 REFERENCE STANDARDS
9.1 The Codes and/or standards referred to in the specifications

shall govern, in all cases wherever such references are made.
In case of a conflict between such codes and/or standards and
the specifications, the latter shall govern. Such codes and/or
standards referred to shall mean the latest revisions,
amendments/changes adopted and published by the relevant
agencies. In case of any further conflict in this matter, the
same shall be referred to the Engineer whose decision shall be
final and binding.
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9.2 Other internationally acceptable standards, which ensure equal

or higher performance than those specified shall also be
accepted.
10.0 DESIGN IMPROVEMENTS
10.1 The Owner/Consultant or the Tenderer may propose changes

in the specification of the equipment or quality thereof for
effecting improvements in design and if the parties agree upon
any such change the specification shall be modified
accordingly.
10.2 If any agreed upon change is such that it affects the price and
schedule of completion, the parties shall agree in writing as to
the extent of any change in the price and/or schedule of
completion before the Tenderer proceeds with the change.
Following such agreement the provision thereof shall be
deemed to have been amended accordingly.
11.0 ENGINEER'S SUPERVISION
11.1 To eliminate delays and avoid disputes and litigation it is

agreed between the parties to the Contract that all matters
and questions shall be referred to the Engineer and his
decision shall be final.
11.2 The work shall be performed under the direction and

supervision of the Engineer. The scope of the duties of the
Engineer, pursuant to the Contract, will include but not be
limited to the following:
i) Interpretation of all the terms and conditions of these

documents and specifications
ii) Review of all the Tenderer's drawings, engineering data

etc.
iii) Witness or authorise his representative to witness tests

and trials either at the manufacturer's works or at site,
or at any place where work is performed under the
Contract.
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iv) Inspect, accept or reject any equipment, material and

work under the Contract.
v) Issue certificate of acceptance and/or progressive

payment and final payment certificates.
vi) Review and suggest modifications and improvements in
completion schedules from time to time.
vii) Supervise the quality assurance programme

implementation at all stages of the works.
12.0 PACKING AND TRANSPORTATION
12.1 All the equipment shall be suitably protected, coated, covered

or boxed and crated to prevent damage or deterioration during
transit, handling and storage at Site till the time of erection.
While packing all the materials, the limitations from the point
of view of availability of railway wagon sizes in India should be
taken into account. The Tenderer shall be responsible for any
loss or damage during transportation, handling and storage
due to improper packing.
12.2 The Tenderer has option to transport the plant and equipment
either by road or by railways, after notifying the
Owner/Consultant the mode of transportation.
12.3 All coated surfaces shall be protected against abrasions,

impact, discolouration and any other damages. All exposed
threaded portions shall be suitably protected with either a
metallic or a non-metallic protecting device. All ends of all
valves and piping and conduit equipment connections shall be
properly sealed with suitable devices to protect them from
damage. The parts which are likely to get rusted, due to
exposure to weather shall also be properly treated and
protected in a suitable manner. All mating surfaces and
journals shall be protected by a rust-inhibiting coat.
13.0 PRESERVATIVE SHOP COATING
13.1 Preservative shop coating shall be rendered as specified in the

Chapter Surface preparation & painting.
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14.0 SAFETY
14.1 Suitable guards shall be provided for protection of personnel

on all exposed rotating and/or moving machine parts. All such
guards with necessary spares and accessories shall be
designed for easy installation and removal for maintenance
purposes.
14.2 The mechanical design of all equipment shall incorporate

features, which will provide the greatest degree of safety to
personnel and allow for ease of maintenance.
14.3 All working parts, as far as possible, are to be arranged for

convenience of operation, inspection, lubrication and ease of
replacement with minimum down time. All like parts on
equipment furnished or on duplicate equipment shall be
interchangeable.
14.4 All equipment shall be complete with approved safety devices

wherever a potential hazard to personnel exists and with
provision for safe access of personnel to and around equipment
for operational and maintenance functions.
15.0 DESIGN CO-ORDINATION
15.1 The Tenderer shall be responsible for the selection and design
of appropriate equipment to provide the best co-ordinated
performance of the entire system. The basic design
requirements are detailed out in Technical Specifications. The
design of various components, sub-assemblies and assemblies
shall be so done that it facilitates easy field assembly and
maintenance. All the rotating components shall be so selected
that the natural frequency of the complete unit is not critical at
or close to the operating range of the unit.
16.0 CO-ORDINATION MEETING
16.1 The Tenderer will be called upon to attend co-ordination

meetings with the Engineer, other Tenderers and the Owner
during the period of Contract. The Tenderer shall attend such
meetings at his own cost at Hyderabad or at any other venue
notified by the Owner/Consultant as and when required and
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fully co-operate with such persons and agencies involved

during those discussions.
17.0 TOOLS AND TACKLES
17.1 The scope of supply of the equipment shall include one (1)
complete set of all special tools and tackles required for the
erection, assembly, dis-assembly and maintenance of the
equipment. These tools and tackles shall be separately packed
and supplied at site.
18.0 NOISE LEVEL
18.1 The equivalent “A” weighed sound level measured at a

distance of 1.5 meters above floor level in elevation and one
meter horizontally from the base of any equipment furnished
and installed under these specifications, expressed in
decibels to a reference of 0.0002 microbar, shall not exceed
85 dBA.
19.0 EQUIPMENT BASES
19.1 A welded steel base plate shall be provided for all rotating
equipment, which is to be installed on a concrete base unless
otherwise agreed to by the Engineer. One common base plate
shall support the unit and its drive assembly and shall be of a
neat design with pads for anchoring the units, shall have a
raised lip all around and shall have threaded drain connections.
20.0 RATING PLATES, NAME PLATES AND LABELS
20.1 Each main and auxiliary items of plant is to have permanently

attached to it in a conspicuous position a rating plate of
non-corrosive material upon which is to be engraved the
manufacturer's name, equipment type or serial number
together with details of the loading conditions under which the
item of plant in question has been designed to operate and
such diagram plates as may be required by the Engineer.
20.2 Each item of plant is to be provided with a nameplate or label

designating the service of the particular equipment. The
inscriptions are to be approved by the Engineer unless already
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detailed in the appropriate sections of the Technical

Specifications.
20.3 Such nameplates or labels are to be of white non-hygroscopic

material with engraved black letter or, alternatively, in the
case of indoor circuit breakers, starters etc. of transparent
plastic material with suitably coloured lettering engraved on
the back.
20.4 Items of plant such as valves, which are subject to handling,

are to be provided with an engraved chromium plated
nameplate or label with engraving filled with enamel.
20.5 All such nameplates, instruction plates, lubrication charts etc.

shall be bilingual with Hindi inscription first, followed by
English. Alternatively two separate plates one with Hindi and
other with English inscriptions shall be provided.
21.0 MAINTENANCE AND OPERATIONAL ACCESS
21.1 All mechanical plant and equipment shall be readily accessible

to operation and maintenance personnel by the provision of
walkways, stairways, ladders and platforms as required for
plant operation, inspection, maintenance, overhaul and
cleaning purposes.
22.0 MAINTENANCE PROVISIONS
22.1 Where practicable, equipment shall be maintained in-situ

within the plant.
22.2 The plant shall however be designed to enable ready removal

and re-installation of equipment without the necessity of
dismantling structural steelwork or mechanical equipment not
related to the operation of the equipment being removed.
23.0 EQUIPMENT HANDLING
23.1 Provisions shall be made for the aided lifting of all items of
equipment, consumables, by-products or products weighing
more than 100 kg, which may require handling during
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construction of the plant or in the due course of plant

operation.
23.2 All items of equipment which may require regular maintenance

(once per year or more than once per year) and weighing more
than 50 kg shall be readily retrievable from its installed
position by wheeled trolley, forklift, mono-rail trolley hoist or
crane, on to road transport at grade level or to a designated
position where maintenance can be performed.
23.3 Where necessary, lifting wells and landing platforms with

removable hand railing shall be provided to facilitate
unimpeded access to grade level.
23.4 Monorail trolleys and cranes of more than 2 tonne capacity

shall have motorized lift and travel motions.
23.5 All lifting device attachment locations on equipment shall be

specifically designed to ensure:
The ready and safe attachment of the lifting gear.

Stable lifting of the equipment.
The lifting loads are safely accommodated and
That the equipment is not damaged.
24.0 SUPERVISION DURING ERECTION, TESTING &

COMMISSIONING
Tenderer should ensure presence of Manufacturer / Designers

of all equipment / system’s representatives at site during
erection, supervision and commissioning of the equipment and
the overall system.
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CHAPTER NO. C PAGE No. 1 of 4
CHAPTER-C
GENERAL SITE INFORMATION
1.0 LOCATION AND ACCESSIBILITY
1.1 The blocks ‘B’ and ‘C’ of Kumaraswamy deposits are situated
at the Southern closure of two hill ranges in Bellary- Hospet
sector and easily accessible by approx. 8.5 km kachha road
available from Ranjitpura village. Alternatively, the deposit
can be approached from Sandur, Tehsil head quarters
through an existing public road by a distance of 15 km. The
deposit is situated at a distance of 60 km from Bellary, Dist.
head quarters and 50 km from Hospet, a mining town.
1.2 The Donimalai Township is already connected by direct bus

services from the state capitals Bangalore and Hyderabad.
The nearest railhead for passenger services is Toranagallu at
a distance of 22 kms from Donimalai Township.
1.3 The distance of Kumaraswamy project from Bangalore and

Hyderabad by road is about 360 km and 460 km
respectively. The Chennai outer harbor is connected by a 600
km BG railway line from Ranjitpura railway station and it is
connected to western coast via Sanvardom by about
389 kms.
2.0 CLIMATE
2.1 The area receives an annual rainfall ranging from 600 mm to

800 mm. The predominant rainy season in this area is
between July and October. Rain also occurs occasionally in
the months of November and January due to northeast
monsoon. The maximum temperature is around 400 C in
summer while minimum temperature is around 150 C in
winter, which occasionally goes to as low as 120 C.
2.2 The above information is for the Tenderer’s general guidance

only and does not relieve him in any of his responsibilities to
NMDC LIMITED MECON
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satisfy himself of the site conditions and sufficiency of his

Tender.
3.0 SOURCE OF WATER
3.1 For the facilities planned at tail end side of down hill
conveyor, the filtered water shall be drawn from the
overhead tank near service centre for dust suppression
system, drinking water, sanitary purposes, etc. and from the
dedicated water tank near the service centre for fire
suppression system.
3.2 For the facilities at Donimalai (i.e for TH-3, TH-4, TH-5, TH-6
& connected conveying systems) the filtered water shall be
drawn from the main pipe line proposed from Donimalai
water supply system to hill top.
4.0 SOURCE OF POWER
4.1 For the facilities envisaged at tail end side of down hill
conveyor, the power shall be made available at 6.6kV switch
gear at 33/6.6kV sub-station near crushing plant
4.2 For the facilities at Donimalai (i.e for TH-3, TH-4, TH-5,
TH-6, conveyors 727, 727-1, 727-2, etc.), power shall be
made available from the existing 11kV sub station at
Donimalai.
5.0 METEOROLOGICAL DATA
5.1 Meteorological data of the project site is furnished in the

following Table.
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Relative Humidity Wind Velocity (km/hr) Temperature ( °C )

Month Rainfall (mm)
Max. Min. Max. Min. Max. Min.
Jan-96 77 42 9.4 2.7 26 17.5 0
Feb-96 81 27.5 29 0.1 31.5 16 0
May-96 91 24 32.7 0 37 24 0
Jun-96 96 44 98.2 0 34 17.5 226.4
Jul-96 91 48.5 26.3 5.3 29 20 0.5
Oct-96 96 59 68.3 0 27 15 192
Nov-96 95 28.2 50 0.1 29 12 17
Dec-96 99 50 90 0.9 26 12 55.6
Mar-97 91 45 29.4 0 32 18 20.6
Apr-97 99 20.1 47.3 0 33 16 16.9
May-97 99 24.7 60.7 1.6 34 18 6.7
Jun-97 78 45 58.3 0 34.5 16 48.4
Oct-97 95 32 23.7 0 29 19 71.4
Nov-97 95 38 25.7 2.1 28 19.5 80.6
Dec-97 95 38 36.1 2.3 27 18.5 100.2
Apr-98 96 26 40.2 0 34 16 3
May-98 96 35.3 72.4 1.2 33.3 16 42.26
Oct-98 96 47 80 1.7 28 19 298.2
Nov-98 95 40 32.2 1.7 27 17.5 54.3
Dec-98 95 36 49.9 2.2 26 12 0
Mar-99 91 31 28.4 <1.6 33 20 0
Apr-99 91 45 38.5 1.8 34 19.5 0
May-99 95 48 49.4 3 34 19 14
Nov-99 95 66 22.6 0.7 24 18 5.4
Dec-99 95 45 16.7 0.2 28.5 15.5 2.5
Jan-00 95 29 15.4 0.2 30 16 0
Feb-00 95 25.5 20.3 0.5 30 16.5 0
Dec-00 88 51 28.6 <1 25 13 0
Jan-01 87 53 24.6 <1 27 17 0
Feb-01 71 46 22.2 <1 31.5 18 0
Mar-01 75 39.5 27.1 0.3 34 19 0
Apr-01 96 40.5 28.4 0.2 33.5 19.5 0
May-01 91 44 81.9 0.3 33 20 0
Oct-01 96 50 31.01 0 28 17 249.63
Nov-01 96 58 12.01 1.88 27.5 18 3.81
Oct-02 94.5 38.5 10.8 0.6 28.5 13 24.5
NMDC LIMITED MECON
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Relative Humidity Wind Velocity (km/hr) Temperature ( °C )

Month Rainfall (mm)
Max. Min. Max. Min. Max. Min.
Nov-02 95 28.5 14.1 0.5 28.5 15 0

Dec-02 90.5 37 63 <1 26.8 17.5 0
Jan-03 90 34 37.7 1.7 25 15 0
Feb-03 95 30 26.8 1.7 30.5 18.5 0
Mar-03 78 32 23.2 <1 34.5 21 0
Apr-03 74 31 41.9 <1 35.5 22 7
May-03 70 29 59 1.6 36.5 23.5 0
Oct-03 91 43.5 37.4 <1 26 18 0.6
Nov-03 95 35 28.4 0.4 26 16 14
Jan-04 83 40 16.2 1.5 26 18 0
Feb-04 81 41 13.2 2 29 16 0
Apr-04 76.6 44.6 35.1 <1 40 21 0
May-04 86.7 58.3 35.7 1.4 33 20 0
Oct-04 84.9 73.5 14.1 3.1 26 19 7
Nov-04 86.8 60.5 28.8 1 28.5 17 2
Jan-05 90 29 12.3 4.9 30 13 4.3
Feb-05 88 22 20.1 <1 30 15 0
Apr-05 98 29 19.21 1.54 32.5 18.5 18
May-05 96 29 21.23 2.68 35 23 491
Oct-05 96 36 20.8 <1 29.5 17.5 161.5
Nov-05 95 36 22.4 <1 25 15.5 15
Dec-05 92 37 18.2 <1 26 14 0
Jan-06 82 51 19 <1 28.5 13.5 0
Mar-06 56.6 34.6 11 2 30.3 24.8 0
Apr-06 58.3 30.5 14 1 39.6 16.8 10.1
May-06 59.7 25.6 24 2 39.1 18.7 4.7
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CHAPTER NO. D PAGE No. 1 of 12
CHAPTER - D
SCOPE OF WORK AND BATTERY LIMITS
1.0 SCOPE OF WORK
1.1 The scope of the Tenderer of this package starts from

Conveyor no.718 receiving output from Scalping Screen and
the Secondary Cone Crusher. The material from the above
conveyor will be conveyed to the existing Screening Plant at
Donimalai through a system of conveyors including 4.9 km
long single flight down hill conveyor no. 723. The material
from Kumaraswamy mines will be discharged at the extended
tail end of existing Donimalai Tripper Conveyor no. 122 at
new Transfer House no. TH-4 for further conveying to the
existing screening plant. Also, Iron Ore from Donimalai will
be tapped from the existing tripper conveyor no. 122 (by
extending the travel of the tripper on conveyor no. 122) and
conveyed to the proposed conveyor to new screening plant at
Transfer House no. TH-3 through system of conveyors & also
by reversing the conveyor no. 727. Provision will also be
kept in the system at Transfer House TH-3 for feeding the
material from Kumaraswamy mines to the proposed new
screening plant.
1.2 Overall scope of work covered under this package is

furnished in the following paragraphs. Detailed scope of work
and battery limit under civil, structural, mechanical, electrical
etc. furnished in the respective chapters Q1 to Q10 shall be
complementary to the scope given here in under.
1.3 The units and facilities considered under this package are
broadly indicated in the Tender drawings enclosed with this
document (Refer Chapter “L” – List of Tender drawings). The
dimensions, sizes, facilities, levels and other details furnished
in these drawings are indicative only. Tenderer must
envisage, design and provide facilities as per the overall
requirement suitable for proper operation, maintenance and
satisfactory performance of the system to achieve
performance guarantee parameters.
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1.4 Scope of work / services enumerated below shall be

considered by the Tenderer, even if the same is not indicated
in the respective chapters.
2.0 OVERALL SCOPE OF WORK
The scope of services under this package shall be taken up

on Lump Sum Turn Key basis.
2.1 The scope of work shall cover design, engineering,

manufacture, supply of equipment including spares for 2
years normal operation, insurance spares, interconnected
chutes, valves and fittings, hoisting and handling equipment,
shop testing, painting, packing & forwarding, transportation
to site, loading, unloading & storage at site, comprehensive
insurance, site fabrication, assembly at site, erection, all site
testing, painting at site, integration and commissioning,
handing over and performance guarantee of the plant &
equipment, civil & structural works, soil investigation &
survey, electrical, instrumentation & automation works,
illumination, air conditioning & ventilation system, fire
detection & suppression system, fire fighting facility,
preparation of drawings and documents, training of personnel
etc. and others as required to make the plant complete in all
respects for operation & guaranteed performance to meet the
specifications indicated in this document for systems covered
under package-II .
2.2 All work, facilities and services required for successful

commissioning of the system are to be included in the scope
of this tender whether specifically mentioned in this
document or not.
2.3 The plants / units / equipment specified under Chapter-D &

Chapter-Q1 to Q10 shall be deemed to be complete in all
respects. The completeness in respect of auxiliary equipment
or accessories not specified with specific parameters shall be
as per the requirement of the main plants / units.
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2.4 Any equipment, fittings, materials or supplies which may not

be specifically mentioned in the specification or drawings but
which are necessary for smooth and normal operation of the
plants / units / equipment under this contract shall be
provided by the contractor without any commercial
implication. The plants / units / equipment must be complete
in all respects and shall be in perfect running condition, as
individual plants / units / equipment, as well as integral with
the total plant / unit / equipment covered under this contract.
2.5 The equipment furnished shall be complete in every respect

with all mountings, fittings, fixture and standard accessories
normally provided with such equipment and/or needed for
erection, completion and safe and efficient operation of the
plant and systems as required by applicable codes/practice
although may not have been specifically detailed out in the
technical specification unless included in the list of exclusion.
2.6 The scope indicated in Technical Specification shall be

complimentary to the scope given above.
2.7 The scope shall include, but not limited to, the following plant
and equipment, structures, facilities and services:
i) Conveyor no. 718 for conveying Iron ore from scalping

screen and secondary cone crusher to transfer house TH-1
along with belt weigh scale and inline magnetic separator.
ii) Transfer House TH-1 at head end of conveyor no. 718.
iii) Conveyor no. 719 for conveying Iron ore from transfer house
TH-1 to top of RCC silo along with metal detector.
iv) RCC silo of 1000T effective storage capacity with structural

shed over the silo.
v) Belt feeder no. 720 (with VFD) at the bottom of RCC silo
along with inline magnetic separator.
vi) Transfer House TH-2 at the head end of belt feeder no. 720 &
tail end of conveyor no. 721.
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vii) Tail / drive house at tail end of down hill conveyor no. 723.
viii) 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 / rectangular gantry for the conveyor
c. RCC / structural trestle
d. State of art electrics with controlled starting & braking
system
xii) Parking / maintenance shed PS-2 for traveling trolley near

head end of down hill conveyor no. 723.
xiii) 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
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conveyor no. 122 to Transfer House TH-3 in reverse direction

for further conveying to the proposed new screening plant.
xv) Transfer House TH-4 at head end of reversible conveyor 727.
xvi) Extension of tail end of existing tripper conveyor no. 122 by

approx. 12m from the existing Transfer House (at head end
of existing down hill conveyor 121 & tail end of existing
tripper conveyor no. 122) to Transfer House TH-4 at head
end of reversible conveyor no.727 to receive material from
reversible conveyor no. 727.
xvii) Extension of travel of tripper on existing tripper conveyor

no. 122 by 28m approx. (towards tail end of conveyor
no. 122) in order to tap the material from the above tripper
& feed the same to reversible conveyor no. 727 in reverse
direction at Transfer House TH-5.
xviii) Transfer Station at the tail end of conveyor 727-1 (for

receiving material from the extended position of the tripper).
xix) Conveyor 727-1 from above transfer station to Transfer

House TH-6.
xx) Transfer House TH-6 at the head end of conveyor 727-1.
xxi) Conveyor 727-2 for conveying material from Transfer House

TH-6 to Transfer House TH-5. The above conveyor will feed
material to reversible conveyor 727 in reverse direction so
that the same can be conveyed to the proposed new
screening plant through a conveyor from Transfer House
TH-3.
xxii) Transfer House TH-5 at the head end of conveyor 727-2.
xxiii) Handling and hoisting facilities including cranes, hoists for

Transfer Houses, Tail/drive house of down hill conveyor,
parking/ maintenance stations for traveling trolley, top of
RCC silo, etc. and electric winch for belt changing.
xxiv) Dust suppression facility (dry fog type), air–conditioning and

ventilation facility wherever specified.
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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.
xxxi) Complete civil construction work including 1000T (effective

storage) RCC silo with liners, trestles for down hill conveyor
(for height less than 12 m), foundations for conveyor trestles
& transfer house columns, MCC and control room / battery
room, etc.
xxxii) 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.
xxxiii) Approach road to TH-3 from the kachcha road already

developed by NMDC.
xxxiv) 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.
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xxxvii) Fire fighting system (Fire extinguishers)
xxxviii) Complete structural work including structures for transfer

houses, maintenance platforms, technological structures,
conveyor galleries, trestles, etc.,
xxxix) Water Supply and sewerage disposal system as required at

TH-1, TH-2, TH-2A, RCC Silo, Tail/ drive house of down hill
conveyor, TH-3, TH-4, TH-5, TH-6 Control Room/MCC rooms,
etc.
xl) Drawings and documents including operation and

maintenance manuals.
xli) Training of Owner’s personnel.
xlii) Soil investigation and survey, if necessary.
xliii) Office building for accommodating the offices of the operating

and maintenance personnel.
xliv) Electrical cum Control rooms required for accommodating the

different electrical equipment, control station, PLC, etc.
xlv) Provision for belt changing including a hardstand area of

300 m x 10 m at 2 locations along with suitable approach
from the existing road for laying of belt.
xlvi) Any other facility required to complete the plant as per the
system requirement.
3.0 DESIGN CRITERIA
3.1 General
3.1.1 This specification is for Engineering, procurement,

manufacture, testing, supply and construction of Downhill
Conveying System including all infrastructure and auxiliary
facilities required for the system. All work, facilities and
services, required for successful commissioning the system
are included in the scope of work of this specification whether
specifically mentioned in this specification or not.
NMDC LIMITED MECON
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3.1.2 The Tenderer shall study the specification and satisfy himself
thoroughly regarding the workability and suitability of the
equipment and system offered by him. He shall take full
responsibility for the guaranteed and satisfactory
performance of the system.
3.1.3 All working parts shall be arranged for convenience of

operation, maintenance, inspection, lubrication and ease of
replacement with minimum downtime. All like parts on
equipment furnished or on duplicate equipment are to be
interchangeable. Efforts should be made to minimize the
variety of repetitive items like belts, idlers, bearings, etc.
Efforts shall also be made to maximize interchangeability.
3.1.4 All equipment shall be complete with adequate safety devices

wherever a potential hazard to personnel exists and with
provisions for safe access to personnel to and around
equipment for operation and maintenance functions. These
items will include not only those usually furnished with
elements of machinery but also the additional covers, guards,
handrails, etc. which are necessary for safe operation.
3.1.5 The layout indicated in the enclosed drawings is based on

survey carried out by NMDC. The actual data including
ground level, conveyor level, location of road, power lines
etc. may deviate from that indicated. As such the Tenderer
shall carryout detailed survey and soil investigation. It
will be the sole responsibility of the Tenderer to provide the
complete system including foundation based on correct
disposition of the existing structures, soil conditions.
3.1.6 The Tenderer shall carryout test of raw materials wherever

necessary for arriving at proper design parameters of
equipment to be supplied.
3.1.7 The location of some of the existing facilities/ equipment/

structures is tentative/ indicative. It shall be verified by the
Tenderer at site with respect to the actual data/ details of
equipment/ facilities existing and he shall provide system/
equipment/facilities matching properly with these, without
undue interference with existing structures/ facilities.
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3.1.8 All diversions, modifications, dismantling and reinstallation of

the existing facilities, if required for installation of proposed
system is included in the scope of the Tenderer. Such
diversions, modifications, dismantling of existing facilities
shall be carried out in a well planned manner including
reinstallation of dismantled structures, if required, without
causing disturbance to the normal operation of the existing
units.
4.0 CODES & STANDARDS
4.1 All equipment, systems and works covered under this

specification shall comply with all currently applicable
statutes, regulations and safety codes in the locality where
the equipment will be installed. All equipment and systems
shall comply in all respects with the requirements of codes
and standards as indicated in the various equipment
specification.
4.2 In case of non-availability of Indian Standards other

International standards of repute such as British/ DIN/
American/ JIS/ GOST etc. are acceptable. Where Indian
standards are available only approved equivalents of other
International Standards will be acceptable. Contractor /
Vendor shall furnish English translations of all standards to
be offered as approved equivalents to the Indian Standards
specified in this Technical specification.
4.3 In the event of any conflict between the codes and standards
referred to in this specification and the requirements of this
specification, the latter shall govern.
5.0 PROPOSED PLANT LAYOUT
5.1 The proposed layout of the plant has been shown in enclosed
tender drawings. However, the Tenderer shall design the
layout based on the size of the various plant & equipment
offered by them, their operation & maintenance requirement
etc.
NMDC LIMITED MECON
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5.2 The following aspects shall be given due consideration by the

Tenderer in finalizing the plant layout.
i) Logical and conspicuous location of various plant units

to render sequential flow of process and at the same
time optimization on communication system, pipelines,
cabling etc.
ii) Adequate clearances and access around equipment for

their normal operation, routine inspection and main-
tenance with specific regard to the emergency atten-
dance of the plant & equipment.
iii) Proper hook approach of cranes for handling and

maintenance of major equipment.
iv) To make use of natural ventilation and daylight to

reduce energy consumption.
v) The Transfer Houses TH-1, TH-2, TH-2A, TH-3, TH-4,

TH-5 & TH-6, tail / drive house of down hill conveyor,
RCC silo, parking / maintenance stations for traveling
trolley, etc. shall be designed with adequate clearances
and hoisting / handling facilities for the erection /
maintenance of conveyor drives, pulleys, etc.
6.0 TECHNICAL REQUIREMENT- BASIS OF PLANT DESIGN
6.1 The down hill conveying system shall be designed to operate

at a rated capacity of 1800 tph for which the system shall be
designed for a minimum capacity of 2000 tph.
6.2 The material characteristics are tabulated below:
1. Material Haematitic Iron Ore

2. Plant Capacity 7.0 million tones per year
3. Physical Characteristics of ROM Ore
a. Bulk Density 2.2 to 2.5 t/m3
b. Angle of Repose 35 Deg.
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c. Angle of Surcharge 20 Deg.

d. Moisture Content 4 to 5%
e. Specific Gravity 4.5 to 5.2
f. Abrasive work index Up to 0.9572
g. Compressive Strength 4500 kg/cm2 (approx.)
Highly Abrasive, Massive, Laminated
h. Nature of Ore
Compact Mass
i. %Fe (Approximate) 58 to 65
4. Size
From Secondary Crusher
a. and undersize chute of (-) 100 mm 100 %
Scalping Screen
5. Duty Condition Continuous
6. Rated Capacity 1800 tph
7. Design Capacity 2000 tph
7.0 BATTERY LIMITS AND LIMITS OF CONTRACT
7.1 The battery limit starts at the tail end of conveyor no. 718 (in
secondary crusher house) including the skirt board at loading
zone and ends at the existing tripper conveyor no. 122 with
regard to tail pulley extension & tapping of material from
tripper (travel extended towards tail end).
The foundations for the tail pulley & short posts of conveyor
no. 718 inside the secondary crusher building and the
conveyor gallery with gallery support & foundation up to 2m
from axis 2 of secondary crusher building is included in the
scope of package-I Tenderer. Package-II Tenderer shall
furnish the load data and other information for the above
foundations & gallery of conveyor no. 718 to Package-I
Tenderer for providing the same.
7.2 The scope of Electrics at tail end of down hill conveyor shall
start from tapping of 6.6 kV power supply from client’s 6.6kV
HT switch gear available at 33/6.6kV substation near
crushing plant. The scope shall include complete electrics and
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llumination of all conveyor galleries, Transfer Houses, etc.

including the electrical room.
For electrical equipment at TH-3, TH-4, TH-5, TH-6, etc.,

tapping of power supply at existing NMDC 11kV Donimalai
substation shall start from CICO panel. The supply of CICO
panel is also included in the scope of the Tenderer. However,
the I/C power supply (including cable) to CICO panel shall be
taken care by NMDC. The scope shall include complete
electrics and illumination of all conveyor galleries, Transfer
Houses, etc. including the electrical rooms.
7.3 The scope of civil and structural work starts 2m away from
axis 2 of Secondary Crusher building. The scope also
includes Transfer Houses, all conveyor trestles, leveling of
the areas for accommodating various facilities, approach
roads for all facilities, etc.
7.4 Water supply shall be from a take off point near outlet flange
of the main hill top reservoir located near the service center
(at FGL 1042.00 m (Abs)) for dust suppression system,
drinking water, sanitary purpose, etc.
7.5 Water supply shall be from a take off point near outlet flange
of the dedicated water reservoir for fire fighting system
located near the service center (at FGL 1042.00 m(Abs)) for
fire detection & suppression system.
8.0 STATUTORY CLEARANCES
The successful tenderer shall take the responsibility of

obtaining clearance from all statutory bodies including DGMS
with the assistance of NMDC Limited.
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CHAPTER NO. E PAGE No. 1 of 4
CHAPTER - E
PERFORMANCE GUARANTEE & WARRANTY
1.0 After the system is completely erected at Owner’s site, each

item/equipment shall be thoroughly inspected for correctness
and completeness of the installation and they shall be
subjected to final tests as to performance and guarantee to
be carried out in the presence of Tenderer or his
representative and OWNER or his representative to
demonstrate that the performance of the equipment
conforms to relevant standards and specification and meet
the requirements as given in this specification. The tests /
checks to be conducted shall be generally as under:
1.1 For conveyors and belt feeders, the load test shall be
conducted in stages. The equipment shall be run for 8 to 10
hours continuously at no load, 25%, 50%, 75% & 100% of
the rated capacities or at a rate mutually agreed upon
between Tenderer and OWNER / their representative. The
intervening period shall be available for making adjustments
and arrangements by the Tenderer as may be required.
1.2 All the specified speeds of the equipment shall be

measured under full load conditions.
1.3 Proper operation of the limit switches, safety

switches, speed sensors etc., shall be demonstrated by the
Tenderer in the presence of OWNER or his representative.
1.4 For the Down hill conveyor no. 723, proper functioning of the
braking system during normal braking and emergency
braking situations in all loading conditions shall be
demonstrated by the Tenderer in presence of OWNER or his
representative.
1.5 For the Down hill conveyor 723, proper training of the belt
specially in the zone of horizontal curvatures with no spillage
shall be demonstrated by the Tenderer for all loading
conditions, including at the designed capacity in the presence
of OWNER or his representative.
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1.6 For the Reversible conveyor no. 727, proper functioning of

the braking system during normal braking and emergency
braking situations in all operating conditions shall be
demonstrated by the Tenderer in presence of OWNER or his
representative.
1.7 During operation of the equipment at no load and at full load,

performance of all the drives shall be checked in respect of
current drawn by the motors, temperature rise, vibrations,
gear box noise and its heating, bearing heating etc.
Consumption of power shall be measured and compared with
the respective rated values.
1.8 Any other observations/tests felt necessary for judging

the performance of the equipment and as mutually agreed
between Tenderer and OWNER /Consultant shall be carried
out.
1.9 If during the test runs, there is an interruption exceeding 2

hours due to any cause other than power failure or
shortage of input materials for which the owner is
responsible, the test run shall be discontinued and fresh
date shall be decided mutually by both the parties.
1.10 For all auxiliary equipment/systems like hoisting / handling

equipment, dust suppression system, pumps etc., the PG test
shall be conducted for checking their functional requirements
as per specification.
1.11 The equipment / system shall be considered to have

performed satisfactorily when:
i) Material is delivered to the existing tripper conveyor

no. 122 at Donimalai, at the rated capacity of 1800 tph
as indicated in this specification with all drives and
accessories functioning properly.
ii) Material is tapped from the existing tripper conveyor

no. 122 and conveyed to the proposed conveyor at
TH-3 feeding material to new screening plant at the
rated capacity of 1800 tph through system of
conveyors including the reversible conveyor no. 727
(running in reverse direction ) with all drives and
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accessories functioning properly.
iii) The system runs successfully for a continuous period

of 03 days working in 3 shifts at the rated capacity
with in a test period of 1 week.
iv) The system availability in the PG test period is

minimum 95%.
v) The Tenderer successfully demonstrates a system

design capacity of 2000 tph with the starting/ running/
braking systems working satisfactorily for a period
mutually decided between the Tenderer and the
Owner.
1.12 Performance guarantee tests shall be conducted within 6

months from the date of commissioning.
2.0 LIQUIDATED DAMAGES (LD) FOR NON-FULFILLMENT OF

GUARANTEE VALUES
In case of non-fulfillment of the performance values, LD shall

be levied on the Tenderer. The LD to be levied for the
various guarantee parameters shall be as follows:
2.1 LD FOR NON-PERFORMANCE
In the event of performance not meeting the guaranteed

parameters, (Clause 1.11(i) above) the OWNER shall levy LD
at the rate of 1% of the total contract price for every 1%
shortfall in the performance or part thereof subject to a
maximum of 5% of the total contract price. The system
having shortfall in performance beyond 5% shall be rejected.
2.2 LD FOR NON-AVAILABILITY
The equipment availability shall be minimum 95% during the

Warranty period. For every 1% drop in availability, 1% of the
total contract price will be levied as LD, subject to a
maximum 5% of total contract price.
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3.0 WARRANTY
3.1 The system as well as equipment / components supplied shall

be guaranteed for a period of 12 months from the date of
successful commissioning during which the Tenderer shall
repair / replace any defective parts of the works performed
by him.
3.2 In case of non-availability, the Owner shall have the right to

encash the performance bank guarantee submitted by the
contractor.
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CHAPTER NO. F PAGE No. 1 of 9
CHAPTER-F
SURFACE PREPARATION AND PAINTING

1.0 GENERAL
1.1 This specification covers the materials, tools, facilities and

quality requirement for surface preparation and painting of
steel structures, equipment, piping, ducts, chutes etc.
1.2 The term "painting" referred herein covers rust preventive,

preventive and decorative coating along with surface
protection.
1.3 Surfaces made of aluminium, brass, bronze, stainless steel,

cast iron and other corrosion resistant alloys are not required
to be painted unless specified except for aesthetic purposes or
for identification bands.
1.4 All machined mating surfaces (eg. flanges ) shall be properly

cleaned, greased and protected before despatch.
1.5 The complete paint system for any item includes the
following activities
i) Proper surface preparation

ii) Application of primer coats
iii) Application of intermediate coats
iv) Application of finished coats
1.6 All the above coats shall be of quality paint products and of
approved make as stipulated in this specification. The work
shall also include supply of all paint materials as per
specification described herein and of approved quality.
2.0 SURFACE PREPARATION
2.1 Surface preparation being a pre requisite for any paint

application, shall be such as to clean the surface thoroughly
of any materials which will be conducive to premature failure
of the paint substrates.
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2.2 All surfaces shall be cleaned of loose substances and foreign

materials, such as dirt, rust, scale, oil, grease, welding flux,
etc. irrespective of whether the same has been spelt out in
the standards in order that the prime coat is rigidly anchored
to the virgin metal surface.
2.3 The acceptable surface preparation quality / grade are

described under each painting system. The procedures
covered are solvent cleaning, hand tool cleaning, power tool
cleaning and blast cleaning.
2.4 Solvent cleaning
The surface shall be cleaned by wiping, immersion, spraying

or vapour contacting of a suitable solvent or washing with an
emulsion or alkaline solution to remove oil, grease, dirt, old
paint, etc. Solvent cleaning shall not remove rust, scales, mill
scales or weld flux. Therefore, before application of paint,
solvent cleaning shall be followed by other cleaning
procedures as stated elsewhere.
2.5 Hand tool cleaning
The surface shall be cleaned by vigorous wire brushing done

manually to St-2 quality. This method effectively removes
loosely adherent materials, but would not affect residues of
rust or mill scales that are intact and firmly adherent.
2.6 Power tool cleaning
The surface shall be cleaned by electric or pneumatic tools to

St - 3 quality. The tools shall be used carefully to prevent
excessive roughing of surface and formation of ridges and
burns. This method will remove loosely adherent materials
but would not affect residues of rust or mill scales that are
firmly adherent.
2.7 Blast cleaning
The surface shall be cleaned by impingement of abrasive

materials, such as graded sand at high velocity created by
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clean and dry compressed air blast. This method will remove
loosely adherent materials as well as adherent scales and mill
scales. Prior to application of blast, heavy deposit of oil and
grease are removed by solvent cleaning and excessive
surface scales are removed by hand tools or power tool
cleaning. The surface shall be cleaned to Sa - 2 1/2 quality
i.e. 95 % of surface area is free from all rust, mill scales and
visible residues, foreign materials, etc. The blast cleaning is
not recommended for sheet metal work.
3.0 PRIMER PAINTS ( P )
Primer paints shall be applied only on dry and clean surfaces.
3.1 Primer paint P1 - ( Phenolic - Alkyd based )
A single pack air drying phenolic modified alkyd composition

with zinc phosphate as a primer paint.
Air drying time : • About 60 minutes (touch dry)

• Overnight (hard dry)
Dry film thickness : • 40 microns (min)

(DFT / Coat)
3.2 Primer paint P2 - (Epoxy based)
A two pack air drying Epoxy polyamide with zinc dust of at

least 92 % zinc dust on the dry film.
Epoxy content (% wt.) : • 8 to 10
Air drying time : • About 10 minutes (touch dry)

• 2 Hours (hard dry)

(DFT / Coat)
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3.3 Primer paint P3 - (Ethyl zinc silicate, EZS, based)
A two pack heavy duty zinc dust rich silicate primer which
protects the surface with just a single coat.
Total Solids (% wt.) : • 84 + 2
Density ( gm/CC ) : • 3.07 + 0.05
Air drying time : • To top coat 16 Hours

(DFT / Coat)
4.0 INTERMEDIATE PAINTS ( I )
These paints shall be applied over primer coats as an

intermediate layer to provide weather proof seal of primer
coats.
4.1 Intermediate Paint I -1 (Phenolic alkyd based)
A single pack high build phenolic based paint of synthetic

micaceous iron oxide.
Air drying time : • 4 to 6 Hours (touch dry)

• 2 Days (hard dry)

(DFT / Coat)
Temperature : • upto 100 deg C dry heat

resistance
Compatible with : • Primer P-1
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4.2 Intermediate Paint I -2
A two pack air drying high build epoxy resin based paint with
MIO.

• 7 days full cure

(DFT / Coat)
5.0 FINISH PAINTS ( F )
Finish paint coats shall be applied over primer coats and

intermediate coats after proper cleaning and touch up of
primed coats.
5.1 Finish Paint F-1
A single pack air drying high gloss phenolic alkyd modified

synthetic enamel paint suitably pigmented.

• 24 Hours ( hard dry )

(DFT / Coat)

Intermediate I -1
Colour : • Generally all shades
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A two pack air drying epoxy polyamide enamel suitably

pigmented.
• 7 days ( full cure )

(DFT / Coat)

Intermediate I -2
Colour : • Generally all shades
A single pack heat resistant silicon resin based paint with

leafing aluminium powder.

• 24 Hours ( hard dry )

(DFT / Coat)
Compatible with : • No primer except Primer P-3

(shall be applied on blast
cleaned steel surface)
Colour : • Smooth Aluminium.
6.0 PAINT APPLICATION
6.1 Paint shall be applied in accordance with paint

manufacturer's recommendations. Manufacture of paints,
mixing of paints, etc. shall be as per the IS codes of practice.
The work shall generally follow IS 1477 - 1971 ( Part II ).
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6.2 Paint shall not be applied when the ambient temperature is 5

deg C and below or 45 deg C and above. Also paint shall not
be applied in rain, wind, fog or at relative humidity of 80 %
and above unless the manufacturer's recommendations
permit. Application of paint shall be only by spraying or
brushing as per IS 486 - 1983 and IS 487 - 1985.
6.3 Each coat of paint shall be continuous, free of pores and of

even film thickness without thin spots.
6.4 Each coat of paint shall be dry sufficiently before application

of next coat.
6.5 The colour code to be followed during painting shall be

intimated to the successful Tenderer during finalisation of
order.
6.6 In the event of conflict between this general procedure for

painting and the paint manufacturer's specification, the same
shall be immediately brought to the notice of the
Owner/Consultant. Generally in cases of such conflicts,
manufacturer's specifications / recommendations shall
prevail.
6.7 General compatibility between primer and finishing paints

shall be certified by the paint manufacturer supplying the
paints.
6.8 Areas, which become inaccessible after assembly shall be

painted before assembly (after painting clearance has been
given by the inspecting authority) after requisite surface
cleaning as specified.
6.9 Surfaces which cannot be painted but require protection shall

be given a coat of rust inhibitive grease according to IS 958 -
1975 or solvent deposited compound according to IS 1153 -
1975.
6.10 Parts of steel structures embedded in concrete shall be given

a protective coat of Portland cement slurry immediately after
fabrication and after surfaces of this part is thoroughly
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cleaned from grease, rust, mill scales, etc. No paint shall be

applied on this part.
6.11 The proposed make, quality and shade of the paint shall have
the approval of the Owner/Consultant.
6.12 Zinc rich primer paints which have been exposed several
months before finishing coat is applied shall be washed down
thoroughly to remove soluble zinc salt deposits.
6.13 The machine-finished surfaces shall be coated with white lead

and tallow before shipment or before being put out into the
open air.
6.14 Total DFT for heat resistant paints should not exceed 100 -
120 microns, otherwise flaking occurs (as per paint
manufacturer's recommendations).
6.15 Heat resistant paints should be applied by brush.
7.0 PAINTING SCHEME
7.1 For a complete painting scheme of any item being painted,

all types of paints are to be procured from the same
manufacturer as approved by the Owner/Consultant.
7.2 Legend
SP - Surface preparation quality

(2) P-1 - Two ( 2 ) coats of primer paint type P-1
(1) I-1 - One ( 1 ) coat of intermediate paint type I -1
(2) F-1 - Two ( 2 ) coats of finish paint type F-1
DFT - Dry film thickness
Type of paint products like P-1, P-2, P-3, I -1, I -2, F-1,
F-2 and F-3 have been specified under earlier clauses.
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7.3 The painting scheme to be followed for various equipment /

structures is briefly given below for guidance to the Tenderer.
Sl. SP Painting scheme Total

Description
No At shop At site DFT
(1) I -1
1. Steel structure St 3 (2) P-1 + 205
(2) F-1
Mechanical (1) I -1
equipment (temp. +
not over 80 deg C) (2) P-1 (2) F-1
205
2. Both static and Sa 2 ½ Or Or
(260)
rotary equipment (2) P-2 (1) I -2
for indoor or +
outdoor duty (2) F-2
Equipment with
hot surfaces
3. Sa 2 ½ P-3 (2) F-3 100
(temp. 200 deg C
and above)
7.4 The painting schemes to be followed for Electrics, Civil works,

Structural works, etc. are appearing in the respective
chapters and the same shall overrule similar clauses, if any
appearing in this chapter.
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CHAPTER NO. G PAGE No. 1 of 3
CHAPTER-G
QUALITY ASSURANCE, INSPECTION AND

TESTING
1.0 GENERAL REQUIREMENT OF QUALITY ASSURANCE
1.1 All materials, components and equipment covered under the

technical specification for this Project shall be procured,
manufactured, tested, erected and commissioned as per a
comprehensive Quality Assurance Programme. It shall be the
primary responsibility of the Tenderer to draw up and
implement such a programme which shall be duly approved by
the Owner / their authorised Inspection Agency.
1.2 The detailed Quality Assurance Plan (QAP) for manufacturing

and testing of equipment shall be prepared by the Tenderer
and submitted for approval by the Owner / Owner’s Inspection
Agency.
2.0 INSPECTION AND TESTING
2.1 The equipment shall be inspected by the Owner and / or

Owner’s Inspection Agency at manufacturer’s works prior to
despatch. The equipment will be inspected as per the tests
pre-identified in the approved QAP to ensure conformity of
the same with relevant approved drawings, data sheets,
technical specification, National / International Standard.
2.2 The Tenderer shall finalise the QAP within the stipulated
schedule mentioned in the Purchase Order and the QAP shall
be submitted in four sets (Specimen blank QAP formats
enclosed as Annexure – A & B shall be adopted). In case of
any sub-contracting, the QAP shall be prepared by the
Tenderer in consultation with his sub-contractor to avoid any
complication later.
2.3 The Tenderer shall provide full and free access of the
Inspection Agency to the manufacturer’s works to carry out
any stage inspection to ensure the quality of the equipment
being manufactured.
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2.4 Only on readiness of the equipment and approval of all

relevant drawings & QAP, the Tenderer shall give “Inspection
Call” (Specimen blank format enclosed shall be adopted) to
the Owner & the Inspection Agency with a clear notice of 10
days for inspection. The Inspection Call shall be accompanied
by the manufacturer’s internal inspection report, test
certificates, purchase order, sub-purchase order, technical
specification, approved QAP and approved drawings / data
sheets. The Inspection Call without above documents shall be
ignored. In case of any approved subcontracting, only the
main Tenderer shall give the Inspection Call enclosing
internal inspection / test reports of the sub-contractor duly
verified by the main Tenderer. In case the equipment offered
for inspection is found not ready, all the cost of the visit of
the Inspection Agency shall be borne by the Tenderer.
2.5 The Tenderer shall furnish all relevant documents and test
certificates as required by the Inspection Agency during
inspection. Materials shall be tested only in recognised Test
House.
2.6 The Tenderer shall delegate a representative / coordinator to

coordinate with the Inspection Agency on all inspection
matters.
2.7 No equipment shall be offered for inspection in the painted

condition unless otherwise agreed by the Owner.
2.8 The Tenderer shall ensure that the equipment and materials
once rejected by the Inspection Agency are not reused in the
manufacture of plant and equipment. Where parts rejected
by the Inspection Agency have been rectified as per pre-
agreed procedure, such parts shall be segregated for
separate inspection and approval before being used in the
work.
2.9 The Tenderer shall carry out their internal inspection and
obtain clearance from statutory bodies as required for the
equipment prior to offering any such equipment for Owner’s
inspection.
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2.10 The Tenderer shall provide all required instruments, tools,

necessary testing and inspection facilities free of cost to carry
out the inspection. These instruments and testing machines
shall be calibrated by an agency of National / International
recognition and the calibration shall be valid during the
inspection period.
2.11 The Inspection Agency shall have the right to demand for re-
testing of any material / re-calibration of the instrument and
testing machine & the charges for the above will be borne by
the Tenderer.
2.12 Performance tests of any particular equipment which cannot

be conducted / demonstrated either partially or wholly at the
manufacturer’s works, shall be conducted after erection at
site in presence of Owner and their Inspection Agency. In
such cases, prior approval of the Owner shall be obtained.
2.13 No equipment shall be despatched before inspection and

issue of Inspection Certificate and despatch clearance from
the Owner / Inspection Agency.
2.14 In case of waiver category items, the same shall be pre-

identified in the QAP itself. For such items, the Tenderer shall
furnish necessary certificate, test reports, etc., as agreed
upon and indicated in the QAP. For these items also the
Tenderer shall obtain “Inspection Waiver Certificate” and
despatch clearance from the Inspection Agency before
effecting despatch of equipment.
2.15 The issue of Inspection Certificate / Waiver Certificate for any

equipment or component thereof does not absolve the
Tenderer from his contractual obligations towards subsequent
satisfactory performance of the equipment at site. Should
any equipment be found defective, in whole or part thereof
after receipt at site or during erection / commissioning and
testing shall be made good by the Tenderer free of cost.
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CHAPTER NO. H PAGE No. 1 of 18
CHAPTER-H
CONSTRUCTION, ERECTION, TESTING AND

COMMISSIONING
1.0 GENERAL
1.1 The Tenderer shall keep a competent representative who

shall be Resident Engineer and shall remain as `In-charge' of
Tenderer's work-site and also remain answerable to the
Owner / Consultant for all activities of the Tenderer at site.
Before his placement at site, the Tenderer shall submit his
bio-data to the Owner / Consultant for his approval.
1.2 The `Resident Engineer' shall supervise the work of all men of
the Tenderer working at site. He shall work in complete
harmony and co-operation with Owner's engineers and
manufacturer's engineers working at site. All statutory rules
and labour laws prevailing in the area must be observed by the
Tenderer. All safety measures against occurrence of accidents
must be taken effectively. Resident Engineer shall not be
withdrawn without written permission of the Owner /
Consultant. If any of the Tenderer's personnel is found
unsuitable for the job, the Tenderer shall remove him forthwith
and a suitable replacement shall be posted at site within a
reasonable time without any suffering to work. No
compensation for withdrawal of unsuitable or unqualified
person(s) from site or for posting suitable person(s) to site at
any stage of the project shall be allowed by the Owner /
Consultant.
1.3 The Tenderer shall execute the works in a professional

manner so as to achieve the target schedule without any
sacrifice on quality and maintaining highest standards of
safety and cleanliness.
1.4 The Tenderer shall co-operate with the Owner / Consultant

and any other Contractors/ Agencies working at site and
arrange to perform his work in a manner so as to minimise
interference with other Contractors’/Agencies works. The
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Owner’s Engineer shall be notified promptly of any defect in

other Contractor’s/Agencies works that could affect the
Tenderer’s work. If rescheduling of Tenderer’s work is
requested by the Engineer in the interest of overall site
activities, the Tenderer shall comply the same with. In all
cases of controversy, the decision of the Owner’s Engineer
shall be final and binding on the Tenderer without any
commercial implication.
1.5 The Owner’s Engineer may hold meetings of all the

Tenderers/Agencies working at Site at a time and a place to
be designated by the Engineer. The Tenderer shall attend
such meetings if called upon to do so, take note of the
decisions of the Engineer and shall strictly adhere to those
decisions in performing his Work.
1.6 The Tenderer shall be responsible for performance of his

Work in accordance with the specified construction schedule.
If at any time the Tenderer is falling behind the schedule, he
shall take necessary action to make good such delays by or
otherwise accelerate the progress of the work to comply with
the schedule and shall communicate such action in writing to
the Owner’s Engineer, satisfying that his action will
compensate for the delay. The Tenderer shall not be allowed
any extra compensation for such action.
1.7 The works under execution shall be open to inspection and

supervision by the Owner’s Engineer at all times. The
Tenderer shall give reasonable notice to the Engineer before
covering up or otherwise placing beyond the reach of
inspection any work in order that same may be verified, if so
desired by the Engineer.
1.8 The Tenderer shall comply with all the rules and regulations
of the local authorities, all statutory laws including Minimum
Wages, Workmen Compensation etc. All registration and
statutory inspection fees, if any, in respect of the work
executed by the Tenderer shall be to Tenderer’s account.
1.9 All the works such as cleaning, checking, leveling, aligning,

assembling, temporary erection, opening, dismantling,
surface and edge preparation, fabrication, machining,
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chipping, scraping, fitting-up, bolting/welding, etc., as may

be applicable in such erection and are necessary to complete
the work satisfactorily, are to be treated as incidental and the
same shall be carried out by the Tenderer as part of the
work.
1.10 Equipment and material, which are wrongly installed, shall be

removed and reinstalled to comply with the design
requirement at the Tenderer’s expense, to the satisfaction of
the Owner’s Engineer.
1.11 Throughout the period of construction of the Works the

Tenderer shall maintain the whole area of his operations in a
clean, tidy and safe condition and shall arrange his materials
in an orderly manner, all to the satisfaction of the Engineer.
1.12 All rubbish, etc. shall be systematically cleared from the

working areas and, if not removed directly from the Site,
shall be deposited at general collecting points provided by
the Tenderer and agreed with the Engineer, pending removal
from the Site. Where practicable, screening shall be provided
to prevent the ingress of dust and dirt to any part of the
Works. The Tenderer shall clearly state, in the appropriate
schedule, what provision is being made for disposal of waste
materials both on and off-site.
1.13 The Tenderer shall not cause pollution of the Site land
drainage system or any watercourse by waste products from
any source whatsoever. Whenever any pollution is
attributable to any act or omission on the part of the
Tenderer, the Tenderer shall clear the pollution as soon as
possible and make early arrangements to remedy the cause.
1.14 The Tenderer shall make himself familiar with all statutory
requirements relating to the discharge of effluent from the
Plant and shall take all steps to ensure that these are not
contravened by the disposal of effluent from the site. No
dangerous or noxious waste products, chemicals or materials
shall be disposed of, on or off the Site without proper
treatment to make the quality comply with environmental
regulation.
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1.15 The Tenderer shall take all necessary measures to ensure the
safe collection and disposal of waste oils pertaining to those
Works or plant for which he has responsibility and to ensure
the prohibition of any discharge of waste oils into surface
waters, ground waters or drainage systems of any kind and
any deposit and/or discharge of waste oils on to the ground
or floors of buildings and any uncontrolled discharge of
residues resulting from the processing of waste oils or the
cleaning of oil contaminated surfaces with solvents.
1.16 In the event that the Tenderer fails to comply with the
above, the Owner reserves the right to carry out such work
on his behalf and to recharge accordingly.
1.17 The Tenderer shall carry out all repairs to damage to roads,
drains, footways, paved areas, boundary walls and fences
etc. and clean all fouled roads and pavings etc., whether
public or existing at site, caused by or in any way attributable
to the handling/transport of plant or materials by the
Tenderer or any Sub-contractor and indemnify the Employer
against loss, damage or claims by the Local Authority or
others for damage to or fouling of roads, pavings etc., by
reason of unusual traffic or other causes.
1.18 The Tenderer shall at all times ensure that the public roads,
giving access to site, are kept clean of any materials
deposited by traffic from the Tenderer or his subcontractors.
The tenderer shall also ensure dust suppression of site roads.
1.19 The tenderer shall be responsible for the Watch and ward to
ensure security and safety of materials under the Tenderer's
custody.
2.0 ERECTION, TESTING & COMMISSIONING
2.1 General
2.1.1 The Tenderer shall furnish all labour, supervision, consumable

materials, tools and tackle and services necessary for
receiving, unloading and storing, transportation pre-assembly
at site, if required, complete erection, testing and
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commissioning of all items included to complete the plant

unit as specified in the specification.
2.1.2 Omission of any specific reference to any method, parts,

accessories or materials required for proper and efficient
execution of the work shall not, in any way relieve the
Tenderer from his responsibilities from providing such
facilities and performing the complete erection, testing and
commissioning at no extra cost to the Owner & without any
time over-run.
2.2 EQUIPMENT, MATERIAL & SERVICES TO BE PROVIDED

BY THE TENDERER
2.2.1 Receiving of materials.
2.2.2 Unloading of materials from ships, rails and other means of

surface or air transport carriages, clearing from ports and
customs.
2.2.3 Transportation / shifting of unloaded material to storage

area.
2.2.4 Proper stacking and storing of materials under Tenderer's

custody.
2.2.5 Checking of all materials with shipment list/consignment

note, reporting for missing or damaged items, repairing
damages and cleaning before erection, claiming from
insurance agencies etc.
2.2.6 Preservation of plant & equipment at storage area/ site.
2.2.7 Maintaining proper record of the materials and place of

storage for quick identification as and when required.
2.2.8 Issue of materials from stores and maintaining detail account

of the same as required.
2.2.9 Transportation/shifting of material from stores to erection

site.
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2.2.10 Final adjustment of foundation levels by chipping and

dressing, checking location, elevation etc. of anchor bolts and
grouting of anchor bolts and base-plates.
2.2.11 Pre-assembly at site after proper checking/overhauling as

required.
2.2.12 Erection and subsequent cleaning/flushing as required,

re-commissioning check to ensure correctness of erection.
2.2.13 Testing and commissioning services as required.
2.3 MAN/MATERIAL SUPPLY
2.3.1 The Tenderer shall furnish all labour (supervisory, skilled,

unskilled and administrative), all consumable materials,
transport vehicles, mobile cranes, other lifting devices,
hydraulic jacks, all erection tools, tackles and equipment,
precision levels including micro levels, dial and other gauges,
surface plates, straight edges, special tools like vacuum
cleaners, blowers, radiography and stress relieving
equipment, pumps and other equipment necessary for
hydro-testing, compressed air testing and all other necessary
implements in sufficient numbers as may be required for
timely and efficient execution of the contract. The materials
supplied shall be of the best quality, the specification and
quality of which have to be approved by Owner / Consultant.
2.4 SUPERVISION DURING ERECTION
2.4.1 The Tenderer shall be required to provide, at proper time, the

necessary supervisory engineers, supervisors and other
supervisory personnel duly qualified and in sufficient number
for transportation, erection, pre-commissioning and post
commissioning check up, start-up, testing and trial operation
of plants and equipment.
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2.5 SEQUENCE OF ERECTION WORK
2.5.1 All packing cases and packages shall be opened in presence

of the Owner or his authorised representative. Timber
packing cases shall be carefully opened to avoid damage to
materials or timber. Nails and packing strips should be pulled
out with suitable appliances and kept separately in a
container and not thrown away at random. All timber of
packing cases shall have to be sorted out and stored properly
at a suitable place as directed by the Owner / Consultant.
From time to time packing materials, timber, nails and strips
shall be delivered back to the Owner or otherwise disposed of
as directed by the Owner. The timber reclaimed from the
packing cases or any other material shall not be used by
Tenderer for rendering facility in the erection work or any
other job without prior permission of the Owner / Consultant.
All timber and packing materials shall remain the property of
the Owner.
2.5.2 Each material after stripping from boxes or received loose,

shall be carefully inspected, checked with shipping list and
identified with erection drawing if necessary. The Tenderer
shall be completely responsible to make all necessary
arrangements, application and follow procedure to process
claim on underwriters, obtain replacement/repair/rectify and
modify as required of all such damaged/defective/lost
equipment and material at no extra cost to the Owner in
order to execute the work in satisfaction to the Owner /
Consultant within the stipulated contract time.
2.5.3 Once the materials are inspected, the same shall be

preserved properly and adequately protected from theft and
deterioration or damage due to rain, storm, dust, and water,
tampering by causal visitors or workers. The Tenderer shall
prepare and maintain stores, ledgers and bin cards for all
materials in his custody.
2.5.4 Carrying out all repairs to damages that might have occurred
during transit and in subsequent storage or handling and
modifications and rectification work and replacement of all
lost parts, are under the Tenderer's Scope.
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2.6 ERECTION
2.6.1 Erection work shall be carried out in the manner and

sequence as may be directed by respective equipment
manufacturer's supervisory engineers and the Owner's
engineer.
2.6.2 As erection proceeds each assembled part before being

boxed up with a view to erecting it finally, shall be inspected
and approved by the concerned supervisor. Should any
defect be found out during such inspection, the Tenderer
shall make it good as per directives from Owner's engineer.
2.6.3 All necessary radiography shall be included in the scope of

work of the Tenderer. Tenderer shall furnish all instruments,
isotopes, films etc. for conducting radiography and equip
himself fully. Necessary operators of all testing equipment
shall be provided by the Tenderer. Dark room facilities with
air-conditioners for storing and processing radiography films
and equipment, as necessary, shall have to be arranged by
the Tenderer.
2.6.4 The equipment shall be placed on respective foundation or

support, leveled and aligned with precision measuring
instruments, checked for proper clearance between moving
and stationary parts wherever applicable and grouted on the
foundation.
2.6.5 All fabrication and engineering work incidents to erection, like

scaffoldings, structural forming for pre-assembly, transport
and erection etc. shall have to be done by the Tenderer at his
own cost. The structural steel required for such work shall be
arranged by the Tenderer. Also, any fabrication work like
cutting, grinding, welding, fitting up etc. which in the opinion
of the Owner / Consultant are incidental to the erection at
site shall have to be done by the Tenderer. Any defect in the
fabrication shall have to be rectified by the Tenderer at his
cost without any commercial/contractual implication.
2.6.6 All piping work shall be done as per approved drawings.
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2.6.7 Particular attention shall be given towards removal of buckles

and other forms of distortion.
2.6.8 Holes in plate work to assist in erection should be avoided.

Lugs required for erection shall be removed and projections
of weld shall be chipped and ground flush.
2.6.9 Misalignment in vertical joints shall not exceed 10% of plate

thickness or 1.5 mm, whichever is larger. Misalignment in
horizontal joints shall not exceed 20% of upper plate
thickness with a maximum of 3 mm for plate thickness above
8 mm and a maximum of 1.5 mm for plate thickness upto 8
mm.
2.6.10 All equipment shall be safe guarded from wind or other

external causes by providing suitable steel cables/guys until
completion of erection.
2.6.11 Welding sequence shall be adopted in such a way so as to

minimise distortion due to weld shrinkage and shall be got
approved from the Owner / Consultant prior to
commencement of work.
2.6.12 Welding shall not be carried out on wet surfaces and shall be
protected from high winds/rains/water.
2.6.13 All materials such as electrodes, gaskets, bolts, nuts, etc.

shall be of reputed make and conforming to relevant Indian
Standards. Prior approval of Owner / Consultant shall have to
be obtained before commencement of work. Manufacturer's
test certificate shall have to be provided when called for.
2.7 ERECTION OF BELT CONVEYORS
2.7.1 Conveyors shall be installed complete with idlers, pulleys,

take-up carriages, take-up weights, idler structures,
reducers, couplings, guards, drives, bases, motors and all
other equipment and accessories.
2.7.2 Belting shall be installed and joined by permanent hot

vulcanized splice. The splicing and vulcanizing of belt shall
be done by the Tenderer as per belt manufacturer’s
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instructions. Belting shall be installed in strict accordance

with manufacturer’s recommendation. The installation and
vulcanization of belts, both fabric and steel cord, shall be
carried out by persons having specific experience and
knowledge of job. If required, the Tenderer shall hire the
services of special agency for the job. All the tools and
consumables including vulcanizing equipment shall be
arranged by the Tenderer.
2.7.3 Drive station, head pulley and take-up pulley shall be

accurately aligned so that deviation of their longitudinal axes
with respect to each other as well as with respect to the
conveyor axis is within 3 mm.
2.7.4 Conveyor supports and idler supports shall be aligned both

with respect to plan and elevation.
2.7.5 Alignment of idler supports shall be carried out using optical

instruments. The deviation between the center line of central
horizontal idler with respect to the longitudinal axis of the
conveyor shall not exceed 2 mm. Deviation in height shall be
within + 2 mm.
2.7.6 Conveyor belt scrapers at head and tail pulleys shall be

adjustable for proper cleaning. Anchor bolts shall be
straightened where necessary.
2.7.7 Conveyor belt shall be mounted with the help of winch to be

arranged by Tenderer. Before spreading the belt, all the
idlers and pulleys shall be cleaned.
2.7.8 Special care shall be taken to align conveyor belts for no load
and loaded conditions. Conveyor idlers and pulleys shall be
mounted in their respective positions at right angles to
direction of belt travel for proper belt alignment.
2.7.9 The chutes and liners consisting of several parts shall be

assembled, erected and shall be completely welded together
with the stiffeners and fastened.
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2.7.10 Erection Tolerances
Unless specified otherwise by equipment manufacturers,

equipment shall be installed with the tolerances indicated
below:
a. Supporting structures for In height 3 mm,

drive pulleys, tensioning
pulley, intermediate frame, In horizontal plane –
electric motor, gearbox 1/1000 of length in mm.
and idler supporting
structure.
b. Driving pulley 1/1000 of length of pulley
in vertical plane.
c. Axis of conveyor and 3 mm in horizontal plane.
centerline of pulleys.
d. Tension pulley +2 mm in vertical plane
+2 mm in horizontal plane
e. Idler arrangements +2 mm in vertical plane
2 mm in horizontal plane
f. Deviation in conveyor 2 mm for 1 m length but
center line 15 mm max for total
length
g. Absolute bearing vibration
velocity (mms) for rotating
machines (to be measured
by vibration measurement
instrument)
i. Upto 15 kW Less than 0.7 mm / sec
ii. Above 15 kW Less than 1.1 mm / sec
2.8 EQUIPMENT INSTALLATION & WORKMANSHIP
The equipment installation and workmanship shall be as

follows:
2.8.1 Assembly of Equipment
a) Units, which due to weight, size or other consideration

arrive in a disassembled state, shall be assembled at
site.
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b) Protection of equipment from damage, dust and

exposure to corrosive factors shall be a prime
consideration throughout the period of installation,
commissioning and final handing over to owner.
2.8.2 Prior to installing equipment, related work of other trades

shall be inspected to ensure that anchor bolts, inserts,
sleeves, openings, foundations etc. are provided at the
proper time and in the correct locations and at the correct
level.
2.8.3 Lubrication
a) The Tenderer shall be responsible for the lubrication

requirements of all equipment from the initial run to
final lubrication before handing over to Owner. All
lubricants shall be supplied by the Tenderer for the
equipment supplied by them.
b) Equipment shall be lubricated in accordance with

manufacturer’s recommendation.
c) Bearings for driving and driven equipment shall be

checked and lubricated in accordance with the
manufacturer’s instructions.
2.8.4 All packing, glands and flange joints shall be checked and
tightened as necessary during trial runs and commissioning.
Should any packing or gasket or gland require renewal or
replacement during the period, such renewals shall be made
by the Tenderer from the materials to be supplied by him.
3.0 SAFETY REGULATIONS
3.1 Only scaffolds which meet the requirements of any governing

laws shall be used in the projects.
3.2 All burning and welding equipment shall conform to, and be
used in accordance with, regulations governing such
equipment. No burning or welding shall be done at any place
on the site until location where such work is to be done is
approved.
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Welding near/at/in hazardous areas (like gas/oil etc.) shall be

done only after having all the fire protection/fighting
equipment at hand.
3.3 Adequate fire protection shall be available before work shall

proceed.
3.4 All warning signs shall be observed.
3.5 Use of explosives shall comply with all regulations.
3.6 Tenderer shall require his employees to wear hard hats at all
times when they are in an area where they are in danger
from falling objects.
3.7 Goggles shall be worn whenever there is a possibility of flying

particles or splashing corrosive fluid.
3.8 Safety belts shall be used by men working in high places

when no handrails or other guards are in place.
3.9 Any loose materials like cotton/jute/oiled clothes etc. shall

not be thrown hither and thither but disposed to safe places
to avoid any accident/fire etc.
3.10 Tenderer shall be solely responsible for the dissemination of

all safety regulations including those written here, those
promulgated by Owner and those dictated by good practice,
and shall ensure that all his employees and those of his sub
Contractors are conversant with same.
4.0 Inspection
4.1 After completion of erection and/or installation and before

start-up, each plant and equipment and all its appurtenances
shall be thoroughly cleaned and then, inspected in the
presence of Owner's engineer for correctness, soundness and
completeness of installation and acceptability for start up.
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4.2 All works to be carried out by the Tenderer shall be subjected

to inspection by the Owner's Engineer as well as other
statutory inspection authorities. The work shall be carried out
as per applicable specifications, codes of practice, drawings
and instructions of Engineer and Boiler Inspectorate where
applicable. The Tenderer shall provide necessary facilities,
instruments, personnel etc. for carrying out the inspection as
above and shall comply with the instructions given.
4.3 A checklist in triplicate shall be furnished for the approval of

Owner / Consultant wherein all items to be checked and
necessary instructions shall be listed. Inspection and
checking shall strictly follow this check list. On conclusion of
the Joint Inspection and checking, two (2) copies of the
check list shall have to be handed over to the Owner /
Consultant. The check lists after checking shall have to be
jointly signed by the Tenderer's supervisor and the Owner's
Engineer to ensure that all inspection and checking have
been properly carried out. However, such endorsement shall
not relieve the Tenderer from the responsibility in ensuring
proper erection, cleaning & safety.
4.4 During inspection all clearance, alignment and important

measurements and adjustments as may be directed shall be
noted by the Tenderer for future reference and guidance.
Two (2) copies of such notes shall be delivered to the Owner
/ Consultant.
5.0 PRE-COMMISSIONING TESTING
5.1 After alignment of all equipment, alignment tests shall be

carried out by the Tenderer to check levelling, clearance,
eccentricity etc. Measurements shall be witnessed and
acceptance shall be certified by the Owner / Consultant.
5.2 Hydro testing shall be conducted for all pressure parts after
installation at required pressure. All necessary blanking
arrangement for such hydro testing shall be furnished by the
Tenderer. All necessary test pump, temporary piping etc.
shall be supplied by the Tenderer.
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5.3 Other testing as mentioned in the various specification

enclosed shall be carried out.
5.4 After the hydrostatic tests, the Tenderer shall carry out
thorough flushing of all lines with water to the satisfaction of
the Owner / Consultant. After the flushing, all water shall be
drained and the piping shall be dried by blowing air or other
approved method.
5.5 During flushing the velocity of fluid shall be maintained as

close as possible to the operating velocity.
5.6 The cleaning sequence and the temporary arrangements for

the same shall be developed by the Tenderer and got
approved from the Owner / Consultant.
5.7 Supply of all instruments, temporary piping, instrument

calibration, pumps etc. for cleaning and testing shall be
under the scope of the Tenderer.
5.8 Modifications/rectification as felt necessary by the

Owner's/Consultant's Engineer/Inspector shall be carried out
at no extra cost, to meet the specified performance.
6.0 START-UP (PRE - COMMISSIONING)
6.1 On completion of erection of the equipment and before the

start-up, equipment shall be inspected by the Owner/Engineer
and the Tenderer for correctness and completeness of
installation and acceptability of start up, tending to initial
pre-commissioning tests at site. The list of pre-commissioning
tests to be performed shall be as mutually agreed and included
in the Tenderer's quality assurance programme.
6.2 The Tenderer's Engineers for commissioning and start-up

specifically identified shall carryout all the pre-commissioning
tests at site. On completion of inspection, checking and after
the pre-commissioning tests are satisfactorily over, the
complete equipment shall be placed on initial operation
during which period the complete equipment shall be
operated integral with sub-systems and supporting
equipment on no load, on successful completion of which the
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consultant / Owner will issue Preliminary Acceptance

Certificate.
7.0 TRIAL OPERATION AND COMMISSIONING
7.1 The plant shall then be on Trial Operation during which period
all necessary adjustments shall be made by the Tenderer while
operating over the full load range on enabling the system to be
made ready for commissioning
7.2 The duration of Trial Operation of the complete equipment /

system shall be as mutually decided between the tenderer and
Owner / consultant . The Trial Operation shall be completed
successfully provided that each item of the equipment can
operate continuously at the specified operating characteristics
for the period of Trial Operation.
7.3 During the period of Trial Operation, minor interruptions

caused during the continuous operation shall not affect the
total duration of Trial Operation. However, if in the opinion of
the Engineer, the interruption is long, the Trial Operation shall
be prolonged for the period of interruption.
7.4 A Trial Operation report comprising of observations and

recording of various parameters to be measured in respect of
the above Trial Operation shall be proposed by the Tenderer.
This report, besides recording the details of the various
observations during trial run, shall also include the dates of
start and finish of the Trial Operations and shall be signed by
the representatives of both the Owner/Consultant and the
Tenderer. The report shall have sheets, recording all the
details of interruptions occurred, adjustments made and any
minor repairs done during the Trial Operation. Based on the
observation, necessary modifications and/or repairs to the
plant shall be carried out by the Tenderer to the full
satisfaction of the Owner / Consultant. The system is
commissioned on successful completion of trial runs, when the
complete system operates for a continuous period of 72 hours
during which the individual systems / plants and the project as
a whole achieves 66.67% of rated capacity. On commissioning,
the Owner / consultant will issue Commissioning Certificate
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to enable the tenderer to carry out performance guarantee

tests.
7.5 After successful commissioning, the plant will be taken over

and will be operated by the Owner under overall supervision of
the Tenderer.
8.0 Performance Guarantee Tests
8.1 The final tests to demonstrate the performance guarantees

shall be conducted at Site, by the Tenderer in association with
the Owner. Such tests will be completed within six (6) months
from the date of commissioning.
8.2 These tests shall be binding on both the parties of the Contract
to determine performance of the equipment with the
performance guarantees.
8.3 The required instrumentation and control equipment shall be

made available during such tests. The Tenderer will calibrate
and submit calibration certificates of all such measuring
equipment and devices as far as practicable. However non-
measurable parameters shall be taken into account in a
reasonable manner by the Engineer, for the requirement of
these tests. The Engineer will apply corrections in calculation
as he may consider proper to take into account conditions
which do not correspond to the specified conditions.
8.4 Any special equipment/ instrument, tools and tackles

required for the successful completion of the Performance
Guarantee Tests shall be provided by the Tenderer, free of
cost.
8.5 The guaranteed performance figures of the equipment shall be

proved by the Tenderer during these Performance Guarantee
Tests. Should the results of these tests show any decrease
from the guaranteed values, the Tenderer shall be required to
modify the equipment to enable it to meet the guaranteed
performance. In such case, performance guarantee tests shall
be repeated within one (1) month, from the date the
equipment is ready for re-test and all cost for modifications
including labour, materials and the cost of additional testing to
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prove that the equipment meets the guarantees, shall be

borne by the Tenderer.
8.6 The specific tests to be conducted on equipment / system shall

be as specified in the Technical Specifications under Chapter-E.
Final Acceptance Certificate will be issued by the Owner on
successful completion of performance guarantee tests and
after the Tenderer has completed all his obligations.
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CHAPTER NO. I PAGE No. 1 of 6
CHAPTER-I
ENGINEERING SERVICES
1.0 GENERAL
1.1 The Tenderer shall be responsible for providing all

equipment, material and services including design and
construction of all civil, structural and architectural works
specified or otherwise which are required for a complete
plant meeting the intent of this specification, ensuring high
degree of reliability, availability, operability and
maintainability. The equipment, system/sub-systems and
components shall conform in all respects to high standards of
engineering, design and workmanship and shall be capable of
performing in continuous commercial operation in a manner
acceptable to the Owner and shall also be in line with the
current practices for reliable and efficient functioning of
plants of similar size and rating.
1.2 The Tenderer shall render complete engineering services for

the project including complete detailed engineering, design
submission and documentation as specified and as required
for a good design and installation ensuring efficiency,
operability, availability, maintainability and reliability of the
plant and efficient archiving of plant documentation for future
reference. As part of the overall project management
activity, the Tenderer shall be responsible for proper
engineering, co-ordination and management during various
phases of execution of the contract.
1.3 At any stage during the performance of the work, the

Owner/Consultant may require up-gradation/improvements
in the Contracted Plant and consequent modification in the
equipment/system designs in view of additional information
available at a later date(s) or feedback(s) received during
execution/operation of similar units. If so desired by the
Owner/Consultant, the Tenderer shall make the necessary
design modifications and carry out the up-
gradation/improvements in the Plant. Commercial and time
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implications of such action shall be mutually agreed between

the Owner/Consultant and the Tenderer.
1.4 It is not the intent to give details of every single task to be

carried out by Tenderer. However, all engineering, supply
and erection of plant and equipment work required for the
satisfactory completion of the plant/systems as specified
shall be carried out by the Tenderer. Broadly, the following
are the minimum requirements in respect of scope of major
items of work:
i) Tenderer shall submit design calculations, criteria for

selection and sizing of plant, equipment and systems,
for approval by the Owner/Consultant.
ii) Interface engineering and complete coordination work

among various sub-vendors of equipment/packages
included in the Tenderer’s scope.
iii) Preparation of detailed technical specifications

including data sheets, tender drawings and bill of
material for all bought out items, as also finalization of
corresponding sub-contractors.
iv) Review of sub-contractors data, drawings, design

calculations, schedules, bill of materials, instruction
manuals etc., for all equipment, before forwarding
them to Owner/consultant for approval.
v) Preparation of civil construction drawings for all

buildings and equipment showing foundation details
and full details regarding equipment loads, floor
openings, details of embodiments etc. These
documents shall be preceded by appropriate design
calculations, static and dynamic analysis as necessary.
vi) Preparation of structural design and fabrication,

drawings for all buildings, galleries showing foundation
details and full details regarding equipment loads, floor
openings, etc. These documents shall be preceded by
appropriate design calculations, static and dynamic
analysis as necessary.
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vii) Preparation of consolidated schedules and bill of

materials.
viii) Sizing of all equipment as per the stipulated design

criteria. Carrying out design calculations for all
conveyors, carrying out the dynamic analysis of
downhill conveyor in starting/running/braking in all
loading combinations including the calculations for the
horizontal curvature.
ix) Final revision of all documents.
x) Preparation and compilation of operating Manuals and

Maintenance Instructions.
xi) Preparation and submission of certified final as-built

drawings and documents for all areas.
xii) Preparation and submission of all erection and

assembly drawing schedules and instructions, which
may be required at, site.
xiii) Preparation and submission of procedure strategy for

erection of major equipment taking into consideration
the layout of plant and auxiliaries.
2.0 POST–CONTRACT STAGE DOCUMENT SUBMISSION AND

APPROVAL PROCEDURE
2.1 The Tenderer shall furnish a comprehensive and detailed

schedule of drawings and design documents, which shall be
submitted by him after award of contract indicating
submission dates against each document. The list shall be
subject to the approval of the Owner/Consultant.
2.2 The documents shall be divided into two categories:
i) For approval
ii) For information/reference only
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2.3 In preparing the schedule, the Tenderer shall allow three (3)
weeks for review and comments by the Owner/Consultant for
each submission of a document.
2.4 This schedule of drawing and design document submission

shall require approval by the Owner/Consultant before award
of Contract.
2.5 The number of sets of drawings / documents to be submitted

shall be the following unless specified other wise.
• Four (4) Sets to the Owner.

• Six (6) sets to the Consultant.
2.6 The successful Tenderer shall supply the following drawings/

documents at the time of delivery of equipment along with
soft copies of all the approved drawings/ reference drawings
and documents in a CD:
Refer Clause No. 4.0- of Chapter. N
2.7 Unless specified otherwise, the following categories of

documents shall require approval of the Owner/Consultant:
Refer Clause No. 1.0 of Chapter N
2.8 Unless specified otherwise, the following categories of

documents/drawings would be treated for
information/reference only. The Tenderer shall, however,
incorporate all additional information and clarifications in
these documents/drawings as and when desired by the
Owner/Consultant:
3.0 OPERATING MANUALS AND MAINTENANCE

INSTRUCTIONS
3.1 The Tenderer shall submit to the Owner/Consultant,

instruction manuals for all equipment / system covered under
the contract at least thirty (30) days before the first despatch
of the equipment.
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3.2 The operating manuals and maintenance instructions shall be

in sufficient detail to enable the Owner to operate, maintain,
dismantle, re-assemble, adjust or replace all equipment and
components during the life time of the plant. The manuals
shall be specifically prepared for the contracted plant. Only a
collection of manufacturer’s standard leaflets shall not be
acceptable as the manuals.
3.3 The operating manuals and maintenance instructions manual

shall be submitted in the form of one (1) reproducible
original and six (6) copies as well as two (2) copies in
compact disks (CDs).
3.4 The information provided shall include:
i. A complete inventory of all items of plant, with

identification details; procedure for ordering spares.
ii. Service manuals for all plant and equipment giving full
descriptions, drawings and specifications of the main
items and auxiliary items such as power packs,
hydraulic equipment, actuators, lubricating pumps,
thrusters for brakes, catalogues for major bought out
items, etc., performance/rating curves.
iii. A separate electrical manual covering items such as

switchgear, cabling, instrumentation, controls,
protection, cabling layouts and wiring diagrams.
iv. A schedule of recommendations of routine

maintenance of all electrical and mechanical
equipment, recommended inspection point,
information on detection, cause and rectification of
troubles and faults.
v. A lubrication schedule with all necessary drawings

diagrams to identify the lubrication points.
vi. Manufacturer’s literature / catalogues.
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3.5 The instruction manuals shall be subject to the approval of

Owner/Consultant.
3.6 If after the commissioning and the initial operation of the

plant, the instruction manuals require
modifications/additions, the same shall be incorporated by
the Tenderer and the updated final version of the manuals
shall be submitted.
4.0 SPARE PARTS CATALOGUES
4.1 The Tenderer shall submit ten (10) sets of spare parts
catalogues.
5.0 “AS-BUILT” DRAWINGS / DOCUMENTS
6.0 PLANT HANDBOOK
6.1 The Tenderer shall submit to the Owner, a plant handbook

which shall contain all approved design basis and design
calculations, the design and performance data of various
plant, equipment and systems covering the complete project
including single line flow diagrams, etc. prior to handling over
of the plant.
6.2 The plant handbook shall be submitted in ten (10) copies in

original along with four (4) copies in Compact Disks (CDs).
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CHAPTER NO. J PAGE No. 1 of 6
CHAPTER-J
PROJECT MANAGEMENT SERVICES

1.0 RESPONSIBILITY
1.1 The Tenderer shall identify a separate and independent

project management team headed by a Project Manager for
the execution of this project.
1.2 The responsibilities of the Project Management team shall

cover the following areas:
a) Planning and Monitoring

b) Engineering Management
c) Contracts Management
d) Quality Management
e) Construction Management
f) Site Management
g) Resource Control
h) Manufacturing and Production Control
2.0 ORGANISATION
2.1 The Tenderer shall furnish a detailed organisation chart for

the project management team, clearly identifying the key
personnel in each of the areas mentioned above. The
expected number of executives, managerial and supervisory
staff at different levels shall also be indicated separately for
headquarters, central coordination cell and site Organisation
indicating names, qualifications and experience.
2.2 The project management team at the head office shall be

headed by a senior level executive designated as the Project
Manager who shall be responsible to Owner/Consultant for
the execution of the project.
2.3 The site should have a competent Construction Manager for

all site operations with sufficient level of authority to take site
decisions. The organisation chart for site should indicate the
various levels of experts to be posted for supervision in the
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Civil, Mechanical, Electrical, and Control & Instrumentation

fields for construction, erection & commissioning of the
Project.
3.0 PROGRAMMES AND SCHEDULES
3.1 The Tenderer shall prepare an overall project schedule

identifying critical paths, priority activities and target dates
for completion of various activities using MS-PROJECT
software. Management information reports at 3 levels (level
1, 2 & 3) will be brought out for monitoring of the time
schedules.
3.2 The programmes supplied by the Tenderer as part of the

Contract shall fully inter-relate design, engineering, approval
of drawings by the Consultant /Owner, placement of order for
bought out items, manufacturer, erection and
commissioning. This shall also consider activities for finalising
of order on Civil, Structural contractors, electrical
contractors, erection contractors, obtaining approvals from
statutory bodies, etc. Events shall be identified in all
programmes and agreed with the Consultant. Events shall
indicate points in the programmes at which a significant
stage for reporting to management. All programmes
containing scheduled dates including those for design,
manufacturer and for site erection shall be adhered to by the
Tenderer and shall not be changed except as may be agreed
by the Owner/Engineer.
3.3 The Tenderer shall designate a Planning Representative who

shall be readily available at all reasonable times to the
Engineer and who shall be of sufficient status to have free
access to the Tenderer’s management staff and to the
Tenderer’s and Sub-Contractors workshops, site works etc.,
and shall be able to represent the Tenderer on all matters of
planning and progress.
3.4 Engineering Schedules
These schedules shall cover various design submissions

indicating different engineering activities to be performed.
Such schedules shall be furnished by the Tenderer for each and
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every plant/systems/equipment item covered in the scope of

this specification.
3.5 Manufacturing and Delivery Schedule
The Tenderer shall submit to the Engineer his manufacturing

and delivery schedules for all equipment within sixty (60)
days from the date of issue of the Letter of Acceptance. Such
schedules shall be in line with the detailed network for all
phases of the work of the Tenderer. Such schedules shall be
reviewed, updated and submitted to the Engineer, once in
every two months thereafter, by the Tenderer. Schedules
shall also include the materials and equipment purchased
from outside suppliers. In the despatch programme, the
Tenderer shall indicate a schedule of estimated programme,
tonnages specifically identifying various oversize
dimensioned consignments (ODC). All despatch details and
item lists shall be made available to both Owner/Consultant
& site immediately after shipping.
3.6 Erection Schedules
The Tenderer shall provide the Owner/Consultant all the

information covering erection sequence, testing and
commissioning activities. These schedules may be based on
the recommended erection procedures and will be subject to
discussions/agreements with the Owner/Consultant
subsequent to the award of contract.
3.7 The Tenderer shall provide the Owner/Consultant all such

schedules in electronic media within a time schedule to be
agreed between Owner/Consultant and Tenderer at the time
of award. The Tenderer’s project management software shall
be compatible with that of the Owner/Consultant and the
input data shall be furnished to the Owner/Consultant.
4.0 MONITORING & PROGRESS REPORTING, MANAGEMENT

INFORMATION SYSTEM
4.1 The progress reports shall be submitted every month, one

from the head office of the Tenderer and another from the
site office. Reports shall include such schedules, charts and
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drawings, as the Owner/Consultant considers necessary for

adequate monitoring the Contract. The report shall be made
available to the Owner/Consultant at least five working days
prior to scheduled progress review meeting.
4.2 The progress report should necessarily include the following

sections:
a) Report on key milestones

b) Management summary indicating critical areas with
details of actions initiated and effect on the project
schedule.
c) Detailed package wise status of engineering
submissions, quality plan submissions and approval,
procurement manufacture and dispatch, plan for
succeeding month, back log during month and plan for
making up the backlog.
d) Construction progress: Civil / Structural, Electrical,
Piping etc unit-wise.
e) Action needing attention of the Owner/Consultant.
4.3 In addition to the above, as the project execution progresses,

the Tenderer shall generate more frequent reports on
progress in critical areas so that actions can be expedited.
The exact format and contents of the progress reports shall
be finalized by the Tenderer in consultation with the
Owner/Consultant.
5.0 CONSTRUCTION MANAGEMENT
5.1 Based on the L-1 Master Network Program, within two (2)
months of the award of the Contract, the Tenderer shall
submit a program of construction/erection/commissioning,
either in continuation with the manufacture and dispatch or
separately for the implementation. These programmes would
be amplified showing when the civil drawings shall be
released by him and construction of civil works shall be
completed by him to facilitate start of erection and
subsequent activities and shall form the basis for site
execution and detailed monitoring. The three monthly rolling
programmes with the first month’s program being tentative
based on the site conditions would be prepared based on
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these L-3 programmes. The Tenderer shall also be involved

along with the Owner/Consultant to tie up detailed resource
mobilization plan over the period of time of the contract
matching with the performance targets.
5.2 Access for Progress Monitoring
The Owner’s Engineer or his nominated representative shall

be entitled at all reasonable times to visit all premises where
design and manufacturing of the plant is being carried out in
order to monitor and verify progress.
6.0 COMMISSIONING MANAGEMENT
a) For commissioning of the various equipment / system

covered under the scope of Contract, Owner will form
an organization structure which may consist of some
committees. The Tenderer shall nominate his
representative on one or more of the committee as
decided by the Owner/Consultant.
b) Testing/Commissioning Schedule
These shall be prepared for the various equipment/

systems under consideration and shall contain sections
like detailed testing method, programmes, safety,
individual responsibility and results.
c) Standard Check Lists
Standard checklists shall be prepared for use at the

completion of erection to ensure correct erection,
testing and operation
d) Instrument proving Schedules
These schedules shall be prepared for proving various

instruments associated with all equipment/packages.
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Note: Schedules and lists under items (b), (c) and (d) above
shall be submitted at least six (6) months before the actual
commissioning of the equipment/systems.
e) Test Reports
After the completion of commissioning activity of

equipment/systems, the Tenderer shall prepare the
test reports which shall include all the relevant
information related to various commissioning checks,
tests carried out, any deviations/commissions noticed
with respect to the intended design requirements,
sequence of various commissioning activities as
actually adopted vis-à-vis as recommended in the
procedures, programmes schedules achieved and any
other such information as required. These test reports
shall be submitted in requisite number of copies to the
Owner/Consultant and this should be duly signed
jointly by the Owner / consultant and the Tenderer /
Equipment supplier, who are involved during the
commissioning activities.
7.0 PROJECT PROGRESS REVIEW MEETINGS
7.1 Periodic project progress reviews will be held at least once

every month at the office of NMDC at Hyderabad for review
of site progress. These meetings will be attended by the
Tenderer and their leading sub-contractors. Decisions will be
taken to expedite/speed up the progress. Minutes of such
meetings will be issued and circulated to all concerned for
reference and action. The Tenderer shall be responsible for
ensuring that actions placed on him in such meetings are
carried out in time.
7.2 In addition to the above, a suitable frequency and forum of

periodic meetings between the Tenderer and the Owner’s
Engineer will be decided upon as part of erection coordination
procedure.
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CHAPTER NO. K PAGE No. 1 of 17
CHAPTER-K
SITE SERVICES
1.0 SCOPE OF WORK / SERVICES
Scope of work / Services to be covered by the Tender are the

following but not limited to:
1.1 Custody of all the materials till the plant is officially taken
over by the Owner after complete erection and successful
trial run and commissioning.
1.2 Comprehensive insurance for the plant, equipment and

materials.
1.3 Transportation of materials to their respective places of

erection and erection of the complete plant and equipment as
supplied under this specification.
1.4 Trial run and commissioning of individual equipment/sub-

systems and the plant as a whole to the satisfaction of the
Owner/Consultant, including supply of temporary equipment
and services for chemical cleaning, steam blowing as well as
performance guarantee tests.
1.5 Supply and application of the final paints on all the

equipment to be erected under this specification.
1.6 Deployment of all skilled and unskilled manpower required

for erection, supervision of erection, watch & ward,
commissioning and other services to be rendered under this
specification.
1.7 Deployment of all erection tools and tackles, construction

machinery, transportation vehicles and all other implements
in adequate number, capacity and size.
1.8 Supply of all consumables e.g. welding electrodes, cleaning

agents, diesel oil, lubricant etc., as well as materials required
for temporary supports, scaffolding etc as necessary.
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1.9 Construction of all civil, structural & architectural works,

including construction of foundation for all equipment
supplied as required, grouting of equipment on foundation
after alignment, and all the related activities as detailed
elsewhere.
1.10 Taking approval of all statutory authorities e.g. boiler

Inspector, Factory Inspector, Inspector of Explosives etc., for
respective portions of work under the jurisdiction of such
statutes or laws.
1.11 Quality assurance of all work executed at site.
1.12 Providing support services for the Tenderer’s erection staff

e.g. construction of site offices, temporary stores, residential
accommodation and transport to work site for erection
personnel, insurance cover, watch & ward for security and
safety of the materials under the Tenderers custody etc., as
required.
1.13 Maintaining proper documentation of all the site activities

undertaken by the Tenderer as per the Performa mutually
agreed with the Owner/Consultant.
1.14 Providing ‘Industrial Relations; unit and Medical’ unit to take

care of his erection staff. The Owner shall have no obligation
in this regard.
1.15 Taking clearance from statutory authorities wherever

applicable.
2.0 SITE ORGANIZATION
2.1 The Tenderer shall maintain a site organization of adequate

strength in respect of manpower, construction machinery and
other implements at all times for smooth execution of the
Contract. The organization shall be informed from time to
time, as required, to make up for slippages from the
schedule without any commercial implication to the Owner.
The site organization shall be headed by a competent
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construction manager having sufficient authority to take

decisions at site.
2.2 A separate Quality Control Department shall be included in

the site organization with adequate number of competent
quality control personnel, instruments etc., to ensure desired
quality standards of all site-works.
2.3 On award of Contract, the Tenderer shall submit to the

Owner/Consultant a site organization chart indicating the
various levels of experts to be deployed on the job. The
Owner/Consultant reserves the right to reject or approve the
list of personnel proposed by the Tenderer. The persons,
whose bio-data have been approved by the
Owner/Consultant, will have to be posted at site and
deviations in this regard will not be permitted.
2.4 The Tenderer shall also submit to the Owner/Consultant for

approval a list of construction equipment, erection tools,
tackle etc., prior to commencement of site activities. These
tools and tackles shall not be removed from site till
completion of commissioning and deviations in this regard
will not be permitted.
3.0 SITE RECORDS OFFICE
3.1 The Tenderer shall maintain suitability staffed records office

to maintain updated records of all relevant documentation
and test certificates and to see that these are available to
meet obligations to all statutory bodies and to any
commissioning committee, work in parties or test teams,
which are established to meet the needs of the Contract.
These records shall be maintained and retained until
handover on completion of all works on site and shall be
subject to Audit by the Owner/Consultant’s Engineer.
3.2 The relevant documents envisaged will include
a) Site Register for lifting appliances, cranes, slings,

hooks, lifting beams and tackle for construction of the
works either mobile or fixed.
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b) Site Register for lifting appliances, cranes, slings,

hooks, beams and tackle supplied as part of the
permanent works.
c) Scaffold Register.
d) Commissioning documents
e) Test Certificates from works and site.
i) Civil
ii) Mechanical
iii) Electrical
iv) Control and Instrumentation
f) Operation and Maintenance Instructions
g) Quality Assurance documents
h) Site Register for all portable electrically powered

apparatus and tools, both temporary and permanent.
i) Site Registers of all modifications carried out during

execution by deviating from the approved drawing
giving modification number against each. Such
modifications shall have to be authorized / approved
by the Owner’s Engineer.
j) Measurement, inspection & alignment protocols
k) Mechanical completion protocol.
l) Performance test protocols
m) Handing over / Taking over protocols
n) Final Acceptance Protocol
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4.0 GENERAL GUIDELINES FOR FIELD ACTIVITIES
4.1 The Tenderer shall execute the works in a professional

manner so as to achieve the target schedule without any
sacrifice on quality and maintaining highest standards of
safety and cleanliness
4.2 The Tenderer shall co-operate with Owner/Consultant and

any other Contractors/Agencies working at site and arrange
to perform his work in a manner so as to minimize
interference with other Contractors’/Agencies works. The
Owner’s Engineer shall be notified promptly of any defect in
other Contractor’s / Agencies works that could affect the
Tenderer’s work. If rescheduling of Tenderer’s work is
requested by the Engineer in the interest of overall site
activities, the Tenderer shall comply the same with. In all
cases of controversy, the decision of the Owner’s Engineer
shall be final and binding on the Tenderer without any
commercial implication.
4.3 The Owner’s engineer may hold meetings of all the

Contractors/Agencies working at Site at a time and a place to
be designated by the Engineer. The Tenderer shall attend
such meetings if called upon to do so, take note of the
decisions of the Engineer and shall strictly adhere to those
decisions in performing his work.
4.4 The Tenderer shall be responsible for performance of this

work in accordance with the specified construction schedule.
If at any time the Tenderer is falling behind the schedule, he
shall take necessary action to improve such delays by or
otherwise accelerate the progress of the work to comply with
the schedule and shall communicate such action in writing to
the Owner’s Engineer, satisfying that his action will
compensate for the delay. The Tenderer shall not be allowed
any extra compensation for such action.
4.5 The works under execution shall be open to inspection and

supervision by the Owner’s Engineer at all times. The
Tenderer shall give reasonable notice to the Engineer before
covering up or otherwise placing beyond the reach of
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inspection any work in order that same may be verified, if so

desired by the Engineer.
4.6 The Tenderer shall comply with all the rules and regulations
of the local authorities, all statutory laws including minimum
wages, workmen compensation, etc. all registration and
statutory inspection fees, if any, in respect of the work
executed by the Tenderer shall be to Tenderer’s account.
4.7 All the works such as cleaning, checking, leveling, aligning,

assembling, temporary erection opening, dismantling,
surface and edge preparation, fabrication, machining,
chipping, scrapping, fitting-up, bolting/welding, etc., as may
be applicable in such erection which are necessary to
complete the work satisfactorily, are to be treated as
incidental and the same shall be carried out by the Tenderer
as part of the work.
4.8 Equipment and material which are wrongly installed shall be

removed and reinstalled to comply with the design
requirement at the Tenderer’s expense, to the satisfaction of
the Owner’s Engineer.
4.9 It shall be the responsibility of the Tenderer to provide

ladders on columns for initial works till such stairways are
completed. For this, the ladder shall not preferably be
welded on the column and shall be prefabricated clamping
type. No temporary welding on any structural member is
permitted except under special circumstances with the
approval of the Owner’s Engineer.
5.0 SAFETY HEALTH AND HYGIENE REQUIREMENT
5.1 The Tenderer shall advise in his offer and be responsible for:
The management organization for implementation of

health and safety on site.
The identification of site hazards and assessment of

risks.
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The system of notifying all employees of the site safety

plan method, statements and site safety rules.
A schedule of safety meetings. The arrangements for

site induction course, training and security. The
arrangements for emergency plans, safety inspections
and auditing.
5.2 The Tenderer shall ensure the safety of all workmen,

materials and equipment either belonging to him or to others
working at site. He shall observe safety rules & codes
applied by the Owner at site without exception.
5.3 The Tenderer shall notify the Owner/Consultant of his

intention to bring to site any equipment or material which
may create hazard. The Owner/Consultant shall have the
right to prescribe the coefficients under which such
equipment or materials may be handled or prohibited the use
of the same for safely reasons. Tenderer shall abide
Owner/Consultant’s decision in such cases. No claim for
compensation due to such prohibition will be entertained by
the Owner.
5.4 Storage of petroleum products & explosives for construction

work shall be as per rules and regulation laid down in
Petroleum Act, Explosive Act and other relevant acts.
Approvals as necessary from Chief Inspector of Explosives or
other statutory authorities shall be the responsibility of the
Tenderer.
5.5 The Tenderer shall be responsible for safe storage of his and
his sub-contractor’s radioactive sources.
5.6 All requisite tests & inspection of handling equipment, lifting

tools & tackle shall be periodically done by the Tenderer.
Defective equipment shall be removed from services. Any
equipment shall not be loaded in excess of its recommended
safe working load.
5.7 All combustible waste and rubbish shall be collected and

removed from the work site at least once each day. Use of
undercoated canvas paper, corrugated paper, and fabricated
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carton, plastic or other flammable materials shall be

restricted to the minimum and promptly removed.
5.8 The Tenderer shall provide adequate number of the fire

protection equipment of the required types for his stores,
office, temporary structures, labour colony etc. Personnel
trained for fire fighting shall be made available by the
Tenderer at site during the entire period of the Contract.
5.9 All electrical appliances used in the work shall be in good

working condition and shall be properly earthed. No
maintenance work shall be carried out on live equipment.
The Tenderer shall maintain adequate number of qualified
electricians to maintain his temporary electrical installation.
5.10 All workmen of the Tenderer working in construction site

shall wear safety helmets, safety boots and safety belts. The
Tenderer shall take appropriate insurance cover against
accidents for his workmen as well as third party.
5.11 All burning and welding equipment shall conform to, and be
used in accordance with, regulations governing such
equipment. No burning or welding shall be done at any place
until such location is approved.
5.12 Welding near/at/in hazardous areas (like gas/oil etc.) shall be

done only after having all the fire protection/fighting
equipment at hand.
(a) Adequate fire protection shall be available before work

shall proceed.
(b) All warning signs shall be observed.
(c) Use of explosives shall comply with all regulations.
5.13 Tenderer shall require his employees to wear helmets at all

times when they are in an area where they are in danger
from falling objects. Goggles shall be worn whenever there
is a possibility of flying particles or splashing corrosive fluid.
When working around caustic or acid solutions, workmen
shall wear gloves, goggles and protective shoes.
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5.14 Suitable scaffolds should be provided for workmen for all

Works that cannot safely be done from the ground or from
solid construction except such short period Work as can be
done safely from ladders. When a ladder is used an extra
Mazdoor shall be engaged for holding the ladder and if the
ladder is used for carrying materials as well suitable
footholds and handholds shall be provided on the ladder and
the ladder shall be given an inclination not steeper than ¼ to
1 (¼ horizontal and 1 vertical).
5.15 Scaffolding or staging more than 3.5 Meter above the ground
or floor, swung or suspended from an overhead support or
erected with stationary support shall have a guard rail
properly attached, bolted, braced and otherwise secured at
least 1 Meter high above the floor or platform of such
scaffolding or staging and extending along the entire length
of the outside and ends thereof with only such openings as
may be necessary for the delivery of materials. Such
scaffolding or staging shall be so fastened as to prevent it
from swaying from the building or structure.
5.16 Working Platform, Gangways and Stairways should be so

constructed that they should not sag unduly or unequally,
and if the height of the Platform or the Gangway or the
Stairway is more than 3.5 Meters above ground level or floor
level they should be closely boarded, should have adequate
width and should be suitably fenced, as described above.
5.17 Every opening in the floor of a building or in a working

platform be provided with suitable means to prevent the fall
of persons or materials by providing suitable fencing or
railing whose minimum height shall be 1 Meter.
5.18 Adequate precautions shall be taken to prevent danger from

electrical equipment. No materials on any of the Sites of
Work shall be so stacked or placed as to cause danger or
inconvenience to any person or the public. The Tenderer shall
also provide all necessary fencing and lights to protect the
public from accident and shall be bound to bear the expenses
of defense of every suit, action or other proceedings at law
that may be brought by any person for injury sustained
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owing to neglect of the above precautions and to pay any

damages and costs which may be awarded in any such suit,
action or proceedings to any such person or which may with
the consent of the Tenderer be paid to compromise any claim
by any such person.
5.19 All necessary personal safety equipment as considered

adequate by the Engineer-in-Charge should be kept available
for the use of the persons employed on the Site and
maintained in a condition suitable for immediate use, and the
Tenderer should take adequate steps to ensure proper use of
equipment by those concerned.
(a) Workers employed on mixing Asphalted materials,

Cement and lime mortar shall be provided with
protective footwear and protective goggles.
(b) Those engaged in white washing and mixing or

stacking of cement bags or any materials which is
injurious to the eyes shall be provided with protective
goggles.
(c) Those engaged in welding works should be provided

with Welder’s protective eye-shields.
(d) Stone-breakers shall be provided with protective

goggles and protective clothing and seated at
sufficiently safe intervals.
(e) When workers are employed in sewers and manholes,

which are in the use, the Tenderer shall ensure that
the manhole covers are opened and are ventilated at
least for an hour before the workers are allowed to get
into the manholes and the manholes so opened shall
be cordoned off with suitable railing and provided with
warning signals or boards to prevent accident to the
Public.
(f) The Tenderer shall not employ men below the age of
18 and women on the work of painting with products
containing lead in any form. Whenever men above the
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age of 18 are employed on the Work of lead painting,

the following precautions should be taken:-
(i) No paint containing lead or lead products shall

be used except in the form of paste or ready-
made paint.
(ii) Suitable face masks should be supplied for use

by the workers when paint is applied in the form
of spray or a surface having lead paint dry
rubbed and scraped.
(iii) Overalls shall be supplied by the Tenderers to

the workmen and adequate facilities shall be
provided to enable the working painters to wash
during and at cessation of Work.
5.20 Provision should be made for prompt first-aid treatment of all

injuries likely to be sustained during the course of the Works.
5.21 Use of hoisting machines and tackle including their

attachments, anchorage and supports shall conform to the
following standard or conditions:-
(a) These shall be of good mechanical construction, sound

material and adequate strength and free from patent
defect and shall be kept in good repairs and in good
working order.
(b) Every rope used in hoisting or lowering materials or as

a means of suspension shall be of durable quality and
adequate strength and free from patent defects.
(c) Every crane driver or hoisting appliance operator shall

be properly qualified and no person under an age of 21
years should be in-charge of any hoisting machine
including any scaffold winch or give signals to the
operator.
(d) In case of every hoisting machine and of every chain

ring hook, shackle, swivel and pulley block used in
hoisting or lowering or as means of suspension the
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safe working load shall be ascertained by adequate

means. Every hoisting machine and all gear referred to
above shall be plainly marked with the safe working
load. In case of hoisting machine having a variable
safe working load, each safe working load of the
conditions under which it is applicable shall be clearly
indicated. No part of any machine or of any gear
referred to above in this paragraph shall be loaded
beyond the safe working load except for the purpose of
testing.
(e) In case of departmental machine, the safe working

load shall be notified by the Engineer-in-Charge. As
regards Tenderer’s machines, the Tenderer shall notify
the safe working load of the machine to the Engineer
whenever he brings any machinery to Site of Work and
get it verified by the Engineer concerned.
5.22 Motor, Gearing, Transmission, Electric wiring and other

dangerous parts of hoisting appliances should be provided
with efficient safeguards, hoisting appliances should be
provided with such means as will reduce to the minimum the
risk of accidental descent of the load, adequate precautions
should be taken to reduce to the minimum the risk of any
part of a suspended load becoming accidentally displaced.
When workers are employed on electrical installations which
are already engaged, insulating mats, wearing apparel such
as gloves, sleeves and boots as may be necessary should be
provided. The workers should not wear any rings, watches
and carry keys or other materials which are good conductors
of electricity.
5.23 All scaffolds ladders and other safety devices, mentioned or

described herein shall be maintained in safe condition and no
scaffold, ladder or equipment shall be altered or removed
while it is in use. Adequate washing facilities shall be
provided at or near places of work.
5.24 These safety provisions should be brought to the notice of all

concerned by display on a Notice Board at a prominent place
at the work spot. The persons responsible for compliance of
the Safety Code shall be named therein by the Tenderer.
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5.25 To ensure efficient enforcement of the rules and regulations

relating to Safety precautions, the arrangements made by
the Tenderer shall be open to inspection by the Labour
Officer/ owner/ Engineer of MECON or their representative.
5.26 Notwithstanding the above clauses there is nothing in these

to exempt the Tenderer, to exclude the operations of any
other Act or Rules in force in the country.
6.0 FIRST AID
At every workplace, there shall be maintained in a readily

accessible place first-aid appliances including an adequate
supply of sterilized dressings and sterilized cotton wool. The
appliances shall be kept in good order and in large work places
they shall be placed under the charge of a responsible person
who shall be readily available during working hours.
7.0 ACCOMMODATION OF LABOUR
7.1 The Tenderer shall during the progress of the Works provide,
erect and maintain at his own expense and to approve
standards and scales all necessary temporary living
accommodation.
7.2 Washing and bathing places
(a) Adequate washing and bathing places shall be provided.

(b) Adequate latrines and urinals for workmen/labour.
(c) Such places shall be kept in clean and drained
condition.
7.3 Disposal of excreta
Unless otherwise arranged for by the local sanitary authority,

arrangements for proper disposal of excreta by incineration at
the workplace shall be made by means of a suitable incinerator
approved by the local Medical, Health and Cantonment
Authorities. Alternatively excreta may be disposed off by
putting a layer of night soil at the bottom of pucca tank
prepared for the purpose and covering it with a 15 cms layer of
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waste or refuse and then covering it up with a layer of earth

for a fortnight (when it will turn into manure).
7.4 The Tenderer shall at his own expense carry out all
instructions issued to him by the Engineer-in-Charge to effect
a proper disposal of soil and other conservancy work in
respect of the Tenderer’s work people or employees on the
Site. The Tenderer will bear the cost of any charges levied by
the Concerned Authority for the execution of such Work on
his behalf.
7.5 Provision of sheltering during rest
(a) At every workplace there shall be provided free of cost

suitable sheds, for meals and rest for the use of labour.
The height of the shelter shall not be less than 3.5 M
from the floor level to the lowest part of the roof.
(b) On completion of the Works the whole of temporary

buildings shall be cleared away, all rubbish burnt,
excreta or other disposal pits or trenches filled in and
effectively sealed off and the whole of Site left clean
and tidy to the entire satisfaction of the Engineer and
at the Tenderer’s expense
8.0 STORAGE AND PRESERVATION
8.1 The Tenderer shall arrange for proper and safe storage of
materials till the same are taken over by the Owner as per
terms of the Contract. Manufacture’s instructions for
preservation shall be strictly followed.
8.2 All empty containers, packing materials, gunny bags,

transport frames as also surplus and unused materials shall
be the property of the Owner and returned to the Owner by
the Tenderer.
9.0 SITE CLEANLINESS AND WASTE DISPOSAL
9.1 Throughout the period of construction of the works the

Tenderer shall maintain the whole area of his operation in a
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clean, tidy and safe condition and shall arrange his materials
in an orderly manner, to the satisfaction of the Engineer.
9.2 All rubbish, etc., shall be systematically cleared from the

working areas and, if not removed directly from the Site,
shall be deposited at general collecting points provided by
the Tenderer and agreed with the Engineer, pending removal
from the Site. Where practicable, screening shall be
provided to prevent the ingress of dust and dirt to any part of
the works. The Tenderer shall clearly state, in the
appropriate schedule, what provision is being made for
disposal of waste materials both on and off-site.
9.3 The Tenderer shall not cause pollution of the Site land
drainage system or any watercourse by waste products from
any source whatsoever. Whenever any pollution is
attributable to any act or omission on the part of the
Tenderer, the Tenderer shall clear the pollution as soon as
possible and make early arrangement to remedy the cause.
9.4 The Tenderer shall take all necessary measure to ensure the
safe collection and disposal of waste oils and to ensure the
prohibition of:
(a) Any discharge of waste oils into surface water, ground

waters or drainage systems of any kind.
(b) Any deposit and or discharge of waste oils on to the

ground or floors of buildings and any uncontrolled
discharge of residues resulting from the processing of
waster oils or the cleaning of oil contaminated surface
with solvents. In order to ensure compliance with this
requirement the Tenderer shall provide suitable
vessels for the collection of all waste oils. Where large
quantities of waste oils need to be stored prior to
being disposed of in bulk suitable storage tanks shall
be provided by the Tenderer for this purpose.
(c) Any processing waste oils causing air pollution which

exceeds the level prescribed by existing statutory
provisions. In the event that the Tenderer fails to
comply with the above, the Owner reserves the right
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to carry out such work on his behalf and at the

Tenderer’s cost.
10.0 DAMAGE TO PUBLIC OR EXISTING SITE ROADS
10.1 The Tenderer shall make good the damage to roads, drains,
footways, paved areas, boundary walls and fences etc and
clean all fouled roads and paving etc., whether public or
existing at site, caused by or in any way attributable to the
handing/transport of plant and materials by the Tenderer and
indemnify the Employer against loss, damage or claims by
the Local Authority or others for damage to or fouling of
roads, paving etc., by reason of unusual traffic or other
causes
11.0 SANITATION AND DRAINAGE
11.1 The provision and maintenance of all temporary and

permanent water drainage and sewage disposal at site shall,
during the construction period, be the responsibility of the
Tenderer, who shall ensure that all national and local
statutory requirements for the effluent discharge are
complied with.
11.2 The permanent and the temporary surface and foul water
drainage systems shall all be separate. The Tenderer shall
make his own arrangements for foul drainage from the site
during the construction period. A sewage treatment plant of
the requisite capacity to meet the permanent requirement for
the site, shall be installed under this contract. This must be
capable of producing an effluent to meet the required
national and local discharge standards at all times.
12.0 CLEAN CONDITIONS
Where relevant, the Tenderer shall include in his supply of

temporary work, maintenance and operation of clean
conditions changing facilities, necessary amenities etc.
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13.0 LABOUR MANAGEMENT AND SITE INDUSTRIAL

RELATIONS
13.1 The Tenderer shall be wholly and entirely responsible for

establishing and maintaining a strategy for sound labour
management practices, good industrial relations and
acceptable levels of labor productivity to achieve completion
of the works within program and budget. A statement of this
strategy must be submitted with the offer.
13.2 The Tenderer shall establish to the satisfaction of the

Engineer, Site Contractor’s Group, to determine site labour
practices and ensure their effective implementation and
observance by all concerned. The Engineer reserves the
right to observe proceedings at Group meetings.
13.3 The Tenderer, to the satisfaction of the Engineer shall employ

Site Industrial Relations Manager (together with any
necessary staff) to support line management in operating an
effective labour strategy and to collect and collate
employment data covering all site workers.
13.4 The Contractor shall be required to promptly inform and

advise the Engineer of all matters relating to the
management of site labour. The contractor and all his sub-
contractors shall also make available to the Engineer details
of labour deployed, by occupation or trade, on etc of the
major site activities arranged so that manning levels involved
in modules and elements set out are clearly identifiable. This
information shall be reported against programmed manning
levels required. Other reports and data may be required
regularly or occasionally on all matters concerning the
employment of workpeople on site.
13.5 The appointment of all sub-contractors remains the

responsibility of the Contractor including the assessment of
their proposed site labour policies.
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CHAPTER NO. L PAGE No. 1 of 1
CHAPTER NO. L
LIST OF TENDER DRAWINGS
Sl NO Drawing No. Description
Alignment and Elevation for Down Hill Conveyor
1. MEC/01/Q6DH/KIOP/II/201/TS
no. 723
Layout of Proposed Road Approaches at Tail End
side of Downhill Conveyor no. 723.
3. MEC/01/Q6DH/KIOP/II/203/TS Equipment Flow Sheet
Arrangement of Conveyor nos. 718, 719 & 721, Silo
Building and Tail End of Downhill Conveyor no. 723.
Arrangement for Tapping of Material from Tripper
5. MEC/01/Q6DH/KIOP/II/205/TS Conveyor no. 122 and Feeding to Reversible
Conveyor no. 727.
6. MEC/01/Q6DH/KIOP/II/206/TS G.A. of Transfer House TH-3.
7. MEC/01/Q6DH/KIOP/II/207/TS G.A of Conveyor no. 727(Reversible).
Floor Plans at Various Levels of Transfer House TH-
3.
Floor Plans for facilities at Tail End side of Downhill
Conveyor no. 723.
Datasheet for conveyor nos. 718, 719, 721, 727-1
& 727-2.
3-Roll 35° –Trough Carrying Idler for
1200mm BW.
Two Roll 10° fixed V-Type Return Idler for 1200mm
BW.
13. MEC/01/Q6DH/KIOP/II/213/TS 5-Roll Impact Garland Idler for 1200mm BW
Downhill Conveyor Power Distribution Single Line
Diagram (Typical).
Automation System Configuration Diagram for
Downhill Conveyor.
Flow Diagram for Water Supply Facility
at Hill Top Area.
Process & Instrumentation Diagram for Fire
Detection & Suppression System.
Plan & Sections for Fire Detection & Suppression
System of Conveyor No. 723.
Typical block diagram of VVVF drive for DHC 723 &
reversible conveyor 727
20. MEC/01/Q6DH/KIOP/II/220/TS Dimensions of Standard Pulley for 1200 mm BW
NMDC LIMITED MECON
LIMITED

CHAPTER NO. M / Part 1 of 2 PAGE No. 1 of 5
CHAPTER-M / Part 1 of 2
DOCUMENTS / DRAWINGS TO BE
SUBMITTED ALONG WITH THE TENDER
IMPORTANT: SOFT COPY OF THE QUESTIONNAIRE AND DESIGN DATA

SHEET ( CHAPTER – M / Part 2 of 2 ) IS FURNISHED IN
COMPACT DISC WITH THIS DOCUMENT. TENDERER TO
RETURN THE SAME WITH ALL COLUMNS FILLED IN AND
SUBMIT ALONG WITH THE BID.
IN ADDITION TO THE SOFT COPY, HARD COPY OF THE

SAME SHALL ALSO BE SUBMITTED ALONG WITH THE BID
DOCUMENT.
1.0 GENERAL
1.1 Name and address of the Tenderer
1.2 Previous experience of the Tenderer, list of similar equipment

supplied.
1.3 Whether the Tenderer has any technical collaboration with any
other company/organization for this project
1.4 If answer to question 1.3 above is yes, furnish the following

details
a. Name & address of the collaborator
b. Nature of the collaboration in detail
c. Previous experience of the collaborator
1.5 List of drawings and literature enclosed with the offer.
1.6 Is it the Tenderer’s intention, if awarded the contract, to comply

fully in all respects with Owner’s specification covering the work.
If not, he shall state specific deviations in detail.
NMDC LIMITED MECON
LIMITED

1.7 Have drawings and all other technical data been included in
your tender as required.
1.8 Weight of Technological structure in “Tonnes” (counter

weight to be indicated separately).
1.9 Power, water and accommodation requirement for site work.
1.10 Land requirement for site fabrication work, stores, site office,
etc.
2.0 DOCUMENTS / DRAWINGS / INFORMATION
Tender shall be accompanied by the following drawings/

documents to enable the Owner/Consultant to assess the
important technical features of the equipment offered.
2.1 Mechanical
2.1.1 Layout drawing of the total system as contained in this

package.
2.1.2 System description describing the total downhill conveying

system being offered by the Tenderer with all salient
features.
2.1.3 G.A drawing of the self propelled traveling maintenance

trolley indicating salient features.
2.1.4 General arrangement drawings for all belt conveyors showing

the elevations, cross section & plan of equipment along with
technical parameters, clearances & over all dimensions.
2.1.5 General arrangement drawings for all other equipment

included under the scope.
2.1.6 Drive list with major technical particulars of drives. The

Tenderer shall check adequacy of all the drives before
quoting and shall stand guarantee for the same.
NMDC LIMITED MECON
LIMITED

2.1.7 Plan and elevations of various transfer houses, Silo and

conveyor galleries with dimensions envisaged by the
Tenderer considering all other equipment installed therein.
The Tenderer shall check and confirm the levels and
dimensions indicated in Technical specification and drawing
and shall also confirm the space provided in various transfer
houses with respect to layout of his equipment along with
maintenance, erection and other facilities.
2.1.8 Design calculations for downhill conveyor no. 723 including

results of dynamic analysis depicting the conveyor behavior
under varying loading conditions along its length. Computer
simulation of dynamic analysis shall also be demonstrated
during techno-commercial discussions.
2.1.9 List of hoisting and handling facilities provided in Transfer

Houses, tail/drive house of down hill conveyor,
parking/maintenance stations of self propelled traveling
trolley and other locations for maintenance purposes.
2.2 Electrics, Automation & Control:
2.2.1 Overall Single line diagrams for Power distribution & shop
electrics & illumination
2.2.2 Electrical rooms layout
2.2.3 Bill of Quantities for electrics
2.2.4 P&I diagram for the package with all auxiliary equipment /
system / facilities indicating all mounted instruments and PLC
displayed measurement using ISA symbols (tentative).
2.2.5 Tentative instrument list and IO list / count.
2.2.6 Brief details of instruments, valves, UPS and PLC.
2.2.7 Catalogues of offered equipments.
2.2.8 System configuration diagram along with write-up on the

system
NMDC LIMITED MECON
LIMITED

2.2.9 Control Philosophy of the downhill conveyor no. 723

describing features of control during starting, running and
braking under various loading conditions along its length and
braking in no-power situations & emergency condition.
2.2.10 Control Philosophy of the reversible conveyor no. 727

describing features of control during starting, running and
braking under different operating conditions and braking in
power fail situations& emergency condition.
2.3 Tenderer shall submit a time bar chart along with the Tender
indicating starting, completion date and schedule of design,
supply of drawings, procurement, manufacturing, assembly,
shop testing, inspection, erection, testing, commissioning
and performance guarantee, etc., of the equipment and
system conforming to the indicated time schedule.
2.4 Training considered for Owner’s technical personnel in the

offer indicating type of training (at site / manufacturer’s
works / abroad) no. of persons trained and duration.
2.5 List of deviation from Technical specification.
2.6 Equipment-wise list of tools and tackles.
2.7 Equipment-wise list of insurance spares.
2.8 Equipment-wise list of two years normal operation spares.
2.9 Questionnaire to be filled in by the Tenderer
2.10 The Tenderer shall fill questionnaire and design data sheet as
per Part – 2 of 2 and submit with his offer. The information is
required in this form to facilitate tender processing and
better understanding of the equipment offered even though it
may duplicate information presented elsewhere in his offer.
2.11 This questionnaire does not supersede instructions in the

tender document relating to the description and other
information to be submitted with the offer to ensure
a complete understanding of the equipment/ system offered.
NMDC LIMITED MECON
LIMITED

2.12 Tender paper without completely filled in questionnaire shall

be considered incomplete and is liable for rejection.
2.13 Tenderer shall also enclose soft copy (2 copies in CD) of the
questionnaire and the design data sheet duly filled in the
format furnished.
NMDC LIMITED MECON
LIMITED

CHAPTER-M / Part 2 of 2
QUESTIONNAIRE AND DESIGN DATA SHEETS TO BE FILLED

IN & TO BE SUBMITTED ALONG WITH THE TENDER
1.0 GENERAL
1.1 Questionnaire to be filled in by the Tenderer
1.1.1 The Tenderer shall fill in this questionnaire and submit with
his offer. The information is required in this form to facilitate
tender processing and better understanding of the equipment
offered even though it may duplicate information presented
elsewhere in his offer.
1.1.2 This questionnaire does not supersede instructions in the

tender document relating to the description and other
information to be submitted with the offer for a complete
understanding of the equipment offered and its position.
1.2 Design data sheets
1.2.1 Tenderer shall also review, revise and fill up the attached
design data sheet for various items of down hill conveyor no.
723 and reversible conveyor no. 727.
1.3 Tender paper without completely filled in questionnaire and

filled in design data sheet shall be considered incomplete and
is liable for rejection.
NMDC LIMITED MECON
LIMITED

IMPORTANT:
SOFT COPY OF THE QUESTIONNAIRE AND DESIGN DATA

SHEETS (CHAPTER-M/ Part2 of 2) IS FURNISHED IN COMPACT
DISC WITH THIS DOCUMENT. TENDERER TO RETURN THE SAME
WITH ALL COLUMNS FILLED IN AND SUBMIT ALONG WITH THE
BID.
IN ADDITION TO THE SOFT COPY, HARD COPY OF THE SAME

SHALL ALSO BE SUBMITTED ALONG WITH THE BID DOCUMENT.
IF THE TENDER DOCUMENT IS DOWN LOADED FROM THE WEB

SITE, THEN THE SOFTCOPY OF THE QUESTIONNAIRE AND
DESIGN DATA SHEETS WILL BE E-MAILED TO THE TENDERER
ON SPECIFIC REQUEST TO contractsblr@meconlimited.co.in OR
BY FAX TO 080-2657 6352 GIVING THE FOLLOWING
PARTICULARS.
1. Name of the Company :
2. Postal Address :
3. Contact Person’s name :

& Designation
4. Telephone No. :
5. Fax No. :
6. E-mail address :
NMDC LIMITED MECON
LIMITED

1.0 MECHANICAL
1.1 BELT CONVEYOR (To be furnished for each conveyor)
Sl.
Description Unit Data
No.
1. Conveyor Number --
2. Capacity tph
a) Design tph
b) Rated tph
3. Length m
4. Lift / Drop mm
5. Belt speed m/sec
6. Belt Width mm
7. Belt- Type & rating --
8. Troughing Angle Deg.
9. Coasting time Secs.
10. Drive Motor kW
Regenerative Power in case
11. kW
of Down Hill Conveyor
12. Details of Brake if applicable --
Details of holdback if
13. --
applicable
Maximum operating Tension
14. Tonnes
at design capacity
Type of carrying / return
15.
idlers
Idler spacing carrying/return
16. m
side
Gear Box-Type, Size,
17. --
Reduction Ratio & Rating
18. Coupling-HS/LS details --
19. Pulleys-Dia, bearing size --
Type of belt scrapers-
20. --
External & Internal
NMDC LIMITED MECON
LIMITED

Motor –Type, RPM, KW &

21. --
Voltage, Quantity
22. Type of control --
23. Take up details --
Provision of safety switches
24. Yes/No
as per specification
Control philosophy for down
25. hill Conveyor no. 723 Yes / No
furnished
Details of self propelled
26. traveling trolley for down hill Yes / No
conveyor no. 723 furnished
Control philosophy for
27. reversible Conveyor no. 727 Yes / No
furnished
Brief write up on belt turn
28. over device furnished for Yes / No
Down hill Conveyor 723
1.2 BELT FEEDER (To be furnished for each belt feeder)
Sl.
No.
1. Equipment Number --
2. Length m
3. Belt width m
4. Speed range m/min
5. Capacity
a) Design tph
b) Rated tph
Drive Motor-Type, kW,
6. kW
RPM & Voltage
7. Type of control --
8. Total weight tonnes
NMDC LIMITED MECON
LIMITED

1.3 IN LINE OVER BAND MAGNETIC SEPARATOR (To be

furnished for each inline over band magnetic separator)
Sl.
No.
2. Make --
3. Type --
4. Magnet size ( L x B x H ) mm
5. Duty --
6. Belt width mm
Details of weight & size
7. of the items that can be --
lifted
8. Operating height mm
9. Type of coil
Magnet cooling
10. arrangement &
Insulation class
KW Rating for conveyor
11. kW
& Magnet
Stainless steel drive
12. pulley considered for Yes / No
conveyors with ILMS
1.4 METAL DETECTOR (To be furnished for each metal

detector)
Sl.
No.
2. Make --
3. Type --
Type of material
4.
detected
Minimum size of metal
5. particle that can be mm
detected
NMDC LIMITED MECON
LIMITED

1.5 BELT WEIGH SCALE (To be furnished for each belt weigh
scale)
Sl
No
2. Make --
Load Cell-Make, Type,
3. --
Capacity
Accuracy of belt weigh
4. %
scale
% of
designed
5. Weighing range
capacity
of conv.
1.6 HYDRAULICALLY OPERATED GATES
Sl
No
2. Size of the gate mm
Details of the hydraulic
3.
system
Power pack motor
4. kW
Rating
NMDC LIMITED MECON
LIMITED

1.7 EOT CRANE (To be furnished for each crane)

Sl
No
Equipment Number /
1. --
Qty.
2. Location --
3. Make --
4. Type --
5. Governing Standards
6. Capacity tonnes
a) Main Hoist tonnes
b) Aux. Hoist tonnes
7. Span m
8. Class of Crane --
9. Lift – Main / Aux.Hook m
10. Speed
a) Main Hoist m/min
b) Aux. Hoist m/min
c) Cross Travel m/min
d) Long Travel m/min
11. Motor (Type & kW)
a) Main Hoist
b) Aux. Hoist
c) Cross Travel
d) Long Travel
Brakes details (Type &
12.
size)
a) Main Hoist
b) Aux. Hoist
c) Cross Travel
d) Long Travel
13. Type of control of Crane --
Total weight of the
14. tonnes
Crane
NMDC LIMITED MECON
LIMITED

1.8 ELECTRIC HOISTS ( Furnish location wise )
Sl
No
2. Location --
3. Make --
4. Type --
5. Governing standard
6. Capacity tonnes
7. Class of Duty --
8. Lift m
Headroom of Electric
9. mm
Hoist
Total weight of Electric
10. tonnes
hoist
1.9 MANUAL HOIST ( Furnish location wise )
Sl
No
2. Location --
3. Make --
4. Type --
5. Capacity tonnes
6. Governing standard
7. Lift m
Total weight of Manual
8. tonnes
hoist
NMDC LIMITED MECON
LIMITED

1.10 DUST SUPPRESSION SYSTEM – DRY FOG TYPE
Sl No Description Unit Data
1. Type --
2. Make --
3. Locations --
No of spray bar
4. Nos.
assemblies.
Material of spray bar
5. ---
assemblies.
No of nozzles per
6. Nos.
assembly.
Type of nozzles with
7. ---
flow ratings
No of Pressure
8. Nos.
regulating units.
No of flow activation
9. Nos.
stations.
Nozzles - Material of
10. Nos.
Construction.
11. Compressor
a) Capacity CFM
b) No. of Compressors Nos.
c) Pressure Kgf/cm2
d) Motor rating kW
12. Pump
a) No. Of Pumps Nos.
b) Capacity CFM
c) Pressure Kgf/cm2
d) Motor rating kW
13. Electrics
14. Instrumentation
NMDC LIMITED MECON
LIMITED

1.11 AIR-CONDITIONING FACILITY
1.11.1 Compressor
Sl.
No.
1 Type
2 Make / Model
2 Refrigerant used
3 Cooling capacity Kcal/hr
1.11.2 Compressor Motor
Sl.
No.
1 H.P
2 Make / Model
2 Nominal power
consumption
3 Power supply
requirement
1.11.3 Evaporator
Sl.
No.
1 Make / Model
2 Tube material
3 Diameter of tubes
4 Fin material
5 Nos. of Fins/ inch
6 Nos. of rows
1.11.4 Condenser
Sl.
No.
1 Make / Model
2 Tube material
3 Diameter of tubes
4 Fin material
NMDC LIMITED MECON
LIMITED

5 Nos. of Fins/ inch

6 Nos. of rows
1.11.5 Evaporator Fan
Sl.
No.
1 Make / Model
2 Air Circulation CFM/unit
3 Fan motor H.P.
4 RPM
5 No. of Speeds
1.11.6 Condenser Fan
Sl.
No.
1 Make / Model
2 Air Circulation CFM/unit
3 Fan motor H.P.
4 RPM
5 No. of Speeds
1.11.7 Filter
Sl.
No.
1 Type of filter
2 Filtration level
1.11.8 Refrigerant Piping
Sl.
No.
1 Pipe material
2 Liquid line O.D.
3 Suction line O.D.
4 Insulation of pipes
NMDC LIMITED MECON
LIMITED

1.11.9 Water Pumps
Sl.
No.
1 Make / Model
2 Nos. with standby
3 Capacity
4 Total Head m Wc
5 Material of casing,
impeller
6 Speed rpm
7 Shaft Power kW
8 Efficiency
9 Drive arrangement
10 Overall dimensions &
Weight in Kg.
1.11.10 Cooling Tower
Sl.
No.
1 Make / Model
2 Nos. with standby
3 TR Capacity
4 Flow rate max.
5 Power consumption
6 Material of construction
for body, fill, louvers
7 Fill specification, make
8 Overall size
9 Water temp. inlet &
outlet 0C
1.11.11 Water Piping
Sl.
No.
1 Make / Model
2 Pipe material
3 Size, thickness and
quantity considered
NMDC LIMITED MECON
LIMITED

4 No. and type of valves

5 Insulation material and
thickness
6 Chilled / Condenser
water Qty.
7 Velocity of water
through pipe
1.11.12 Ducting
Sl.
No.
1 Materials of duct
construction
2 Thickness of GI coating
3 Quantity of ducts in m2.
1.11.13 Duct Insulation
Sl.
No.
1 Materials of insulation
2 Thickness
3 Cladding
1.11.14 Acoustic Insulation
Sl.
No.
2 Thickness
3 Finish
1.11.15 Under Deck Insulation
Sl.
No.
2 Thickness
3 Finish
4 Qty. m2.
NMDC LIMITED MECON
LIMITED

1.11.16 Supply / Return Air diffusers / Grilles
Sl.
No.
1 Size of diffusers/
quantity of air from
diffuser / m3/ h.
3 No. of diffusers
4 Details of volume &
direction control damper
5 Velocity in diffuser
1.11.17 General
Sl.
No.
1 Overall dimensions of
the Indoor Unit
2 Overall dimensions of
the Outdoor Unit
3 Weight of Indoor unit
4 Weight of Outdoor unit
1.12 PRESSURIZED VENTILATION SYSTEM
1.12.1 Tube axial flow fan
Sl.
No.
1 Capacity in m3/hr
2 Total pressure drop in

kg/m2
4 Terminal box
arrangement
5 Drive details
6 Power consumption
NMDC LIMITED MECON
LIMITED

7 Drive kW
8 Efficiency
9 Make and model
10 Special features if any
11 Noise level at 1 m
distance
1.12.2 Relief Damper / Gravity open louver

Sl.
No.
1 Size of damper.
2 General arrangement
drawing
3 Details of material of
constructions
4 Blades
5 Frame
Details of link
6 mechanism.
1.13 EXHAUST VENTILATION SYSTEM

1.13.1 Tube Axial Fan
Sl.
No.
1 Capacity in m3/hr
2 Total pressure drop in
kg/m2
4 RPM
5 Drive details
6 Power consumption
7 Efficiency
8 Fixing details
9 Make and model
10 Special features if any
11 Noise level at 1 m
distance
NMDC LIMITED MECON
LIMITED

1.14 Electrics
Sl.
No.
1 Details of the contactors
/ relays, etc.
2 Material and sizes of
cables
3 Details of controls
1.15 Fire acting damper
Sl.
No.
1 Size of fire acting
damper.
drawing
constructions
4 Blades
5 Frame
Details of link
6 mechanism.
7 Details of solenoid
1.16 Volume Control damper

Sl.
No.
1 Size of damper.
drawing
constructions
4 Blades
5 Frame
Details of link
6 mechanism.
NMDC LIMITED MECON
LIMITED

1.17 FIRE DETECTION AND SUPRESSION SYSTEM
SL.
DESCRIPTION CONFIRMATION
NO.
Whether scope includes design & engineering,
1. manufacture, procurement, testing & inspection as per Yes/No
TS.
Junction boxes quantity to confirm clause 4.28 to 4.48 Yes/No
2.
of chapter no. Q9 are considered..
LHS cable, deluge valve and junction boxes quantity
confirm to relevant clauses and in line with layout
3. Yes/No
diagram no. MEC/ 01/Q6DH/KIOP/II/218/TS and
MEC/01/Q6DH/KIOP/II/219/TS.
FAP Battery back up duration for at least 4 hours in full
4. Yes/No
alarm condition.
Scope includes information on earthing as per clause
5. Yes/No
4.45. of chapter no. Q9
Components considered for fire detection and alarm
6. Yes/No
system confirm to clause 4.33 of chapter no. Q9
Whether infrared detectors considered are as per the
7. Yes/No
technical specification.
Deluge valve control panel specification to confirm
8. Yes/No
clause 4.38 of chapter no. Q9
Scope shall include provision of necessary encasing
9. Yes/No
pipes while crossing road, drain etc.
Whether display board considered is as per technical
10. Yes/No
specification.
11. Filled up data sheets enclosed. Yes/No
Whether all required cables and LHS CABLES
12. Yes/No
considered as per specification
2.0 ELECTRICAL
NMDC LIMITED MECON
LIMITED

2.1 6.6 kV SWITCHGEARS & 11kV switchgear
A SWITCHGEAR
1 Manufacturer’s name & type
2 Max. rated continuous current without
exceeding specified temperature rise
3 Maximum continuous voltage
4 Insulation level
PF withstand voltage
Impulse withstand voltage
5 Fault rating of cubicle with breaker
and busbars
Short time rating KA (RMS)
1 Second
Dynamic stability withstand in KA
(Peak)
6 Whether panel suitable and tested for Yes/ No
internal arcing faults
B BREAKER
1 Manufacturer’s Name
2 Type of Breaker VCB
3 Rated current at Max. Design ambient
with breaker inside the cubicle.
4 Insulation level
a) Impulse withstand KV (Peak)
b) 1 Min. P.F withstand KV (RMS)
5 Fault rating
a) Symmetrical breaking capacity at
rated voltage KA (RMS)
b) Asymmetrical breaking capacity at
rated voltage KA (RMS)
6 Spring assisted /Stored
Operating Mechanism
energy
7 Mechanical indications
Breaker trolley position
Breaker ON/OFF
Charging spring
8 Earthing device: Separate earthing Yes/ No
device with audivisual indication and
blocking solenoid for live line
NMDC LIMITED MECON
LIMITED

C CURRENT TRANSFORMER
1 Rated continuous current
2 Rated short time current …KA (RMS)…………..Seconds
D POTENTIAL TRANSFORMERS
1 Winding connection
2 Basic insulation level:
Impulse withstand voltage
1 Minute power frequency withstand
E BUSBARS
1 Continuous rating at design ambient
temperature
2 Temperature rise of busbars at rated
continuous current over design Ambient
3 Whether busbars are insulated for rated BIL
and shrouds provided at tap off
points/joints
2.2 LT SWITCHBOARDS (MCC/ MLDB/ PDB)
2.2.1 SWITCHBOARD
1 Rated insulation voltage

2 Rated short time withstand current
3 Degree of protection for enclosure
4 Incoming Entry Cable/Duct, Top/Bottom
2.2.2 BUSBARS
1 Material of main busbar / supports

2 Material and c/s of aux. Busbars
3 Temperature rise of main busbar over
design ambient at
(i) Rated current
(ii) Rated short circuit current
Rated insulation voltage for PVC sleeves
on Busbars and shrouds at joints
NMDC LIMITED MECON
LIMITED

2.2.3 AIR CIRCUIT BREAKERS
1 Rated insulation voltage

2 Rated current (free air)
3 In panel rated current
4 Self powered Yes/ No
5 Rated ultimate short circuit breaking
capacity
6 Rated service short circuit breaking
capacity
7 Utilization category
8 Micro processor based trip devices offered Yes/ No
9 Site selectable inverse/definite time
characteristic for E/F and S/C Yes/No
10 Whether U/V relay provided Yes/ No
11 Operating mechanism
12 Type for I/C & B/C feeders Manual/Motorized
13 Type for O/G feeders Manual/Motorized
14 Trip free design Yes/No
15 Stored energy type Yes/No
16 Electrical and mechanical anti-pumping
feature provided Yes/No
2.3 POWER/ DISTRIBUTION / LIGHTING/ BOOSTER

TRANSFORMERS (To be filled in for each rating offered)
1. Make
2. Power supply system in which
transformer is to be used
a) Primary side (HV) max. volt
b) Secondary side (HV) Max. volt
c) System earthing
d) Max. & Min. 3 phase and 3 phase line max/min
to ground max/ min
• Ground fault
• Primary side (HV) MVA
• Secondary side (LV) MVA
3. Transformer application
NMDC LIMITED MECON
LIMITED

4. Transformer type
a) Indoor/out door
b) Dry type/liquid filled/oil filled
c) Core type/shell type
5. Rated no load voltage kV
a) HV winding
b) LV winding
6. Cooling liquid and method of cooling
7. Rated MVA at rated voltage and principal
tap.
8. Whether designed for over loading as
per IS-6600.
9. Maximum temperature rise over design
ambient temperature degrees C at rated
kVA and principal tap
a) Top oil by thermometer method
b) HV & LV winding by resistance
c) Hot spot temperature degrees C
(Based on design ambient)
10. % Impedance voltage at rated current: Base MVA, voltage
frequency principal tap and 75 deg-c:
11. % Reactance voltage at rated current, Base MVA, voltage
Frequency, principal tap.
12. Tappings
a) Off circuit/ On load
b) Manual/ Automatic
c) No. of steps
d) % Variation per step
e) Winding on which tappings are
provided
13 External dead short circuit withstand
capability of transformer on any tapping
for 3phase, 2phase, line to ground fault
across LV windings: (Assuming infinite
system on both sides)
14. Losses at rated voltage, current (ONAN
rating) ONAN and frequency at principal
tap.
a) No load loss kW
b) Load loss at 75 deg-C in kW
c) Total losses at 75 deg-C in kW
15 Vector group-
NMDC LIMITED MECON
LIMITED

16 Insulation level
a) One minute Power Frequency
withstand voltage / 1.2/50 micro-
seconds impulse withstand voltage
• HV winding
• LV winding
b) Induced over voltage withstand
• HV winding kV (rms)
• LV winding kV (rms)
17 Bushings Line Neutral
bushings bushings
HV /LV LV
a) Voltage class kV as per is:
b) Current rating amps
c) Impulse withstand:
(1.2/50 micro sec. wave)
d) 1minute power frequency withstand
voltage:
Wet kV (rms):
Dry kV (rms):
e) Creepage distance
Total mm:
Protected mm:
18 L. V neutral bushing current

transformers
(Applicable for Distribution transformer
only)
• Number .of cores
• Class
• Knee point voltage
• CT secondary resistance at 75'c
• Short time rating sec
• Magnetising current at Vk /2, Vk /4
• Accessibility without removing
active parts
19 Terminal arrangement
a) High voltage
b) Low voltage
c) LV neutral
NMDC LIMITED MECON
LIMITED

20 Vacuum withstand capability

• Main tank with active parts mm of
hg
• Main tank without active parts mm
of Hg
• Radiators and accessories mm of
Hg
21 Gauge pressure withstand capability
• Main tank without active parts
kg/cm square
• Radiators & accessories kg/cm
square
• Fully assembled tank including
• Accessories kg/cm square
22 Efficiency at 75 deg C
23 Time constants of windings: ONAN
• HV
• LV
24 Time constant of transformers ONAN
• Minutes.
25. Efficiency at 0.8 pf at 100%, 75% 50 %
& 25% FL
2.4 LT MOTOR & 690V MOTOR

The motor technical data sheet as given below shall be submitted
along with Tender for each motor.
A MOTOR DETAILS
1 Name of manufacturer
2 a) Rated voltage
b) Voltage variation
3 a) Rated frequency
b) Variation in frequency
4 No. of phases
5 a) Motor kW at design
ambient temperature.
b) Motor kW at 40 0 c
6 Frame size
7 Rated speed
8 No of Poles
9 Starting Method
NMDC LIMITED MECON
LIMITED

10 Rotor Type
11 Rated load current
12 Enclosure class of protection IP -
13 Cooling Method
14 Hazardous area suitability
15 Class of Insulation
16 Temperature rise over
ambient 0 c
17 a) Locked rotor current / rated
current
b) Starting torque / Rated
torque
c) Pull out torque / rated
torque
18 a) No. of equally spread starts
/ hour
b) No. of successive starts
from cold condition
c) No. of successive starts
from hot condition
19 External paint shade
20 Epoxy based painting YES / NO
21 Noise level
22 Vibration rating
23 Efficiency
24 Power factor
25 Starting Duty
26 Terminal Box location (viewed R.H.S / LHS
from DE side)
27 Terminal Box IP
28 Space heaters provided YES / NO
29 Temperature detectors YES / NO
provided If YES, then
a) Type PTC / Pt-100
b) No. of detectors
B CONNECTED LOAD
DETAILS
1 Connected load type
2 Connected load tag no
3 Shaft absorbed Kw
4 Coupling type
NMDC LIMITED MECON
LIMITED

2.5 HT/ LT CAPACITORS
2.5.1 Capacitor Units
1. 3 – phase delta connected bank rating

2. Unit capacitor
3. Degree of protection
4. Safety device
5. Inrush current withstand
6. Standard applicable
7. Make
8. Rated voltage
9. Rated kVAR
10. Rated capacitance
11. Rated current
12. Rated frequency
13. Capacitance tolerance
14. Design ambient temperature
15. Temperature rise of container
16. Container type & thickness
17. Type of Impregnation
18. Fuses
a) Internal or external
b) Make
19. Any instrument to sense internal fuse
failure provided.
20. Dielectric
a) Material
b) Watt loss / unit
21. Any internal overpressure dis-connector
provided, If Yes, details
22. Over voltage withstand
23. Over current withstand
24. Service life
25. Dimension
26. Weight
27. Test Voltage, Terminal/ Terminal
28. Test Voltage, Terminal/ Case
29. Cooling medium.
30. Humidity
NMDC LIMITED MECON
LIMITED

31. Altitude
32. Mounting & grounding details
33. Discharge resistors
34. Details Terminals
35. No. of Switching operations
2.5.2 Capacitor Bank
1 kVAR rating
2 No. of units in series / parallel in each bank.
3 No. of banks.
4 Capacitance tolerance
2.6 CABLES
HT / LT CABLES (To be Filled separately)
1 Cable type reference

2 Cable voltage class
3 Type of earthing for which cable insulation is Earthed / unearthed
suitable
4 System fault level for HT cables
5 Short circuit capacity
5.1 Amps (RMS)
5.2 Duration in seconds
5.3 Maximum conductor temperature after short ºC
circuit
5.4 Applicable formula for calculating S.C capacity
for different duration
6.0 Conductor
7.0 Conductor insulation
7.1 Material
7.2 insulation screen
7.3 Wrapped or extruded
8.0 Materials of fillers
9.0 Inner sheath Material
10.0 Armour conductivity
10.1 Type of armour
11.0 Short circuit capacity for 1 sec. kA (RMS)
NMDC LIMITED MECON
LIMITED

2.7 VFD Unit
1 Drive No
2 Drive Rating
3 VFD Rating
4 Following accessories provided
i) Line side Ac reactor/isolation trafo.
ii) RF Filter
iii) Load Side reactor
iv) Sinusoidal filter
5 Power Circuit Devices Provided
i) Line side:
a) Diode Bridge
b) Regenerative braking: GTO
bridge/IGBT bridge.
ii) Output side.
iii) Dynamic braking.
6 EMC compliance
7 Short time overload capacity
a) 125% Hr / sec
b) 150% Hr / sec
c) 200% Hr / sec
d) 300% Hr / sec
8 Nominal voltage rating 415v, 50 Hz (or other
voltage)
a) Voltage range (AC output)
b) Frequency range
9 Supply variations
a) Voltage +10%, -15%
b) Frequency +5%
10 Ambient Temperature
11 Operational features
i) Power loss ride through duration ____ Sec.
ii) No. of Attempts
iii) Parameter lock
iv) Load optimizatio9n for light load
operation
v) Adjustable switching
vi) Frequency
vii) Max. switching frequency ______ Hz
viii) Fundamental p.f. …………
NMDC LIMITED MECON
LIMITED

ix) Total p.f. …………

x) Harmonics (THD) …………%
a) Current …………%
b) Voltage …………%
xi) Efficiency …………%
12 Incoming & Outgoing feeders equipped with
MCCB/ACB, line Contactor etc.
13 Bypass contactor with VFD in series also
envisaged
14 All breakers equipped with microprocessor
release direct acting type
15 All cubicles equipped with air filter fan,
starter for fan, light
NMDC LIMITED MECON
LIMITED

3.0 DESIGN DATA SHEET
Tenderer shall review, revise and fill up the following design data
sheets:
3.1 Down hill conveyor no. 723
3.1.1 Conveyor Belt Data Sheet
3.1.1.1 Design data
Sl. As proposed by
No. Tenderer
1. Belt width mm 1050
2. Belt speed m/s 6.0
3. Design capacity TPH 2000
Trough angle (Carrying /
4. Degree 45 / 30
Return)
5. CEMA % loading %
6. CEMA edge distance mm 80.6
7. Actual % loading %
8. Actual edge distance mm 245
Tape length (not
9. m 9885
including splice)
10. Impact force from lumps N
11. Max running tension kN 426
12. Max dynamic tension kN 629
LRR bottom
13. Special requirements ---
cover
14. High tension pulleys
a. Face width mm 1300
b. Diameter mm 1400
15. Low tension pulleys
b. Diameter mm 1250
NMDC LIMITED MECON
LIMITED

3.1.1.2 Fabrication data:
Sl. As proposed by
No. Tenderer
1. Make of belting --
2. Carcass type -- Steel
3. No. of cords/plies No. 70
4. Cord diameter mm 7.2
5. No. of splice steps No.
6. Belt strength N/mm 3150
7. Running S.F (min.) -- 7.85
8. Dynamic S.F (min.) -- 5.39
9. Top cover thickness mm 9
10. Top cover compound --
11. Bottom cover thickness mm 5
12. Bottom cover compound -- LRR
13. Bottom cover RRF
14. Weight (estimated) Kg/m 38.2
15. Elasticity (estimated) KN/m 225672
Warranties
Warrantied design life time years

Warrantied design life tonnage TPH
NMDC LIMITED MECON
LIMITED

3.1.2 Conveyor braking system data sheet

3.1.2.1 Hold backs
Sl.
Description Unit High Speed Low speed
No.
1. No. required
2. Location (s)
Hold back torque rating
3. kN-m
(CEMA)
4. (200% motor torque) kN-m
5. Load share required?
3.1.2.2 Brakes – General
As
Sl. proposed
No. by
Tenderer
Proportional
spring
1. Types of brakes -- apply /
hydraulic
release
2. Total braking torque required KN-m
3. Stopping time sec
Speed
Controlled
Deceleration ramp (define any Proportional
4. non linear programming or speed --- /Digital
control requirements) Brakes With
Linear Decel.
Ramp
5. Total no. of disks No. 2
6. Disk diameter mm
7. Disk thickness mm
8. No of proportional calipers/disk 1
9. No of digital calipers/disk 1
NMDC LIMITED MECON
LIMITED

Maximum energy absorbed

10. Kw-s 71321
(per stop)
11. Thermal capacity per disk Kw-s
12. No of consecutive stops req. 2
3.1.2.3 Brakes by pulley
As
Sl. proposed
No. by
Tenderer
On drive /
1. Location --
tail pulley
2. Pulley Dia. (with Lagging) mm 1450
3. Pulley RPM(with lagging) RPM 79
4. Pulley shaft Dia. (min.) mm 410
5. High Speed or Low speed ? -- Low
6. Qty. x Nominal Torque per Brake KN-m
NMDC LIMITED MECON
LIMITED

3.1.3 Data sheet for drives
3.1.3.1 Motors / Drives - General
As
Sl. proposed
No. by
Tenderer
TEFC Sq.
Types of motor(s) Cage
1.
induction
motors
2. Make
3. Model No.
4. No of poles 6
5. Motors synchronous speed RPM 1000
2
6. Drive inertia (per motor) Kg-m 47.5
7. Drive efficiency % 96
8. Total installed nameplate power kw 750
9. Total qty. x np power of motors kw 2 x 750
10. Max. running power required kw 1066
11. Max. regen. power produced kw -1278
Type of drive/starter (VFD, fluid VFD with
12. coupling soft-start,etc) regenerative
capacity
13. Starting torque limit % NP
14. Acceleration time Sec 120.0
Acceleration ramp (Define dwell 6 Sec linear
speed and duration or any non ramp to 5%
linear ramping function required) speed 6 sec.
15. Dwell @5%
speed. 108
sec S-Ramp
to full speed
NMDC LIMITED MECON
LIMITED

3.1.3.2 Motors/gear reducers by pulley
As
Sl. proposed
No. by
Tenderer
Location Pulley no.
1. P12 (Drive /
tail pulley)
2. Pulley dia (with lagging) mm 1450
3. Pulley RPM (with lagging) mm 79
4. Pulley shaft dia. (min.) mm 410
5. Qty. x np power of motors kW 2 x 750
6. Motor shaft dia mm
Type of gear reducer (bevel (B)or B/H
7.
bevel helical (B/H))
8. Reducer gear ratio 12.65:1
9. Reducer power rating kW 1125
10. Reducer low speed shaft dia mm
11. Reducer high speed shaft dia mm
3.1.3.3 Couplings
Sl.
No.
1. Type
2. Make
3. Model no.
4. Torque rating KN-m
5. Max. speed rating RPM

6. Service factor
7. Allowable parallel offset mm
8. Allowable angular offset Deg.
NMDC LIMITED MECON
LIMITED

9. Shaft end float mm

2
10. Rotational inertia (mk ) Kg-m2
11. Coupling material
NMDC LIMITED MECON
LIMITED

PACKAGE NO – II VOLUME - III of V
3.1.4 Conveyor Idler data sheet
3.1.4.1 Design Data
Carrying Idler Return Idler Impact Idler
Sl. As As As
Description Unit proposed proposed proposed
No. Data Data Data
by by by
Tenderer Tenderer Tenderer
1. No. of Rolls/Set No. 3 3 3
2. Roll Diameter mm 152.4 152.4 152.4
3. Rotational Speed RPM 754 754 754
4. Trough Angle Deg. 45 30 45
5. Idler Roll Length (equal rolls) mm N/A N/A N/A
Center Roll Length (if not
6. mm 350 350 350
equal)
Wing Roll Length(if not
7. mm 450 450 450
equal)
8. Max. Load per Idler Set N 5053 3365 946
NMDC LIMITED MECON
LIMITED

3.1.4.2 Fabrication/Installation Data
Sl. As As As
No. Data Data Data
by by by
1. Make -- -- -- --
2. Model No. -- -- -- --
3. Roll shell thickness mm 4.0 4.0 4.0
4. End disk thickness mm 4.0 4.0 4.0
5. Bearing Type/Series -- 6306 6306 6306
6. Shaft Diameter mm 30 30 30
7. Rotating Weight Kg 22.62 22.62 22.62

(per idler set estimated)
Rotational Inertia kg-
8. 109648 109648 109648
(idler mk2 -estimated) mm2
9. Idler Pitch/Spacing m 2.67 8.00 0.50
10. Vertical Installation tolerance mm 1 1 1
NMDC LIMITED MECON
LIMITED

Load rating N 7568 7698 7568

11.
12. L10 Lifetimes (estimated)
13. Center Roller
a. Minimum hrs 70620 304383 --
b. Median hrs 83398 370368 --
14. Wing Roller
a. Minimum hrs 78194 45485 --
b. Median hrs 423139 64182 --
3.1.5 Conveyor Pulley Data Sheet
NMDC LIMITED MECON
LIMITED

HEAD END PULLEY TAIL END PULLEY MATERIAL-LOADING

BELT CLAMP BELT CLAMP
P1 DRIVE
HOLD- P12
P2 BACK P11
P5 P3 P10 P9
BELT CLAMP
BELT CLAMP P8
P4
BELT TURNOVER BELT TURNOVER

COUNTER
OTHER PULLEYS WEIGHT
P6
P7
MOVABLE TAKE-UP
TROLLEY
NMDC LIMITED MECON
LIMITED

3.1.5.1 Design Data (for pulley nos. P1 to P6)
Pulley no. P1 Pulley no. P2 Pulley no. P3 Pulley no. P4 Pulley no. P5 Pulley no. P6
Sl. As As As As As As
Descript
No. Unit proposed proposed proposed proposed proposed proposed
ion Data Data Data Data Data Data
by by by by by by
Tenderer Tenderer Tenderer Tenderer Tenderer Tenderer
1. Pulley
Type
(drive,
high-
HIGH HIGH HIGH HIGH HIGH HIGH
tension -- TENSION TENSION TENSION TENSION TENSION TENSION
non-
driven,
low
tension)
2. Pulley
Diameter
mm 1250 1250 1250 1250 1250 1250
(With out
lagging)
3. Pulley face
mm 1300 1300 1300 1300 1300 1300
width
4. Hub
centers mm 983 944 944 944 944 982
(estimated)
5. Bearing
centers mm 2025 1925 1925 1925 1925 1925
(min.)
NMDC LIMITED MECON
LIMITED

6. Shaft
mm -- -- -- -- -- --
Length
T1
7. KN 279.3 279.3 279.3 254.0 256.0 221.0
Magnitude
T1
8. Deg. 192.5 8.1 192.3 12.5 192.5 7.6
Direction
T2
9. KN 279.3 279.3 279.3 254.0 255.0 221.0
Magnitude
T2
10. Deg. -171.5 11.1 191.3 12.5 192.5 0.0
Direction
11. Wrap angle Deg. 184 183 179 180 180 172
Driven on
12. both ends
-- No No No No No No
Overhung
13. load (right -- No No No No No No
shaft end)
a. Load -- -- -- -- -- --
Moment
b. arm
-- -- -- -- -- --
Overhung
14. load (left -- No No No No No No
shaft end)
a. Load -- -- -- -- -- --
Moment
b. arm
-- -- -- -- -- --
NMDC LIMITED MECON
LIMITED

3.1.5.2 Fabrication/Component Data (for pulley nos. P1 to P6)
Descript
by by by by by by
Shell mm
1. Thickness
40 40 40 40 40 40
End Disc mm
2. Thickness
120 120 120 120 120 120
Shaft Dia mm
3. At Hubs
380 380 380 380 380 380
Shaft Dia mm
4. At Bearings
320 320 320 320 320 320
Shaft
5. -- 1045 1045 1045 1045 1045 1045
Material
Pillow Block
6. Bearing -- 23072 23072 23072 23072 23072 23072
Series
KN-
7. Hub Torque -- -- -- -- -- --
m
Hub
KN-
8. Bending -- -- -- -- -- --
Moment m
NMDC LIMITED MECON
LIMITED

Locking
9. -- -- -- -- -- -- --
Device
a. Make -- -- -- -- -- -- --
b. Model No. -- -- -- -- -- -- --
Lagging
10. Type
-- Rubber Rubber Rubber Rubber Rubber Rubber
Lagging
11. mm 20 20 20 20 20 20
Thickness
NMDC LIMITED MECON
LIMITED

3.1.5.3 Design Data (for pulley nos. P7 to P12)
Descript
by by by by by by
1. Pulley
Type
(drive,
high-
HIGH HIGH HIGH HIGH HIGH
tension TENSION TENSION TENSION TENSION TENSION
Drive
non-
driven,
low
tension)
2. Pulley
Diameter
mm 1250 1250 1250 1250 1250 1400
(With out
lagging)
3. Pulley face
mm 1300 1300 1300 1300 1300 1300
width
4. Hub
centers mm 982 944 944 944 944 906
(estimated)
5. Bearing
centers mm 1925 1960 1960 1960 1960 2025
(min.)
NMDC LIMITED MECON
LIMITED

6. Shaft
mm -- -- -- -- -- --
Length
T1
7. KN 220.0 372.0 372.0 377.0 378.0 378.0
Magnitude
T1
8. Deg. 180.0 -11.0 169.1 -10.5 -135.0 -4.9
Direction
T2
9. KN 220.0 372.0 372.0 378.0 377.0 467.0
Magnitude
T2
10. Deg. 180.0 -11.0 169.1 44.5 174.0 -10.9
Direction
11. Wrap angle Deg. 180 180 180 125 129 186
Driven on
12. both ends
No No No No No Yes
Overhung
13. load (right -- No No No No No Yes/No
shaft end)
a. Load -- -- -- -- -- --
Moment
b. arm
-- -- -- -- -- --
Overhung
14. load (left -- No No No No No Yes /No
shaft end)
a. Load -- -- -- -- -- --
Moment
b. arm
-- -- -- -- -- --
NMDC LIMITED MECON
LIMITED

3.1.5.4 Fabrication/Component Data
Descript
by by by by by by
Shell mm
1. 40 40 40 40 40 50
Thickness
End Disc mm
2. 120 120 120 120 120 120
Thickness
Shaft Dia mm
3. At Hubs
380 380 380 380 380 410
Shaft Dia mm
4. At Bearings
320 320 320 320 320 340
Shaft
5. Material
-- 1045 1045 1045 1045 1045 1045
Pillow Block
6. Bearing -- 23072 23072 23072 23072 23072 23072
Series
KN-
7. Hub Torque -- -- -- -- -- --
m
Hub
KN-
8. Bending -- -- -- -- -- --
Moment m
NMDC LIMITED MECON
LIMITED

Locking
9. -- -- -- -- -- -- --
Device
a. Make -- -- -- -- -- -- --
b. Model No. -- -- -- -- -- -- --
Lagging
10. Type
-- Rubber Rubber Rubber Rubber Rubber Ceramic
Lagging
11. mm 20 20 20 20 20 25
Thickness
NOTE:
1. Tenderer shall review, revise & fill up the above data sheets and submit along with their offer.
2. The revision shall include an explanation of any item that are not consistent with the original specifications.
3. OEM produced documents containing the same information are an acceptable substitute.
4. Tenderers are encouraged to provide the specifications for a superior design in addition to the base bid.
5. Drive pulley shaft size does not include allowance for unknown overhung loads.
NMDC LIMITED MECON
LIMITED

3.2 Reversible conveyor no. 727
3.2.1 Conveyor Belt Data Sheet
3.2.1.1 Design data
Sl. As proposed by
No. Tenderer
1. Belt width mm 1050
2. Belt speed m/s 3
3. Design capacity TPH 2000
Trough angle (Carrying / 45 / 30
4. Degree
Return)
5. CEMA % loading % 68.8
6. CEMA edge distance mm 80.6
7. Actual % loading % 48.7
8. Actual edge distance mm 151.1
Tape length (not 614
9. m
including splice)
10. Impact force from lumps N
11. Max running tension kN 189
12. Max dynamic tension kN 197
LRR bottom
13. Special requirements ---
cover
14. High tension pulleys
b. Diameter mm 1000
15. Low tension pulleys
b. Diameter mm 800
NMDC LIMITED MECON
LIMITED

3.2.1.2 Fabrication data:
Sl. As proposed by
No. Tenderer
1. Make of belting --
2. Carcass type -- Steel
3. No. of cords/plies No. 70
4. Cord diameter mm 4.1
5. No. of splice steps No.
6. Belt strength N/mm 1000
7. Running S.F (min.) -- 6.12
8. Dynamic S.F (min.) -- 5.89
9. Top cover thickness mm 12
10. Top cover compound --
11. Bottom cover thickness mm 6
12. Bottom cover compound -- LRR
13. Bottom cover RRF
14. Weight (estimated) Kg/m 30.9
15. Elasticity (estimated) KN/m 71642
Warranties
Warrantied design life time years

Warrantied design life tonnage TPH
NMDC LIMITED MECON
LIMITED

3.2.2 Conveyor braking system data sheet
3.2.2.1 Hold backs
Sl.
No.
1. No. required --
2. Location (s) --
3. kN-m
(CEMA)
Hold back torque rating kN-m
4. (200% of motor torque)
5. Load share required?
3.2.2.2 Brakes - General
As
Sl. proposed
No. by
Tenderer
Spring
apply /
1. Type of brake --
hydraulic
release
2. Total braking torque required KN-m 60
3. Stopping time sec 7
Deceleration ramp (define any
4. non linear programming or speed ---
control requirements)
5. Total no. of disks No.
6. Disk diameter mm
7. Disk thickness mm
8. No of proportional calipers/disk Nos.
9. No of digital calipers/disk Nos.
Maximum energy absorbed
10. Kw-s 1081
(per stop)
11. Thermal capacity per disk Kw-s
NMDC LIMITED MECON
LIMITED

12. No of consecutive stops req. 2
3.2.2.3 Brakes by pulley
As
Sl. proposed
No. by
Tenderer
On drive /
1. Location --
head pulley
2. Pulley Dia. (with Lagging) mm 1050
3. Pulley RPM (with lagging) RPM 54.6
4. Pulley shaft Dia mm 250
5. High Speed or Low speed ? -- Low
6. Qty. x Nominal Torque per Brake KN-m
3.2.3 Data sheet for drives
3.2.3.1 Motors / Drives - General
As
Sl. proposed
No. by
Tenderer
TEFC Sq.
Type of motor Cage
1.
induction
motors
2. Make
3. Model no
4. No of poles 6
5. Motors synchronous speed RPM 1000
2
6. Drive inertia Kg-m 31.8
7. Drive efficiency % 96
8. Total installed name plate power kw 400
9. Total qty. x np power of motors kw 1 x 400
NMDC LIMITED MECON
LIMITED

10. Max. running power required kw 332

11. Max. regen. power produced kw -191
Type of drive/starter (VFD, fluid VFD with
12. coupling soft-start, etc) regenerative
capacity
13. Starting torque limit % NP
14. Acceleration time Sec 30.0
Acceleration ramp (Define dwell
15. speed and duration or any non
linear ramping function required)
3.2.3.2 Motors/gear reducers by pulley
As
Sl. proposed
No. by
Tenderer
Location Pulley no.
1. P1 (Drive /
head pulley)
2. Pulley dia (with lagging) mm 1050
3. Pulley RPM (with lagging) mm 54.6
4. Pulley shaft dia mm 250
5. Qty x no. power of motors kW 1 x 400
6. Motor shaft dia mm
Type of gear reducer (bevel (B)or B/H
7.
bevel helical (B/H)
8. Reducer gear ratio 18.175:1
9. Reducer power rating (min.) kW 600
10. Reducer low speed shaft dia mm
11. Reducer high speed shaft dia mm
NMDC LIMITED MECON
LIMITED

3.2.3.3 Couplings
Sl.
No.
1. Type
2. Make
3. Model no.
4. Torque rating KN-m

5. Max. speed rating RPM
6. Service factor
7. Allowable parallel offset mm
8. Allowable angular offset Deg.
9. Shaft end float mm
2
10. Rotational inertia (mk ) Kg-m2
11. Coupling material
NMDC LIMITED MECON
LIMITED

3.2.4 Conveyor Idler data sheet
3.2.4.1 Design Data
Sl. As As As
No. Data Data Data
by by by
1. No. of Rolls/Set No. 3 3 3
2. Roll Diameter mm 152.4 152.4 152.4
3. Rotational Speed RPM 376 376 376
4. Trough Angle Deg. 45 30 45
5. Idler Roll Length(if equal) N/A N/A N/A
Center Roll Length (if not
6. mm 350 350 350
equal)
Wing Roll Length(if not
7. mm 450 450 450
equal)
8. Max. Load per Idler Set N 6116 2678 1732
NMDC LIMITED MECON
LIMITED

3.2.4.2 Fabrication/Installation Data
Sl. As As As
No. Data Data Data
by by by
1. Make -- -- -- --
2. Model No. -- -- -- --
3. Roll shell thickness mm 4.0 4.0 4.0
4. End disk thickness mm 4.0 4.0 4.0
5. Bearing Type/Series -- 6306 6306 6306
6. Shaft Diameter mm 30 30 30
7. Rotating Weight Kg 22.62 22.62 22.62
(per idler set estimated)
Rotational Inertia kg- 109648 109648 109648
8. (idler mk2-estimated) mm2
9. Idler Pitch/Spacing m 2.67 8.00 0.50
10. Vertical Installation tolerance mm 1 1 1
NMDC LIMITED MECON
LIMITED

11. Load rating N 7568 7698 7568

12. L10 Lifetimes (estimated)
13. Center Roller
a. Minimum hrs 94725 1000000 N/A
b. Median hrs 96337 1000000 N/A
14. Wing Roller
a. Minimum hrs 320435 579008 N/A
b. Median hrs 337931 579501 N/A
3.2.5 Conveyor Pulley Data Sheet
NMDC LIMITED MECON
LIMITED

HEAD END PULLEY
DRIVE
P1
P2
TAIL END PULLEY
P6 P5 P3
P4
NMDC LIMITED MECON
LIMITED

3.2.5.1 Design Data

Descript
by by by by by by
1. Pulley
Type
(drive,
high-
Low Low Low Low
tension Drive Low Tension
Tension Tension Tension Tension
non-
driven,
low
tension)
2. Pulley
Diameter
mm 1000 800 800 800 800 800
(With out
lagging)
3. Pulley face
mm 1300 1300 1300 1300 1300 1300
width
4. Hub
centers mm 983 1071 1046 1046 1046 1046
(estimated)
5. Bearing
centers mm 1920 1760 1760 1760 1760 1920
(min.)
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6. Shaft
mm
Length
T1
7. KN 197.0 96.8 62.1 59.4 62.1 62.3
Magnitude
T1
8. Deg. -188.6 -9.5 9.4 90.0 270.0 9.4
Direction
T2
9. KN 96.2 96.2 61.7 59.8 61.5 61.6
Magnitude
T2
10. Deg. 189.4 189.5 270.0 90.0 191.0 10.6
Direction
11. Wrap angle Deg. 198 19 81 180 101 180
Driven on
12. both ends
No No No No No No
Overhung
13. load (right -- Y/N No No No No No
shaft end)
a. Load -- -- -- -- -- --
Moment
b. arm
-- -- -- -- -- --
Overhung
14. load (left -- Y/N No No No No No
shaft end)
--
a. Load -- -- -- -- --
Moment --
b. arm
-- -- -- -- --
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3.2.5.2 Fabrication/Component Data
Descript
by by by by by by
Shell mm
1. 30 20 20 20 20 20
Thickness
End Disc mm
2. 80 60 60 60 60 60
Thickness
Shaft Dia mm
3. 250 180 180 180 180 180
At Hubs
Shaft Dia mm
4. At Bearings
210 140 140 140 140 140
Shaft
5. Material
-- 1045 1045 1045 1045 1045 1045
Pillow Block
6. Bearing -- 23048 22234 22234 22234 22234 22234
Series
KN-
7. Hub Torque --- -- -- -- -- --
m
Hub
KN-
8. Bending -- -- -- -- -- --
Moment m
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Locking
9. -- -- -- -- -- -- --
Device
a. Make -- -- -- -- -- -- --
b. Model No. -- -- -- -- -- -- --
Lagging
10. Type
-- Rubber Rubber Rubber Rubber Rubber Rubber
Lagging
11. Thickness
mm 25 20 20 20 20 20
NOTE:
1. Tenderer shall review, revise & fill up the above data sheets and submit along with their offer.
2. The revision shall include an explanation of any item that are not consistent with the original specifications.
3. OEM produced documents containing the same information are an acceptable substitute.
4. Tenderers are encouraged to provide the specifications for a superior design in addition to the base bid.
5. Drive pulley shaft size does not include allowance for unknown overhung loads.
NMDC LIMITED MECON
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CHAPTER NO. N PAGE No. 1 of 14
CHAPTER – N
DOCUMENTS/DRAWINGS TO BE SUBMITTED BY
THE SUCCESSFUL TENDERER
1.0 APPROVAL CATEGORY
Following design data, calculation and drawings shall be

submitted by the successful Tenderer for approval prior to
commencement of manufacture / fabrication.
1.1 GENERAL
1.1.1 System layout drawing showing all buildings and other

installations with co-ordinates, approach roads, etc.
1.1.2 Material Flow Diagram
1.1.3 System description describing the total down hill conveying

system offered by the Tenderer
1.1.4 Master list of drawings under approval category and reference

category along with tentative schedule for submission.
1.1.5 L-1 network indicating starting, completion date and schedule of

design, supply of drawings, procurement, manufacturing,
assembly, shop testing, inspection, erection, testing,
commissioning and performance guarantee test, etc.
1.1.6 L-2 & L-3 Network
1.1.7 Detailed Billing Schedule
1.1.8 Quality Assurance Plan for all Mechanical, Electrical, Civil &
Structural items.
NMDC LIMITED MECON
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1.2 MECHANICAL
1.2.1 General arrangement drawings of all belt conveyors and belt

feeders showing to the scale the elevation, cross section and
plan of equipment along with technical parameters, clearance
and overall dimensions.
1.2.2 General arrangement drawing for equipment like In line over

band magnetic separator, metal detector, belt weigh scale, EOT
cranes, Electric & manual hoists, hydraulically operated gates,
etc. showing to the scale the elevation, cross section and plan of
equipment along with technical parameters, clearance and
overall dimensions.
1.2.3 General arrangement drawing showing the extension of tail end

of existing tripper conveyor no. 122 and the extension of travel
of tripper on conveyor no. 122
1.2.4 General arrangement drawing for self propelled maintenance

trolley for the down hill conveyor no. 723 indicating the
constructional and other salient features.
1.2.5 Design calculations for downhill conveyor including results of

dynamic analysis depicting conveyor behaviors under varying
loading conditions along its length, calculations for selection of
motor, gear box, couplings, belting, pulleys, brakes, hold backs,
etc.
1.2.6 List of hoisting and handling facilities provided in transfer

houses, top of silo, tail/drive house, parking/maintenance
station for maintenance trolley on down hill conveyor, etc. for
maintenance purpose.
1.2.7 Floor plans and elevation of various transfer houses, tail/ drive
house & parking/maintenance station for maintenance trolley on
down hill conveyor, RCC silo, etc. with dimensions considering
all equipment installed therein.
1.2.8 Standard gallery cross section
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1.2.9 Any other drawing, design calculation or supporting document

which may be asked by the owner / consultant.
1.2.10 List of bought out items and vendor list.
1.3 ENVIRONMENTAL (A/C & VENTILATION AND DUST

SUPRESSION SYSTEM)
1.3.1 Layout drawing of the System
1.3.2 G.A drawing of individual equipment
1.3.3 P & ID of System
1.3.4 List of instruments with their make, type and model number
1.4 HYDRO ENGINEERING AND FIRE DETECTION &

SUPRESSION SYSTEM
1.4.1 Technical specification of each components, units/ sub-units and

cables.
1.4.2 General arrangement and mounting details of all units/sub-

units.
1.4.3 Configuration diagram of complete system showing detector and

other field devices connection
1.4.4 Cable routing and detector layout.
1.4.5 G.A Drg. for Medium velocity water sprays (MVWS) system with
points numbered serially.
1.4.6 Piping details for MVWS systems.
1.4.7 Detailed water requirement calculations for MVWS system (i.e.

for conveyor galleries & each junction area).
1.4.8 Water requirement for total system.
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1.4.9 G.A. Drg. for all piping arrangements at battery limit and deluge
valve location.
1.4.10 Process and Instrumentation drawing of the Fire Detection and

Suppression System.
1.4.11 General arrangement drawings for all electrical equipment,

showing dimensional and mounting details, cable entry and
front view details.
1.5 ELECTRICAL
1.5.1 Overall Single line diagram (HT, LT & Lighting).
1.5.2 Design basis for various electrical equipment.
1.5.3 Power distribution schemes.
1.5.4 Single line diagram, schematic drawing, Bill of materials for HT

switchgears , NGR, PMCCs , MCCs , PDBs , MLDBs , SLDBs ,
DCDBs , ELDBs, Battery and chargers , VFDs ,Control panels
etc.
1.5.5 Dimensional GA drawing of HT switchgears , NGR, PMCCs ,

MCCs , PDBs , HT Capacitor banks, Busduct, MLDBs , SLDBs ,
DCDBs , ELDBs , Battery and chargers , VFDs , UPSs, Local
control panels, Field devices (BSS, PCS etc), brakes, brake
panels, rotor control panels, resistance boxes, Lighting poles,
Welding receptacles, indicating foundation details, cable gland
plate location front view of the above equipment / panels
indicating arrangement of relays, controls, operating heights.
1.5.6 Technical data sheet for transformers, HT & LT switchgear, NGR,

Motors (HT & LT), cables, UPS, Battery and battery charger,
Ventilation & AC, PLC, PA system, Lighting equipment, VFD,
Field devices (i.e. PSS, BSS, SS, Limit switch, encoder Etc.) etc.
finally being supplied.
NMDC LIMITED MECON
LIMITED

1.5.7 Sizing calculations for Transformers, HT & LT Cables, Bus duct,

CT & PT, HT & LT capacitor bank, Battery, UPS
1.5.8 Buried cable trench drawing
1.5.9 Electrical equipment layout drawings for all buildings and floors.
1.5.10 Electrical & control rooms layouts.
1.5.11 11kV OH line routing drawing.
1.5.12 Overhead lines component drawings (AB switch, DO fuse,

Insulators, LA, Double pole structure).
1.5.13 Drawings pertaining to approval by statutory authorities.
1.5.14 Master single line diagram for illumination (covering lighting

transformer’/s, MLDB, SLDB, Feeder pillars & feeder vise
connected load)
1.5.15 Street Lighting layout and LUX level calculations.
1.5.16 Drive list
1.5.17 Cable trenches along with detailed sectional views.
1.5.18 Layout of electrical rooms with sectional views.
1.5.19 Electrical equipment layout drawings.
1.5.20 Cable routing drawings with sections showing cable trays, trench
details for reference.
1.5.21 Cross sectional drawing of cubicles / panels indicating busbars,

CTs, cable, breaker, seal-off bushing, and LV chambers.
1.5.22 Calculations for selection of type / rating etc. of various

equipment / Rotor resistance calculations, drives and
NMDC LIMITED MECON
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components, Instrumentation, earthing and lightning

protections, cables, illuminations, busbars etc.
1.5.23 Relay settings.
1.5.24 Motor data sheet, GA drawing of motor indicating locations of

stator TB, neutral TB, space heater TB, ETD / BTD TB, shaft
details, keyway details, vibration pads, earthing connections etc.
and GA of all TB's
1.5.25 Lighting design calculation area wise to establish the number of

fittings required to achieve the desired level of illumination.
1.5.26 The layout of LDBs, EDBs, SDBs, lighting fixtures & controls,
power socket outlets, concealed / surface wiring routing
drawings, equipment for each buildings.
1.5.27 SLD, GA drawings and component list for all the equipment like
transformer, lighting distribution boards, fixtures etc.
1.5.28 Earthing and Lightning protection calculation and drawings for

various electrical premises, plant, buildings and equipment.
1.5.29 Soil resistivity test report
1.5.30 PAT and FAT procedures & Formats, Factory Acceptance Tests,
Pre-commissioning Tests & Procedures, Provisional handing over
tests and protocols, Post guarantee test procedures and
protocols.
1.6 AUTOMATION & CONTROL
1.6.1 Process and Instrumentation diagrams
1.6.2 Input-Output list
1.6.3 System architecture drawing
1.6.4 Control Philosophy for the total system.
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1.6.5 Control philosophy of the downhill conveyor no. 723 describing

features of control during starting, running and braking under
various loading condition along its length and braking in no
power situation and emergency situation.
1.6.6 Control philosophy of the reversible conveyor no. 727 describing

features of control during starting, running and braking under
various operating conditions and braking in no power situation
and emergency situation.
1.6.7 Specification of PLC and its accessories with catalogues
1.6.8 Hardware Design Manual
1.6.9 Specification of Instruments, UPS and its accessories with

catalogues
1.6.10 Panel GA drawings
1.6.11 Factory Acceptance Test
1.7 CIVIL
1.7.1 Engineering Design criteria for civil works and conceptual design
studies, evaluations and optimization for major structures.
1.7.2 Civil construction drawings, design calculations and architectural

drawings for civil buildings, equipment foundations, etc. covered
under this package.
1.8 STRUCTURAL
1.8.1 Engineering Design criteria for steel structural works and

conceptual design studies, evaluations and optimization for
major structures.
1.8.2 Design drawings and design calculations for all steel structures
covered under this package.
NMDC LIMITED MECON
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Note: In addition to the above drawings/ documents,

drawings /documents listed under the various chapters , if any,
shall also be furnished by the Successful Tenderer.
2.0 THE CONTRACTOR SHALL SUBMIT FOLLOWING

DRAWINGS AND DOCUMENTS AND OBTAIN NECESSARY
CLEARANCE PRIOR TO GIVING INSPECTION CALL TO THE
OWNER / CONSULTANT
2.1 Separate schedules of all idlers, pulleys, motors, gearboxes,

couplings, brakes, belting and other repetitive items of
equipment with all necessary quantity, dimensions, type, rating,
specification, usage and drawings of each variety.
2.2 Sub-assembly drawings with quantity, usage, dimensions, bill of

materials, specification of components, make, etc. wherever
sub-assemblies will be offered for Owner’s / Consultant’s
inspection. Circuit diagram and other necessary details shall also
be provided in case of electrical items.
2.3 Component drawings with detailed dimension, specification,

make, quantity, usage wherever components are offered for
Owner’s / Consultant’s inspection.
2.4 Test results (in proper units and dimensions) carried out by the
Contractor.
2.5 For Hydro, following documents shall be furnished along with

Inspection Call:
- Hydro Test Certificate
- Chemical Test Certificate
- Warranty Certificate
- Mechanical Test Certificate
- Approved QAP
MARKING
The valves shall be clearly and permanently marked with the
following:
- Manufacturers name and the trade mark.
- Year of manufacture
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- ISI / BS Certification Mark

- Size of valve
- Rating / class
- Direction of flow
2.6 Any other clarification, detail, standard, design basis or

calculation asked by Owner/Consultant for the purpose of giving
approval/clearance of drawing for inspection.
2.7 The specification of material to be used and material test

certificates for structural steel and mechanical components.
2.8 All drawings pertaining to one type of equipment shall be

submitted in one lot as far as possible.
3.0 THE FOLLOWING DRAWINGS/DOCUMENTS SHALL BE

SUBMITTED FOR REFERENCE
3.1 MECHANICAL
3.1.1 Drive schedule incorporating motor ratings, belt ratings & belt
tensions, details of couplings, gearboxes, drive pulleys, brakes,
holdbacks, etc.
3.1.2 Calculation for all belt conveyors & belt feeders for selection of
motor, belt tension, coasting time, selection of belts, gearbox,
couplings, pulleys, brakes etc.
3.1.3 General arrangement drawing for surge hopper.
3.1.4 General arrangement drawing of trolley for EOT cranes.
3.1.5 General arrangement drawing for gear boxes, coupling and

brakes.
3.1.6 General arrangement drawing for pulleys and idlers.
3.1.7 General arrangement drawing for conveyor hoods.
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3.1.8 List of safety switches.
3.1.9 Speed torque curves for hydraulic couplings & equipment.
3.1.10 Lubrication schedules giving location, types of lubricants, grades

and name of manufacturer, frequency of lubrication and
quantify of initial fill.
3.1.11 Catalogues/technical literature of all bought out items.
3.1.12 Foundation details including the static & dynamic loads.
3.1.13 Calculation for working life of idlers.
3.1.14 Calculation for bearing diameter and working Life of pulleys.
3.1.15 Pulley design calculation
3.1.16 Erection & maintenance manuals for the equipment & system.
3.1.17 Motor power, Brake calculations and Structural calculations for

EOT Cranes.
3.1.18 G.A drawing of chutes, skirt boards, discharge hoods, etc with
dimension, support details, bill of materials etc.
3.2 ELECTRICAL
3.2.1 Cable Schedules and External wiring drawings, interconnection /

hook up drawing
3.2.2 Internal wiring drawings of all the cubicles and equipments Inter
panel-wiring drawings.
3.2.3 External connection diagrams /Loop schematics for

instrumentation.
3.2.4 Hardware design manual and Software design manual
NMDC LIMITED MECON
LIMITED

3.2.5 Type test certificates and technical details of transformers, panels,

breakers, CT, PT, Busbars, cables, Motors and other all
equipment.
3.2.6 For motors-Routine test certificates, Test Certificate for residual

unbalance, Motor characteristic curves
3.2.7 Routine test and site test reports for all equipments.
3.2.8 Operating and maintenance manuals for all equipment including

maintenance schedules for all equipment.
3.2.9 Catalogues for all components and equipments
3.2.10 Equipment location and routing of cables
3.2.11 Cable routing drawings with sections showing cable trays, trench
details for reference.
3.2.12 Motor characteristics curves
3.2.13 Training schedule
3.3 AUTOMATION & CONTROL
3.3.1 Software Design Manual
3.3.2 Instrument List
3.3.3 Installation diagram
3.3.4 Cable Schedule
3.3.5 Cable Routing Layout
3.3.6 Control room layout
3.3.7 Sizing calculations
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3.3.8 I/O assignment
3.3.9 Logic description
3.3.10 External-Internal wiring diagram
3.3.11 Graphic displays
3.3.12 Earthing Layout
3.3.13 Test and Inspection Report
3.3.14 Heat load for PLC room equipment
Note: In addition to the above drawings/ documents,

drawings /documents listed under the various chapters , if any,
shall also be furnished by the Successful Tenderer.
IN ADDITION TO THE ABOVE, OWNER / CONSULTANT

RESERVES THE RIGHT TO INSIST ON THE SUBMISSION
OF CALCULATION AND / OR DRAWINGS FOR ANY
MECHANICAL, STRUCTURAL OR ELECTRICAL
COMPONENTS FOR APPROVAL OR REFERENCE.
4.0 DRAWINGS / DOCUMENTS TO BE SUBMITTED ALONG

WITH EQUIPMENT IN 10 (TEN) SETS AT THE TIME OF
DELIVERY OF EQUIPMENT ALONG WITH SOFT COPIES OF
ALL THE APPROVED DRAWINGS/ REFERENCE DRAWINGS
AND DOCUMENTS IN A CD:
4.1 All final GA drawings and complete assembly and sub-assembly

drawings of the equipment supplied
4.2 Drawings of all equipment received from sub-suppliers.
4.3 Operation and maintenance manuals.
4.4 Detailed manufacturing drawings of all fast wearing and spare

parts along with complete specifications, sketches and
manufacturers catalogue.
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4.5 Test reports and inspection reports (at the time of inspection).
4.6 Detailed erection schedule and manuals, assembly/ erection

drawings, erection sequence, special precautions to be followed
during assembly/ erection.
4.7 Instruction manuals for testing and commissioning.
4.8 Safety manuals and requirement of special tools and tackles for
subsequent inspection/maintenance.
4.9 Descriptive literature and drawings to illustrate the working

principles, method of assembly and dismantling.
4.10 Spare parts list giving complete list of replaceable parts for two
years normal operation and maintenance indicating clearly
operational, consumable, maintenance, replacement spares. The
spare parts list shall be accompanied by necessary
specifications, catalogues and drawings and shall be supplied
in the form of table giving item designation and application,
name of manufacturer, manufacturer’s specification, type and
form, reference drawing number, standards used, quantity
installed, quantity recommended for two years normal
operation, and in addition for electrical equipment the item
designation shall show the entire module to be replaced incase
of defect in any component. Detailed instructions both for
original installation and future replacement shall be furnished.
5.0 FINAL AS BUILT DRAWINGS / DOCUMENTS
5.1 The Tenderer shall provide and keep up to date “As built
drawings” of all civil and structural works constructed and all
equipment and accessories and miscellaneous metal works
erected or installed. These drawings shall show all changes and
revisions from the original drawings and specifications, including
the exact “As-built” locations, sizes and kinds of equipment and
accessories, miscellaneous metal works, embedded piping and
electrical systems and other concealed items of work. These
drawings shall be kept in Tenderer’s field office but shall be
NMDC LIMITED MECON
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made available at all times for review of the Engineer. At the

end of every work, all entries, changes or revisions made in the
drawings by the Tenderer shall be checked and approved by the
Engineer.
5.2 One reproducible on polythene film, CDs and 6 (six) prints of all
these drawings / documents shall be submitted progressively to
the Owner after taking over of the plant by the Owner. These
drawings / documents shall be marked “FINAL AS BUILT”.
Following also shall be submitted along with above:
• All licensed software and application, PLC/SCADA software in

CD’s.
• Site test reports, PAT & FAT reports and factory test
certificate volumes.
• Operation maintenance manuals, equipment & system

catalogues, list of spares volumes
6.0 QUALITY OF DRAWINGS
Standard size drawings only shall be submitted. The drawings

shall be of good quality, legible and made in CAD or inked. Soft
copies of all approved drawings shall be sent to Consultant and
Owner by e-mail with in one week of approval of respective
drawings. The drawings shall be in “AutoCAD” format and other
documents shall be in PDF/jpeg format. The drawings on CDs
shall be vectorised and minimum letter size shall be 3 mm.
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CHAPTER NO. O PAGE No. 1 of 12
CHAPTER-O
SPARES, SPECIAL TOOLS & TACKLES

1.0 GENERAL
1.1 Tenderers shall include in his price cost of supply of sufficient

quantity of commissioning spares necessary for the successful
commissioning of the system and equipment offered. The
Tenderer shall consider quantity of such commissioning spares,
based on his experience and submit a list of such
commissioning spares in his tender. In case of any shortfall in
the commissioning spares, additional spares as required shall
be supplied by the successful Tenderer at his own cost and in
time, so that commissioning till fulfilment of guarantee is in no
way affected due to want of spares.
1.2 Tenderer shall also supply special maintenance tools, tackles

and instruments along with each equipment required for
maintenance and testing of equipment. List of minimum tools
and tackles to be considered by the Tenderer is furnished at
Clause 2.3. However, if the Tenderer feels that any additional
tools and tackles over and above the list furnished are
required, then the same shall be indicated and shall also be
included in the price quoted and the list furnished.
1.3 Tenderer based on his experience and critical nature of the

equipment & system under the scope shall furnish a list of
Insurance spares and spares required for normal operation and
maintenance.
1.4 Commissioning spares shall be despatched along with the plant

and equipment.
1.5 Spare parts for two years normal operation of the plant and
special maintenance tools shall be despatched in the sequence
that they arrive at site prior to commencement of start up
operations, but not prior to the supply plant and equipment.
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1.6 Tenderer shall furnish an itemised list with descriptions,

quantities, etc. considered by him under Tools and tackles,
instruments, Insurance spares and two year spares along with
the tender.
1.7 The final list of tool, tackles, instruments, insurance and two
year spares will be finalised with the successful Tenderer. The
quoted price shall be valid till the expiry of warranty period.
2.0 MINIMUM LIST OF SPARES, TOOLS, ETC., TO BE

CONSIDERD BY THE TENDERER
The Tenderer shall offer a list of Two years operation &

maintenance spares, Insurance spares required with each
equipment of the plant. Such list shall include the following
minimum items:
2.1 TWO YEAR NORMAL OPERATION & MAINTENANCE

SPARES
2.1.1 MECHANICAL
Sl.
Item Description Unit Quantity
No.
(BELT CONVEYORS / DOWNHILL CONVEYOR / BELT
FEEDER)
Pulley assembly - each type and size
A.1 complete with bearings and plummer Set 1
blocks.
Liners for brake assembly - each type and Set 2
A.2
size (for conveyor provided with brake)
Rollers for Idler assembly- each type (See Nos. 5%
A.3
Note # 1 & 2)
A.4 Coupling - each type and size Nos. 1
A.5 Zero Speed switch Nos. 4
A.6 Pull Chord Switch Nos. 15
A.7 Belt sway switch Nos. 20
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Sl.
No.
Gearbox: Input shaft with bearings and
A.8 Set 1
seals –for each type and size of gearbox.
A.9 Skirt Rubber –25 meter length Lot 1
Blade assembly for each type of belt scraper

A.10 Sets 5
– Primary, secondary and return side
Wheels assembly for self propelled traveling
A.11 Sets 8
trolley
A.12 Impact bar for Belt Feeders (complete set) Sets 2
CRANES
A.13 Brake shoe with liners – each type and size Set 1
AC, VENTILATION & DUST

SUPPRESSION SYSTEM
A.14 PUMPS
A.14.1 Coupling bush for each type Set 1
A.14.2 Pump bearings for each type Set 1
A.14.3 Motor bearings for each type Set 1
A.14.4 Gland packing for each type Kg 1
A.15 Fans
A.15.1 Fan bearings for each type Set 1
A.15.2 Motor bearings for each type Set 1
A.15.3 Fan belt for each type Set 1
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Sl.
No.
A.16 AC Unit
A.16.1 Filter for each type Set 1
Temperature / Speed controller for each

A.16.2 Set 1
type
A.16.3 Cutout switches for each type Set 1
A.17 Air-compressor
A.17.1 Suction filter Set 1
A.17.2 Oil filter Set 1
A.17.3 Compressor bearing Set 1
A.17.4 Motor bearing Set 1
A.18 Dust Suppression System
A.18.1 Flow activation station of each type Set 1
A.18.2 Pressure reducing units of each type Set 1

A.18.3 Nozzles of each type Set 2
A.18.4 Spray bar assemblies of each type Set 2
A.18.5 Pressure gauges Nos. 4
A.18.6 Sensors Nos. 8

Isolation-Globe/Check valve – Set of each
A.19 type for A/C & Ventilation and Dust Set 1
Suppression Systems
Filters of each type for A/C & Ventilation
A.20 Set 1
and Dust Suppression Systems
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Sl.
No.
HYDRAULIC SYSTEM FOR
HYDRAULICALLY OPERATED GATE
BELOW SURGE BIN
A.21 Suction filters - each type and size. Nos. 4
Seal kit for Hydraulic cylinders – for each
A.22 Sets 2
type and size
HYDRO ENGINEERING INCLUDING
FIRE DETECTION & SUPRESSION
SYSTEM FOR DOWN HILL CONVEYOR
A.23 CI Gate valve – 200 NB Nos. 1
A.24 CI Ball Valve – 80NB Nos. 25
A.27 Butterfly Valve – 50NB Nos. 2
A.28 Deluge Valve with accessories – 80NB Nos. 13
A.29 Pressure reducing valve – 200 NB Nos. 1
A.30 Spray Nozzles Nos. 390
A.31 CI Basket type strainer – 200 NB Nos. 1
A.32 Junction Boxes Nos. 5
A.33 LHS cable RM 500
A.34 IR Detectors Nos. 2
A.35 Addressable interface unit Nos. 10
A.36 Pressure switches Nos. 5
A.37 Pressure Gauges Nos. 5
A.38 Local control panel Nos. 5
A.39 Outdoor Hooter Nos. 5
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Sl.
No.
Master electronic circuit card for each type 1 no. of
A.40 Nos.
of panel each type
A.41 MCP Nos. 3
NOTES:
1) At least one no. in case 5% is less than one.
2) In case the quantity of 5% happens to be a fraction the
same shall be rounded off to the next higher number.
2.1.2 ELECTRICAL
Sl. No. Item Description Unit Quantity

B. TRANSFORMERS
B.1 Bushing (Primary & secondary) One of Set 1

each type & size for each transformer
B.2 Oil temperature indicator, for each Set 1
transformer
B.3 Winding temperature indicator for each Set 1
transformer
6.6 kV SWITCHBOARD / 11 kV SWITCHBOARD
B.4 Protective relays (numerical) – One of each Set
1
type for each board
B.5 PT Primary fuses – ( One set of 3 nos.) –
Set 1
For each board
Control MCB’s - One of each rating – For
B.6 Set 1
each board
B.7 Microprocessor based multifunction meter No. 1
– For each board
B.8 Breaker trip coils – For each board Nos. 2
B.9 Breaker closing coils – For each board Nos. 2
B.10 Spring charging motors – For each board Nos 2
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B.11 Spring charging limit switch – For each Nos 2
board
B.12 Test, Service positions limit switch – For Nos 2
each board
B.13 HT Fuse (VCU) – For each 6.6kV board Nos 3
B.14 Coils for VCU – one no. of each type – For No. 1
each 6.6kV board
BATTERY CHARGER (For each board)
B.15 Thyristors Nos. 2
B.16 Diodes (Blocking) Nos. 2

Contactors (One no. each of AC & DC side
B.17 Nos. 2
per set)
B.18 Relay Cards of each type per set Set 1
B.19 Selector switch Nos. 2
DCDB
B.20 Incoming MCCB for each board Nos. 1

Outgoing MCB for each board
B.21 Nos. 2
PMCC , MCC , ILLUMINATION AND
CONTROLS
B.22 ACB
i) Closing coil for each board No. 2
ii) Trip coil for each board No. 2
iii) Spring charging motor for each No. 2

board
iv) Micro processor based release for No. 1
each board
v) Limit switches
Service / Test position for each board No. 2
Spring charging for each board No. 2

NMDC LIMITED MECON
LIMITED


B.23 MCCB
i) Shunt trip coil of various rating for No. 4
each board
ii) 1 No + 1 NC aux. Contact for each No. 15
board
iii) Door operating kit with handles for No. 4
each board
B.24 MPCB of each rating for each board Sets 4
Bimetal over load relay for each rating for Set 1

B.25
each board
Power contactor of each rating for each Sets 2
B.26 board
Indication lamps (LED assly) of various No. 60 (Total)

B.27 colours for each board
Control Selector switches & Limit switches Sets 2
B.28
of each type for each board
B.29 Pushbutton stations/LCS for each board Nos. 3
B.30 CT’s of each rating for each board Sets 3
Indicating meters of each rating for each Sets 2

B.31
board
B.32 Miniature circuit breaker of each rating Sets 10
B.33 Sodium vapour lamps 70watt Nos. 30
Sodium vapour lamp of other wattage’s of Sets 10

B.34 each type
Control gear components consisting of Sets 10
B.35 ballast PF correcting capacitors, igniter’s for
the above HPSV fittings of each type
B.36 ELCB’s of all ratings Sets 10
63A Welding receptacle Nos. 5

B.37
NMDC LIMITED MECON
LIMITED


BRAKES/ BRAKE RECTIFIER
B.38 Brake rectifier set – One of each rating Sets 1
B.39 Brake liner pad – One no for each brake Set 1
B.40 Brake coil – One no for each brake Set 1
SLIP-RING INDUCTION MOTOR
B.41 Slip-ring assembly – One of each type Set 1

Brush holder assembly - One no of each
B.42 Sets 3
type
B.43 Carbon brushes – One no. of each type Sets 20
Bearing for DE & NDE - One no. of each
B.44 Sets 1
type / Size
SQUIRREL CAGE INDUCTION MOTOR
Bearing for DE & NDE- 1 No. of each
B.45 Sets 1
type/size
2.1.3 AUTOMATION & CONTROL

C.1 Analog and Digital I/O cards of each type Nos. 20 % *
C.2 Processor Module Nos. 1
C.3 Power Supply Module of each type Nos. 1
C.4 Communication Module of each type Nos. 2
*NOTES:
1) At least one no. in case 20 % is less than one.
2) In case the quantity of 20 % happens to be a fraction
the same shall be rounded off to the next higher
number.
NMDC LIMITED MECON
LIMITED

2.1.4 PLANT COMMUNICATION
D.1 Complete field station No. 3
D.2 Outdoor loud speaker No. 6
2.2 INSURANCE SPARES
Sl No Item Description Unit Quantity
BELT CONVEYOR (INCLUDING

DOWNHILL CONVEYOR & BELT
FEEDER)
1 Complete gear box assembly of each type
No. 1
and size
2 Complete brake assembly including drum
Set 1
/ disk for each type and size of brake
3 Hydraulics and controls for the brakes for
Set 1
conveyor provided with brake
4 Motor for downhill conveyor no. 723 No. 1
2.3 LIST OF TOOLS & TACKLES
Following listed minimum tools and tackles shall be considered

as part of the main equipment by the Tenderer and shall be
supplied. (Cost to be included as part of the main equipment)
NMDC LIMITED MECON
LIMITED

2.3.1 MECHANICAL
Sl. Item Description Unit Quantity

No
Vulcanizing machine for steel cord belting
upto 1200 mm, complete with the
Set 1
associated auxiliary equipment, tools and
1.0
tackles.
Vulcanizing machine for textile belting upto
2.0 1200 mm, complete with the associated Set 1
auxiliary equipment, tools and tackles.
3.0 6.0T Portable winch with 30m wire rope No. 2*
Winch for take up of down hill conveyor
4.0 no. 723, capacity to suit take up weight. No. 1*
5.0 Bearing pullers (manual) No. 1
6.0 Torque wrench with socket 75 – 150 kg.M Set 1
7.0 Adjustable spanners (upto 50 mm) Set 1
Dial gauge, 0 to 10 mm, LC = 0.01 mm

8.0 with magnetic stand No. 1
9.0 Splice kit for down hill conveyor belting Set 2
*Notes:
1. Winch for take up of down hill conveyor no. 723 to be installed

at take up tower.
2. Two nos. portable winches to be supplied loose. (Tenderer to
finalise the capacity and length of wire rope to facilitate belt
changing for Downhill Conveyor no. 723.)
NMDC LIMITED MECON
LIMITED

2.3.2 ELECTRICAL AND INSTRUMENTATION & CONTROL
Sl No Item Description Unit Quantity

1. Insulation tester 500V (Megger) No. 2
4. Earth tester No. 2
5. Digital Tong tester No. 2
6. Digital Multi-meter with Graphic display No. 2
7. Tool box No. 2
8. Crimping tool (2.5 to 240sq mm) Set 2
9. Insulation stripper Set 2
10. Analog multi meter No. 2
11. Analog tong tester (AC/DC) No. 2
12. Electronic Release testing Kit No. 2
Hand held calibrator with all necessary
13. No. 1
accessories
NMDC LIMITED MECON
LIMITED

CHAPTER NO. P PAGE No. 1 of 15
CHAPTER-P
LIST OF PREFERRED MAKES

1.0 BOUGHT OUT ITEMS
1.1 The Tenderers shall ensure that the specific makes being
offered by him are from among the preferred makes and
meet the technical specifications given in the tender.
Vendors other than those listed below are subject to approval
by Owner / Consultant.
1.2 In case any / all of the preferred makes do not meet the
technical specifications given in the tender, the Tenderers are
requested to bring the same to the notice of the tender
issuing authority and suggested alternate makes with
confirmation from such parties that their equipment meets
specifications and that their equipment with the given
specifications is working satisfactorily (at locations to be
specified) for review of the Owner.
1.3 All such proposals should be included along with the Offer as
the post-order correspondence on change of makes cannot
be agreed to.
1.4 Item for which preferred makes are not indicated shall be
procured only after approval of the make by client/
consultant.
NMDC LIMITED MECON
LIMITED

2.0 PREFERRED MAKES
2.1 MECHANICAL PLANT EQUIPMENT / COMPONENTS
SL.
ITEMS PREFERRED MAKES
NO.
M.1 Variable Speed Hydraulic HAGGLUNDS / REXROTH / VICKERS
Motors
M.2 Hydraulic System VICKERS / REXROTH / DENISON
M.3 Hydraulic Cylinders VELJANHYDAIR / NUCON REXROTH /
USHA TELEHOIST / WIPRO / VICKERS
/ PARKER HANNIFIN
M.4 Cable reeling drum ELECON / CONTORQ
M.5 Conveyor Belting (Nylon) MRF / PHOENIX –YULE / ORIENTAL /
SEMPTRON – NIRLON / HINDUSTAN
RUBBER / NORTHLAND RUBBERS
M.6 Conveyor Belting (Steel IMAS / PHOENIX-YULE /
cord) BRIDGESTONE
M.7 Conveyor idlers ELECON / TRF / KALI MATERIAL
HANDLING / KRUPP / PRAYAS
CASTING PVT. LTD.
M.8 Gear Boxes: Helical / ELECON / NAW / FMG / PETL
Bevel helical type
M.9 Couplings: Geared Type NAW / CONCORD / FMG / ELECON /
PETL
M.10 Couplings: Resilient type FENNER INDIA / GBM
M.11 Couplings: Fluid Type VOITH INDIA / PETL / FLUIDOMAT
M.12 Hydraulic Brakes (for SIEGERLAND BREMSEN / BUBENZER
conveyors) BREMSEN / SVENDEBORG / VOITH
M.13 Locking assembly between RINGFEDER, GERMANY / BIKON, UK /
Shaft & hub for Pulleys TAS SCHAFER
M.14 Bearings:
(a) For Idlers SKF /FAG / TATA /NBC / NTN
(b) For pulleys and others SKF/ FAG / NTN
(c) Adapter Sleeves SIBCO / FAG / NTN
(d) Plummer blocks SIBCO / WINCO / MASTA
M.15 Lubricating system GRINDWELL NORTON / LINCON /
DELIMON PROTOS
NMDC LIMITED MECON
LIMITED

SL.
NO.
M.16 Liners:
(a) Mn Steel STEEL CAST BHAVNAGAR/ RAIPUR

ROTOCAST / MARTOPEARL / ACQUA
ALLOYS / MUKAND / ACC NIHON /UP
STEEL/ KOWTHA STEEL PRODUCTS
VIJAYAWADA / SHREE HANS ALLOYS
(b) 6 mm chrome carbide DEMECH, PUNE / ADOR FONTECH /
overlay over 10mm MS WEAR RESIST, BARODA / DURA WELD,
plate NAGPUR / KILBURN / TRITON / L & T
CASTODUR
( c ) Rubber Liners TEGA / KAVERI
(d) Polymer Liner KAVERI / TEGA / SHALIMER / SUPER
SLICK
M.17 Belt scrapers HOSCH / KAVERI / TIP TOP
(Primary & Secondary)
M.18 Impact Bars TEGA / KAVERI
M.19 Electric Hoist ARMSEL / VOLTAS / INDEF / AVON /
BIDYUTENGG./DEMAG CRANES, PUNE
/ GRIP ENGINEERS, SECBAD /
ELECTROMECH, PUNE
M.20 Manual Hoist INDEF / TRACTEL TIRFOR /

W.H.BRADY
M.21 EOT Crane MILLERS INDIA (ACME) / WMI /
MUKAND / ARMSEL / FAFECO /
ANUPAM CRANES / L&T /
KHANDELWAL
M.22 Metal Detector MR EQUIPMENT
M.23 Thrustor brake for crane ELECTROMAG / SPEED-O_CONTROL
M.24 Belt Weigh Scale PBL / THERMO-RAMSEY / SCHENCK /
CONVEY WEIGH
M.25 Fasteners TVS / FITTIGHT
M.26 Lubricants IOC / HPC / BALMER LAWRIE /
CASTROL/ VEEDOL
M.27 Puller MAX-PULL / TRACTEL TIRFOR /
PULLMAN
NMDC LIMITED MECON
LIMITED

SL.
NO.
M.28 Paints ASIAN / J & N / ADDISON GARWARE /
BERGER / SHALIMAR / GOODLAS
NEROLAC
M.29 Dry Fog dust Suppression TPS / KAVERI / SPRAYING SYSTEMS /

System F. HARLEY / C-DOCTOR
M.30 Inline Over band Magnetic EMI / ELECTROMAG / POWER BUILD
Separator / ERIEZ
M.31 Compressor KIRLOSKAR / ELGI / IR / KP / CP /
ATLAS CAPCO
Horizontal Centrifugal KIRLOSKAR/ BEACON WEIR/ MATHER &
M.32
Pumps PLATT/ KSB/ GREAVES/ VOLTAS
M.33 Sump pumps KBL/ Kishore/ KSB
M.34 GI Pipes Jindal/ Zenith /Tata/ Ajantha

Stewarts & Lloyds /Sivanandha/ NL
M.35 GI pipe fittings
Hazra & Son.
SAIL, ITC, JINDAL, Ajanta, Zenith,
M.36 Steel pipes Maharastra Seamless, Prakash Tubes
Gujarat Steel Tubes, Kalinga.
Tube Bends, Jindal, Ajanta Shivananda,
M.37 Steel pipes fittings
EBY Industries.
IVPL, Fouress, and NRV Audco,, BDK,
M.38 Gate /Sluice valves
BHEL, Kirloskar
Audco/ Alfa Laval/ Fishers/ Keystone/
M.39 Ball Valves
Virgo.
Alfa Laval/ Audco/ BDK/ Fouress/
M.40 Butterfly valves Intervalve/ Keystone/ Jash /Virgo/Tyco /
AVC
M.41 Strainer Otoklin, Superflow, Triveni.
M.42 Water spray nozzles Reliable, Kidde, HD Fire, Spray Safe

HD Fire, Kidde, Total walther (Germany),
M.43 Deluge valves
Simplex(USA).
Automatic air release-cum -
M.44 IVPL, Leader, Shivdurga
break valve
NMDC LIMITED MECON
LIMITED

SL.
NO.
Outside coating & Wrapping
M.45 Llyods / STP
for pipes
Cori Engg. P. Ltd,/ Hitech joints/ RRD
M.46 Rubber dismantling joints brothers, Calcutta./ Wren
Voltas/ Blue Star/ Carrier.
M.47 Air conditioning system
Flow Link / Almonard/ C. Doctor/

M.48 Ventilation system
Dustven
ACCO/ Flakt wood/ Reitz India/
M.49 Centrifugal Fan
Universal/ Laxmi.
M.50 Filter Aerosol/ Thermadyne / John Fowler
M.51 Voltage Stabilizers Oricon/ V-Guard/ Syntech.
M.52 Pre-fabricated ducting Western Air Ducts / Rola Star
M.53 Dampers HPS / Ajantha
NMDC LIMITED MECON
LIMITED

2.2 ELECTRICAL EQUIPMENT/COMPONENT
SL.
NO.
E.1 Power, Distribution BHEL / BHARAT BIJILEE / KEC / AREVA
Transformer / CGL/ Voltamp
E.2 Lighting transformer P.S. Electricals ( Chennai ), INDCOIL

( Dry type lighting trafo)
E.3 Converter Transformer Voltamp, ABB/CGL/KEC/Bharat Bijilee/
BHEL
E.4 HT switchboard ABB / SIEMENS / AREVA / CGL
E.5 HRC Fuses (HT) AREVA / SIEMENS /ABB/CGL
E.6 Capacitor (L. T) Universal cables limited, Satna /
KHATAU / CGL / ASIAN /MEHER
/SIEMENS
E.7 Capacitor (H. T) Universal cables limited, Satna /
ASIAN / ABB /CGL
E.8 Numerical Relays SIEMENS / AREVA / ABB
E.9 CT & PT (33 & 6.6 KV) AREVA/ CGL/BHEL / PRAGATI / ABB /
JYOTI / TELK
CT & PT (0.415KV) AE / KAPPA /SIEMENS / SILKAANS /
WEBER-OERSTED /PRECISE / PRAGATI
E.10 Vacuum Contactors AREVA / SIEMENS / CGL/ABB
E.11 Cable Termination Kits ( Raychem / MECP /Densons
heat shrink type)
E.12 Lighting Arrestors ABB/OBLUM / CGL /ELPRO / AREVA
/LAMCO
E.13 Micro processor based ENERCON / SWIFT / NEPTUNE / ABB /
meters SIEMENS
E.14 V.C.B. SIEMENS/CGL / AREVA/ ABB
E.15 L.T. Motors KEC / CGL /SIEMENS BHARAT BIJILEE
/ ABB / AREVA
E.16 H.T. Motors KEC /CGL / SIEMENS / BHEL / AREVA /
ABB
E.17 PCC/PMCC/ MCC SIEMENS /GEPC / SCHNEIDER / L&T
E.18 L. T. Air Circuit Breaker L & T/ SIEMENS/ SCHNEIDER /GEPC
E.19 MCCB / MPCB L & T/ SIEMENS/ SCHNEIDER /GEPC
E.20 LT Power & Auxiliary L & T/ SIEMENS/ SCHNEIDER /
Contactors GEPC
NMDC LIMITED MECON
LIMITED

SL.
NO.
E.21 Bi-metallic Overload L & T/ SIEMENS/ SCHNEIDER / GEPC
Relays
E.22 VVVF Drives SIEMENS /ABB / ROCKWELL
AUTOMATION / CegelecL
E.23 Protection and auxiliary ABB / AREVA/ EASUN REYROLLE
Relays (Electromechanical)
E.24 Indicating meters AE / IMP / MECO / RISHABH
E.25 Light Fittings PHILIPS / CGL/ BAJAJ/SIGMA
E.26 HT Cables UNIVERSAL / NICCO / POLYCAB / RPG
CABLES / (ASIAN) / CCI
E.27 LT power and control UNIVERSAL / NICCO / CCI / RPG
Cable CABLES (ASIAN) / POLYCAB / FINOLEX
E.28 Battery Charger Amar Raja / Caldyne / Universal / AE /
Chhabi Electricals/HBL Nife
E.29 Decorative switches & Anchor / Lisha
sockets
E.30 MS tubular Street light Bajaj Electricals, Unique Electrotech
pole Pvt. Ltd, Pune, K.L.Industries,
Mumbai, Ridhidhi Poles Pvt. Ltd,
Baroda Tube Poles, Mumbai, sigma,
Subham poles.
E.31 Photo electric cell/ Nature Kakatiya energy systems Pvt Ltd,
switch (Hyderabad ), Advance electronics
(Kolkata)
E.32 UPS DB power electronics, HI-REL
electronics, Numeric power
systems, Power one micro systems,
Emerson
E.33 NGR fail safe relay M/s. Startco Engineering limited,
Canada.
E.34 Neutral Grounding Resistor S R Narkhede/ PEFCO/ Resitech
Electricals/ Ohmark Controls
E.35 HT Reactors PS Electricals / Shrihans Electricals /
Trench electrics / Western Hivolt /
Quality power Electrical equipment (P)
Ltd.
E.36 Insulators JAYASHREE/ASSOCIATED
POECELAIN/WS INDUSTRIES
NMDC LIMITED MECON
LIMITED

2.3 INSTRUMENTATION EQUIPMENT/COMPONENT
SL.
NO.
Programmable Logic ABB, Rockwell Automation, GE Fanuc,
I.1
Control Siemens, Schneider
Panels, Cabinets,
I.2 Pyrotech, Rittal, Hoffman, BCH
Operator Desk
I.3 Relays Omron, Siemens, Phoneix, OEN
Push Buttons & Teknic, L&T, Siemens, Bharatia Industries
I.4
Indicating Lamps Ltd.
I.5 PC / Workstation IBM, HP, Dell
I.6 Laptop IBM, HP, Dell
I.7 TFT Monitor HP, Dell, Samsung, LG, Viewsonic
I.8 Laser Printer HP, Canon, Samsung
I.9 Ethernet Switches Cisco, Foundry, Nortel, Extreme
Elmex Controls Pvt. Ltd., Connectwell,
I.10 Terminals
Phoenix, Wago, Weidmuller
I.11 UPS Emerson, Hirel, DB Power, APC
I.12 Battery Exide, Amaraja, Panasonic
Fisher- Xomox, Fouress Engineering (I) P.
I.13 Butterfly Valve
Ltd, Deltech, L&T (Audco), Keystone
Key Stone, Fouress Engineering (I) P. Ltd,
I.14 Ball Valve
Samsons, L&T (Audco)
Electro-Pneumatic IL, MIL, Fouress Engg., ABB Introl Moore
I.15
Positioner Control
Virgo, Automax, EI-O-matic, MIL, Fisher-
I.16 Pneumatic Actuator Xomox, Fouress Engineering (I) P. Ltd,
Keystone, L&T (Audco)
NMDC LIMITED MECON
LIMITED

SL.
NO.
Shav-Norgen (I) P.Ltd, Placka, Scharaedar
I.17 Air Filter Regulators
Duncan, Hydro pneumatics
Festo, Scharaedar Duncan, Seitz Rotex,
I.18 Solenoid Valves
Asco, Avcon
I.19 Limit Switches Siemens, Jayashree, Jai Balaji
I.20 Position Transmitter IL, MIL, Fouress Engg, Samsons
Endress + Hauser, Khrone Marshall,
I.21 Magnetic Flow Meter
Yokogawa, Emerson (Rosemount)
Pressure / DP / Level /
I.22 Rosemount, Yokogawa, ABB, E&H
Flow Transmitter
Ultrasonic Level E&H, Siemens (Miltronics), Krohne-
I.23
Transmitter Marshall, Chemtrol (Vega)
Radar Level
I.24 Rosemount, E&H, Chemtrol (Vega)
Transmitter
Pressure Gauge / AN Instruments, General Instruments,
I.25
Switch Pyroelectrics, WARREE, WIKA
General Instruments, Industrial
I.26 RTD Instrumentation, Pyroelectrics Instruments
Ltd., Nagman, Detriev, Navin
Temperature
I.27 YBL, THL, Emerson,ABB
Transmitter
Capacitance type level
I.28 Endress + Hauser, Nivo, K-Tek, SBEM
transmitter
Instrument Signal Asian Cables, Thermopad Cables, Cords
I.29
Cable Cable, Delton, Finolex, Fort Gloster
Instrument Control Asian Cables, Thermopad Cables, Cords
I.30
Cable Cable, Delton, Fort Gloster, Polycab
Instrument Power Asian Cables, Thermopad Cables, Cords
I.31
Cable Cable, Delton, Fort Gloster, Polycab
NMDC LIMITED MECON
LIMITED

SL.
NO.
I.32 Fiber Optic Cable Avaya, Finolex Cables, Optel, Lucent
I.33 Hooter Kharej, Pepl
Surge Protection
I.34 OBO, MTL, Forester, Telematic
Devices
IR Detectors and
Devices ODTI, Patol, Protectowire, pyrotronics,
I.35
UL /FM /ULC /MIL Det-Tronics, IAS Morley
/LPC Approved
Fire Alarm Control

Panels SIEMENS / EST/ JOHNSON CONTROLS /
I.36
UL /FM /ULC /MIL /LPC HONEYWELL / NOTIFIER
Approved
Break Glass Type
Manual Call Points
Including Hand Sets. SIEMENS / EDWARDS / HONEYWELL /
I.37
NOTIFIER
UL /FM /ULC /MIL /LPC
Approved
Fire detection power & Universal cables /CCI /Delton /Govind
I.38
control Cables /KEI /Asian /NICCO /PLOYCAB /Torrent
I.39 LHS Cables UL/FM approved (Kidde / Equivalent )
Batteries AMCO/SABNIFE/AMARA RAJR/EXIDE /

I.40
PANASONIC
Electronic display
I.41 Keltron/ Vipa/ Magnetodynamics
board
I.42 PA System BNA, BOSCH (PHILIPS)
NMDC LIMITED MECON
LIMITED

2.4 CIVIL WORKS
2.4.1 GENERAL
The makes and manufacturers shall preferably be from the

following list. Wherever applicable all products shall have BIS
certification marking. In case the same is not available in the
market or incase of a change in trade name, equivalent
makes/ re-designated manufacturer shall be used with the
approval of Consultant.
In case of items not covered in the list, the material shall be

the best available in the market and each item should have
BIS certification mark.
SL.
NO.
C.1 TILES:
i) Terrazzo and cement M/s. NITCO; M/S. NEC; M/S. NIMCO.
tiles.
ii) White glazed tiles. M/s. H R Johnson;
C.2
M/s. Somani Pilkington; Spartek .
iii) PVC tiles. M/s. Bhor Industries.,
M/s. Premier Vinyl Flooring Ltd
METALLIC FLOOR M/s. Triveni Color Industries
HARDENER. (Floornate)
M/s. Heatly & Gresham (India) Ltd
C.3 M/s. De-Rust Chemical Corporation of
India (Ferronite)
M/s. Cement Research Corporation Pvt
Ltd. (Stilonite)
WOODEN DOORS / M/s. Indian Plywood Mfg. Co. Ltd
BLOCK BOARDS / M/s. Kit Ply Industries Ltd;
PLYWOOD/ M/s. Nuboard M/s. Sitapur,
PARTICLE BOARD. M/s. Kutty Flush Doors
M/s. Mysore Plywood Ltd; M/s. Joinery
C.4
Manufacturer; M/s Northern Doors
M/s. Wood India, Calcutta; M/s Pioneer
Timber product, Chandigarh
M/s Sakti Flush doors
or equivalent approved manufacturer
NMDC LIMITED MECON
LIMITED

SL.
NO.
STEEL DOORS & WINDOWS M/s. Sen Harvic; M/s AGEW;
M/s. Hopes Metal; M/s. Multiwyn
C.5
M/s NCL Seccolor Ltd.
or equivalent approved manufacturer
ROLLING SHUTTERS M/s. SwastikRollling Shutters &
Engg. Co. (P) Ltd.,
C.6 M/s Hercules Rolling Shutters &
Engg Works. or equivalent approved
manufacturer
ALUMINIUM DOORS, M/s. Ajit India; M/s. Alumilite; M/s.
C.7 WINDOWS, WALL SPANS. Indal; M/s. Jindal.
M/S Triveni
GLASS.
M/s Modigaurd
C.8 (Plain/Frosted,Garless,
M/s Saint gobain
Bajra etc.)
Or equivalent approved manufacturer
HARDWARE FITTINGS M/s Jayant Metal Manufacturing Co.
& FIXTURES. M/s Shalimar Hardware.
C.9
Everite. M/s Godrej & Boyce mfg. Ltd.
or equivalent approved manufacturer.
A/C SHEETS. M/s Asbestos Cement ltd. (Everest);
C.10 M/s Charminar
WATERSTOPS. M/s Basecon; M/s Pask;
(PVC/RUBBER) M/s Asian Engg. Products;
M/s Capnhans india Ltd;
C.11
M/s Fixopan Engrs. Pvt. Ltd.
Or equivalent approved
manufacturer.
EXPANSION JOINT AND M/s Shalitex; M/s Tiki Tar industries;
TARFELT WATERPROOFING M/ Shalimar Tar Products;
C.12
M/s Lloyd Insulation (I)
INTEGRAL WATER: Accoproof, Cico; Impermo
C.13
PROOFING COMPOUND or equivalent approved manufacturer.
CEMENT BASED: M/s India Waterproofing Co.;
WATERPROOFING M/s All India Waterproofing Co;
C.14 TREATMENT M/s Likproof India Pvt. Ltd.;
M/s Modern Waterproofing Co.;
M/s Nina Industries.
NMDC LIMITED MECON
LIMITED

SL.
NO.
PAINTS AND VARNISH M/s Asian Paints; M/s Goodlas
Nerolac;
M/s Garware Paints Ltd.;
C.15 M/s I.C.I. Paints;
M/s Berger (British) Paints;
M/s Jenson Nicholson;
CEMENT BASED M/s Snowcem India Ltd.
WATERPROOF PAINTS M/s Nitco Paints Pvt. Ltd. (Nitcocent);
& RESINBASED M/s Hindustan Colour
C.16 THERMO PLASTIC PAINTS Chemical Industries;
M/s Terraco (Terraccin & Terracoat);
M/s Surfa Coat Pvt. Ltd.
PRESSED STEEL DOOR: M/s Sen Harvic
FRAMES M/s Techome
C.17
M/s Madhu Industries, Bangalore or
equivalent approved manufacturer.
FALSE CEILING / INDIA GYPSUM LTD.,
C.18
PANELING
C.19 DECORATIVE LAMINATES Decolam , Formica
C.20 PVC/ FRP DOORS Rajashri plastic, Thermodeck
Everite, Hardiwyn,
C.21 DOOR CLOSERS
Dewan Industries
C.22 SEALANTS GE Silicon,Bostik
CONCRETE PAVER BLOCKS Basant Belton,
Adideep Interlock Pavers, PVt. Ltd.,
C.23
Designers Pavings & Tiles Pvt. Ltd.,
Bessers Concrete Paver Blocks.
C.24 SANITARY APPLIANCES Parraware,Hindustan
CP BRASS FITTINGS Jaquar MBM, GEM,
C.25
Kingston,
CP BRASS WASTE Jaquar, ESSO, GEM, Kingston,
C.26
COUPLING, BOTTLE TRAPS
C.27 PVC flushing cisterns Parry ware, Hindware
Mirror Hindustan Pilkinton, Modigaurd. Atul
C.28
glass Works , Golden fish
C.29 Plastic seat and cover Commander,
C.30 Stainless Sink Nirali, Dayana, AMC, etc.
NMDC LIMITED MECON
LIMITED

SL.
NO.
C.31 GI Pipes ITC, Zenith, Ambica
C.32 GI Mallable fittings PEC, MJM. Bimal
C.33 GM gate/ Globe valves Neta, Sant, NEW,Leader
C.34 Ball Valves MBM, Techno, Leader
C.35 CI water quality pipes IISCO
C.36 CI soil quality pipes IISCO, Neco
C.37 SW Pipes & Gulley traps Perfect Kashmira,
C.38 RCC Hume Pipes Indian Hume Pipes, Pranali Premier
C.39 HDPE Pipes & fittings Prince, Gautam
C.40 PVC pipes & fittings Flowgaurd
C.41 Modular floors Unitile
C.42 CI manhole covers Neco
C.43 PVC storage tanks Sintex, Century, Polycon
CEMENT ACC, COROMANDEL, RAJASHREE,
C.44
ZUARI, L&T (ULTRA TECH CEMENT)
C.45 REINFORCEMENT STEEL RINL, SAIL, TATA STEEL
C.46 ADMIXTURES FOSROC, SIKA, ROFF,
Anti- termite M/s Pest Control (I) Ltd.,
C.47
M/s Mysodet Pvt Ltd.,
Note: Structural Steel & Reinforcement Steel can be procured from

any reputed manufacturers but shall conform to the following
in addition to the specifications stipulated in the respective
chapters:
1. Rerolled reinforcement steel / structural steel sourced

from the rerollers shall not be procured / used.
2. The reinforcement steel shall be corrosion resistant

“M” bars conforming to Grade Fe-415 of IS:1786
(latest version.)
3. The rolled structural steel sections and plates

( thickness 20 mm and less) shall conform to Grade-A
(Fe 410 WA) as per IS:2062(latest version). The plates
above 20 mm shall conform to Grade-B (Fe 410 WB)
as per IS:2062(latest version).
NMDC LIMITED MECON
LIMITED

4. Necessary test certificates for these steels in respect of

material properties and strength / test requirements as
per relevant BIS codes as obtained from the
manufacturer shall be furnished to Owner/Consultant.
5. The material procured by the Contractor shall also be

subject to an independent testing by a reputed agency
/ institution arranged by Owner / Consultant at the
cost of Contractor.
NMDC LIMITED MECON
LIMITED

CHAPTER NO. Q1 PAGE No. 1 of 160
CHAPTER-Q1
TECHNICAL SPECIFICATION – MECHANICAL

CONTENTS
SL.
Description
No.
1.0 Scope of Work
2.0 Belt Conveyor
3.0 Down Hill Conveyor no. 723
4.0 Reversible conveyor no. 727
5.0 Belt Feeder
6.0 In line Over Band Magnetic Separator
7.0 Belt Weigh Scale
8.0 Metal detector
9.0 Hydraulically operated gates

10.0 Extension / Modification of existing tripper conveyor no. 122
11.0 Tapping of material from existing tripper on conveyor no. 122
12.0 EOT Cranes & Hoists
13.0 Electric & Manual Hoists
NMDC LIMITED MECON
LIMITED

TECHNICAL SPECIFICATION - MECHANICAL
1.0 SCOPE OF WORK
1.1 The system descriptions, scope of work and battery limits for
this package is described under relevant chapters of this
document.
1.2 The major equipment covered under this specification are

indicated in the list of equipment given below:
CAPACITY Motor
EQPT. QTY.
DESCRIPTION OF EQUIPMENT (Rated / (kW REMARKS
NO. (Nos.)
Design) approx.)
Between secondary
BELT CONVEYOR 1800 / Crusher House &
718 1 37.0
(1200mm BW x 37m L approx.) 2000 TPH Transfer House
TH-1
718A IN LINE MAGNETIC SEPARATOR 1 -- -- On Conveyor 718
ELECTRIC HOIST IN TRANSFER

718B 1 -- -- --
HOUSE TH-1
718C BELT WEIGH SCALE 1 -- -- On Conveyor 718
Between Transfer
BELT CONVEYOR 1800 /
719 1 90.0 House TH-1 to
(1200mm BW x 171m L approx.) 2000 TPH
top of RCC Silo
719A METAL DETECTOR 1 -- -- On conveyor 719
ELECTRIC HOIST AT SHED OVER
719B 1 -- -- --
SILO
RCC SILO WITH STRCTURAL
719C SUPERSTRUCTURE 1 -- -- --
(1000T EFFECTIVE STORAGE)
To match the
NEEDLE GATE AT THE BOTTOM OF
719D 1 -- -- opening of RCC
RCC SILO
Silo
BELT FEEDER WITH VFD 1800 /
720 1 -- Below RCC Silo
(8.5m L approx.) 2000 TPH
720A IN LINE MAGNETIC SEPARATOR 1 --- -- On Belt feeder 720

720B 1 --- -- --
HOUSE TH-2
NMDC LIMITED MECON
LIMITED

CAPACITY Motor
EQPT QTY.
NO. (Nos.)
Design) approx.)
Between Transfer
721 1 11.0 House TH-2 to
(1200mm BW x 30 m L approx.) 2000 TPH
TH-2A
721A METAL DETECTOR 1 -- -- On Conveyor 721
721B BELT WEIGH SCALE 1 -- -- On Conveyor 721

721C 1 -- -- --
HOUSE TH-2A
At Tail / Drive
722 15/5 T DOUBLE GIRDER EOT CRANE 1 -- -- House of Down Hill
Conveyor
MANUAL HOIST FOR MAINTENANCE At Tail / Drive
722A OF 15/5T DOUBLE GIRDER EOT 1 -- -- House of Down Hill
CRANE Conveyor
Between tail/ drive
house to Transfer
2 x 750
House TH-3 and
kW with
DOWN HILL CONVEYOR complete with 2
723 1 -- VFD
(1050 mm BW x 4900 m L approx.) nos. self propelled
(At tail
travelling
end)
maintenance
trolleys
5T UNDER SLUNG EOT CRANE IN At PS-1 (Towards
PARKING / MAINTENANCE STATION tail end of Down
723A 1 --- --
FOR TRAVELLING MAINTENANCE Hill Conveyor
TROLLEY no. 723)
5T UNDER SLUNG EOT CRANE IN At PS-2 (Towards
PARKING / MAINTENANCE STATION head end of Down
723B 1 --- --
FOR TRAVELLING MAINTENANCE Hill Conveyor
TROLLEY no. 723)
SURGE HOPPER (50 cu.m water In Transfer House
724 1 -- --
filled volume) TH-3
At the bottom of
724A HYDRUALICALLY OPERATED GATE 1 -- -- Surge hopper in
TH-3
BELT FEEDER WITH VFD 1800 / Below Surge
725 1 --
(8m L approx.) 2000 TPH Hopper in TH-3
AT TH-3 for
MANUAL HOIST IN TRANSFER maintenance of
726 1 -- --
HOUSE TH-3 head pulley of
down hill conveyor
NMDC LIMITED MECON
LIMITED

CAPACITY Motor
EQPT QTY.
NO. (Nos.)
Design) approx.)
At TH-3 for
maintenance of
726A 1 -- -- belt feeder / Head
HOUSE TH-3
Pulley of down hill
conveyor
At TH-3 for
726B 1 -- -- maintenance of tail
HOUSE TH-3
pulley of conv. 727
400 kW
with
Between Transfer
REVERSIBLE BELT CONVEYOR 1800 / VFD (At
727 1 House TH-3 to
(1050mm BW x 295m L approx.) 2000 TPH head
TH-4
end at
TH-4)
727A 1 -- -- --
HOUSE TH-5
At Transfer House
727B 7.5 T SINGLE GIRDER EOT CRANE 1 -- --
T H-4
Between Transfer
BELT CONVEYOR 1800 / Station at tail end
727-1 1 22.0
(1200mm BW x 13m L approx.) 2000 TPH and Transfer
House TH-6
Between Transfer
727-2 1 110.0 House TH-5 and
(1200mm BW x 73m L approx.) 2000 TPH
TH-6
727C 1 -- -- --
HOUSE TH-6
Existing tripper
conveyor no. 122
shall be extended
by approx. 12m at
Refer Cl. tail end & also
MODIFICATION OF EXISTING 2000 TPH
122 1 No. travel of existing
TRIPPER CONVEYOR (Design)
10.2.1 tripper shall be
extended by
approx. 28 m
towards the tail
end
1.3 The list of equipment and the capacities / KW ratings

indicated are the minimum requirement Tenderer to supply.
However the Tenderer shall verify & ensure the adequacy of
the same and offer higher capacities / ratings (if required)
with justification for the same. Further any additional
NMDC LIMITED MECON
LIMITED

equipment required for proper functioning of the total system

shall be included by the Tenderer in his offer.
1.4 The Capacity of electric hoists shall be finalised considering

the maximum weight of the item to be lifted and also span,
height of lift, hook approaches, etc. of EOT cranes shall be
finalised considering the building sizes and other technical
requirements.
1.5 All the equipment shall be complete in all respects including

their auxiliary facilities.
1.6 SPECIFICATION FOR TECHNOLOGICAL EQUIPMENT
The technical specifications of main material handling

equipment as indicated above are given in subsequent
chapters. All the equipment shall be complete in all respects
including their auxiliary facilities. The main equipment
supplier shall supply all related mechanical, electrical, control,
lubrication systems, etc. for compatibility. If not, the selection
of related sub-systems / equipment shall be approved by the
main equipment supplier.
2.0 BELT CONVEYORS
2.1 GENERAL
2.1.1 Belt conveyors shall be designed in accordance with relevant

Indian standards taking into account the following factors and
considering plant standards for various components:
i) Artificial friction coefficient 0.025 for uphill conveyors

and 0.012 for regenerative downhill conveyor.
ii) Coefficient of friction between lagged pulley surface

and belt to be considered as 0.35.
iii) Coefficient of friction between material & belt to be

considered as 0.6.
iv) Coefficient of friction between material and skirt plates

to be considered as 0.6.
NMDC LIMITED MECON
LIMITED

v) Coefficient of friction between belt and belt cleaner to

be considered as 0.6.
vi) Pressure between belt cleaner & belt to be considered

as minimum 50000 N/m2.
vii) All the drive elements like motor, gearbox, couplings,

idlers and pulleys etc. shall be chosen accordingly as
indicated in this specification.
viii) The troughing angle of the belt on the carrying side to be

considered as 35 Deg.
2.1.2 The technological structure for conveyors like drive and tail
end framework, stringer, short posts, etc. shall be made of
joists and / or channels suitably stiffened and braced. The
spacing of the short posts shall not exceed 3000mm and the
same shall be connected to the floor beams / insert plates by
site welding. The head and tail end frames, however, shall be
bolted to the floor beams. The size of short posts and stringer
members shall not be less than ISMC-125 & ISMC-150
respectively.
2.1.3 Deck plates of minimum 3.15 mm thickness shall be provided

throughout the length of conveyor to avoid spillage of
material on return belt.
2.1.4 The drive unit consisting of motor, gearbox, high speed

coupling, low speed coupling and brakes (wherever
applicable) shall be mounted on common base frame. The
conveyor drive pulley shall be coupled directly with the
gearbox output shaft through coupling and no V—belt or
chain shall be used.
2.1.5 Tenderer shall make his own calculations and ensure the
adequacy of the rating of the individual components of the
conveyor.
2.1.6 All components of identical capacity and duty shall be

interchangeable.
NMDC LIMITED MECON
LIMITED

2.1.7 All parts requiring replacement, inspection or lubrication shall

be easily accessible without the need for dismantling of other
equipment. Safe access for maintenance and removal of all
parts shall be ensured. Suitable lifting lugs shall be provided
in all motors, reducers and drive frames.
2.1.8 Worm reducers shall not be used in any equipment unless

written approval is obtained from the Owner
2.2 SKIRT BOARDS
2.2.1 Skirt boards of minimum 6000 mm length shall be provided

at the loading points of all conveyors. Wherever the loading
points are nearer to each other, the skirt board shall be made
continuous between them. Skirt boards shall flare out in the
direction of belt travel. The thickness of skirt plate shall be
minimum 10 mm. Skirt plates shall be provided with liner of
minimum 10 mm thick MS plate with 6 m thick chrome
carbide overlaid (hard facing) on it. Skirt height shall be
raised (approximately twice the standard height) for the initial
2m portion. The height of the skirt board shall also take into
account the requirement of the dry fog dust suppression
system.
2.2.2 The arrangement for fixing rubber on skirt board including

back rubber at loading points shall be such as to ensure quick
adjustment. Skirt rubber shall be in segments and the design
shall ensure automatic flexing of rubber for proper sealing.
Shore hardness of rubber shall be min. 55 deg. on scale-A,
tensile strength 17 MPa (minimum) & elongation at break
400%(minimum). Skirt rubber shall be minimum 15 mm
thick.
2.3 BELT SCRAPERS
2.3.1 Multi sprung blade type belt scrapers (Primary and

Secondary) shall be provided between the discharge end and
snub pulley such that belt is effectively cleaned. Polyurethane
and Tungsten Carbide blades shall be provided for Primary
and secondary scraper respectively.
NMDC LIMITED MECON
LIMITED

2.3.2 V-shaped scrapers shall be provided on the upper side of the

return belt near the tail end and near VGTU bend pulleys to
remove spilled materials.
2.3.3 One no. additional V-shaped scraper shall also be provided

on the conveyers having belt weigh scales, before belt scales.
2.4 GUARDS
2.4.1 Safety guards shall be provided for couplings, pulleys,

tensioning devices, brakes etc. Vertical take up pulleys shall
be effectively guarded against spilled materials. All plates and
angles used for guards shall be min. 5 mm thick. Wire mesh
guards shall be of min. 4mm dia wires.
2.5 GEAR BOXES
2.5.1 In general, hardened and ground bevel helical gear reduction

units shall be used. Worm and bevel gears shall not be used
unless specified otherwise.
2.5.2 Bevel helical type gear box shall be provided for all
conveyors.
2.5.3 Overhung or split gears and pinions shall not be used.
2.5.4 All gears shall be of hardened and ground and made of

suitable alloy steel with machine cut teeth. All the gear teeth
shall be hardened and ground and finished to suit the service
conditions.
2.5.5 Gear teeth shall be cut in metric module system only.
2.5.6 All gears shall be completely enclosed in oil tight enclosure.
2.5.7 All gear shafts shall be supported in antifriction bearings

mounted in gearbox.
2.5.8 Splash lubrication system shall be used in the gearboxes.
2.5.9 The housing for gearboxes shall be of cast steel or fabricated.

Fabricated gearboxes shall be stress relieved.
NMDC LIMITED MECON
LIMITED

2.5.10 Covers shall be split horizontally at each shaft centreline and

fastened and arranged so that the top half can be removed
for inspection and repair without disturbing the bottom half.
2.5.11 The gearboxes shall be provided with breather vents & oil
level indicators and easily accessible drain plugs.
2.5.12 All gearboxes shall have machined base.
2.5.13 Double V – lip type of seal shall be provided on extended

input and output shafts.
2.5.14 Service factor shall be 2.0 times motor power for all
conveyors except down hill conveyor no. 723 & reversible
conveyor 727 for which it shall be considered inline with
service factor specified under the relevant clause under 3.0.
2.6 COUPLINGS
2.6.1 High Speed coupling
i) For motor rating from 55 kW to 160 kW (both

inclusive), high speed coupling shall be fluid coupling of
multidisc type.
ii) For motors with rating not falling in the above range,
spring type resilient flexible coupling shall be used.
However for conveyors with VVVF drive, the high speed

coupling shall be of spring type resilient flexible coupling.
2.6.2 Low speed coupling
i) Low speed coupling between gearbox output shaft and

drive pulley shall be full-geared coupling.
ii) All coupling bolts shall be replaceable without shifting

the drive components. All couplings shall be provided
with sheet metal guards bolted to the base frame. A
service factor of 1.5 on motor rating shall be
considered for the selection of all couplings. Pin bush
type couplings shall not be used.
NMDC LIMITED MECON
LIMITED

2.7 PULLEYS
2.7.1 Pulleys shall be of extra heavy-duty type & shall conform to
1S: 8531-86 in general.
2.7.2 Material of construction for pulleys shall be as follows:
MATERIAL OF CONSTRUCTION
SL Shaft diameter at hub
DESCRIPTION
NO Drive pulley Non drive pulley
<190 mm ≥190 mm <190 mm ≥190 mm
1 Shell hub & E250(Fe E250(Fe 410W) E250(Fe E250(Fe
diaphragm
410W) quality ‘C’ as 410W) 410w)
quality ‘C’ per IS quality ‘C’ quality ‘C’
as per IS 2062:2006 as per IS as per IS
2062:2006 2062:2006 2062:2006
2 Shaft 45C8 as per 40Cr4Mo3 as 45C8 as 40Cr4Mo3 as
IS-9175 per IS-9175 per IS- per IS-9175
(PART-7)- (PART-22)- 9175 (PART-22)-
1986 1987 (PART-7)- 1987
1986
3 Turbo Cast steel Cast steel
diaphragm
--- Gr.280-520W --- Gr.280-520W
with end
disc as per IS 1030- as per IS
1998 or E250 1030-1998 or
(Fe 410W) E250 (Fe
quality ‘C’ as 410W) quality
per IS ‘C’ as per IS
2062:2006 2062:2006
4 High tensile IS: 1367 IS: 1367 IS: 1367 IS: 1367
Hex. Head
bolts (PC. (PC. 8.8/10.9) (PC. (PC.
8.8/10.9) 8.8/10.9) 8.8/10.9)
NMDC LIMITED MECON
LIMITED

2.7.3 Pulleys having shaft diameter less than 160 mm at bearing

shall have end discs welded to hubs and shell.
2.7.4 Pulleys having shaft diameters of 160 mm and above at

bearing shall be provided with turbo-diaphragm type of end
disc wherein the end disc and hub will be of integral steel
casting.
2.7.5 Pulleys shall be designed and manufactured in such a manner

that there would be no relative movement between the hub
and the shaft. The shaft shall be easily removable from the
pulley when required.
2.7.6 Pulleys having shaft diameter of less than 200 mm at bearing

may be provided with Gib head key or parallel key with a
locking arrangement for preventing axial movement of pulley
drum on the shaft.
2.7.7 Pulleys having shaft diameter of 200 mm and above at

bearing shall be provided with expandable shaft hub
connection (Ring feder type)
2.7.8 For non-driving pulleys with shaft dia less than 160 mm at
bearing, the minimum shell thickness after machining shall be
12 mm.
2.7.9 For all non-drive pulleys with shaft dia greater than or equal
to 160 mm at bearing and for all drive pulleys the minimum
shell thickness after machining shall be 16 mm.
2.7.10 Design Parameter
i) Pulley shaft shall be designed with following service

factors:
Kb = 2.0
Kt = 1.5
Where Kb is service factor for bending and Kt is service

factor for torsion.
NMDC LIMITED MECON
LIMITED

ii) Maximum permissible stresses and other limiting

parameters for design of pulleys shall be as given
below:
VALUE
SL Shaft diameter at hub

DESCRIPITION
NO Drive pulley Non drive pulley
<190 mm ≥190 mm <190 mm ≥190 mm
a Bending
stress 55 MPa 80 MPa 55 MPa 80 MPa
b Shear stress
28 MPa 50 MPa 28 MPa 50 MPa
c Combined
stress due
to bending 38 MPa 60 MPa -- --
and torsion
d Angular
deflection 6 minutes 6 minutes at 6 minutes 6 minutes
at hub hub at hub at hub
e Torsional
0.26
deflection 0.26 Deg./m -- --
Deg./m
f Allowable
pressure at
shaft/hub 100 Mpa 100 Mpa 100 Mpa 100 Mpa
connection
g Allowable
pressure at
100 Mpa 100 Mpa -- --
key
h Shaft
deflection 1 mm/m 1 mm/m 1 mm/m 1 mm/m
length length length length
NMDC LIMITED MECON
LIMITED

2.7.11 The Pulley shell shall be welded, thermally stress relieved and
then machined.
2.7.12 No welding shall be done after machining the shell except for
fixing of balancing weights.
2.7.13 Pulley shaft shall be ultrasonically tested.
2.7.14 Dye-penetration test shall be done for all welded joints.
2.7.15 Adequate radius / fillet shall be provided on the shaft

wherever change of diameter takes place to minimise stress
concentration.
2.7.16 Pulleys shall be statically balanced along with shaft.
2.7.17 Balancing weights, if used, shall be properly welded to the

diaphragm and shall not project beyond the drum face.
2.7.18 Pulley shell concentricity shall be max. ±1 mm (TIR shall be

±2 mm) over the bare pulley.
2.7.19 Tolerance on pulley diameter shall be limited to ±0.2% and

tolerance on rubber lagging thickness shall be limited to
± 0.5 mm.
2.7.20 All drive pulleys shall have hot vulcanized rubber lagging of
12 mm thickness with grooved herringbone or chevron
pattern. Grooves shall be 6 mm wide & 6 mm deep. The
grooves shall be spaced between 30 mm and 40 mm. Non-
drive pulleys shall be lagged with 12-mm thick plain rubber.
2.7.21 The lagging rubber shall have Durometer hardness of 55 to

65 shores, scale A with minimum tensile strength of 17 MPa
and minimum elongation of 400% at break.
2.7.22 In determining pulley diameters, no account shall be taken of

the lagging thickness.
2.7.23 Crowning shall not be provided on the pulley shell.
NMDC LIMITED MECON
LIMITED

2.7.24 In a pulley assembly, one bearing shall be of fixed (by two

locating ring in Plummer block) type, and the other shall be
floating type.
2.7.25 Selection of bearings shall be done for a minimum service life

of 40,000 working hours.
2.7.26 Spherical roller bearings of 222 series with adapter sleeve

and lock nut shall be used for pulleys with shaft diameter at
bearing up to and inclusive of 200mm.
2.7.27 For pulleys with shaft diameter at bearing above 200mm,

spherical roller bearing of 231 series with adapter sleeve and
lock nut shall be used.
2.7.28 Plummer blocks can be made of cast iron for bearing diameter
below 160 mm.
2.7.29 For bearing diameters of 160 mm and above cast Steel

Plummer blocks shall be provided.
2.7.30 All Plummer blocks, which support the pulleys, shall be

horizontally split type with 4-bolt fixing at the base and with
proper grease nipple arrangement for lubrication and dust
proof sealing. The mounting dimensions of Plummer block
shall be as per SKF standards.
2.7.31 The Plummer blocks shall be grease filled and triple labyrinth
type. Dust proof, water proof and oil leak proof synthetic
labyrinth seals shall be provided for each bearing.
2.7.32 All the pulley shaft bearings shall be of self aligning spherical
roller type with adequate sealing and external lubrication
arrangement.
2.7.33 Drive and non-drive pulleys with shaft diameters at bearing

equal to or more than 160 mm are deemed to be critical
pulleys, unless otherwise specified.
NMDC LIMITED MECON
LIMITED

2.7.34 The pulley diameter and shaft diameter at bearing shall be

standardised to the max. extent in line with NMDC’s standard
pulley drawing enclosed (Refer drg. no.
MEC/01/Q6DH/KIOP/II/220/TS).
2.7.35 Inspection of non-critical pulleys shall be done as per quality

plan to be furnished by successful Tenderer and approved by
Owner.
2.7.36 In case of critical pulleys, Owner’s authorized representative

shall attend stage inspection during manufacture. Tenderer
shall submit detailed manufacturing schedule/quality plan for
the same so that the hold points can be frozen for the
purpose.
2.8 MOTOR
2.8.1 The motor for conveyors shall be of continuous duty energy

efficient squirrel cage type suitable for number of switching /
hour and braking requirement as per application.
2.8.2 The motor speed shall be restricted to 1500 rpm for all
conveyors except conveyor nos. 723 & 727 for which the
speed shall be 1000 rpm. (Refer chapter – Electrics for
detailed specification of motors).
2.9 BRAKES
2.9.1 Electro Hydraulic thrustor brakes of approved make shall be

provided wherever required. The brakes of all conveyors shall
have min. 1.5 times the max. calculated torque ratings.
2.9.2 For the selection of brakes, the Tenderer shall furnish the
coasting time for each conveyor considering inertia of all
moving and rotating parts.
NMDC LIMITED MECON
LIMITED

2.10 Holdback
2.10.1 Holdbacks are required on inclined conveyors to

instantaneously stop the reverse motion of conveyors in case
of power failure or otherwise. All holdbacks shall be integral
with the gear box. The rating of the hold back shall be
minimum 1.5 times the calculated hold back torque
requirement. The design of the hold back shall be such that
dust, grease, moisture and extreme temperature do not affect
its operation.
2.11 IDLER
2.11.1 Various types of idlers covered in this specification shall

conform to the following specifications:-
i) Carrying idlers 3 roll type fixed as per enclosed

assembly tender drawing.
ii) Impact idlers 5-roll garland type without rubber

assembly disc as per enclosed tender
drawing.
iii) Return idlers Two roll 10 deg. fixed V type as

assembly per enclosed tender drawing.
2.11.2 Normal spacing for carrying idlers shall be 1000 mm & return
idlers spacing shall be 3000 mm. However, on carrying side
at loading points, idler spacing shall be 400 mm. For the
curved portion (convex), the maximum idler spacing shall be
50% of normal spacing. Self-aligning carrying idlers with
central pivot and guide rollers shall be provided at a
maximum spacing of 40 m intervals.
2.11.3 Transition idler shall be similar to troughing carrying idler in

construction and set at suitable inclination. The transition
idlers shall be generally set at 10 and 20 degree inclination
and shall be adjustable at site. There shall be minimum two
transitional idlers at each end.
NMDC LIMITED MECON
LIMITED

2.11.4 The minimum thickness of any member in idler supporting

brackets shall not be less than 6 mm. All supporting brackets
shall have slotted bolt holes for mounting on/under
supporting steel works which would generally be rolled
channel section. All the outer brackets of the Idler frame on
carrying side shall have C-cross section.
2.11.5 The eccentricity of the idler shall be such that the total
indicator reading shall not exceed 0.8 mm
2.11.6 Total indicator reading shall not exceed 0.2 mm for six nos.
idlers (three on each side) near each belt weigh scale.
2.11.7 Self-cleaning flat return idlers shall be provided at both ends
(near drive & non drive pulley) on the return strand and near
bend pulleys.
2.11.8 Flat return idler shall be provided on the return strand near
the belt weigh scale and near tail end & take-up bend pulleys.
2.11.9 Minimum bearing life of idlers & rollers shall be 30,000

working hours and they shall be grease packed for life.
2.12 TAKE—UP ARRANGEMENT
2.12.1 Take-up trolley for HGTU
The trolley frame shall be made of steel plates and rolled

section in welded construction. The trolley frame shall
preferably be fabricated in one piece. The trolley shall be
fitted with two nos. of rope sheaves in such a way that the
axis of the rope and axis of the tail pulley shall preferably be
in same level. The trolley shall be provided with 4 wheels. The
wheels shall be treaded to suit the track fitted on the tail
frame structure. The wheels & sheaves shall be mounted on
antifriction bearing. The wheels shall have minimum surface
hardness of 250 BHN.
2.12.2 Counterweight of VGTU & HGTU
Counter weight shall be of cast iron/cast steel. Cast Iron

counter weight shall be maximum 10 to 15-kg weight each.
Concrete counter weights of similar design may also be used.
NMDC LIMITED MECON
LIMITED

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 the gallery 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.
NMDC LIMITED MECON
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2.13.2 BELT SWAY SWITCHES
Belt sway switches shall be provided on each conveyor for

protection against excessive sway of the belt. A pair of
switches shall be installed near the head end and a pair near
the tail end. In case of long conveyors, additional switches
shall be installed along the length of conveyor so that
distance between two adjacent switches does not exceed
50m. A pair of these switches shall also be provided before
the belt weighing scales.
2.13.3 BELT SLIP SWITCHES
Belt slip switches shall be provided for each conveyor to stop

the drive in case of excessive slippage of belt or over
speeding. Provision shall be made such that preceding
conveyor does not start unless the running conveyor picks up
80% of the rated speed.
2.13.4 For electrical details refer electrical specification given

elsewhere in this specification.
2.14 CONVEYOR BELTS
2.14.1 Conveyor belts shall be as per the latest Indian Standards or

any other International Standards.
2.14.2 Operating tension of the belt at specified full load shall not
exceed 80% of the rated working strength for NN belting.
2.14.3 Minimum top and bottom cover thickness shall be 10 mm &

4 mm respectively.
2.14.4 All belts shall be joined by hot vulcanized splicing.
2.14.5 Complete specification of the belts shall be furnished by the

Tenderer.
2.14.6 The factor of safety for selection of Belt shall be considered as

minimum 10 for fabric belting.
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2.15 CHUTES
2.15.1 Chute shall be made of min. 10-mm thick mild steel plates.
The chute shall be in segments bolted to each other for ease
of maintenance. There shall not be any top cover in the
discharge chute after the pulley. A poking platform shall be
provided to enable poking from the top with suitable approach
poking platform.
2.15.2 Adequate opening shall be provided in the chute for

withdrawal and adjustment of belt scrapers.
2.15.3 All transfer points shall be provided with non-choking chutes

made of minimum 10-mm thick mild steel plates suitably
ribbed and shall be constructed in small segments for easy
dismantling.
2.15.4 Hinged type sealed inspection doors of minimum

400mm x 400mm size shall be provided at suitable height
and location.
2.15.5 Snub pulley near discharge end shall be covered by the

chutes for collecting spilled material.
2.15.6 Chutes shall be designed such that impact of the material on

the conveyor is minimum. They shall be designed to ensure
continuous flow of material to the center of the belt with
minimum spillage, noise and dust emission.
2.15.7 Minimum valley angle of the chute shall be 60 deg. to the

horizontal. Minimum angle of slope of chute plate shall be 65
deg. The valley angle and slope angle shall be suitably
increased for handling wet or sticky material.
2.15.8 Stone box shall be provided at discharge end of chute

wherever possible for arresting the fall and to form a natural
bed of material for protecting the parent plate.
2.15.9 Chutes shall be oriented as far as possible to ensure

discharge of material in the direction of travel of receiving
belt.
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2.15.10 Liner shall be provided as specified in this specification on all

four sides. One face of the chute shall be bolted for easy
erection of liners. The details of various sizes & fixing
arrangement of Manganese steel liners will be furnished to
the successful Tenderer. The successful Tenderer may select
the liners from amongst these, if feasible, for the purpose of
standardization.
2.16 LINER FOR CHUTES / HOPPERS / SKIRTBOARD / RCC SILO
Surface Details of Liners

Stone box type design with
Impact Zone
40 mm Mn Steel liner
Edge of stone box 50 mm Mn steel liner
Wearing surface
25 mm Mn steel liner
(Abrasion)
Min. 6mm chrome carbide overlaid on
Skirt board
10mm MS plate
Below snub pulley/
5 mm SS 409 M
scraper
(for dribbles)
25 mm Mn Steel liner in conical
portion & for 1.5m vertical surface
RCC Silo
and 16 mm MS liner for the balance
vertical surface
Surge Hopper at
25 mm Mn steel liner
Transfer House TH-3
2.17 Seal plate of min. 3.15 mm thickness with adequate stiffeners

shall be provided below the gallery at road / rail crossing,
above nallahs and above buildings to avoid falling of material.
NMDC LIMITED MECON
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3.0 DOWN HILL CONVEYOR NO. 723
3.1 GENERAL
3.1.1 The long distance single flight downhill regenerative conveyor

no. 723 receiving Iron Ore from conveyor no. 721 and
discharging at transfer house TH-3 constitutes the most
important equipment of this package. The approximate length
of this conveyor is 4900 m with a net drop of approx. 219m.
3.1.2 This conveyor passes through a hilly terrain. The route starts
with approx. 3.5 km downhill section with approx. 318 meter
elevation drop down into a valley. This is followed by approx.
100 meter rise in the last 600 meters. En-route are four
horizontal curves and six vertical curves. There is an existing
plant (BMM Plant), village (Ranjithpura), proposed Pellet Plant
and several roads & rail crossing along the proposed
conveyor alignment. Location and radius of four horizontal
curvatures of the down hill conveyor have been finalised
considering the various constraints along the conveyor
alignment like BMM plant, Ranjintpura village, proposed Pellet
Plant, etc. and hence the alignment shown in the enclosed
tender drawing is binding.
3.1.3 The first horizontal curve is in the middle of the initial

downhill section and has a radius of 2500 meters. The second
and third horizontal curves are also with a radius of 2500
meters near where the profile starts to flatten out. The forth
horizontal curve is at the bottom of the valley with the radius
of 1200 meters.
NMDC LIMITED MECON
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3.1.4 The Tenderer shall take special care in designing the section
of the conveyor with horizontal curvatures and necessary
dynamic analysis shall be carried out to ensure that there is
no belt lifting, spillage or belt drifting problems during
running, starting and stopping under different loading
conditions. The Tenderer shall furnish the detailed dynamic
analysis report for the conveyor under different loading
conditions such as at partial loading (only uphill loaded /
downhill loaded), fully loading & empty conditions to
determine the starting and stopping response of the
conveyor. Tenderer shall also check the tension distribution at
the horizontal curves to allow proper set up of idlers in the
curves.
3.1.5 There are six vertical curvatures (4 concave and 2 convex)

proposed along the profile of the down hill conveyor as shown
on the enclosed tender drawing. The radius of these vertical
curvatures shall be finalised considering the minimum
clearance to be provided between the bottom of the structure
of down hill conveyor/travelling trolley and top of ground as
mentioned under clause no. 3.1.8 at various locations along
the conveyor alignment.
3.1.6 The alignment and proposed profile of the down hill conveyor
are shown in the enclosed tender drawings. The contour
details and existing ground profile shown in the above
drawings is only tentative. Successful Tenderer shall
carry out the survey along the alignment of the down
hill conveyor before taking up detailed engineering of
the down hill conveyor system.
3.1.7 The center line of the tail pulley of down hill conveyor is
located at local grid N+1400.74 & E+843.54 and is
approximately 48 meters before the center of the loading
point. The elevation of the top of tail pulley is 960 m
(absolute). The centreline of the head pulley is located at
local grid N+6051.46 & E+ 1885.39 and the elevation of the
top of the head pulley is 741.10 m (absolute).
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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.
3.1.10 The Downhill conveyor shall be provided with structural

triangular gantry made of pipes (without walkway) /
rectangular gantry (with walkway on one side). The trestles
for the down hill conveyor shall be of RCC / structural design.
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.
NMDC LIMITED MECON
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3.2 Following are the major technical parameters of the down hill
conveyor:
Sl.
Description Unit Specification
No.
1.0 Capacity (Design/Rated) t/hr. 2000 / 1800
2.0 Speed m/sec. 6.0
3.0 Belting
a. Width mm 1050
b. Type Steel Cord
c. Strength N/mm 3150
Cover thickness
d. mm 9/5
(Top / Bottom)
Low Rolling
e. Bottom cover compound
Resistance (LRR)
f. Cover grade DIN X
4.0 Idlers
4.1 Carrying Idler

3 Roll (with
a. Type short center roll
& long wing rolls)
b. Troughing angle Deg. 45
c. Spacing m 2.67
d. Roll diameter mm 152.4
e. Length of center roller mm 350
f. Length of wing roller mm 450
g. Bearing size 6306
4.2 Return Idler

3 Roll (with
& long wing rolls)
c. Spacing m 8.0
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Sl.
No.
5.0 Pulleys
5.1 Drive Pulley (Tail)
a. Diameter (Minimum) mm 1400
b. Min. wrap angle Deg. 185
c. Lagging type Ceramic
d. Lagging thickness mm 25
e. Pulley face width mm 1300
f. Quantity Nos. 1
5.2 Low tension pulleys

Rubber –
Diamond type for
b. Lagging type head pulley &
plain for other
pulleys
c. Lagging thickness mm 20
d. Pulley face width mm 1300
e. Quantity Nos. 11
6.0 Motors
Sq. cage
a. Type Induction Motor
with VFD control
b. Motor rating kW 750
c. Quantity Nos. 2
d. RPM 1000
e. No. of poles 6
f. Voltage V 690
g. Frequency Hz 50
h. Location Tail end
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Sl.
No.
7.0 Reducer
Floor mounted
a. Type Bevel Helical with
swing base
b. Quantity Nos. 2
8.0 Brake
Disc type
Proportional
a. Type
spring apply /
hydraulic release
b. Location Tail pulley
c. Quantity Nos. 2
9.0 Hold back

a. Location Head pulley
10.0 Belt Turnovers

10.1 Head
Flat helix with 45
a. Type degree support
roll at ¼ points
b. Length (min.) m 35
10.2 Tail
Flat helix with 45
a. Type degree support
roll at ¼ points
b. Length (min.) m 35
11.0 Take-up
Automatic
a. Type
horizontal gravity
Approx. 400 m
b. Location from the head
pulley
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Sl.
No.
c. Take-up travel (min) m 12
To be provided
near take-up
d. Winch --
tower for
maintenance
Note: The kW rating, idler diameter, pulley diameter, pulley

shaft diameter, pulley bearing size, brake size, etc.
indicated above are the minimum values to be followed
by the Tenderer. However, the Tenderer may offer
higher ratings with justification for the same.
3.3 Idlers
3.3.1 The carrying and return idlers shall be of 3 roll trough type
(except for the forth horizontal curve where a 5 roll set is
used for the carry side). A 3 roll idler shall be provided for
return side to provide better tracking of the belt, better
control of the belt in the horizontal curves and to reduce belt
flap. The troughing angle shall be 45 degrees for carry side
and 30 degrees for return. The carrying and return idlers
shall be offset so that the center roll is on one side of the
frame and the wing rolls are on the other. This offset allows
easier access to the idlers and more flexibility in supply
standardization. The center roll shall be shorter than the wing
rolls to reduce the load on the center roll and for better
control in the horizontal curves. This allows for an edge
distance on both sides of 100mm when the belt is in the
middle. Pipe frames shall be used for transom supports to
protect the belt from tears if an idler roll were to fail and
allow the belt to sag. The belt would then rest on the pipe and
not the protruding steel support tabs.
NMDC LIMITED MECON
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3.3.2 Following are the suggested technical parameters for the

idlers in four horizontal curvatures:
Sl. Description First Second Third Fourth

No. Horizontal Horizontal Horizontal Horizontal
curvature curvature curvature curvature
1.0 Carrying Idler
a. Type 3 rolls, 45 deg. trough angle 5 roll
b. Length of
350 mm 350 mm
center roller
c. Length of
450 mm 225 mm
wing rollers
d. Idler spacing 2.67 m 1.33m
e. Bearing size 6306
2.0 Return Idler

a. Type 3 rolls, 30 deg. trough angle 3 rolls, 30
deg. trough
angle
b. Length of
350 mm 350 mm
center roller
c. Length of
450 mm 225 mm
wing rollers
d. Idler spacing 8.0 m 4.0 m
e. Bearing size 6306 6306
3.0 Banking Angle

a. Carrying 9.0 deg.
b. Return 16.5 – 14.5 14.5 deg. 14.5 deg. 27.0 deg.
deg.
4.0 Side Guide Spacing

4.1 Carrying side
2.70 m (for
portion of
vertical
convex curve
Inside
a. inside 2.2 m 2.1 m 0.4
(Radius)
horizontal
curve)/ 1.6
(after vertical
convex curve)
NMDC LIMITED MECON
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Sl. Description First Second Third Fourth

No. Horizontal Horizontal Horizontal Horizontal
curvature curvature curvature curvature
b. Outside
100 m
(Radius)
4.2 Return side
a. Inside
100.0 m 4.0 m
(Radius)
2.4 m (end of
horizontal
curve to end
of vertical
convex curve)
Outside / 4.2 m (for
b. 3.2 m 3.5 m 1.5 m
(Radius) portion of
vertical
convex curve
inside
horizontal
curvature)
3.3.3 The idlers in horizontal curvature zones shall be banked away

from the inside of the curve & suitable banking angle shall be
chosen for the carrying and return side along the contour of
horizontal curvature to limit horizontal displacement due to
variation in loading and tension. Lateral belt displacements
must be limited in order to prevent the belt from running into
the structure, to prevent material spillage and maintain
acceptable belt tracking. Also, lateral displacements are
controlled by banking the idlers and placing side guide rolls
on the wing rolls to prevent excessive displacements in
momentary conditions (such as braking).
3.3.4 The type, idler size & spacing of carrying and return idlers in
first three horizontal curvatures shall be same as the other
zones i.e 2.67 m carrying & 8.0 return idler spacing. However
to minimize lateral displacement of the belt, the idler transom
rotates away from the inside of the curve (9 degrees carry,
14.5-16.5 degrees return). The rotation center shall be at
the top middle of the center roll for the carry and return side
respectively. On the carry side, side guide rolls should be
placed at intervals. They should be placed 100mm from the
belt edge when the belt is in the center of the trough.
NMDC LIMITED MECON
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3.3.5 The idlers in the fourth horizontal curvatures (with 1200m

radius) shall be of five roll configuration with additional wing
rolls at steeper angles. When the belt is displaced towards the
inside of the curve (empty belt), the additional idler shall
direct more of the belt in a vertical direction where the weight
of the belt helps to counter the belt movement. Despite this,
it is likely that there will be some contact with the inside side
guide rollers during the normal operation of the carry side
when empty. This static contact force shall be designed to be
less than 100N per side guide roller to minimize belt edge
wear and the possibility of buckling. The outside wing roll
reduces the possibility of belt lift off on the outer edge. The
inside set of wing rolls shall remain at 45 degrees which is the
original troughing angle. The outside set of wing rolls shall
gradually transition from the initial 45 degree trough to a 90
degree trough at a rate of 5 degrees per meter prior to the
start of the fourth horizontal curvature. In other words, the
outer wings go from a 45 degree angle to a 90 degree angle
over a space of 9m. This configuration shall be kept
throughout the horizontal curve and transitioned afterwards
back to the standard idler arrangement.
3.3.6 For all four horizontal curvatures, the idlers shall transition
from a zero degree banking angle in along the straight–away
into the banking angles at the beginning and end of each
horizontal curvature. These transition shall occur along the
straight-away before and after the horizontal curvatures. On
the carrying side, the banking angle shall transition at rate of
approximately 0.5 degree per meter. On the return side, the
banking angles shall transition over the same sections of the
conveyor as the carrying side. The return side banking angles
shall transition at a rate of between 0.8 and 1.5 degrees per
meter.
3.3.7 Special low noise idlers shall be provided in Ranjitpura village

zone.
3.3.8 Carrying side of the down hill conveyor shall be provided with
hoods of hinged design made of min. 3.15 mm thick MS plate.
The hoods shall be designed in such a way that carrying idlers
can be maintained without removing the hood completely.
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3.3.9 At tail end, the top of pulley shall be kept in line with belt
line.
3.3.10 Standards and Codes
Equipment, materials, components and functions shall be

designed, built, rated, tested and shall perform in accordance
with the latest edition relevant Indian / following applicable
codes, standards, requirements and guides
i) ANSI - American National Standards Institute

ii) ASTM- American Society for Testing and Materials
iii) ASME - American Society of Mechanical Engineers
iv) AFMBA- Anti-friction Bearing Manufacturers Association
v) AWS - American Welding Society
vi) CEMA - Conveyor Equipment Manufacturers Association
vii) ISO - International Standards Organization
viii) DIN - West German Industrial Standard
A letter of proof of equivalency for equipment manufactured

in accordance with any standards other than those listed
above shall be submitted.
In addition to these design, material and production

standards, any equipment provided shall conform to the
requirements of all local mine safety regulations.
3.3.11 Idler Performance Requirement
i) General
Idlers shall be designed to operate over the

temperature range and other environmental conditions
specified in the technical specification.
ii) Mounting
Idlers shall have ISO shaft connections. Idler

assemblies shall be configured to meet the belt width
and troughing angles specified.
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iii) Idler Life
L-10 life of the bearings for all types of idlers shall be

min. 60,000 hrs.
iv) Idler TIR
Idler straightness, eccentricity and ovality shall be

checked with the idler roll rotating on its shaft. For idler
TIR value, refer clause no. 3.4.15 - ix
v) Idler drag or Idler Rolling Resistance
The average running friction force at the speed

specified and temperature of 20°C shall be less than
2.5 N/roll when measured as per the method given in
DIN 22112-3.
3.3.12 Idler Fabrication Requirement
i) Idler Roll Dimension
a. Idler roll dimension with regard to roll diameter,

Roll length, shaft diameter, etc. shall be as
specified. The minimum thickness of idler roll
shell shall be considered as 4 mm. However,
Tenderer shall check the adequacy of the above
thickness considering the various technical
parameters of the conveyor.
b. The minimum thickness of idler roll end disk

shall be considered as 4 mm with flat plate
construction. However, Tenderer shall check the
adequacy of the above thickness considering the
various technical parameters of the conveyor.
Also, Tenderer shall also supply their standard
end disk configuration, provided that it conforms
to DIN 22112-2 standards for axial movement,
resistance to ejection and dust and water
tightness.
NMDC LIMITED MECON
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c. All idler dimensions must conform to the

allowable tolerances given in DIN 22112-2.
ii) Shell Material for Standard Steel Idlers
Electric resistance welded tubing shall be used for idler

shells and the same shall conform to the specifications
set forth in ASTM-A513, for electric resistance welded
tubing (ERW).
iii) Bearings
a. Carrying and return idlers shall be equipped with

sealed-for-life deep-groove ball bearings with C3
clearances.
b. Bearings shall be sized appropriately for the load

per idler and the L-10 life specified.
c. One bearing of each roll shall be positively

locked to the shaft with the other free to float
axially.
iv) Lubrication
For most environmental conditions, bearing shall be

lubricated with Mobile Grease 28, or a similar grease
with a base oil kinematic viscosity between 28 and 40
cSt(N/mm2) at 40°C (ISO VG 28-40). For environments
with ambient temperatures below -30°C or above
40°C, an alternate bearing grease shall be considered.
Tenderers are encouraged to make recommendations
as to suitable lubricants for these temperature
extremes.
v) Seals
Idler seal assemblies shall be a multi-labyrinth type for

a minimum rolling resistance. The assemblies shall be
"sealed-for-life" type, factory greased and run in at
approximately 750 RPM.
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vi) Shafts
Idler assemblies shall be equipped with solid bearing

shafts.
vii) Transition Idler Frame
Transition idler frames shall be provided with

adjustable end rolls. Half of the assemblies shall be
adjustable from 0 to 20 degrees and half from 25 to 35
degrees. Adjustments shall be in two and one half
degree increments. The wing rolls shall be mounted in
a slide base that allows horizontal adjustment of the
wing roll position.
viii) Impact Idlers
a. Idlers in fixed loading points subject to impact

loads of less than or equal to 60 kg-m shall be of
base-mounted style with three idler rolls. Wing
angles shall be in accordance with the
requirement.
b. Idlers in fixed loading points subject to impact

loads of greater than 60 kgm shall be 'extra
heavy duty’ idlers arranged in a base mounted
frame. Idler sets shall incorporate three (3) rolls
with wing angles in accordance with the
requirement.
c. Impact Idler rolls shall be rubber disc type, with

the following mechanical properties:
Material rubber grade : Grade S

Hardness (Shore A, Durometer) : 55-65
Minimum tensile strength : 14 Mpa
Minimum Elongation at Break : 300%
d. Idler discs shall be interference fitted to tubes

and longitudinally retained by means of circlips
and washers or equivalent.
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e. The outside diameter of rubber impact class

idlers shall be typically 15 mm greater than the
outside diameter of the standard steel idlers on
the conveyor carry side. The inside diameter of
the rubber rim shall be 80 mm less than the
outside diameter.
ix) Tolerances and Balance
a. Plain steel rolls (excluding weigh idlers) shall be

concentric with the shaft to within:
• 0.30 mm TIR for lengths (L) ≤ 700 mm

• 0.30 + 8.33 x 10-4 (L - 700) mm TIR for 700
≤ L <1000 mm
• 0.75 + 5 x 10-4 (L - 1000) mm TIR for
L > 1000 mm
• Rubber covered 1.0 mm
L = length of roll.
Rolls fitted with rubber or plastic discs shall be

concentric with the shaft to within 1.0 mm Total
Indicated Runout (TIR).
b. Rolls and tubes shall be straight to within

L/1000.
c. Idler static out-of-balance shall not exceed the

following:
- Steel Rolls 0.036 Nm

- Weigh Rolls 0.014 Nm
This static out-of-balance shall be such that

when the shell of the roll is placed on knife
edges and rotated at random, the application of
the required torque will cause the shell to move
in the direction of the applied torque.
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3.3.13 Quality Assurance and Documentation
3.3.13.1 Reliability
The successful Tenderer shall submit a quality assurance

procedure. The procedure shall demonstrate the ability to
guarantee, with 90% statistical confidence level that 95% of
the final idler assemblies will meet the specified criteria.
3.3.13.2 Test Reports
i) Straightness, Eccentricity and Ovality
Every idler roll shall be checked for compliance with

design Specification. TIR readings shall be taken on a
complete revolution at the following locations:
a. 15 mm from each end of the roller

b. At midway along the roller barrel.
The successful Tenderer shall supply the aggregated

results of these tests documenting that more than 90%
of the idler rolls meet Specification
ii) Idler Rolling Resistance
The successful Tenderer shall supply the idler rolling

resistance from a 100-hour factory test. The rolling
resistance is defined as the tangential force at the shell
face (N) required to rotate the idler shell about its shaft
and bearings. The idler rolling resistance shall be for a
no-load and full live plus dead load with factory sealed
and greased assembly. The Tenderer submitted values
shall be the average for a minimum of 7 barrel
assemblies. The rolling resistance shall include the
static (breakaway) and dynamic (full speed) values.
90% of the full speed dynamic tests shall meet design
specification.
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iii) Balance
Every roll shall be checked for compliance with the

design specification. The successful Tenderer shall
furnish the aggregated results of these tests
documenting that more than 90% of the idler rolls are
balanced to within 0.15Nm.
3.3.13.3 Storage and installation instructions
Successful Tenderer shall provide documentation for:
i) Instructions for long term storage

ii) Instructions for installation and commissioning
iii) Lubrication requirements
3.3.13.4 Required data sheet for idlers
Tenderer shall review, revise and otherwise complete the

attached design data sheet (Refer chapter-M / Part 2 of 2).
3.3.14 Standard Idler Frames
3.3.14.1 Design Loads and Conditions
i) Rigid idler frames shall be provided for carry side idlers

and return side idlers. Frames shall not deflect
vertically more than 1/1000 of the horizontal span
under full live and dead loads.
ii) Support frames for idlers must conform to relevant

codes with respect to their ability to withstand dead
loads, live loads, wind loads, seismic loads and any
other applicable loading conditions.
iii) Support frames must be stiff enough to resist or damp

out any incidental vibrations caused by idler and belt
motion. Excessive belt flap should not be considered to
be “incidental” vibration and should instead be
eliminated during conveyor design by proper idler
spacing and belt tensioning.
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iv) Support frames shall be strong enough to withstand

the loss of any 2 consecutive idlers, with a full
(flooded) load on the belt. The support frames shall not
deform excessively or become permanently bent
through plastic deformation during such an event.
3.3.14.2 Description and fabrication
i) Support Frames or Beds
a. A single section of support frame, also known as

a bed, will typically support carry side idler pipe
transoms or garlands and return side idler pipe
transom or garland. Each bed will also have a
sheet steel cover panel to reduce exposure of
the belt to direct sunlight to prevent rain water
accumulation in the belt trough and to reduce
wind uplift on the belt.
b. Each bed will consist of support columns

fabricated from structural steel elements
(channels or I-beams) and headers fabricated
from formed sheet steel elements. Diagonal and
horizontal bracing elements consisting of angle
iron or steel pipe shall be added to provide
sufficient rigidity in all directions. A method for
attaching the cover panels to the headers on
each side of the support frames shall be
provided.
ii) Pipe Transom Idler Supports
a. Each idler set, whether carry or return side, shall

be supported by a cross-frame or transom,
constructed from steel pipe bent to conform to
the desired belt trough angle. Support tabs for
the idler shaft ends shall be welded to the
transom. The tabs shall be set below the inner
surface of the transom and shall have rounded
or chamfered ends so that if an idler is lost, the
belt will run on top of the bent pipe and not
contact or snag on the idler support tabs.
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b. Carry side pipe transoms shall be bolted to the

support frame headers. Return side pipe
transoms shall be bolted to attachment points on
the support frame columns.
iii) Pre-fabrication
Support frames and pipe transom shall be designed to

be fabricated for ease of transportation and field
assembly. The support frames shall consist of the
following assembly elements:
a. Concrete sleepers with cast in place anchor bolts

and levelling nuts (if applicable).
b. Support columns with pre-welded / pre-drilled
attachment points.
c. Headers with pre-drilled/pre-punched
attachment points.
d. Diagonal braces with pre-drilled/pre-punched
attachment points.
e. Pre-punched/slotted Expansion joint splice
plates.
f. Carry side pipe transoms with pre-welded/
pre-drilled attachment points.
g. Return side pipe transoms with pre-welded/pre-
drilled attachment points.
h. Pre-punched/slotted cover panel mounting
brackets.
i. Pre-punched cover panels.
iv) Painting
All structural elements shall be painted with an

epoxy-based paint, or powder coat, of sufficient
thickness to provide the finished surface with a 2000
hr. salt-spray rating.
v) Field Assembly
All support frame elements and pipe transoms shall be

so constructed as to allow for bolt-up assembly in the
field with little or no field welding required.
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3.3.14.3 Quality Control
i) To insure that all of the parts conform to design

dimensions, two (2) support frame prototypes,
complete with pipe transoms and idler rolls, shall be
“test-assembled” in or near the shop prior to
authorizing the complete production run. The two
assemblies shall be spliced together to form one
continuous section.
ii) For the purpose of the prototype test-assembly only,

the parts can remain unpainted until the test has been
completed.
iii) Any discrepancies in fabrication found by this test shall

be remedied prior to proceeding with fabrication.
3.4 Belting
3.4.1 General
The belt construction shall be suitable for the loads, material

impact energy, pulley size and idler configurations specified
for the conveyor.
Unless otherwise specified or approved, the equipment shall

comply with the latest revision (including the latest addenda
prior to the date of submission of the bid) of any relevant
Indian / international standards. In general, relevant
standards include those issued by:
i) ASTM: American Society for Testing Materials

ii) CEMA: Conveyor Equipment Manufacturers Association
iii) DIN: German Industrial Standard
iv) ISO: International Standards Organization
v) RMA: Rubber Manufacturers Association
In addition to the these design, material and production

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3.4.3 Performance Requirements

i) Belting
Conveyor belting will be designed and manufactured to

meet the duty requirement. Belt design shall be
compatible with:
a. Quantity and type of material being conveyed

b. Ambient and material temperatures
c. Impact forces at transfer chutes
d. Maximum belt tensions
e. Pulley dimensions
f. Idler configuration
ii) Pulley Diameters
The Tenderer shall warranty the belt for the pulley

diameters specified in this specification.
iii) Belt Strength Selection
a. The belts shall be of steel cable construction. The

belt breaking strength shall be selected using a
multiple of the operating rating (SF):
Belt Breaking Strength: ST-XXXX N/mm = SF x OS/W
(where XXXX is the belt’s nominal breaking strength

in N/mm)
Safety Factor (SF): Operating Service Factor Multiple

above the operating strength recommended by
Supplier.
OS: Operating Strength in N steady-state running @

peak tonnage
W: belt width in mm
Operating Strength is matched to motor nameplate
power: OS = TE + T3
where TE is the total drive tractive tension and T3 is
equal to the required slack tension after the drive
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pulley to control, at minimum, belt slip on the drive

pulleys.
b. The Tenderer must recommend the belt breaking

strength and splice endurance strength
(percentage of "ST" width strength — i.e. not
pitch strength) to meet the belt life criteria,
operating criteria, and warranty for the specified
operating conditions. Belt Safety Factor (SF)
shall exceed SF≥ 6.0:1 of the maximum friction
full load operating tonnage and SF ≥ 5.0:1 for all
dynamic or momentary conditions.
iv) Splices
a. The Tenderer shall design the splice and

recommend the minimum splice dynamic
efficiency. Splice design shall be warrantable by
the Tenderer for 50% fatigue strength efficiency
with respect to the belt’s breaking strength for
no less than 15,000 load cycles.
b. Tenderer shall provide belt reels that minimize

field splices.
c. Racetrack and double reel cassette type rolls can

be quoted.
3.4.4 Constructional Requirements and Tolerances
3.4.4.1 Belt Dimensions
i) Belt Width
Tenderer shall provide a full belt width as manufactured

in one fabricating press. The slitting of fabricated belt
to a lesser stock width or making of two belts in one
belt press is not acceptable. The belt shall have molded
edges. The manufactured belt width tolerance shall not
exceed +25 mm/-0 mm within a roll.
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ii) Belt Length
The purchased length may vary +/-3% from the

specified value. The Tenderer shall provide splice
specifications to include splice length, step dimensions,
offsets and trim allowance required in addition to the
basic tape length. The Tenderer shall also state the
number of rolls of belting, the weight and size of each
roll, and estimated length of take-up, including
percentage stretch in the belt prior to permanent set.
The minimum number of rolls (splices) are preferred.
iii) Belt Thickness and Weight
Belt thickness and weight will be dependent on selected

cable sizes and top and bottom cover requirements.
The Tenderer is required to provide revised values for
the estimates of these dimensions given in this
specification.
New belt thickness may vary by + 0.15 mm to

– 0.00 mm from nominal total thickness defined by:
Nominal total thickness = cable dia. + top cover

thickness + bottom
cover thickness.
3.4.4.2 Steel Cables
Steel cables shall be selected to meet the following criteria:
i) Galvanizing
The cables and their wire strands shall be coated with a

heavy duty galvanized plating by hot dip method
before drawing to final wire size. The minimum zinc
coating shall exceed 60 times the wire filament
diameter, expressed in g/m2 (i.e. 1 mm wire diameter
shall have 60 g/m2 minimum zinc coating).
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ii) Cable size and Spacing
a. The successful Tenderer shall optimise cable size

and spacing to return the best economic tender
for belt strength construction.
b. The successful Tenderer shall submit a diagram

of the individual wire or filament sizes, strand
sizes, helix angles and direction and dimensions
within the cable and cable breaking strength.
c. The minimum cable diameter shall be sufficient

to protect against large rock impacts that may
fatigue the contacts between the outer wire of
the inner and outer strands. Cable diameter shall
also be made compatible with splice strength,
pulley diameters and tension range.
d. The cable design shall be selected to maximize

the uniform elongation of all wires and strands
within the cable (load sharing of all filaments) at
full operating load.
e. The "gap"/ distance between cables in the belt

and splices shall be at large enough to ensure
idler troughability for the trough angle specified.
iii) Vertical Tolerances
The steel cables shall be placed in the belt within a

vertical tolerance to maximize cover life and to
minimize excessive wear on the pulley lagging. The
following specification shall apply:
a. 95% of the cables in the belt cross-section shall

not deviate vertically by more than ±1 mm from
the nominal cable centerline.
b. No cable centerline shall exceed ±1.5 mm from

the cord nominal vertical centerline.
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iv) Horizontal Tolerances
The steel cables shall be placed in the belt within a

horizontal tolerance that controls mal-tracking of the
belt theoretical centerline to less than ±40 mm
over one full belt revolution measured at the running
low-tension zone. The following cable specification shall
apply:
a. The absolute cable positions shall not deviate by

more than ±3 mm from the nominal horizontal
position for each cable within each belt roll.
b. Each cable pitch shall be within ±0.5 mm of the

theoretical nominal value.
c. The belt shall have a rubber cover, at the edge,

covering the outer cable with a minimum of
20 mm and a maximum of 35 mm within each
roll.
v) Core Rubber Penetration
a. Cables shall be constructed for full rubber

penetration.
b. Provision for testing limits of air flow passage

within impregnated cords shall be quoted.
3.4.4.3 Impact Fabric Reinforcement Layer
To insure against wire breakage within the steel cords, due to

rock impact, an impact fabric reinforcement layer shall be
constructed into the belt. The fabric layer shall be located 3-4
mm above the steel cord. It shall be treated for maximum
bonding adhesion with the core gum and cover gum.
3.4.4.4 Rubber Cover
i) Top and bottom covers shall have thicknesses as

indicated in this specification. These thicknesses shall be
reviewed by the Tenderer with regards to warrantied
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wear requirements. The belt cover thickness and

physical properties shall be sufficient to meet the
structural requirements and wear criteria.
ii) Since the cover rubber wear is mainly due to abrasion

damage from rock impact and sliding damage at the
transfer-loading station, the Tederer shall provide the
best compound that meets the tonnage warranty. A
natural rubber shall be specified with superior tear and
abrasion resistance.
3.4.4.4.1 Rubber Properties
i) Belt covers shall have the following minimum properties

at 20 Deg. C:
a. Tensile Strength DIN 53504 : 25 N/mm2

b. Hardness DIN 53505 : 60 ±5 Shore A
c. Tear resistance DIN 53507 : 15 N/mm
d. Abrasion Resistance AS 1683-21: 100 mm3
(min)
e. Elongation @ Break exceeds : 450%
f. Cover Separation Strength :15 N/mm (min.)
DIN 22131
(Cover to bonding rubber)
Note: Tenderer may recommend alternative

specifications to these stated values that result in
verifiably superior performance for guaranteed life of
top cover and low rolling resistance of bottom cover.
ii) Belt cover grade shall be of minimum DIN-X rating.
iii) Mildew and ozone protection shall be included in the

rubber compounding.
iv) Surface blemishes must be minimized. Excessive

blemishes indicate poor quality and may compromise
the belt life and necessitate added maintenance.
v) Tenderer shall provide a description of the build up on

idler shells from press release compound (silicon, etc.)
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and/or agents that will plate on roll surface during

normal operation (i.e. waxes, oils, et. al.) Plating of
press release agents, waxes, plasticizers, etc. onto idler
rolls shall not exceed 0.5 mm thick. Successful Tenderer
shall be responsible for cleansing rolls where belt
residue plating or build-up exceeds 0.5 mm.
vi) Splicing of cover sheets, after curing, shall not be

obvious to the eye. Successful Tenderer shall warranty
for life of belt against delamination of cover sheets and
of separation of joint seams. Successful Tenderer shall
state, corrective action if flaws occur.
3.4.4.4.2 Specification for Belt Cover Rolling Resistance
Successful Tenderer to define the belt cover rolling resistance

performance by providing the rubber viscoelastic properties
for the temperature range of –30ºC to +50 ºC in 5 ºC
increments. The visco-elastic properties shall be given at 1%,
2% and 3% strain and 10 Hz excitation frequency for E' and
E" or as rubber master curves. A maximum rolling resistance
coefficient (MRC) shall be provided, with the bid, as a
measure of performance for the temperatures of 10 ºC to 30
ºC. The visco-elastic MRC criteria at 2% strain, 10 Hz, must
not exceed:
RRF = 0.100 @ 0º C
Where : RRF = E”/(E’)4/3 (E’ & E” in N/mm2).
Note: Successful Tenderer may recommend an alternative

specification that results in verifiably superior low rolling
resistance performance
3.4.4.4.3 Belt markings
On both ends of each belting roll, the bottom cover side shall
be branded 50 mm from the belt edge and 7 m from the roll
ends with the following:
• Manufacturer's name
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• Manufacturer's order number and roll sequential serial

number of same specification
• Belt breaking strength rating ST-XXXX N/mm (width
strength) and belt cover gauges “aa” mm top x “bb” mm
bottom (where XXXX, “aa” and “bb” are supplied values)
• Weight per unit of length (kg/m)
• Direction of travel for belt installation indicated by large
arrow on belt and large bold arrow on shipping container.
3.4.5 Splices
i) Splice Dimensions and Materials
The Successful Tenderer shall provide the proposed

splice design, clearly indicating all dimensions to
describe the pattern, including the number of steps,
stages, strand lengths, cable bend length, overlaps,
cable end clearances, skim coat thickness above and
below cable, reinforcement or breaker layer location,
treatment of centre and edge cords, cables removed
and allowable tolerances for cable placement with
respect to vertical and horizontal location. The
proposed splice tie gum or noodle rubber dimensions
and tolerances shall be specified by the Successful
Tenderer
ii) Splice Kit
Preference shall be given to splice kit supply that is

preformed with top and/or bottom cover embossed
with recommended splice pattern that minimizes use of
tackifiers. Use and specifications of all fluids shall be
clearly noted, including general form of ingredients. No
carcinogenic materials are allowed. A molded rubber
splice kit is preferred. Successful Tenderer shall supply
all splice kit materials, including at least two spare kits.
iii) Splice Strength and Endurance
a. The length of rubber in shear and rubber gap

between cables shall provide for a 200% effective
static strength of the theoretical static running
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load on the vulcanised splice, based on static

pullout strength with the splice cable pitch. The
static load shall be calculated on the weakest
section of the splice. The minimum rubber shear
length (splice step) between opposing cables shall
be a minimum of 125 times the cable diameter. If
the Tenderer can define the rubber endurance
stress, at the splice weakest section, for specified
years of full load service, then this method is
preferred and will be acceptable for quantifying
the belt and splice recommendation. The
Successful Tenderer must verify the splice design
by historical records or by destructive testing as
given in DIN 22110 Part III and as noted herein.
b. The Successful Tenderer shall specify all splice

rubber shear stresses and strains, and cable
forces in one splice repeat pattern. The maximum
cable load, in one repeat pattern, shall not exceed
45% of the nominal cable strength. The maximum
rubber shear stress shall not exceed the core
rubber's endurance limit or fatigue life for the
warranted service. Suitable analysis shall
demonstrate the Successful Tenderer's claim.
iv) Core Rubber Cover
Insulation gum (core rubber) shall exceed 1.0 mm

thickness above and below cable after splice
construction. A sample shall be constructed to warrant
the method.
v) Splice Reinforcement
If the Tenderer recommends splice reinforcement

techniques, then the material specification, dimensional
details and stress/strain levels of improvement shall be
specified separate to the splice without reinforcement.
The frames of reference shall be the peak design force
applied to the splice in a flat plane for a minimum of 16
cables.
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vi) Markings
Each splice shall be identified with a sequential serial

number and date of installation that is stencilled into
the bottom cover side.
3.4.6 Quality Assurance Program
The Quality Assurance Program is an important issue. The

Tenderer is encouraged to describe, in the tender document,
the benefits of their quality control procedures and record
keeping including: raw materials, compounding, fabricating
tolerances, humidity and temperature regulation, cable
tension regulation, rejection tolerances, packaging, handling
and shipping, site storage, splicing and installation.
3.4.6.1 Belt Construction
i) Monitoring Method & Rejection Criteria
a. The Successful Tenderer shall furnish

a description of how the belt construction
tolerances will be monitored to comply with this
Specification.
b. The Successful Tenderer shall also furnish a

description of the rejection criteria for improper
cable placement within a roll, and/or rubber
thicknesses that produce too great a variation in
the finished product.
c. Failure to meet the tolerances, and / or failure to

report the measurements may cause rejection of
the roll.
ii) Vertical and Horizontal Tolerances
The Successful Tenderer shall specify the vertical and

horizontal precision and the method used to verify cord
placement tolerance with a hard copy record of the
measurements for each roll. These records shall be
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submitted to the Client upon the completion of each roll

fabrication.
iii) Cable Tension
The Successful Tenderer shall provide monitoring of

individual cable tensioning just prior to the rubber
application. The tension between cables shall not
exceed ±8% of the nominal or average cable tension.
Deviations greater than this allowance shall be reported
according to cable location and magnitude of error.
iv) Cover Blemishes
The Successful Tenderer shall provide the quality

control procedure for belt cover blemishes, blemish
repair and the criteria for rejection of excessive
blemishes. The press-rubber release method and
excessive blemish rejection criteria for belt covers shall
also be furnished by the Successful Tenderer
v) Vulcanizing Press Control and Monitoring
In addition to the cable tension and position

monitoring, the following quality control (Q/C)
procedures shall be made a part of this specification
with a hard copy report:
a. Press pressure and time

b. Moisture and contamination control of cable to
maximize adhesion to rubber
c. Press thermocouple locations and temperature
monitoring
d. Procedure for rejection due to tolerance non
conformance
3.4.7 Splice Construction
i) The Successful Tenderer shall provide the Quality

Control (Q/C) procedure for the splicing. The Q/C
procedure shall include:
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a. Calibration of vulcanizing press temperature

control and accuracy before allowing actual
splicing
b. Fabrication of test splice before allowing
contractor to proceed with actual splicing. The
test splice shall be submitted to the Purchaser
for X-ray and audit of test piece.
c. Rejection of splice during fabrication.
d. Environmental control of work area.
ii) Successful Tenderer shall provide the following during

installation of the belt
a. Recommended vulcanizing specification for

preheat temperatures and pressure.
b. Vulcanizing time and temperature.
c. Cooling time prior to pressure release.
d. Description and record keeping of all sensor
pickups.
e. Guarantee proper alignment of belt axis within
splice.
f. Belt pulling equipment, tools of the trade and
specify utilities required.
3.4.8 Factory, Laboratory, Field Testing and Documentation
3.4.8.1 Inspections and Tests
i) General
The Successful Tenderer shall indicate the proposed

methods and procedures to verify the component
specifications (quality control) and their final assembly
that meets the criteria set forth herein. The Successful
Tenderer shall furnish certified laboratory test data
indicating results of all tests carried out for this
Specification.
ii) Splice Strength Static Pullout Test
The static pullout strength test (adhesion test) shall be

submitted for a minimum of one sample at each end of
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each roll. The test procedure shall be furnished by the

Successful Tenderer.
iii) Splice Dynamic Fatigue Strength (Efficiency) Test
The Successful Tenderer shall indicate the nominated

splice design dynamic fatigue strength as a fraction of
the belt's cable breaking strength for a minimum of five
years service. The Successful Tenderer shall present
representative field installations or laboratory tests of a
similar design including:
a. Belt and splice specifications

b. Operating specifications
c. Year of installation
d. User contact name and telephone number
iv) Cable Testing
The Successful Tenderer shall submit a quality assurance

procedure for checking the physical properties of cable
against any applicable standards, including:
a. Diameter
b. Breaking strength
c. Elastic modulus
d. Protective coating integrity
e. Mass per unit Length
f. Cord-Diameter
g. Breaking force
v) Rubber Compound Physical Properties
The Tenderer shall provide the following cover and core

rubber physical properties:
a. The glass transition temperature (Tg) at 10

Hz and 1, 2, & 3% strain.
b. Visco-elastic properties (E', E", or MRC).
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vi) Tracking Test
The Successful Tenderer shall witness, during

commissioning, the empty belt tracking for compliance
with the specification. The return strand edge shall be
monitored for three complete belt revolutions at a low-
tension zone. If the recorded belt movement, within any
150-m section, exceeds a total edge travel of 50 mm,
except for the splice region, the belt shall be considered
out of specification and a claim for its expeditious
replacement may be pursued by the Purchaser.
3.4.8.2 Engineering Documentation
i) Belt Construction and Material Selection
The Successful Tenderer must provide all engineering

documentation supporting the selection of the belt
construction as defined in this specification including
but not limited to the followings:
a. Steel cord size and construction

b. Belt Strength and Safety Factor (SF)
c. Splice design and strength calculations
d. Core rubber splice dynamic strength properties
e. Reinforcement fabric construction and physical
properties
f. Cover rubber wear and structural properties
g. Cover rubber rolling resistant properties
h. Rubber aging and fatigue strength properties
from splicing
i. Review of load station chute drawings and
approval of chute design for purposes of
warranty of belt against impact and wear
damage
j. Belt reel centre core drawings
ii) Quality Assurance
The Tenderer must provide all documentation regarding

the Q/C processes and inspections required in section
3.4.6
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iii) Tenderer’s Concerns
Compliance with this Specification does not relieve

Tenderer of the responsibility of furnishing properly
designed equipment, in all ways suited to meet the
operating conditions. Tenderer shall notify, in the Bid,
details of all concerns, which the he believes, may
impair the belt’s performance. Tenderer is encouraged
to investigate and critique the influences of:
a. Rock impact force rating, during loading, to

warrant belt against impact damage
b. Chute design and load station conditions for belt
life warranty
c. Idler trough transitions at the conveyor's head
and tail stations
d. Pulley diameter compatibility with steel cord
bending fatigue
e. Idler compatibility with belt troughing, training
and junction failure
f. Vertical curve radii criteria for tensile and
buckling limitations at belt center and edge cords
g. Proximity of pulleys when bending belt and
considering surface build up or other pulley
surface anomalies
3.4.8.3 The Tenderer shall also include the following in their offer:
i) 2 spare splice kits

ii) Recommended belt rip detection system. The
maintenance aspects shall include belt and splice
replacement, antenna, sensor and electronic faults.
iii) Input to chute design & verification of chute
performance.
iv) Splice Integrity Monitor. Tenderer shall provide the belt
steel cord monitor for corrosion, wire breakage, and
splice signature to have new belt, baseline
measurement, and belt general condition. All cables
shall be included in measurement.
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3.4.8.4 Required data sheet for Belting
The Tenderer shall review, revise and otherwise complete the

attached design data sheet (Refer Chapter-M / Part 2 of 2).
3.4.9 Packaging and Storage
3.4.9.1 Shipping Reel
i) Successful Tenderer is encouraged to ship the largest

available size roll to minimize field splicing.
ii) Cassette reels shall be considered as an alternative.
Successful Tenderer shall note that Purchaser is
indemnified against patent infringements of special reel
concepts.
iii) Successful Tenderer is encouraged to provide belt reels
that minimize field splices.
iv) Racetrack and double reel cassette type rolls can be
quoted.
3.4.9.2 Shipping Container Markings
Shipping container shall have identification marks in large

bold letters which include:
i) Manufacturer's name
ii) Manufacturer's order number and roll sequential serial
number of same specification
iii) Belt breaking strength rating ST-XXXX N/mm (width
strength) and belt cover gauges “aa” mm top x “bb”
mm bottom (where XXXX, “aa” and “bb” are supplied
values)
iv) Weight per unit of length (kg/m)
v) Direction of travel for belt installation indicated by large
arrow on belt top cover right hand side looking in
direction of travel for each pressing and large bold
arrow on shipping container on both sides of crate and
belt reel
vi) Roll assembly weight in kgs including reel assembly
vii) Special storage and handling instructions
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3.4.10 Warranty
i) General
Warranties for tonnage conveyed and for structural

integrity shall begin when the conveyor is put into
service but not later than 6 months after the conveyor
is commissioned. The warranties for wear and
structural integrity shall be prorated for the time of
service beginning after one half the period of the
warranty has expired. For the first half of the warranty
period, the Successful Tenderer shall warrant the belt
at 100% of the replacement value. The belt is out of
warranty when 10% of the width of the belt top or
bottom cover rubber thickness, over the cables, is less
than 3 mm over any contiguous 100 m section of belt
length.
ii) Pulley Diameters
The Successful Tenderer shall warranty the pulley

diameters specified in this specification & recommend
the minimum pulley diameter for the belting selected if
the above diameters are inadequate.
iii) Top Cover Wear
Top cover thickness shall be as specified in this

specification. Tenderer may quote separately an
alternate cover thickness, if necessary to meet
warranty. Successful Tenderer will need to review the
chute loading procedure to warranty that it is
compatible with the specified service life.
iv) Bottom Cover Wear
Bottom cover thickness shall be as specified in this

specification. Tenderer may quote separately an
alternate cover thickness, if necessary to meet
warranty.
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v) Tensile Member
The tensile member shall be warranted on the basis of

total time of service at full operating production. The
warranty shall apply to the structural and operational
integrity of the tensile member, core rubber, and any
reinforcing members.
vi) Splice Warranty
Tenderer shall state in its Bid the splice warranty. The

warranty must exceed eight years.
vii) Cover Sheet Delamination
Successful Tenderer shall warranty for life of belt

against delamination of cover sheets and of separation
of joint seams. Successful Tenderer shall state,
corrective action if flaws occur.
3.4.11 Successful Tenderer’s Obligations
i) Special Requirements
a. Vulcanizing Methodology
Successful Tenderer shall provide, the

recommended vulcanizing specification for
preheat temperatures and pressure, vulcanizing
time and temperature and cooling time prior to
pressure release. The Successful Tenderer shall
provide description and record keeping of all
sensor pickups.
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b. Splice
- Successful Tenderer shall include

additional lengths required for vulcanized
splices, splicing material, compound
cement and all other material necessary
for the required splices. The cement and
tie-gum shall be packed in dated
containers with storage instructions. Splice
kit life shall be indicated. Successful
Tenderer shall notify Purchaser of method
to test splice kit rubber to verify its shelf
life.
- Successful Tenderer shall specify detailed

belt and splice kit handling and site
storage requirements.
- Offer shall also include splice training for

the Purchaser's operating staff during
installation.
- Successful Tenderer shall submit (10)

splice instruction manuals in English.
- Successful Tenderer shall submit the

method and specifications of vulcanizing
for Purchaser’s review.
- Successful Tenderer to supply the quantity

of spare splice kits, their storage
specifications and storage life.
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- Successful Tenderer shall warrant splice

alignment. The belt splice shall track
within ±40 mm (of the theoretical
centerline for 30 m both sides of the
splice, measured on the return strand
edge, at one location adjacent to the tail
zone. If the splice does not track within
the stated tolerances, the splice will be
rebuilt at the Successful Tenderer's
expense.
c. Belt Rip Protection System
Successful Tenderer shall provide the list of

Vendor for the belt steel cord monitor signature
for splice integrity, baseline measurement, and
belt general condition. All cables shall be
included in measurement. Vendor shall be
approved by Purchaser.
d. Belt Markings
All belt identification markings shall be placed

beginning 50 millimeters from the belt edge. The
marking, extending across the belt's width, shall
not exceed 125 mm from the belt's edge.
e. Packaging
- The belt reel shipping size (<4 m height

and <55 tonne weight) shall be specified
by the Tenderer. Successful Tenderer is
encouraged to ship the largest available
size roll to minimize field splicing. The size
and weight shall be limited by
transportation restrictions. Cassette reels
shall be considered as an alternative.
Successful Tenderer shall note that
Purchaser is indemnified against patent
infringements of special reel concepts.
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- The belt reel shall be clearly marked with

the direction of unwinding for installation.
The top cover shall be faced to the outside
of the roll. The direction of unwinding shall
be the direction of belt travel during
normal operation.
- Shipping spool diameter shall be a

minimum of 80 times cable diameter.
3.5 Drive
3.5.1 The conveyor shall be provided with two drives at the tail end
with 2 nos. AC Squirrel Cage induction motors with VFD
control. Each drive at the tail end shall consist of motor, input
coupling, gearbox, output coupling and disc brake. The above
two drives shall be provided on either side of the tail pulley
shaft.
3.5.2 Two motors of 750 kW each (min.), medium voltage, Totally

Enclosed Fan Cooled (TEFC) induction motors shall be
provided. The motor and controllers are sometimes
regenerative and regenerative power shall be fed to the grid.
The motors must be capable of the following at all ambient
temperature conditions:
i) Continuous duty at up to positive or negative

nameplate
ii) 100% torque at 0 rpm for smooth acceleration
iii) Accelerating to (or decelerating from) full speed at up
to 135% torque for 120 seconds
iv) Continuous operation at low speeds for belt inspection
3.5.3 The motor controllers (drives) shall be commonly located in

stand-alone (pre-assembled by electric switchgear factory)
adjacent electric house which contains the high voltage
transformer circuit breaker, MCC station, PLC substation and
air conditioning unit. Optical encoders should be installed on
each motor shaft for torque control of the motor at zero
speed.
NMDC LIMITED MECON
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3.5.4 The motor, gearbox, couplings and brake components shall

be mounted on a drive base platform which has a single point
of contact at its base. The entire drive base platform shall be
free (within small limits) to rotate about the low-speed shaft
of the gearbox which is inline with the pulley shaft. The
conveyor system and motors for this design are sometimes
regenerative, so care must be taken when designing the drive
base to ensure vertical travel of the drive base is limited (i.e.
liftoff is not possible).
3.5.5 Design of mechanical brakes shall be suitable for stopping the

conveyor even at 120% rated speed. Mechanical brakes shall
be designed to have 100% extra braking torques above the
design requirements, which shall be used as a reserve in case
of necessity. The braking system shall be capable of applying
varying torque under different loading conditions to ensure
constant stopping time. The brakes shall be of fail safe design
and ensure minimum wear on mechanical parts.
3.5.6 Required data sheet for Drives
The Tenderer shall review, revise and otherwise complete the

3.6 Reducers

with relevant Indian / latest edition of the following applicable
codes, standards, requirements and guides:
i) AGMA –American Gear Manufacturers Association

ii) ANSI – American National Standards Institute
iii) ASTM – American Society for Testing and Materials
iv) AFBMA – Anti-Friction Bearing Manufacturers
Association
v) AWS – American Welding Society
vi) MPTA – Mechanical Power Transmission Association
NMDC LIMITED MECON
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in accordance with DIN or any standards other than those
listed above shall be submitted.

3.6.2 Performance Requirement
i) General
a. Gear reducers shall be designed to operate over

the altitude, temperature range and other
environmental conditions specified.
b. Gear reducers shall be designed for a duty cycle

of 24 hours/day, 365 days per year, over a 20-
year life cycle.
c. Gear reducers shall generally be of right-angle

Bevel Helical design.
ii) Reversed Loads
The reducer shall be capable of running with the loads

reversed on the gear surfaces and with reverse
reaction on the bearing assemblies.
iii) Bearing and Seals
Individual bearings shall have a minimum modified

bearing L-10 life of 90,000 hours. The reducer
assembly, consisting of all bearings, shall be duty
rating to provide a minimum fatigue life of 20,000 L-10
life hours. All component reliability factors shall be
included. The Successful Tenderer shall supply, the
rated modified bearing L-10 life hours of each bearing
within the reducer.
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iv) Service Factor
a. The gear reducer and its assembled parts shall

be rated, designed, and built to meet or exceed
the motor name plate requirements of a 1.5
mechanical service factor, a 1.0 thermal service
factor, and class 12 gears as set forth by the
American Gear Manufacturing Association
(AGMA), or as specified herein whichever is more
stringent.
b. The Successful Tenderer shall provide all gear

teeth with a "durability" rating greater than or
equal to 1.5 times the connected motor name
plate torque rating.
v) Strength Rating
The Successful Tenderer shall provide all gear teeth

with a "strength rating" to meet or exceed 3 times the
connected motor nameplate torque rating, including
momentary shock and impact factor for starting and
stopping. The impact factor is specified as 150% of the
motor name plate torque, occurring 120,000 times
during the 20 years service life of the gear reducer.
The impact load is considered to be instantaneously
loading the gear teeth randomly at any rotational
position. Momentary overloads are specified as 120%
of the motor name plate torque, occurring for 100,000
rotational cycles of the low-speed shaft during the
service life.
vi) Mechanical and Thermal rating
The mechanical and thermal rating of the selected

reducer shall be greater than or equal to the connected
motor name plate rating or as specified herein
whichever is greater.
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vii) Noise
The Successful Tenderer shall specify the noise

pressure level in DbA at one-meter distance from
reducer with fan attached. This value shall not exceed
85 DbA for all operating conditions and shall be
factored with fans and main drive motor.
3.6.3 Constructional Requirements
i) General
The speed reducers shall be of the right angle bevel-

helical, foot-mounted to a swing base. The reducers
shall be rigidly coupled between the low speed shaft
and the conveyor drive pulley and resiliently coupled to
the motor.
ii) Housing
a. The swing base shall be supported by a resilient

compression link, which is supported by the
elevated steel structure.
b. The speed reducers shall be oil-tight and dust-

proof and with a housing split horizontally
through the bearing bore.
c. All reducer housing shall be painted according to

attached Purchaser's specifications. The reducer-
housing interior shall be painted with a coating
compatible with natural and synthetic lubricants.
d. The reducer housing shall be fitted with a 38-40

mm diameter pipe drain fitting at the lowest
point of oil level to insure complete drainage.
The valve fitting shall be oriented with its flow
axis horizontal.
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e. The Successful Tenderer shall provide vibration

monitoring surfaces or bores to enable owner to
mount temporary vibration monitor probes for
each reducer bearing assembly. Bores shall be
fitted with protective metal screw caps.
iii) Identification
The equipment stainless steel tag I.D. shall include:
a. Mfg. Model No.

b. Ratio
c. Torque rating
d. Thermal Power Rating with and without auxiliary
cooling
e. Mechanical Power Rating
f. Dry Tare weight
g. Oil Capacity
h. Oil Specification
The tag shall be heavily embossed with 12-14 point

letter size.
iv) Cooling
The Successful Tenderer shall provide cooling tube(s)

mounted integral with the housing half. A cooling fan,
mounted integral with the high speed shaft is allowed
to assist cooling. External oil-to-water cooling, which
requires separate pumping, cooling is acceptable but
not encouraged. Other forms of heat exchange systems
are not approved.
v) Inspection
Inspection plates shall be provided in the housing to

adequately inspect each gear mesh.
vi) Cleaning
All housing ribbed surfaces shall be relieved to freely

drain during maintenance wash down.
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vii) Levelling
The swing base shall be provided with levelling bolt

and lug or nut assembly integral with the housing sole
plate for the motor only. The reducer shall mount
directly to machined swing base rail supports.
viii) Lubrication System
a. Where oil circulation is required for cooling, the

lubrication system shall be a pressurized system
integral to the reducer with easy access. The
system shall spray apply lubricant to the full face
of each gear mesh and to each bearing. Two
electric lube pumps shall be provided with one as
a mounted standby spare.
b. Lubrication shall permit continuous running of

reducer operating from creep speed (5% of full)
to full speed.
c. The pressure lube system shall include a full flow

cartridge type oil filtration assembly with clear
maintenance access. Dual cartridges shall be
piped in parallel with cut off valves. One filter
will be operating and one will be a standby. The
duplex filter assembly shall service both pumps.
d. The reducer shall be provided with a means of

protecting the reducer bearings from starting
without proper lubrication.
e. Splash lubrication shall be provided in addition to

the pressurized system. Preference will be given
to the design, which can adequately lubricate the
reducer without the pressure lube system in the
emergency condition.
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f. The lubrication system shall be instrumented to

alarm if reducer has insufficient oil flow, oil level,
dirty filter, or excessive oil heating. Protected oil
sight gage shall be provided. Oil level "dip-stick"
shall be provided with a cover attachment that
prevents contaminant access to oil chamber
when stick is being removed (i.e. cover cap
attached to dip stick). Magnetized drain plug
shall be provided. Magnetized metal bars under
each gear set shall be provided for full width of
each gear.
g. The gearbox shall be designed to minimize the

ingestion of dust. To achieve this, an oil bath
breather shall be provided to filter the reducer's
breathing action. The oil-bath breather shall be
secured to the reducer housing with industrial
grade fasteners. No plastic parts are permitted.
h. Oil charging inlet shall be fitted with a 10 micron

oil filter to clean all makeup oil prior to entering
main gearbox oil reservoir.
i. All lubrication piping shall be fitted internal to

housing.
j. The oil temperature range shall be controlled by

appropriate oil cooling methods. The oil
temperature shall not exceed the specified
operating range of 80° C under design ambient
conditions. Water-cooling is acceptable. Reducer
shall use a single grade of oil for the full
temperature range.
k. The 38-40 mm diameter drain shall be fitted with

a full sealing ball valve, 150 mm long pipe
sleeve, elbow and screwed endcap.
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ix) Bearings and Seals
a. All reducer lubricant seals shall have a minimum

two lip seals for all shafts extending through
housing. The Successful Tenderer shall provide,
in addition to the standard lubricant seals,
grease purged taconite-type external seals on all
shafting projecting through gear housing. All
seals shall be split type with associated housing,
replaceable without removal of couplings,
flywheels, etc.
b. Successful Tenderer shall provide the bearing

and seal manufacturer's name, model number,
and modified L-10 life at rated load.
x) Instrumentation
Tenderer shall provide instrumentation, with digital

outputs, compatible with intrinsically safe
requirements, to alarm the following:
a. Oil flow low

b. Oil pressure low
c. Oil level low
d. Oil temperature high
e. High speed shaft vibration high
f. Oil filter pressure differential high
3.6.4 Required data sheet for Reducer

3.7 Couplings

with the relevant Indian / latest edition of following applicable
NMDC LIMITED MECON
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i) AGMA –American Gear Manufacturers Association

ii) ANSI – American National Standards Institute
iii) ASTM – American Society for Testing and Materials
iv) ASME – American Society of Mechanical Engineers
v) AWS – American Welding Society
vi) MPTA – Mechanical Power Transmission Association
Successful Tenderer shall submit a letter of proof of

equivalency for equipment manufactured in accordance with
DIN or any standard other than those listed above.

requirement of all local mine safety regulations.
Drive Train Couplings shall be designed to transfer torque

from motor to gear reducers and from gear reducers to drive
pulley shaft. The reducers shall be rigidly coupled between
the low speed shaft and the conveyor drive pulley and
resiliently coupled between the reducer high speed shaft and
the motor.
3.7.3 Low Speed Couplings:
3.7.3.1 Low speed coupling Description
i) Type
The coupling shall be of full geared type.
ii) Mounting
The coupling connects the reducer output shaft to

pulley shaft by friction.
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iii) Identification
The coupling shall be stamped with a stainless steel tag

embossed with tag number, torque capacity (N-m),
bore size, keyway size & mass (kg) on the face of each
hub. The lettering shall be highly legible with 12-14
point text size.
iv) Maintenance
Special tools & fittings shall be supplied for proper

coupling assembly and removal.
3.7.3.2 Design
i) Service factor
The low speed coupling shall have a minimum service

rating of 1.5 times the motor nameplate rating.
3.7.3.3 Low speed coupling fabrication
i) Assembly
One coupling half shall be shipped to the pulley

supplier for final fitting.
ii) Construction
Forging materials shall be in accordance with the

applicable requirements of ANSI / ASTM A-521—76
standard for steel, closed-impression die forgings.
3.7.4 High Speed Resilient Coupling
3.7.4.1 Description
i) Type
The coupling shall be of spring type resilient flexible

type.
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ii) Mounting
The High-speed coupling connects the reducer input

shaft to motor assembly. The coupling can
accommodate angular & parallel misalignment, motor
end floats & shock loads. The coupling shall be
attached by key & keyway complying with AGMA
standards for nominated bore & key seats.
iii) Identification
The coupling shall be stamped with a stainless steel tag

embossed with tag number, torque capacity (N-m),
bore size, keyway size & mass (kg) on the face of each
hub. The lettering shall be highly legible with 12-14
point text size.
iv) Maintenance
Special tools & fittings shall be supplied for proper

coupling assembly and removal.
3.7.4.2 Design
i) Service Rating
The high speed coupling shall have a minimum service

rating of 1.5 times the motor nameplate rating.
ii) Misalignment
The high speed coupling shall be capable of operating

at full load with the Allowable parallel offset, Allowable
angular offset and Shaft end float.
iii) Down hill Conveyors
Couplings selected for Downhill conveyor shall be

capable of withstanding shock loads caused by the
torque reversals in the Drive train during start-up and
shut-down of the conveyor.
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3.7.4.3 High speed coupling fabrication
i) Construction
Forging materials shall be in accordance with the

applicable requirements of ANSI / ASTM A-521—76
standard for steel, closed-impression die forgings.
ii) Spring
Spring material shall be rated for the range of ambient

temperature and for any special environmental
conditions.
3.7.5 Required data sheet for Couplings

3.8 Hold Back

with relevant Indian / latest edition of the following applicable
i) AFBMA – Anti-Friction Bearing Manufacturers

Association
ii) AISC – American Institute of Steel Construction
iii) AISI – American Iron & Steel Institute
iv) ASTM – American Society for Testing and Materials
v) ANSI – American National Standards Institute
vi) ASME – American Society for Mechanical Engineers
vii) AWS – American Welding Society
viii) CEMA – Conveyor Equipment’s Manufacturers
Association
NMDC LIMITED MECON
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in accordance with IEC and DIN or any standards other than
those listed above shall be submitted.

i) General
a. Hold back shall be provided on the head pulley of

the down hill conveyor and designed to
immediately lock the drive shaft against reverse
rotation without backlash, restricting the belt
from rolling backward when the power is shut-
off/interrupted in certain loading conditions. The
holdback shall release freely & quickly when
forward rotation is resumed.
b. The holdback assembly shall be designed for

heavy duty mining application with a service life
of 20 years, including fatigue and wear factors,
except for lubrication seals.
ii) Holdback Torque Rating
The holdback peak rating shall exceed 2.5 times the

actual pulley torque. The holdback shall be selected
based on manufacturer's guaranteed torque rating.
iii) Duty Rating
The holdback shall be capable of six stops per hour at

full design load.
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iv) Stress Limits
The holdback cam outer race shall not exceed 32,000

psi at peak momentary load (2.5 times motor
nameplate). The roller maximum Hertz compressive
stress shall not exceed 450,000 psi.
3.8.3 Constructional Requirements
i) General
a. Holdback shall be a multiple roller unit,

completely sealed against dust.
b. All wearing surfaces shall be of alloy steel, and

adequately heat-treated for minimum distortion
and wear under the loads encountered.
c. Holdback shall be symmetrical to permit

mounting for required rotation. Direction of free
shaft rotation shall be indicated by a permanent
mark.
ii) Torque Arm
Steel torque arms shall be furnished for each holdback.

The torque arm shall be rated at 2.5 times the
holdback nameplate rating.
iii) Mounting
a. The holdback shall be mounted to the pulley

shaft extension, outboard of the pulley pillow
block bearing.
b. Torque shall be transmitted by a shear key or as

an option a Ringfeder or Bikon friction-less
locking device with hydraulic release. The
Successful Tenderer shall provide the peak and
momentary torque ratings of both locking
methods.
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c. The torque arm shall be supported in the

horizontal position.
iv) Lubrication
a. Lubrication shall be provided by a sealed oil

chamber. Lubrication reservoir shall be provided
with sight level gauge, capped oil filling pipe,
drain plug and pressure relief fitting.
b. Taconite type grease seals shall be provided.

Dust seal end cap shall be furnished on outboard
end. Grease seals shall have hydraulic grease
fitting and grease relief fitting.
c. Lubrication shall be provided by proper oil for the

conditions specified.
d. Holdback shall be lubricated to protect the

internal surfaces against corrosion during
shipment and storage.
v) Bearings
Wherever possible, bearings shall be relubricatable,

anti-friction type, ball or roller bearings with a
minimum L-10 life equivalent to 20 year plant life
expectancy at the machine Design Duty Cycle, but no
less than 100,000 L-10 life hours. Bearing Life Rating
shall be determined in accordance with AFBMA
Standards No. 9 and No. 11.
vi) Bearing Temperature Sensor
Bearing temperature monitors (RTD's) for each

holdback shall be provided.
3.8.4 Safety Guards
i) All holdbacks shall be fitted with guards in accordance

with local statutory requirements.
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ii) Particular attention shall be given to guarding the pinch

point that occurs between the torque arm and the
support.
3.8.5 Coating
Holdbacks and torque arms shall be treated with a durable

surface finish protection system.
3.8.6 Preparation for Shipping
All holdbacks shall be supplied without lubricant but shall

have a vapor phase inhibitor added prior to dispatch to
protect the internal surfaces against rust during the period of
storage prior to use.
3.8.7 Required data sheet for Holdback

3.9 Drive Train Swing Base
3.9.1 Drive train swing base shall be provided for the drives of
down hill conveyor.

with the relevant Indian / latest edition of following applicable
i) ANSI – American National Standards Institute

ii) ASTM – American Society for Testing and Materials
iii) AWS – American Welding Society
iv) MPTA – Mechanical Power Transmission Association
Successful Tenderer shall submit a letter of proof of

equivalency for equipment manufactured in accordance with
DIN or any standard other than those listed above.
NMDC LIMITED MECON
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3.9.3 Swing Base Requirement
3.9.3.1 Drive train Swing base shall be designed to accommodate

mounting requirements for the following drive train elements:
i) Motor
ii) Gear Reducers
iii) Brakes
iv) Couplings
v) Holdback Torque arm reaction lugs
vi) Safety guards
Bases shall be designed to prevent the retention of water,

dust and spilled materials.
3.9.3.2 Swing base Description
i) Mounting
a. The Swing base shall allow mounting for the

motor, reducer, couplings, guards and brake
assembly. The Tenderer shall provide torsional
stiffness and bending stiffness calculations of
bedplate assembly. The calculations shall
indicate the maximum swing base x-y-z plane
deflections with the swing base simply
supported. Successful Tenderer shall furnish
supporting sketch of deflection calculation.
b. Swing base reaction point shall be located to

balance centre-of-gravity of all component
weights with 80% of motor nameplate reaction
torque resulting in zero bending moment on low
speed coupling at this rating.
c. Tenderer shall provide 25 mm thick machined

rails for reducer sole plate and motor supports.
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d. Holding down bolts shall be readily accessible

and arranged to enable the use of standard bolts
e. Tapped holes in bases for mounting components

shall not be used.
f. Base frames for shaft mounted drive units shall

be complete with torque arm reaction lugs,
appropriate torque arms and support bracket.
Torque arm mount shall not provide any
horizontal restraint.
g. Conveyor torque arm support brackets shall be

supplied to permit sufficient movements of
assembly to separate the gear reducer to pulley
shaft coupling halves by 50 mm.
ii) Stiffness
a. Tenderer shall provide a swing base assembly

with sufficient bending & torsional stiffness such
that the reducer gear backlash adjustment is not
altered for mechanical and thermal loading
conditions.
b. Bases shall be designed to be sufficiently rigid in

all directions to withstand static & dynamic loads
imposed by the equipment and those imposed
during transport & erection.
iii) Lifting
Lifting lugs shall be provided for reducer assembly and

for complete swing base assembly.
3.9.3.3 Swing base Fabrication
i) General
a. Bases shall be fabricated from steel unless

otherwise approved.
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b. After welding & prior to machining, fabricated

bases shall be stress relieved.
c. Where cast base plates are approved, the

casting shall be aged prior to machining.
d. Mounting pads on bases shall be machined flat in

one setting i.e. no end-for-ending.
e. Bases shall be provided with blocks and

adjusting screws to assist the alignment of all
components. Vertical stainless steel jacking
screws shall be provided where appropriate to
assist on-site levelling of components. Flat burr-
free packers shall be used.
f. Equipment shall be fully dowelled or fitted with

welded snug blocks after final field alignment.
g. Tenderer shall provide all machining, shimming,

aligning, match making and final assembly for
the reducer, pedestal bearing supports, attached
high speed & low speed couplings, brake
callipers and motor to swingbase. The motor
machined support rails shall be dimensioned to
allow 10 mm of shimming for motor alignment.
This is specified to facilitate variance between
motor supply and spares.
h. The Tenderer shall provide attachments and shall

mount, connect and align brake, couplings and
reducer to swingbase assembly.
i. Shaft alignment shall be maintained under all

conditions in accordance with the specified
alignment tolerances.
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ii) Welding
a. Welding shall not be performed with mechanical

equipment mounted, to avoid damage to
bearings and gears by direct or stray electric
currents. Snug blocks welded alignment shall not
only be undertaken with earth clamp
immediately adjacent to welding.
b. Welding design and execution shall be adequate

for equipment specified design and mechanical
requirements.
c. Welding shall be performed by qualified welders

and shall be supervised by a fully qualified
supervisor.
d. Except for guards, continuous welding shall be

used on all fabricated items.
iii) Surface Protection
Base frames shall be treated with a durable surface

protection system in accordance with the specified
requirements.
iv) Instrumentation
A NEMA 4 (or equal) electrical junction box shall be

provided to terminate all electrical and instrumentation
equipment on the drive swing base. AC and DC
connections shall be routed and terminated in separate
zones in box.
3.9.4 QUALITY ASSURANCE & DOCUMENTATION
i) Successful Tenderer shall provide torsional stiffness

and bending stiffness calculations of bedplate
assembly. The calculations shall indicate the maximum
swing base x-y-z plane deflections with the swing base
simply supported. Successful Tenderer shall furnish
supporting sketch of deflection calculation.
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ii) Successful Tenderer shall provide drawing and

calculations showing that the swing base reaction point
is located so as to balance centre-of-gravity of all
component weights with 80% of motor nameplate
reaction torque, resulting in zero bending moment on
low speed coupling at this rating.
iii) Successful Tenderer shall provide a calculation showing

that the bending & torsional stiffness of the swing base
is such that that the reducer gear backlash adjustment
is not altered for all mechanical & thermal loading
conditions.
iv) Successful Tenderer shall provide lifting drawings,

indicating the total weight and centre-of-gravity of
swing base with the drive train elements installed.
3.10 Brakes
3.10.1 Brake Type
Down hill conveyor shall be provided with 2 nos. caliper-disk

type brakes at the tail station. These brakes shall be fail safe,
spring applied and hydraulically released. Brakes shall be
mounted on the drive pulley shaft which in turn shall be
coupled to the low speed shaft of the gear reducer.
i) Equipment, materials, components and functions shall

be designed, built, rated, tested and shall perform in
accordance with the relevant Indian / latest edition of
following applicable codes, standards, requirements
and guides:
a. AGMA – American Gear manufacturers

Association
b. ANSI – American National Standards Institute
c. ASTM – American Society for Testing and
Materials
d. AFBMA – Anti-Friction Bearing Manufacturers
Association
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e. AWS – American Welding Society

f. MPTA – Mechanical Power Transmission
Association
g. AISC – American Institute of Steel Construction
h. AISI – American Iron & Steel Institute
i. ASME – American Society for Mechanical
Engineers
j. CEMA – Conveyor Equipment’s Manufacturers
Association
k. HMI – Hoist Manufacturer’s Institute
l. NBS – National Bureau of Standards
m. NEC – National Electrical Code
n. NEMA – National Electrical Manufacturer’s
Association
o. SAE – Society of Automotive Engineers
p. JIC – Joint Industrial Council
ii) A letter of proof of equivalency for equipment

manufactured in accordance with DIN or any other
standard other than those listed above shall be
submitted.
iii) In addition to these design, material and production

standards, any equipment provided shall conform to
3.10.3.1 General
Depending on the conveyor requirements, the brake system

shall consist of the following components:
i) Brake disks and hubs

ii) Caliper assemblies
iii) Hydraulic package
iv) Programmable Logic Controller (PLC)
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3.10.3.2 Service Conditions and Lifetime
i) Brake systems shall be designed to operate over the

altitude, temperature range and other environmental
conditions specified in the technical specification.
ii) The brake shall be designed for heavy-duty mining

application including a minimum service life of 25
years, excepting normal brake wear pad replacement.
iii) The hydraulic and electrical systems shall be rated for

continuous duty, 24 hours per day, for the life of the
conveyor.
3.10.3.3 Braking Torque
Under normal wear and all heat conditions, the brakes shall
be able to apply and maintain torque between 90% and
110% of the torque specified in the Design Data Sheets, over
the specified stopping time period, considering fading and any
other inherent variations in torque.
3.10.3.4 Thermal Rating
i) The brakes shall be capable of stopping a fully loaded

conveyor 3 times per hour in a 24-hour period.
ii) The brake shall be capable of re-engagement with full

holding capacity within 6 minutes of a prior full load
emergency stop without impairing the brake
components, excluding normal brake lining wear.
3.10.3.5 Brake Operation Definitions and Specifications
i) Fails safe
Fail-safe shall be considered to mean: Upon any

malfunction of the hydraulic pump, brake calipers,
hydraulic pressure supply or return lines, control valve
actuation or power supply failure, PLC failure, the brake
will apply.
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ii) Normal Braking
Braking under programmed control is considered

normal braking. Programmed control will be comprised
of some combination of proportional controlled calipers
and digital deployment of fixed-torque calipers.
iii) Emergency Braking
Braking under power failure, proportional control failure

or PLC malfunction when the hydraulic pressure is
reduced according to a preset curve is considered
emergency braking.
iv) Over speed Braking
Braking under large over speed conditions (over 25%)

when the hydraulic pressure is rapidly reduced to zero
by dumping the caliper fluid directly to the tank is
considered over speed braking.
v) Required Brake Lag Time
The brake lag time is the time from when the PLC gives
the brake command to when the brake caliper just
touches the brake disk. The shortest possible lag time
is best for the fixed-torque brakes & the lag time for
the fixed-torque brakes shall not exceed 0.125
seconds. When actuated by means of proportional
control, lag time of proportional calipers shall not
exceed 0.500 seconds. Upon application by solenoid
vent valve, lag time of proportional calipers shall not
exceed 0.250 seconds.
vi) Required Brake Actuation Time:
The brake actuation time is the period required to

increase torque from 0 to 100%. The shortest possible
actuation time is best for the fixed-torque brakes;
actuation time for the fixed-torque brakes shall not
exceed 0.125 seconds. When actuated by means of
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proportional control, actuation time of proportional

callipers to full torque shall not exceed 0.500 seconds.
Upon application by solenoid vent valve, actuation time
of proportional calipers shall not exceed 0.250 seconds.
3.10.4 Structural Requirements
3.10.4.1 Attachment Points
Tenderer shall provide envelope drawings locating attachment

points and showing the magnitude and direction of equipment
dead and live loads at each point.
3.10.4.2 Attachment Tolerances:
Tenderer shall indicate all critical assembly tolerances, with

disk, required to insure proposed equipment performance.
This shall include maximum hydraulic piping distances, sizes,
and piping specifications.
3.10.5 MECHANICAL REQUIREMENTS
i) Brake Rotor (Disk)
Each brake disk shall be attached by a bolted flange

connection or welded to its hub. This hub will be key-
seated to the drive pulley shaft. Tenderer shall specify
rotor and hub material, mounting tolerances and
location. All disks will be interchangeable inclusive the
hubs.
ii) Brake Calipers
Brake calipers shall be fail-safe, spring set, and

hydraulically released. Caliper detail on all components
shall be provided with the quotation. All calipers shall
be interchangeable. Calipers shall be supplied with a
flow-through oil circuit. Mounting assembly and
hardware shall be provided including location
requirements, mounting flanges, and bolt attachments.
Caliper mounting must allow for thermal expansion of
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shaft on one side of pulley brake disk set. The

expansion allowance shall be 0.080 in.
iii) Manual Release
The brake assembly shall be provided with means and

tools to manually release the brake caliper from the
disk for maintenance purposes.
3.10.6 HYDRAULIC REQUIREMENTS
i) Hydraulic Pressure
The hydraulic system shall have rated maximum design

pressure of 3000 psi and a maximum working pressure
of 2000 psi.
ii) Hydraulic Assembly
The hydraulic assembly shall be furnished complete

with AC motor, couplings, guards, pump, tank, oil
filters, oil level sight gauge, charging fittings, drain
fittings, accumulators, heating and cooling system if
required, and required instrumentation. The hydraulic
assembly shall be designed and constructed to facilitate
ease of maintenance including adequate clearances for
local equipment removal. The pump and motor shall be
rated a minimum of 25% over the working rating.
iii) Heating and Cooling Systems
Oil cooling and heating requirements are to be

established by the Tender according to the operating
conditions. Oil cooling system, if required, must use air
to oil cooling.
iv) Filtration
The reservoir assembly shall be equipped with 10-

micron filtration (maximum particle size passing) on
both pump- suction and discharge lines. Filters shall be
fitted with by-pass check valve if backpressure exceeds
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set point due to filter-restricted flow. A standby filter

system shall be provided with manual switch over from
on-line filter during normal running operation. A visual
indicator shall annunciate status of filter contamination.
v) Sealed Tank
The reservoir assembly shall consist of an

atmospherically sealed tank with a volumetric back-
pressure compensator placed in the oil reservoir tank
to provide a fully sealed and self contained hydraulic
sump. Hydraulic oil charging shall be accomplished only
through a replaceable cartridge type filter. No
atmospheric air vent or breather is allowed in the
hydraulic circuit.
vi) Hydraulic Accumulators
Air over oil accumulators shall be provided for the

following functions:
a. Upon loss of AC pump power, the accumulator

shall provide sufficient pressure and hydraulic
flow control to bring the conveyor to a complete
stop using normal proportional control braking.
b. The accumulator shall provide sufficient fluid

reserve to minimize pump cycling under normal
running condition, (brake fully released). The
minimum acceptable cycling time is 15 minutes.
vii) Solenoid Valves
Hydraulic solenoid valves shall be controlled from the

output of PLC. All solenoid valves shall be 110VAC,
interposing relays are allowed. Emergency braking
valve shall fail open. All others shall fail closed.
viii) Proportional Control Valves
Hydraulic servo or pressure control valves shall be

controlled from the PLC output. The pressure control
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valve shall have an accuracy of no less than ±5% of

the design setting. The PLC shall be equipped with a 4
to 20 mA analog output module.
ix) Relief Valves
Hydraulic relief valves shall be adjustable and

interchangeable with each other for standardization.
The relief valve shall have an accuracy of no less than
±5% of the proposed design setting and shall be
repeatable to that accuracy regardless of ambient or oil
temperature conditions.
x) Hydraulic Manifold
The Tenderer shall provide mounting of all valves one

on common integral metal block manifold. The manifold
shall be ported, relieved, and polished to guarantee
proper hydraulic performance. All valves shall be fully
accessible from the front of the cabinet and easily
removable without removal of any other
instrumentation, hydraulic lines, or valves.
xi) Hydraulic Lines
a. Hydraulic lines shall be solid 304 stainless steel

tubing with flared ends (SAE-5514-37), except
that hydraulic hose may be used on the tank
return line after the pressure control valve, and
as short lengths (less than 1 meter long), for
vibration control adjacent to the brake calipers.
b. Pipe unions and removable lengths of pipe shall

be strategically placed to allow valves, pump,
and component ease of removal and
replacement.
c. The hydraulic lines shall be sized to limit the flow

velocity to no more than 10 m/s.
d. The hydraulic lines shall be designed for

automatic air purging and for gravity drain to
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tank. Oil collection in the line is not allowed

when the brake system is in the deactivated
state.
xii) Hydraulic Fittings
a. All hydraulic fittings and connectors shall be solid

stainless steel.
b. All connectors shall use an ORB (O-Ring Boss)
according to the SAE-5514 standard.
xiii) Hydraulic Fluid
The hydraulic fluid shall be a petroleum base and shall

be compatible with all brake circuit seals. Owner
requires a single hydraulic fluid to operate over the full
range of temperature conditions. The hydraulic fluid
shall be specified with the quotation including the
recommended operating temperature range and
viscosity index at the temperature limits.
xiv) Hydraulic Schematic
Tenderer shall provide a complete hydraulic flow sheet

and schematic with its quotation showing all maximum
flow rates, requirements, orifices, valves and
instrumentation including the pump assembly with
motors, calipers, disk(s), including cutoff and vent
valves for maintenance and manual control.
3.10.7 INSTRUMENTATION REQUIREMENTS
Refer Clause no. 5.10 under Chapter No. Q4.
3.10.8 ELECTRICAL REQUIREMENTS
3.10.8.1 Pump Motor:
The pump motor shall have the following characteristics:
i) 3 phase, 440 volt, 50 Hz

ii) Taconite seals
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iii) Degree of protection: IP(W)-55 (TEFC)

iv) Insulation Class F
v) Temperature Rise: 90°C
3.10.8.2 Enclosures:
All electrical and instrument components shall be enclosed in

an oversized cabinet with adequate working space for easy
access and maintenance.
3.10.8.3 Marshalling Rack:
A marshalling rack shall be provided for all electrical and

instrumentation equipment included in the brake package.
This rack shall be located in the NEMA 4 or eqv. Electrical
enclosure. AC connections shall be routed and terminated
separately from DC instrument signals to minimize
instrumentation signal noise.
3.10.8.4 Operating Voltage:
All control circuits and control components except the

hydraulic pump and auxiliary systems shall be rated for
110 VAC.
3.10.8.5 Control Panel:
A small control panel shall be provided for manual control of

the brake system. All control switches shall be input to the
PLC with no hardwired interlocks. This panel shall be located
close to the main electrical cabinet (locating the panel on the
cabinet door is acceptable). Buttons should be weather proof.
3.10.8.6 Indicator Panel:
A small indicator panel shall be provided for visual indication

of the status of each solenoid valve, instrumentation switch,
caliper position switch, caliper wear switch, and hydraulic
pump. This panel shall be located close to the main electrical
cabinet (locating the panel on the cabinet door is acceptable).
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3.10.9 CONTROL REQUIREMENTS
Refer Clause no. 5.10 under Chapter No. Q4.
3.10.10 Identification
All motors and hydraulic units shall be provided with stainless

steel identification tags. The tag shall be heavily embossed
with 12-14 point letter size.
3.10.11 Motor
The motor I.D. tag shall include
• Tag Number
• Name of motor manufacturer
• Motor type
• Serial number
• Rated power (CV or kW)
• Model
• Rated voltage (V)
• Nº of phases
• Nº of poles
• Rated current (A)
• Frequency (Hz)
• Speed (RPM)
• Insulation class
• Temperature class
• Temperature rise
• Locked rotor current / rated current
• Applicable standard
• Degree of protection
• Service rate
• Connection diagram
• Type of bearings
• Weight (kg).
3.10.12 Hydraulic Unit
• Tag Number
• Manufacturer
• Purchase order
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• Date of fabrication (dd/mm/yy)

• Caliper model nº
• Torque capacity per caliper (kN.m)
• Total torque capacity (kN.m)
• Working pressure (Bar)
• Maximum pressure (Bar)
• Reservoir capacity (liters)
• Hydraulic oil volume (liters)
• Oil specification
• Power supply
• Motor ( V / Hz / _____Phases)
• Control voltage (VAC).
3.10.13 SHIPPING
All equipment shall be packed for safe overseas shipping.
3.10.14 WARRANTY
i) All major pieces of equipment such as, but not limited

to, calipers assemblies, disk rotor assemblies, and
hydraulic assemblies shall be warranted for a period of
2 years after start-up.
ii) The pump assembly shall be warranted for a period of

5 years after startup. Normal wear items such as
caliper pads and hydraulic filters shall be warranted
against defects for at least 90 days following startup,
exclusive of normal wear. Manufacturers’ warranties for
individual components not manufactured by the
Supplier are acceptable provided that these warranties
extend for no less than 6 months following start-up.
3.10.15 QUALITY ASSURANCE AND DOCUMENTATION
3.10.15.1 Shop Testing:
Factory test of the assembled hydraulic circuit and its

functions shall be performed prior to shipping. The test shall
include performance measurements to verify compliance with
this specification.
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3.10.15.2 Documentation:
The successful Tenderer must supply two (2) copies of the

following documents for comment and approval:
i) Hydraulic circuit drawing with a list of hydraulic and

electrical components
ii) Caliper drawings with a list of components
iii) Disk and hub drawings
iv) Catalogues of all hydraulic components
v) Hydraulic unit drive specification
vi) Data sheet of pump motor
vii) Painting specification for steel structures, calipers,
piping, hydraulic and electrical components
viii) Spare parts list for commissioning/start up
ix) Spare parts list for two years operation
x) List of special tools
xi) Piping drawings with detailed specifications
xii) Typical interlock circuit
xiii) Electrical diagrams
xiv) Data sheets of all instruments
xv) Wiring diagrams
xvi) Brake electrical drawing
xvii) Hydraulic oil specification
In addition, the successful Tenderer must supply 2 (two)

copies of installation, maintenance and operation manuals
and 2 (two) copies of the shop test report.
3.10.15.3 Required data sheet for Brakes

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3.11 Control Philosophy

3.11.1 Conveyor no.723 being the critical equipment of this package,
special attention shall be given for the design of this
conveyor. The Tenderer shall develop and offer a fool proof
control philosophy to take care of controlled starting, stopping
and braking of the conveyor under all possible loading
patterns and even under power failure and other emergency
conditions.
3.11.2 The motors are the primary stopping mechanism through VFD
for the down hill conveyor. However, brakes shall be provided
at the tail station to stop the conveyor if the motors trip. The
brake system shall be sized to stop the conveyor under any
loading condition. The system shall be designed with a two
brake discs (with a common hydraulic pack) at the tail.
Brakes shall be of spring applied and hydraulically released
fail safe type. Each disc shall have two identical calipers, one
proportionally controlled and one digitally controlled. Each
caliper shall be responsible for half the required brake torque
per disc. The braking system shall be fitted with battery
backed UPS, brake controller that can control the braking
system even in the event of the power failure.
3.11.3 The hydraulic control shall consist of a PLC controlled

proportional valve circuit in parallel with a solenoid actuated
circuit. The brakes must be fast acting, maximum 250ms to
disk contact and 250ms to 100% torque (slope projected).
This may require putting part of the hydraulic circuit in close
proximity to the calipers. The proportional side of the
hydraulic circuit shall be the primary control circuit when
brakes are used to stop the conveyor. They are used to stop
the conveyor along a pre-defined velocity ramp. The braking
torque and time of application will vary depending on the
conveyor loading profile and will be determined by the PLC. If
power is lost, the brake circuit and PLC will continue to
operate on UPS until the conveyor is stopped. In the event of
UPS failure, the parking circuit on the brakes will open and
brake torque will be applied along a pre-defined curve,
defined by the pressure relief valves and orifices in the
parking circuit.
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3.11.4 PLC at the tail end of the conveyor shall be used to monitor
and control the conveyor and other related local equipment. A
SCADA system should communicate to the PLC and allow the
operator to monitor the operation and health of the conveyor
system, review historical data and initiate starts and stops of
the conveyor. Intelligent bus systems (e.g. Profibus) should
be used where practical to reduce cabling and increase
availability. In addition to the instrumentation typically found
on motors, gearboxes and bearings of these sizes (e.g.
current, temperature, fluid levels, vibration, etc), conveyor
systems typically include instrumentation to detect- belt slip,
belt rip, belt alignment, pull cord and fire.
3.11.5 The conveyor shall be started by accelerating both drives to

5% of full speed for a period of 6 sec to take some of the sag
out of the standing belt. The belt shall then be started along
an ‘S’ type curve to full speed. This may take approx. 120
seconds regardless of material loading on the belt.
3.11.6 The Tenderer shall consider following different modes of

stopping of the conveyor such as:
a. Normal motor stopping condition

b. Power failure condition
c. Power & VFD controller failure condition
d. Power, VFD & Brake controller failure condition
3.11.7 Motor Stop
The conveyor shall be normally stopped with both motors

following a 60 second velocity ramp. This results in the best
control of tension in the system and should be used whenever
possible, including shutdowns caused by traditional hard-
wired interlock trips.
3.11.8 Proportional Brake Stop
In the event of an electrical trip of the motors, the brakes

shall be used. If the UPS is still working and the velocity
signals are still present, the stop is done using the
proportional control circuit of the brakes following a 60
second ramp. The parking circuit shall be energized only
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when the conveyor is stopped. The stopping time may vary

from 20 to 69 seconds depending on the loading of the belt.
3.11.9 Uncontrolled (Emergency) Stop
If a proportional brake stop is not possible or the velocity has

exceeded the control ramp bands, the parking circuit shall be
vented through a controlled circuit. This is the least desirable
of the stops and results in greater dynamic tension variations.
This is due to the brakes having sufficient stopping torque to
bring the downhill loaded condition to a stop in a reasonable
period of time. The stopping time may vary from 8 to 66
seconds depending on the loading of the belt.
3.11.10 The control system shall ensure smooth start up of conveyor

under all loading conditions with no jerks, belt lifting, spillage
etc. and also ensure minimum belt tension. kW transducers
for each motor to sense load and encoder for sensing speed
for feed back to controls may also be considered.
3.11.11 The starting and stopping times of the downhill conveyor shall
be selected in such a way as to reduce excessive stress on
belt. While selecting the stopping time of the conveyor due
care shall be taken to study the difference in coasting times
of other conveyors in the system and suitable design shall be
adopted to prevent accumulation of material in transfer
chutes.
3.12 Pulleys and Pillow Blocks
i) Equipment, materials, components and functions shall

be designed, built, rated, tested and shall perform in
accordance with relevant Indian / latest edition of the
following applicable codes, standards, requirements
and guides:
a. ANSI - American National Standards Institute

b. ASTM - American Society for Testing and
Materials
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c. ASME - American Society of Mechanical

Engineers
d. AFMBA-Anti-friction Bearing Manufacturers
Association
e. AWS - American Welding Society
f. CEMA - Conveyor Equipment Manufacturers
Association
g. ISO - International Standards Organization
ii) A letter of proof of equivalency for equipment

manufactured in accordance with any other standard
other than those listed above shall be submitted.
iii) In particular, all pulleys shall meet or exceed the

minimum requirements set forth in CEMA B105.1-2003
“Specifications for Welded Steel Conveyor Pulleys with
Compression Type Hubs.”
3.12.2 Pulley Requirement
3.12.2.1 General
i) Pulleys shall be designed to operate over the

temperature range and other environmental conditions
specified.
ii) Unless specified otherwise, pulleys shall have live

shafts and shall rotate in pillow block (plummer block)
bearing assemblies.
iii) Finite element analysis or other methodology, subject

to approval, shall be used to verify the pulley design.
Radial and shear loading due to the belt shall be
modeled along with any overhung loads that may exist.
The locking device pressure shall be accounted for in
the analysis.
iv) All pulleys shall be welded construction with T-shaped

end discs made from forged or cast steel. Shell interior
stiffener rings or discs are not allowed at final
assembly.
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v) The weld connection between the shell and end discs

shall be in an area of reduced stress peaks where first
class welding and testing of the seams shall be
possible. Welding shall be ground smooth to the base
material.
3.12.2.2 Standardization
The pulley and shaft assemblies of the same type shall be

interchangeable in every respect for pulleys of the same type
in any other location. Pulleys shall be classified by type as
follows:
i) High Tension Pulleys
a. Drive pulleys
b. Non-driven head or tail pulleys at the top of a
significant slope.
c. Any pulley whose normal running tension
exceeds 60% of the maximum running tension
for any pulley on the conveyor in question.
ii) Low Tension Pulleys
a. Non-driven head or tail pulleys.

b. Take-up pulleys.
c. Bend pulleys for drives, take-ups, and turn-
overs.
d. Any pulley whose normal running tension is less
than 60% of the maximum running tension for
any pulley on the conveyor in question.
iii) Pulleys used to rotate the belt along its axis as it

moves through a turn-over shall be considered a
separate class of pulley and are not subject to the
same loading criteria as the high-tension and low-
tension pulleys that are used to change the belt’s
direction of motion.
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3.12.2.3 Nominal Loads
i) Nominal pulley loads are calculated by applying a

simulated load to the conveyor that would cause the
motors to reach overloading the reach 100% torque
during static (steady state) running conditions and
computing the tension for this load condition.
ii) The maximum Von Mises stress anywhere in the pulley

computed using these loads shall not exceed 70% of
the yield stress.
3.12.2.4 Momentary Peak Loads
i) Peak pulley loads shall be calculated by applying a

simulated load to the conveyor that would cause the
motors to reach 100% during static (steady state)
running conditions and computing the peak tension for
this load condition during acceleration. The results of
these calculations are summarized in the Pulley Data
Sheet.
ii) The maximum Von Mises stress anywhere in the pulley

computed using these loads shall not exceed the yield
stress anywhere in the pulley assembly.
3.12.2.5 Dimensions
Diameters of pulleys shall be selected to be compatible with

the belt steel cord diameter as specified by the belt Vendor
and in this technical specification.
3.12.2.6 Pulley Stress Allowances
All pulleys shall be fabricated for infinite life at the stress

cycles and loads imposed. Tenderer shall make allowance, in
the stress calculations, for momentary starting and stopping
loads which exceed the maximum steady state forces by
more than 25%.
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3.12.2.7 Pulley Fabrication
i) Pulleys shall be of welded steel construction.
ii) All welding on engineered pulleys shall be in

accordance with AWS D1.1 Sections 2, 3, 4, and 5 or
equivalent standard. All welds shall be visually
examined and tested in their entirety, by ultrasonic or
radiography, and by magnetic particle method in
accordance with AWS D1.1 or equivalent standard, with
acceptance levels as indicated for Dynamically Loaded
Structures. All welds shall be full penetration.
iii) All weldments shall be thermally stress relieved prior to

machining. No weld repair using air arc or welding shall
be allowed after stress relief unless a subsequent
second stress relief cycle is performed. Pulley stress
relieving temperatures shall be lower (by
0
approximately 25 C) than the construction
temperature of cast end disks (if applicable).
iv) Weld filler materials shall be low hydrogen and shall be

used with oven control. All internal surface welds shall
be machined to a smooth surface not to exceed 125
RMS (micro inches) or as otherwise specified herein. All
weld undercutting shall be removed by machining.
3.12.2.8 Painting, Cleaning and Surface Preparation
i) Pulley end discs only shall be prime painted. The outer

surface of the pulley (area to be lagged) is not to be
painted. Machined bores are to be coated with a rust
inhibitor. Pulleys are to be shipped to the specified
lagging applicator in a suitable crate or cradle to
prevent damage during normal transportation.
ii) Shafts shall be coated with a rust inhibitor and shipped

to the Purchaser (or between sub-suppliers) in rugged
crates suitable for handling with fork lifts and for
outside storage for two years or longer.
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3.12.2.9 SHELL AND END DISK REQUIREMENTS
3.12.2.9.1 General
i) Both sides of the shell and end discs connection shall

be welded using large smooth fillets. Fillet reinforced
full penetration welds shall be used.
ii) The change in thickness from end disc to shell shall be

tapered to avoid stress concentrations at the joint.
iii) It is preferred for high tension pulleys that integral cast

steel 'T' section end disc and shell rims shall be used,
connected to the shell using full penetration butt welds.
iv) Unless specified otherwise, pulley shell and end discs

shall be designed for a fatigue life based on the
endurance limit for the material under design running
tensions, with consistent factors of safety.
v) Pulley shells need not be heat treated unless

recommended by the manufacturer, however, heat
treatment is preferred for plate end disc type pulleys.
vi) Shell and end disc assembly shall be stress relieved

after welding and prior to machining.
vii) The stress relieved shell and end disc assembly shall be
machined such that the pulley face is concentric with
the shaft at all positions along the face:
- 0.75 mm Total Indicator Reading (TIR) for non-

drive pulleys
- 0.50 mm Total Indicator Reading for drive
pulleys.
viii) No witness marks shall be visible between the end disc

centre, or rim edges and on or near the hub bore after
machining.
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3.12.2.9.2 Shell Design
i) The finished thickness of the shell after machining shall

not be less than the calculated required thickness.
ii) Maximum principal stresses (axial bending, radial,

hoop, torsional) shall not individually exceed +20
percent of the material yield strength.
iii) Combined maximum stress shall not exceed 80% of

the material yield strength, in accordance with the
Maximum Strain-Energy Theory for native metal, and
40% of the material yield strength in the zone of the
weldment.
iv) Fatigue stress reversal range shall not exceed +18% of

the material yield strength for each principal stress.
The fatigue life shall be computed and a Modified
Goodman Diagram or its equivalent shall be furnished
by the successful Tenderer which illustrates the
maximum principal stress reversal range of the rim
metal. The location of each maximum principal stress
shall be indicated. At minimum, the values shall be
given at the belt centerline and at the circumferential
weld joint, not on the disk centerline or less than the
rim thickness inside of the end disk centerline.
3.12.2.9.3 Shell Fabrication
i) Construction
a. Pulleys shall have shells manufactured from

carbon steel. Shell material shall have a
minimum yield strength of 248 mPa and carbon
content limited to a maximum of 0.30%.
b. Successful Tenderer shall orient rim plate

metallurgical grain perpendicular to shell
curvature (parallel to shaft axis).
c. Longitudinal seam welds shall be prepared for
full penetration butt weld with back gouging as
necessary.
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ii) Tolerances and Surface Finish
a. Drive pulley shell outside diameter shall be

machined to within ±0.25 mm of the nominal
dimension.
b. The shell thickness after machining shall equal or

exceed the design thickness and the maximum
thickness shall not exceed the minimum
thickness by more than 10%.
c. The difference in diameter of the shell measured

at opposite ends shall not exceed 0.6mm.
d. Shell surface finish after machining shall be

between 250 and 500 RMS for lagged pulleys.
e. For 300 mm and greater diameter shaft sizes,

internal plate surface shall be ground or
machined free of all notches greater than 0.5
mm deep after fabrication is complete.
3.12.2.9.4 End Disk Design
i) Peak and Fatigue Stresses
a. Maximum principal stresses (+/-: radial,

tangential; shear) shall not individually exceed
50% of the material yield strength.
b. The maximum combined triaxial stress shall not

exceed 80% of the material yield strength in
accordance with the Maximum Strain-Energy
Theory.
c. Fatigue stress reversal range shall not exceed

± 18% of the material yield strength for each
principal stress. A Modified Goodman Diagram or
its equivalent shall be furnished by the
successful Tenderer which illustrates the
maximum principal stress reversal range of the
rim metal. The location of each maximum
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principal stress shall be indicated. At minimum,

the values shall be given at the belt centerline
and at the circumferential weld joint, not on the
disk centerline or less than the rim thickness
inside of the end disk centerline.
d. Hubs for all pulleys shall be heavy duty solid

steel and shall form an integral part of the end
disc.
e. Hub locking contact pressure stress shall not

exceed the material yield strength when the
stress is evaluated at the steady-state rated
design loading for the combined bending, shear
and compressive forces. The stresses produced
by the locking device shall be incorporated in the
design stresses for the hub and end disk.
3.12.2.9.5 End Disk Fabrication
i) Construction
a. End disks may be fabricated from a steel plate,

steel forging or steel casting. No welded
construction is allowed in the zone of the end
disk and locking hub. For end disk thickness of
less than 38 mm, and with disk fitted on the
shell inside diameter, the disk shall be welded to
the shell on both its outside and inside face.
Each weld shall penetrate at least one-half of the
end disk thickness. For an end disk thickness
greater than 38 mm, the attachment of the end
disk to the shell shall be provided by a
circumferential weld in the zone of the shell
assembly.
b. End disk material shall have a minimum yield

strength of 248 mPa and carbon content limited
to a maximum of 0.30%. End disk material is to
be cast or rolled steel of a consistent chemistry
to facilitate welding both at manufacture and in
any subsequent repair work.
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c. Weldments are to be free of undercutting on disk

interior.
d. Material thickness shall everywhere exceed

13 mm after machining. However, the min.
thickness of pulley shell and end disc shall be
inline with the enclosed data sheet.
e. Surfaces shall be finished to 125 RMS (micro

inches) unless noted herein.
ii) Painting
Pulley end discs only shall be prime painted. The outer

surface of the pulley (area to be lagged) is not to be
painted. Machined bores are to be coated with a rust
inhibitor. Pulleys are to be shipped to the specified
lagging applicator in a suitable crate or cradle to
prevent damage during normal transportation.
3.12.2.10 LOCKING DEVICE REQUIREMENTS
i) Model
Bikon Model Dobikon 1015, Ringfeder Model 7012 or

7015 or larger locking assembly, or Owner’s approved
equal, shall be used to secure the pulley shaft to the
end disk. Equal sizes shall be used for both ends.
ii) Locking Device Design
a. Torsional Capacity
- The locking device shall be sized for at

least 3 times the nominal torque based on
nameplate motor power.
- The locking device shall be sized such that

transmitted rotating bending moment
does not exceed 35 percent of the locking
unit's torsional capacity as specified by the
manufacturer.
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- The locking device shall have self-locking

tapered internal metal surfaces, which
minimizes additional tension on the
locking bolts due to shaft bending.
b. Hub Locking Contact Pressure
Hub locking contact pressure stress shall not

exceed the material yield strength when the
stress is evaluated at the steady-state rated
design loading for the combined bending, shear
and compressive forces. The stresses produced
by the locking device shall be incorporated in the
design stresses for the hub and end disk.
c. Covers
Protective covers for the locking devices shall be

provided. The covers shall be attached to the
end disks. The covers shall have felt seal backing
to minimize moisture access to the locking
devices. The locking devices shall be packed with
a suitable non-trenching, water resistant grease,
at final assembly.
3.12.2.11 SHAFTING REQUIREMENTS
i) Shaft Design
a. General
- Shaft design loads shall be determined

from belt tension load cases specified,
using the nominal and momentary
maximum tensions defined above.
- Shafts shall be designed using the ASME

code for the design of torque transmission
or other established method.
- All conveyor pulley drive shafts shall be

designed to transmit the connected motor
NMDC LIMITED MECON
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power including service factor, as well as

locked rotor torque (2.5 x bnominal
motor torque). Shafts with brakes also
shall be designed for the brake torque.
- Overhung loads imposed on the shaft (e.g.

from right angle shaft mounted reducer
drives, brakes or other sources) shall be
taken into account in the design of the
shaft.
- Shafts shall be designed with a safety

factor SF=1.75 as a minimum. All load
combinations shall be considered.
Successful Tenderer is requested to supply
his shaft calculations for review.
- Shaft with keyways is not permitted.

Slope, in radians, of the shaft deflection
curve at pulley hubs, under pulley design
load conditions, shall not exceed the value
specified by the locking device supplier or
as follows, whichever is the more
stringent:
Engineered pulleys for steel cord : 0.00065

belting and / or Ringfeder type
locking device
b. Shaft Fillets
Wherever a shaft is reduced in diameter, the

fillet radius shall be at least half the difference in
the diameters or 10% of the smaller diameter,
whichever is greater. Stress concentrations
resulting from the step-down shall be included in
stress calculations. Dye penetration inspection of
all turndown areas after machining shall be
performed. End turndown on shafts under 150
mm (6 inch) in diameter at the bearing shall not
be permitted.
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c. Stress Concentrations
- Shafts shall have a 1.3 mm raised journal

and machined locking assembly mounting
journal at each end disk attachment. The
journal shall be no wider than the locking
assembly, with 3 mm fillet radii, the
purpose being to minimize stress
concentration caused by the edges of the
locking assembly.
- Alternative methods of minimizing the

stress at the locking ring connection may
be suggested.
d. Peak Stress
- The maximum stress between shaft,

locking device, and hub shall not exceed
70% of yield.
- Allowable maximum shaft stresses are as

follows:
Bending only : 146 mPa
Combined Stress:
Shear at hub, not keyseated : 74 mPa

Shear at turndowns : 74 mPa
e. Deflection
The slope angle of shaft deflection, measured at

the end disk enter line, shall not exceed 0.0015
radians. Deflection shall be computed without
end disk constraint.
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f. Stress Calculations
- Shear stresses shall be computed by FEA

or according to the method given in Belt
Conveyors for Bulk Materials, fifth or sixth
edition, by CEMA, with Kb=1.5 and
Kt=1.0.
- At turndowns, stress concentration factors

shall be applied for bending and torsion,
as per Stress Concentration Factors by
Peterson, Wiley-Interscience ISBN 0-471-
68329-9 (fig. 78 & 79).
g. Fatigue
The shaft contact pressure under the locking

device shall be calculated for the inside and
outside shoulders. The alternating stress range,
at the shoulders, shall not exceed the shaft
material's endurance limits as defined by the
Modified Goodman Diagram.
ii) Shafting Fabrication
a. Material
Shafts shall be commercial cold rolled steel,

turned and polished ASTM A108 Gr C1045 or
better.
b. Construction
Conveyor drive and non-drive pulley shafts shall

be machined from hot forged blanks. Shafts shall
be manufactured to standard commercial
tolerances for diameter and straightness. No
surface heat treating is allowed.
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c. Surface Finish
- Shaft surface finish shall be machined to a

minimum of 125 RMS (micro inches).
- Shaft journals and fillet radii shall be

machine finished not to exceed 63 RMS
(micro inches).
d. Dimensional Tolerances
- Coupling mounting surfaces shall be

concentric with the nearest bearing
journal within 0.0003 times the bearing
journal diameter or 0.025 mm, whichever
is the greater.
- Shafts shall be machined and have fine

machined surfaces in the area of the
locking device, bearing lands and
couplings. The diameter, tolerance and
shaft finish in these areas shall be as
recommended by the respective
manufacturer.
e. Painting
Shafts shall b3 coated with a rust inhibitor and

shipped to the Purchaser (or between sub-
supplier) in rugged crates suitable for handling
with forklift trucks and for outside storage for
two years or longer
3.12.2.12 LAGGING REQUIREMENTS
i) General
a. All pulleys shall be lagged in accordance with the

details specified in this technical specification.
b. The Tenderer is encouraged to quote an

alternative drive lagging that will substantially
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increase lagging life, improve the drive friction

coefficient, and that has superior shear
properties to withstand the substantial torsional
driving forces and abrasive action.
ii) Non-driven Pulley Requirements
a. Non-driven pulley lagging shall be lagged with

20 mm plain lagging.
b. The hardness of the lagging shall be shore 45.
iii) Driven Pulley Requirements
Driven pulleys shall be lagged with 25 mm thick

diamond lagging. The lagging pattern shall be a
diamond with the horizontal groove apex included
angle at 60 degrees. The space between grooves shall
be 60 mm. The groove depth 8 mm and width 6 mm.
The hardness of the lagging shall be shore 65.
iv) Shear Requirements
Tenderer shall warrant that the vulcanized lagging

assembly meets all shear load requirements. The
minimum shear load shall be computed at 2.40 times
the maximum running tractive tension, a pulley lagging
coefficient of f = 0.35, that sets the active arc of
contact for permissible lagging shear, and corrections
for grooving of the lagging shall be applied.
v) Tolerances
a. Lagged pulleys shall be concentric after lagging

to within 1.5 mm TIR.
b. The difference in diameter of the lagged shell

measured at opposite ends shall not exceed
0.8 mm.
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3.12.2.13 PILLOW BLOCK REQUIRMENTS
i) Pillow Block Design
a. Loads
- The pillow block bearings shall support the

pulley and shaft belt line forces and shall
support any overhung loads and reaction
forces produced by shaft-mounted drive
assemblies.
- Pillow blocks sizing shall allow for 2 %

resulting axial load in all cases.
- For split-housing pillow blocks, the pillow

block shall be oriented so that the load
vector is directed through the base of the
pillow block. The load vector direction
shall deviate less than 45o from a line
perpendicular to the mounting base plane
of the pillow block.
b. Required Components
The conveyor pillow blocks shall include, but not

be limited to the following components:
• Housing
• Bearing
• Tapered adapter with fast locking and
removal device
• Lubrication & grease fittings
• Taconite seals
• Bearing End Caps, where specified
• Pillow block housing shim stock
c. Housing
- Pillow blocks, flanged units and take up

units shall have double row, fully self
aligning, spherical roller bearings with
adapter sleeve mounting.
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- Pillow block housing shall be adaptable for

either fixed or floating bearings.
- Misalignment shall not be limited by the

seal. Each pulley shaft shall have one
fixed and one expansion type bearing, the
fixed bearing being on the drive end of
any driven shaft.
d. Bearings
- Pillow blocks and bearings shall be

designed for heavy duty hard rock mining
application, including a service life of 20
years, including fatigue and wear factors,
except for seal wear. The design AFBMA L-
10 life shall be 100,000 hours minimum.
The hours shall be computed for the loads
and speeds specified.
- Normal internal clearance bearings shall

be used. Bearings shall be fitted such that
initial and final clearances are in
accordance with the bearing
manufacturer's instructions. Records of
bearing installation clearances shall be
maintained and submitted.
e. Tapered Adapter & Locking Collar
- Bearing inner race shall be fixed to the

pulley shaft with a tapered adapter sleeve
and locking collar. The bearings shall be
hydraulically installed and removed. Set
screws are not acceptable.
- Successful Tenderer shall supply a

description on the proposed method of
quick hydraulic mounting and removal
assist for bearing assemblies with bores
over 200 mm in diameter.
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f. Lubrication & Grease Fittings
- All bearings shall have provisions for

grease lubrication. Successful Tenderer
shall supply the specifications for the
recommended lubricant and lubrication
frequency.
- Housings shall be drilled and tapped to

receive grease nipples. Holes provided for
bearing re-greasing shall be fitted with
blank plugs. Holes provided for seal
purging shall be fitted with grease nipples.
- Unless specified otherwise, grease nipples

shall be of the button type, Tecalemit
industrial round head or approved
equivalent.
g. Ends
- All pillow blocks shall have one end closed

and one end open except drive pulley,
which shall have both ends open on both
pillow blocks.
- Bearing end caps shall be provided on all
bearings except driven shafts and pulley
bearings with speed indicators.
h. Dimensions
- Successful Tenderer shall specify housing

end-float dimension for each bearing size.
Successful Tenderer shall provide pillow
block housing envelope and clearance
dimensional drawings, locating attachment
points.
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i. Seals
Pillow block bearings shall be fitted with taconite

type seals that protect bearings against loss of
lubricant and entrance of corrosive matter.
Taconite seals shall be provided with their own
grease fittings. The successful Tenderer shall
provide the Taconite seal design proposed
including dimensional details.
j. Bearing Temperature and Vibration Monitoring
Where specified, housings shall be fitted with

suitable adaptors for attachment of condition
monitoring sensors.
ii) Pillow Block Fabrication and Installation
a. Housing Construction
- Pillow block housing shall be manufactured

of ductile iron, cast steel, or other
approved materials suitable for the
minimum operating temperatures and
impact loads.
- The base of the bearing housing shall be

machined parallel to the bore.
- Lifting lugs or eye bolts shall be fitted to

housings for shafts of 150 mm and larger.
b. Installation
- Pillow block assemblies shall be factory

adjusted, greased and ready to install on
shafts.
- Pillow blocks shall be provided with sub-

base plates complete with jacking screws
for adjustments.
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c. Mounting
- Pillow blocks larger than 60 mm shall be

furnished with four bolt bases. Bolts shall
have self-locking nuts or shall be provided
with two nuts per bolt. All pillow blocks
shall supplied with required fasteners
(length to be determined).
- All mounting holes shall be slotted. Hold

down bolt holes shall be spot faced to
provide an area large enough to allow a
standard plain washer under the head of
the mounting bolt. Hold down holes shall
be reamed, not cored.
- All housings of the same size shaft shall

have the sole of the bottom surfaced
machined to the same bearing centers.
Replacement assemblies will meet the
same dimensional position such that
pulley alignment will not be required upon
housing replacement.
3.12.2.14 QUALITY CONTROL AND DOCUMENTATION
i) General
a. Purchaser shall have access to all inspection

records at all times. Purchaser reserves the right
to select an independent laboratory to perform
non-destructive testing.
b. All non-destructive testing shall be performed

after final stress relief. Successful Tenderer is
encouraged to perform additional earlier
inspections to guarantee final delivery schedule.
c. The successful Tenderer shall designate a

qualified quality control (Q.C.) officer prior to
pulley fabrication. The Q.C. officer shall be
responsible for maintaining all records and
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witnessing all inspection stages noted herein. In

addition to the above noted inspection, the Q.C.
officer shall witness, and certify the acceptance
of, all test specified in this section.
ii) Drawing and Data Requirement
a. Before fabrication, all drawings listed in this

sections shall be submitted for approval by
Consultant / Client.
b. General arrangement drawings with bill of

materials shall be submitted for approval before
manufacturing. These drawings shall clearly
show all major dimensions, components make
and model nos., tolerances., finishes, weights of
each component.
c. Detail drawings showing all welding details

including weld configurations, materials
(consumables), tolerances and finishes.
iii) Required data sheet for Pulleys and pillow blocks
Tenderer shall review, revise and otherwise complete

the attached design data sheet (Refer Chapter-M /
Part 2 of 2).
iv) Identification
Each pulley and shaft shall be identified by stampings

on each which include Supplier’s name or logo,
Purchaser’s drawing number, purchase order number
and a unique serial number.
v) Balancing
All pulley assemblies shall be statically balanced in

accordance with ISO Standard 1940 (Grade G40).
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vi) Fatigue Analysis
The successful Tenderer shall provide the rim butt,

fillet, and "J" groove welds fatigue analysis for tension,
compression and shear for the longitudinal and
circumferential welds, and surface finishes in
accordance with British Standard for Welding, BS 5400
Part 10: 1980. Steel, concrete and composite bridges:
Code of practice for fatigue
vii) Manual
The successful Tenderer shall submit the Quality

Control manual that shows the quality control
procedures for the Purchaser’s review. The procedures
shall include the following
• Testing and documentation of steels

• Selection, control and storage of welding
consumables
• Weld procedure qualification methods
• Pre and post weld heat-treatment methods –
the control and recording the same
• Inspection of completed welds and proposed
acceptance standards
• Surface finish of ground welds
• Machining tolerances and dimensional
inspection checks
• Heat treatment procedures
• Testing and acceptance criteria for shafts
The Successful Tenderer shall furnish inspection,

rejection and correction standards for prefabrication,
fabrication and final assembly.
viii) Welding Practice
a. Successful Tenderer shall submit the welding

procedures, weld groove dimensions, type of
welding equipment to be used, and post welding
finishing methods. Inspection report(s) shall be
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submitted to Purchaser on all pulleys prior to

delivery.
b. Fillet welds shall be 100% visually and either

ultrasonically or magnetic particle tested. Welds
shall be investigated with all three standard
transducers (45o, 60o, and 70o). Butt welds shall
be either ultrasonically or radiographically
tested. Welds shall be inspected by certified
welding inspectors only.
c. All welds shall be magnetic particle inspected

over their entire lengths in accordance with
ASTM E-709. Alternatively, circumferential welds
shall pass radiographic inspection method ASTM
142 (1986) with acceptance standards.
ix) Rim Quality Control
a. Marking of rim metallurgical grain structure,

which shall be perpendicular to shell curvature
prior to fabrication.
b. Steel castings, forgings, and platework shall be

ultrasonically (US) inspected. The US procedure
shall be in accordance with ASTM A-609-81 and
A-609-81 S1, with an acceptance Level II. Steel
castings shall undergo magnetic particle
inspection over their entire surface in accordance
with ASTM E-709-80 and ASTM E-125-80.
Acceptance criteria for magnetic particle
inspection shall be zero linear discontinuities.
Castings shall pass X-ray testing per ASTM E446
Level II. The surface of steel castings shall be
machined free of pitting and surface cracks with
surface defects not exceeding 2.5 mm in depth
and 5.0 mm in length at the thinnest section in
diameter.
c. Successful Tenderer shall provide a

circumferential electronic measure of the rim
thickness profile at three points along the axis;
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one at the pulley centerline, and one 150 mm

from each end disk centerline to verify section
6.4.2. An analog graph of the thickness
measurement shall be provided with the final
inspection documents.
x) End Disk Quality Control
Steel castings, forgings, and plate work shall be

ultrasonically (US) inspected. The US procedure shall
be in accordance with ASTM A-609-81 and A-609-81
S1, with an acceptance Level II. Steel castings shall
undergo magnetic particle inspection over their entire
surface in accordance with ASTM E-709-80 and ASTM
E-125-80. Acceptance criteria for magnetic particle
inspection shall be zero linear discontinuities. Castings
shall pass X-ray testing per ASTM E446 Level II. The
surface of steel castings shall be machined free of
pitting and surface cracks with surface defects not
exceeding 2.5 mm in depth and 5.0 mm in length at
the thinnest section in diameter.
xi) Shafting Quality Control
a. All shafting shall be ultrasonically inspected.

After machining, the entire surface of the shaft
must pass wet fluorescent MPI per ASTM E709.
No cracks are permitted.
b. All forgings shall be ultrasonically inspected

before machining in accordance with ASTM A388.
xii) Final Assembly
Final assembly shall be inspected for concentricity,

control across pulley face, balance, 100% application of
lagging, general fit and torque reading of locking
elements. Dimensional specifications and tolerances
are verified to conform to this specification and
Supplier's design drawings for the shafting, end disk
and shell assemblies. Stress relieving of pulley
assembly shall be verified.
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3.12.2.15 WARRANTY
Except as indicated below, pulleys shall be guaranteed

against all deficiencies in performance and defects in design,
material, and workmanship for 24,000 hours of service, but
not to exceed 4 years after conveyor start-up. Any
corrections, adjustments, replacements or repairs shall be
made promptly, at no cost to the Purchaser. Successful
Tenderer’s obligation for guarantee, warranty, and service
shall apply to the process related and specified performance
characteristics of this specification in the same manner as do
deficiencies in material and workmanship.
3.13 Belt turnovers shall be provided at both ends of the conveyor

on the return side in order to keep the dirty side of the belt
away from the idlers and pulleys so that the return strand
spillage and build up on the idlers are eliminated. Support
rolls with side guide rolls should be spaced evenly at 45 deg
intervals. The turn over length shall be selected as per the
belt supplier’s recommendation. However, the turnover length
shall not be less than 35m at both tail and head ends.
`
3.14 Belt cleaners shall be provided at both ends of this conveyor.
At the head end pulley, a primary scraper and a secondary
scraper should be used, with the dribble ending up in the
surge hopper. At the tail, a counter rotating brush shall be
used to remove any material that might have been collected
or dried along the return.
3.15 At both head and tail ends, two sets of dual-stage belt clamps
(one on the carrying side and another on the return side after
the belt turnover) shall be provided. These belt clamps will be
used to clamp the belt so that the maintenance work can be
done on the beltline components (pulleys, belt, etc.) without
the tension of the belt weight pulling down the hill. The
clamps will also be used for the belt installation and splicing.
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3.16 Take-up
Take-up shall be of automatic horizontal gravity type and the

same shall be provided at appox. 400m from the head end of
down hill conveyor with suitable arrangement for motorized
release (through winch) of belt tension for belt jointing or any
other maintenance work. An cable winch as part of the
reeving system shall be provided to de-tension an empty belt.
Take up tower shall be provided with ladders and
maintenance platform at suitable location for maintenance
along with sand pit.
3.17 Tenderer to provide belt-laying area of approx. 10m x 300m

at suitable 2 locations along the conveyor alignment with
suitable winch for handling/pulling min. 300m belt for belt
changing and belt vulcanising. The above locations shall be
finalised considering the possible road approach available.
3.18 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, near
Ranjitpura village and near proposed Pellet Plant to avoid
falling of material.
3.19 Safety switches
3.19.1 Pull cord switches shall be provided at 200m interval on both

sides of the down hill conveyor.
3.19.2 Belt sway switches shall be provided on conveyor for

protection against excessive sway of the belt. A pair of
switches shall be installed near the head end and a pair near
the tail end. Also, belt sway switch shall be provided at end of
each horizontal curvature. Belt sway switches shall be
installed along the length of conveyor so that distance
between two adjacent switches does not exceed 200m.
3.19.3 Zero speed switch shall be provided at suitable location.
3.19.4 Conveyor belting shall be provided with belt rip protection

system along with the sensor & related instrumentation for
hooking up to PLC.
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3.20 Self propelled travelling maintenance trolley
3.20.1 In order to access and maintain the conveyor throughout the

length of the down hill conveyor no. 723, two nos. self
propelled maintenance trolleys shall be provided. A structural
shed for parking and maintenance of the above travelling
trolleys shall also be provided along with hoisting facility at
two locations (i.e one shed at head end and the other shed
near tail end of the down hill conveyor). The size of the sheds
shall be finalised considering the size of the self propelled
trolleys, inclination / declination of the conveyor and also
provision for movement of truck inside the shed for
maintenance purpose.
3.20.2 Following shall be considered in the design of the self

propelled travelling maintenance trolleys:
i. The carrying capacity of each trolley shall be finalised

considering the following:
a. Min. 5 persons (approx. 400 kg) for carrying out

maintenance
b. Maintenance tools & tackles weighing approx.
200 kg
c. Spare idlers. Idler brackets, etc. weighing
approx. 300 kg
ii. Fail safe arrangement for movement of the trolley

shall be provided for the hilly area.
iii. Each trolley shall be provided with two nos. drives i.e
one working and one stand-by.
iv. The drive system for the long travel of the trolley shall
be variable speed type along with fail safe brake.
v. Provision shall also be kept to move the trolley by

manual mode in case of any eventuality.
vi. The vehicle shall be fully rain protected.
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vii. It shall be possible to access the return belt using a

suitable foldable platform. Suitable safety interlock
shall be provided to disable travel of trolley when the
above platforms are extended.
viii. The trolley shall be designed for climbing the steepest

inclination and safest descent in the declined portion.
ix. A diesel generator shall be provided in the trolley to

supply electric power for lighting, welding, hoist, power
tools, etc.
x. In addition to the above, the following shall also be

provided in the trolley:
a. Working bay on both sides of the conveyor

b. Belt lifting equipment (for idler / idler frame
changing)
c. Hoist for lifting / lowering spares / tools up to
500 kg.
d. Lighting of the vehicle including flood light for
maintenance and head light
e. A safety escape ladder with fall prevention
system
f. Space for storage of idlers for replacement
g. Storm clamp for securing the vehicle with
conveyor structure
h. Tool box
3.21 The technical specification for belt conveyors mentioned

under clause no. 2.0 is also applicable for down hill conveyor
no. 723 for clauses not specified under clause no. 3.0 for
down hill conveyor no. 723.
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4.0 REVERSIBLE CONVEYOR NO. 727
4.1 GENERAL
4.1.1 Conveyor no. 727 is part of an overland conveyor system

whose battery limit starts after a planned 1000t RCC silo in
the vicinity of the Kumaraswamy mine crushing plant and
ends at existing tripper conveyor no. 122 near Donimalai
screening plant. It consists of a downhill conveyor (Conveyor
no. 723) 4.9 km long and a reversible conveyor (Conveyor
727) 295 m long.
4.1.2 The route for Conveyor no. 727 consists of a 295 m uphill
section with a 49 m rise. It is an inclined conveyor with
approx. 9.43 deg. inclination. The conveyor passes through a
deep valley. An elevated truss is required to be provided over
the valley and the conveyor is as much as 64 m above the
bottom of the valley. Conveyor no. 727 shall be capable of
carrying material in either direction. In the forward direction,
it shall receive material from a Surge Hopper no. 724 in
Transfer House TH-3 via a belt feeder no. 725 (with VFD)
and convey the same to the extended tail end portion of the
existing tripper conveyor (Conveyor no. 122). When the new
screening plant is completed, Conveyor no. 727 shall be
capable of running in the reverse direction (downhill). When
in this operating mode, the conveyor shall receive material
from Conveyor 727-2 at Transfer House TH-5, approximately
40 m from the head end of conveyor no. 727. This material
shall be discharged from the tail end of Conveyor 727 onto a
new conveyor leading to the new screening plant.
4.1.3 Refer the enclosed tender drawing for reversible conveyor no.
727 showing the arrangement of conveyor.
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4.2 Following are the major technical parameters of the reversible

conveyor no. 727:
Sl.
No.
1.0 Capacity (Design/Rated) t/hr. 2000 / 1800
2.0 Speed m/sec. 3.0
3.0 Belting
a. Width mm 1050
b. Type Steel Cord
c. Strength N/mm 1000
Cover thickness
d. mm 12/6
(Top / Bottom)
Low Rolling
e. Bottom cover compound
Resistance (LRR)
f. Cover grade DIN X
4.0 Idlers
4.1 Carrying Idler

3 Roll (with
& long wing rolls)
c. Spacing m 2.67
4.2 Return Idler

3 Roll (with
& long wing rolls
c. Spacing m 8.0
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Sl.
No.
5.0 Pulleys
5.1 Drive Pulley
b. Min. wrap angle Deg. 200
Rubber –
c. Lagging type Diamond type
drive Pulley
d. Lagging thickness mm 25
e. Pulley face width mm 1300
f. Quantity Nos. 1
5.2 Low tension pulleys

Rubber –
Diamond type for
b. Lagging type head & tail
pulleys and plain
for other pulleys
c. Lagging thickness mm 20
d. Pulley face width mm 1300
e. Quantity Nos. 5
6.0 Motors
Sq. cage
a. Type Induction Motor
with VFD control
b. Motor rating kW 400
c. Quantity Nos. 1
d. RPM 1000
e. No. of poles 6
f. Voltage V 690
g. Frequency Hz 50
h. Location Head end
7.0 Reducer
Floor mounted
a. Type Bevel Helical with
swing base
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Sl.
No.
8.0 Brake
Caliper type
a. Type Spring apply /
hydraulic release
9.0 Hold back *

a. Location Head pulley
10.0 Take-up
Automatic
a. Type
Vertical gravity
As close as
b. Location
possible to TH-3
c. Take-up travel (min.) m 1.5
*- A holdback shall be provided to prevent runback of the

loaded belt. Since the conveyor is reversible, the
brake system must act as a holdback device.
Note: The kW rating, idler diameter, pulley diameter, pulley

shaft diameter, pulley bearing size, brake, etc.
indicated above are the minimum values to be followed
by the Tenderer. However, the Tenderer may offer
higher ratings with justification for the same.
4.3 Idlers
Both carrying and return idlers shall be of three roll type with
a shortened center roll. The dimensions and spacing of the
carrying and return idlers shall be same as idlers envisaged
for down hill conveyor no. 723 in order to reduce the number
of spares required for the system.
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4.4 Drive
4.4.1 The conveyor shall be provided with one no. 400 kW Sq. Cage
Induction motor with VFD at the head end. The motor shall
have bi-directional capability. The drive system shall also
require regenerative capacity sufficient for continuous
downhill operation.
4.4.2 The drive shall also be provided with a braking system. The
brakes shall also be required to act as a holdback, or parking
brake, for uphill operations.
4.5 Take-up
Take-up shall be of vertical gravity take-up type and the

same shall be located as close as possible to tail end of
conveyor near Transfer House TH-3.
4.6 Belt maintenance clamps shall be located at both the head

and tail ends for belt and pulley maintenance.
4.7 Conveyor no. 727 shall be provided with conventional

structural gallery with side walkways. The conveyor gallery
shall be of open type with hinged hood for the carrying side of
the conveyor. As the conveyor is passing through a deep
valley, elevated truss needs to be provided for the conveyor
in the valley zone. The conveyor shall be provided with
structural trestles.
4.8 Carrying side of the reversible conveyor no. 727 shall be

provided with hoods of hinged design made of min. 3.15 mm
thick MS plate. The hoods shall be designed in such a way
that carrying idlers can be maintained without removing the
hood completely.
4.9 Seal plate of min. 3.15 mm thickness with stiffeners shall be

provided below the gallery at road crossing to avoid falling of
material.
4.10 In addition to the technical specification specified under

clause no. 4.0 for reversible conveyor no. 727, the following
are also applicable:
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i) Various clauses specified under 3.0

ii) For Clauses not specified under 3.0, clauses specified
under 2.0 are applicable.
4.11 Required data sheet for belting, idlers, brakes, drive and
pulleys & pillow blocks for conveyor no. 727

attached design data sheets (Refer Chapter-M / Part 2 of 2).
5.0 BELT FEEDER
5.1 Belt feeders shall be provided at the following locations:
i) Belt feeder no. 720 below 1000T RCC (effective

capacity) silo
ii) Belt feeder no. 725 below surge hopper no. 724 in
TH-3
5.2 The width of the belt feeder shall be finalised considering the
capacity of the material and the speed.
5.3 The troughing angle of the belt feeder shall be considered as

20 deg.
5.4 The belt feeder shall be complete with all pulleys, Conveyor
belt, idlers, skirt board, Screw take-up, Discharge chute,
discharge hood, drive, technological structure, belt scraper
etc.
5.5 Belt feeder drive shall be provided VFD speed control.
5.6 Bevel helical type gear box shall be provided for belt feeder
drive.
5.7 Belt feeder shall be designed for heavy-duty application

capable of extracting material from fully loaded silo and
conveying specified material under specified environmental
conditions.
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5.8 The housing of the gearbox shall be cast steel or fabricated

steel. The gear reducer service factor shall be minimum of 2.0
based on installed motor power. Worm gear reducers are not
acceptable.
5.9 Conveyor belting shall be of NN, with cover grade M 24 and

shall conform to relevant clauses of IS: 1891 - (Part1) - 1988
or any other standard of International repute acceptable to
Owner. The belt shall have adequate number of plies to
handle the tensions likely.
5.10 Belting shall be free from longitudinal and traverse buckling,

wavy cords or other unevenness that would cause localized
points of flexing when belt is in service.
5.11 Top and bottom cover thickness of belting shall be minimum

10 and 4 mm.
5.12 Belt feeders shall be provided with impact bars at the loading
point.
5.13 All components of the idler assemblies shall be designed,

manufactured and tested as per IS: 8598 - 1987 or any other
standards of International repute acceptable to Owner.
5.14 Pulley shall be of extra heavy-duty type. Pulley assemblies

shall conform to 1S: 8531-86. The pulley assemblies shall be
completely balanced before assembly. Pulley shall be made of
welded steel and stress relieved before machining. Pulley
shall be rubber lagged.
5.15 Manually adjustable vertical gate for adjusting the bed height
shall be provided.
5.16 The external and internal belt scrapers shall be of segmented

elastomount multi sprung blade type. External scraper shall
be provided with Tungsten carbide tips and the internal
scrapers with polyurethane blades.
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5.17 Screw take-up of minimum 300 mm travel shall be provided

at the tail end of belt feeder. The screw and nut shall be of
stainless steel. The screw shall be SQ threaded of minimum
M30 size.
5.18 Skirt board shall be provided for full length of the belt feeder.
Liner shall be provided for skirt board & chute (refer cl. no.
2.16 for details of liners)
5.19 Belt weigh scale mounted on conveyor no. 721 shall be

interlocked with the belt feeder no. 720 mounted below the
silo for regulating the feed to down hill conveyor no. 723.
6.0 IN LINE MAGNETIC SEPARATOR
6.1 In line magnetic separator shall be installed at the discharge

end of the following conveyor / belt feeder for removal of
stray/ tramp iron:
i) Conveyor no. 718
ii) Belt feeder no. 720
6.2 The magnetic separator shall be complete with belt, magnet,

rectifier, control push buttons, suspension bars, frame and
drive unit. The magnetic separator shall be used for
separating magnetic particles from the material being
conveyed. The separated magnetic materials shall be
discharged at a suitable place away from transfer house to
the ground through a chute. The above chute along with
supporting arrangement shall be included in the scope of the
Tenderer. The top portion of the chute below the magnetic
separator shall be made of SS 409M and the lower part shall
be fabricated from MS plates suitably lined with 5mm thick.
SS 409M at wearing surfaces.
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6.3 The magnetic separator shall be suspended from the top

through turnbuckles and D-shackles of suitable capacity. The
minimum adjustment in turnbuckles shall be 200mm. The
magnetic separator shall be suspended from the travelling
trolleys to be provided at the bottom of the monorail. Also, it
shall be possible to shift the magnetic separator using the
travelling trolleys away from the conveyor centre line for
maintenance.
6.4 The following shall be considered for design / selection of

magnetic separator.
6.5 The following shall be considered regarding ILMS:
i) Type - In line Magnetic Separator

(4 pulley type)
ii) Weight to be lifted - Min.50mm long nail and

max.1000mm long rod
(max 15 Kg)
iii) Coil winding - Double fibre glass covered

copper strips
iv) Cooling - Air cooled
v) Class of insulation - Class – H
vi) Min operating - 500 mm

height to be
considered
vii) Duty - Continuous duty
6.6 Drive pulley shall be of stainless steel for the conveyor no.
718 and belt feeder no. 720.
6.7 Bevel helical type gear box shall be provided for belt drive.
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7.0 BELT WEIGH SCALES
7.1 Belt Weigh Scale shall be Electronic type, Microprocessor

bases with load cells, speed sensors with necessary cables
and accessories. The belt weigh scales shall provide
continuous weighing of the material being conveyed on the
belt conveyor so as to indicate the rate of flow of material and
to integrate and display the total material flow through the
belt over a period of time. Belt weigh scales shall be provided
for the following conveyors:
i) Conveyor no. 718
ii) Conveyor no. 721
7.2 The weigh scale shall be of robust design suitable for trouble
free operation in the dusty area. They shall have sufficient
overload capacity.
7.3 Microprocessor shall multiply load cell signal and conveyor

speed signal in digital form to generate signal for tonnes/hour
(tph) material conveyed on belt. This unit shall have facilities
like auto tare, auto calibration, self diagnostics, etc. The
stored values after calibration shall not change due to power
failure. The weigh scale unit shall have 4-20mA isolated
output for connection to PLC for feed rate. The unit shall also
have RS-485 port for communication. The weigh scale unit
shall conform to IP65. The unit shall have a local LCD to
display the rate of flow, totaliser, belt speed, over load, fault,
alarms, annunciation, etc. All output shall be compensated for
50 deg. Ambient.
Following hardwired signals as minimum shall be considered

to PLC with display in HMI stations:
i) 4-20mA Signal for Flow rate

ii) Potential free contact for Totaliser
iii) Potential free contact for Fault
iv) Potential free contact for Overload
v) Potential free contact for Programmed output
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7.4 The belt scale shall be complete in all respects to meet the
requirement of data logging facility as described elsewhere.
The unit shall be complete with excitation source, transmitter,
amplifier, junction boxes, special cables etc.,
7.5 The weighing frame structure shall be designed such that the
load cell output does not get affected by spurious vibrations
of belt conveyor and only vertical forces exerted by the
material being conveyed by the belt conveyor is transmitted
to the load cell.
7.6 The equipment shall be designed such that no error in

measurement or reading occurs due to unevenness of the
belt. All the conveyors where the belt scales are installed are
with 35 deg. troughing idlers and 10 deg. V return idlers.
7.7 The equipment shall be provided with static weight as well as

electronic calibration facilities. In electronic calibration facility,
the belt scale shall be automatically calibrated from remote
(central control) station by pressing calibration switch.
7.8 The load cell shall be of stainless steel, strain gauge

(compression) type, hermetically sealed conforming to IP 68
and temperature compensated over 0 to 70 deg. C. The load
cell shall be of robust type capable of withstanding shock
loads and overloads up to 200% without mechanical damage
and shall be freely mounted at both the ends to avoid
transverse force errors. Permissible load shall be 150%,
repeatability and non-linearity shall be 0.002% & 0.005%
respectively. Load cell accuracy shall be 0.04%. Accuracy of
load cells shall not be affected by variation of tensions, over
load, noise, vibration, temperature variation, electrical
disturbances, long measuring cables etc.
7.9 Speed Sensor shall be digital, brushless with cast aluminum

housing conforming to IP65 min. and with output as
pulses/revolutions.
7.10 The display of rate of flow and total material conveyed over a
particular period shall be given in (a) PLC HMI station (b)
Belt weigh scale panel
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7.11 The belt scales shall be capable of giving recording within

+/- 0.5% variation of actual weight of material conveyed by
the belt conveyor in the range of 20%-110% of design
capacity of belt conveyor.
8.0 METAL DETECTOR
8.1 Metal detectors shall have high reliability with enough

sensitivity to detect foreign material like brass, copper,
stainless steel, manganese steel, ferrous materials, bars,
scraps, etc. below the burden of iron ore. Metal detector shall
be provided for the following conveyors:
i) Conveyor no. 719
ii) Conveyor no. 721
8.2 The equipment shall have provision for automatic static

calibration with adjustable sensitivity.
8.3 Metal detectors shall be completely solid state using latest

state of art technology. It shall be suitable for 45ºC ambient
and RH of 100%. The search sensor shall be protected from
rain and direct sunlight by means of a non-metallic covering
other than wood. Control unit shall have adjustable controls
for sensitivity, ON/OFF push buttons, reset table operation
counter, audio-visual alarms local remote selector switch and
all other necessary controls for trouble free operation of metal
detector. Control unit box shall be suitable for mounting on
wall, column, structure, etc, with IP-65 degree of protection.
It shall be constructed from FRP of thickness not less than 2
mm.
8.4 The metal detectors shall also have the following features:
i) The coils shall be protected against being struck by an

oversized ore/ material.
ii) In order to counteract interference from external

sources such as motors, lighting and radio-transmitters
and to nullify the effect of climate changes / ageing,
dual receiver coils are to be used.
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iii) LED display of COAST COUNT to indicate the number of

pieces of tramp iron detected since last reset shall be
provided so that the operator is alerted for the pieces
of tramps if any, between tramp marker and coil before
restoring conveyor. 2NO+2NC contacts shall be
provided for remote indications, tripping of conveyor,
hooter etc.,
iv) TOTAL COUNT, which can not be reset, shall also be

provided on the same LED display on demand.
v) The location of tramp metal pieces shall be indicated by

sand marker.
vi) Idlers near the metal detector shall be made of

stainless steel (AISI 304).
8.5 Construction Requirement
i) Fibreglass enclosure (with IP-65 degree of protection)

shall be provided for all type of coils.
ii) Suitable tramp metal markers shall be provided.
iii) Local control panel shall be provided with IP-65 degree

of protection.
9.0 HYDRAULICALLY OPERATED GATE
9.1 Hydraulically operated gate no. 724A shall be provided below

the surge hopper no. 724 at Transfer House TH-3.
9.2 The gates shall be hydraulically operated by hydraulic

cylinders connected separately to both the segments of the
gate.
9.3 All the hydraulic cylinders shall be connected to a common

power pack. Flow switch, temperature switch, pressure switch
and level switches shall be duplicated in the hydraulic system.
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9.4 After erection of hydraulic system and piping, the

interconnecting pipe shall be chemically cleaned, passivated
and flushed with the system oil before putting the system in
operation for operating the various actuators.
9.5 The gate shall be designed for opening / closing with the load
due to material in the surge bin.
9.6 The gate shall be sturdy in design and shall be fabricated

from rolled steel plates and sections.
9.7 The gate shall have wear resistant Mn Steel liner 25mm thick
and shall slide on rollers mounted on anti-friction bearings.
9.8 Limit switches shall be provided to prevent over closing or

over opening
9.9 Provision shall also be kept for operation of the gate

manually.
9.10 Suitable maintenance platform along with approach ladders

shall be provided for maintenance of hydraulically operated
gate.
10.0 EXTENSION / MODFICIATION OF EXISTING TRIPPER

CONVEYOR NO.122
10.1 Tail end of the existing tripper conveyor no. 122 shall be
extended by approx. 12m from the existing Transfer House
(at head end of existing down hill conveyor 121 & tail end of
existing tripper conveyor no. 122) to Transfer House TH-4 for
receiving material from reversible conveyor no. 727. Refer
the enclosed tender drawing showing the above arrangement.
10.2 Following shall be considered by the Tenderer for extending

the tail end of existing tripper conveyor no. 122:
10.2.1 New drive along with the drive supporting arrangement for
the existing tripper conveyor no. 122 considering the
extension at the tail end of the conveyor. Following are the
various technical parameters and drive details of the existing
tripper conveyor:
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i) Belt width : 1200 mm

ii) Capacity : 2000 tph
iii) Belt speed : 2.166 m/sec.
iv) Lift : 2.45 m (due to tripper)
v) Troughing angle : 20 Deg.
vi) Length (existing) : 152.25 m
vii) Belting : NN1500/6, M-24, 10/4
Cover thickness
viii) Pulley details : Will be furnished to the successful

Tenderer
ix) Idler details
a. Carrying : 139.7 mm dia., 20 deg. 3 roll,

30mm dia at brg.,1m spacing
b. Return : 139.7 mm dia., Flat single roll,

30mm dia at brg.,3m spacing
x) Existing drive details
a. Motor : 75 kW (280S), 1440 RPM, 415V

b. Gear Box: SCN-280 (Elecon), Helical,
31.5:1 ratio with integral
hold back
c. High speed coupling : Resilient, 110 size

(GBM)
d. Low speed coupling : Geared, 108 size
(Hi-Cliff)
10.2.2 New NN belting of adequate rating, if required, for the

extended length of the conveyor at tail end.
10.2.3 Additional idlers required for the extended portion of the

tripper conveyor at the tail end.
10.2.4 Additional safety switches (Pull cord & Belt sway) required for
the extended length along with the additional cable.
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10.2.5 Shifting of the zero speed switch along with additional length
of cable required.
10.2.6 Shifting of the tail pulley along with the pulley supporting
arrangement (the suitability of using the existing tail pulley
along with support shall be studied by the Tenderer).
10.2.7 New pulleys (including pulley on tripper) along with

supporting arrangement, if required, for the existing conveyor
no. 122 after extension based on the revised belt rating.
10.2.8 Supporting arrangement for the conveyor for the extended
portion.
10.2.9 New deck plate at the loading zone near the tail end of tripper
conveyor after shifting.
10.2.10 Covered structural gallery for the extended portion of the

existing conveyor no. 122
10.2.11 Modifications in the existing transfer house for shifting the tail
end of tripper conveyor.
10.2.12 New skirt board along with supporting arrangement at the
shifted loading point of tripper conveyor at transfer house
TH-4.
10.2.13 New V-type belt cleaner on the return side near the tail end.
10.2.14 Any other items to be provided / modifications to be carried

out for shifting the tail end of the existing tripper conveyor
no. 122.
11.0 TAPPING OF MATERIAL FROM EXISTING TRIPPER ON

CONVEYOR NO. 122
11.1 Travel of tripper on existing tripper conveyor no. 122 shall be

extended by 28m approx. (towards tail end of conveyor
no. 122) in order to tap the material from the above tripper &
feed the same to reversible conveyor no. 727 in reverse
direction at Transfer House TH-5 for further conveying to new
screening plant. Refer enclosed tender drawing showing the
above arrangement.
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11.2 The following shall be considered for the extension of travel of

tripper on existing conveyor no. 122:
11.2.1 Additional length of rail along with the rail supporting

arrangement for the extended tripper travel.
11.2.2 Extension of power & control supply arrangement for the

extended tripper travel along with additional cable & cable
trolley and supporting arrangement for the same.
11.2.3 Modifications in the floor bracing of conveyor gallery of

existing conveyor no. 122 at the point of tapping of material
from the tripper (in the extended portion), if required.
Providing grating at the discharge point from the tripper at
the gallery walkway level.
11.2.4 Shifting of the buffer stop and travel limit switch to the end of
extended travel of the tripper along with additional control
cable required.
11.2.5 Strengthening of portion of tripper conveyor gallery structure

for the extended tripper travel, if required.
11.2.6 Providing hold down pulley on the tripper to avoid belt lift-off.
11.2.7 Any other items to be provided / modifications to be carried

out to extend the travel of the tripper
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12.0 EOT CRANES & HOISTS
12.1 Following are the EOT cranes envisaged under package-II:
i) Tail / Drive house of down hill conveyor shall be

equipped with one no. of minimum 15/5 T capacity DG
EOT Crane.
ii) Transfer House TH-4 shall be equipped with one no. of

minimum 7.5 T capacity Single Girder EOT Crane.
iii) Parking / maintenance stations PS-1 & PS-2 for the

travelling trolley shall be equipped with one no. of
minimum 5 T capacity Under Slung EOT Crane in each
building.
The technical parameters of the cranes to be considered by

the Tenderer shall be as follows.
1. Tail / Drive House of Down Hill Conveyor
Type : Double Girder EOT Crane

Location : Tail / Drive House of Down Hill
Conveyor no. 723
Class of duty : M5 – as per IS : 3177 - 1999
Minimum Capacity : 15 / 5 T
(MH / AH)
Span (m) : To suit the building size
Height of lift (m) : To suit the requirement
Speeds :
Main hoist : 3.0 m/min approx.
Aux. Hoist : 6.0 m/min approx.
Long travel : 15.0 m/min approx.
Cross travel : 10.0 m/min approx.
Control : Through Pendant
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2. Transfer house TH-4 Crane
Type : Single Girder EOT Crane

Location : Transfer house TH-4
Class of duty : M5 – as per IS : 3177 – 1999
Class-II as per IS : 3938-83 for
Hoists
Minimum Capacity : 7.5 T
(MH / AH)
Span (m) : To suit the Transfer House building
Speeds :
Main hoist : 5.0 m/min prox.
3. Parking / Maintenance Stations for travelling trolley at PS1

& PS2
Type : Under Slung EOT Crane

Location : Parking / maintenance station for
travelling trolley
Class of duty : M5 – as per IS : 3177 – 1999
Class-II as per IS : 3938-83 for
Hoists
Minimum Capacity : 5 T
(MH / AH)
Span (m) : To suit the building dimensions
Speeds :
Main hoist : 3.0 m/min approx.
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12.2 TECHNICAL SPECIFICATION FOR EOT CRANE - GENERAL
i) This specification covers design, manufacture,

fabrication/assembly, shop testing, painting, supply,
storage at site, erection, testing and commissioning
complete with electrical equipment and standard
accessories of Double Girder / Single Girder / Under
slung EOT cranes.
ii) The cranes shall be complete in all respects and any

item not covered in the specification but essential for
proper design and operation shall be included in the
tender.
iii) The cranes covered by this specification shall be

designed & manufactured and tested in accordance
with latest IS: 3177 and IS 807 / AISE no. 6 and other
relevant IS wherever available taking due note of
various requirements laid down in this specification.
iv) The complete crane along with crab unit (hoisting,

aux. hoisting, cross travel drive) and long travel drive
units shall be modular in construction with built in
facility for easy dismantling & maintenance of motors,
brakes, gear boxes and wheels as an independent unit.
Good workmanship, accurate alignment & proper heat
treatment of the various components of the crane shall
be considered as essential features.
v) The Crane shall be complete in all respects including

pendant, electrical & shrouded bus bar.
vi) The Tenderer shall ensure that minimum amount of

assembly at site is necessary for early commissioning
of the crane after delivery. Site welding shall be
avoided as far as possible. The Tenderer before
proceeding with the design details shall satisfy himself
about the site conditions so as to avoid any difficulty in
erection arising out of design.
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vii) The minimum class of duty for the cranes shall be M5

as per IS 3177-99. Wherever suitable Indian Standards
are available, it shall be followed without deviating
from this specification. International standards shall be
followed wherever Indian Standards are not available.
viii) The testing of crane including load/overload tests shall

be done at both manufacturer’s and Owner’s works as
per latest edition of IS:807, 3177, 3938, approved QAP
and Owner’s any specific requirement. 100% and
125% load tests shall be included in the above tests
along with measurement of all critical dimensions. The
Owner may ask for special tests to be carried out for
any equipment.
12.3 MECHANICAL
12.3.1 Bridge Girder
The bridge girder shall be fabricated from tested steel plate

and shall be designed as per 1S-807-1976 (latest) and/or
AISE No.6. The total vertical deflection of the girder shall be
as per the relevant Indian standard.
12.3.2 Bridge drive
Individual wheel drive shall be provided and necessary

precautions shall be taken to ensure Synchronized running of
the two motors to prevent cross running of the Crane. All
parts of long travel drive shall be located above platform. The
gearbox shall be mounted on main platform and shall be
coupled to foot mounted motor by means of a full-geared
coupling. The gearbox output shall be connected to the wheel
axle by means of floating shaft and flexible half geared
couplings. The use of open gearing is not permitted. Not less
than 50% of Long travel wheels shall be positively driven
unless agreed otherwise.
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12.3.3 Trolley drive
Traverse mechanism shall consist of a motor connected to 2-3

stage horizontal or vertical reducer through full flexible gear
coupling. Low speed shaft of the reducer shall be connected
to the driving wheels by means of intermediate shaft and
gear coupling. Brake shall be mounted at the outboard end of
the first pinion
12.3.4 Hoist Mechanism
Hoisting mechanism shall consist of electric motors connected

to 2-3 stage horizontal reducer through full gear coupling.
Torque shall be transmitted from output shaft of the reducer
to single/double drums by means of suitable flexible coupling.
Brake shall be mounted on outboard end of the first pinion.
Connection between Rope Drum & Gear Box
One of the following arrangements shall be adopted for

connecting the rope drum with the gearbox.
i) Flexible joint, incorporating flexible geared coupling

housed within the drum.
ii) Fully flexible geared coupling between the drum & the
gearbox. Drive of the drum by means of spur gear
mounted on the drum is not acceptable.
12.3.5 End Carriage
The end-carriages shall be of double web plate box

construction/fabricated from rolled steel channels and shall be
connected to the girders by large gusset plates and fit bolts to
ensure maximum rigidity. Drop stops and jacking pads shall
be built - in features of the Crane.
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12.3.6 Wheels
Cross travel and long travel wheels shall be manufactured as

per the provisions laid down in the relevant IS. The wheels
shall be double flanged with straight tread. The wheel shall be
cast or forged type. Material of wheel shall be C55 Mn75, IS
1570. Hardness of wheels shall not be less than 300 BHN.
Wheels shall be keyed to their axles with press fits and shall
be supported on antifriction spherical roller bearings housed
in “L” shaped bearing brackets.
The Electric hoist shall run on two pairs of wheels, a pair of

which shall be driven by motor through reduction gearbox.
The wheels shall be of forged steel, single flanged with
taper/parallel treads to suit the monorail / girder flange. The
wheels shall be mounted on anti-friction roller bearings &
shall be easily removable for repair and replacement. The
diameter of the wheel shall be selected such that skidding
does not take place even under unload condition.
12.3.7 Couplings
Motor shaft shall be connected to the gearbox input shaft

through fully flexible geared coupling. In case of single motor
central drive for traverse motion, out put shaft of the gearbox
shall be connected to the line shaft through half geared
couplings. Intermediate lengths of the line shaft, if any may
be connected through solid flange couplings. Half geared
couplings with floating shaft shall be provided between the
wheel & the line shaft.
12.3.8 Gears
i) Straight and spur/helical gears made of alloy steel,

precision engineered, machined and cut by generating
process on hobbing machine, running on ball/ roller
bearings. All pinion and gears shall be hardened and
tempered alloy steel having metric module.
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ii) Cast steel and overhung gears shall not be used. All
gears shall be enclosed in oil - tight gearboxes. These
gears to be housed in cast steel/ MS fabricated gear
cases. Fabricated gearboxes shall be stress relieved
before machining. For cross travel and long travel
motions, vertical gearboxes with “T” split may be used.
Lubrication pump with filters shall be provided for
vertical gearboxes having center distance exceeding
400 mm. For creep motion planetary type gearbox
shall be used, if creep speed is specified for any
motion.
12.3.9 Bearings
Antifriction ball/roller bearings with grease nipples for

lubrication shall be used throughout except where required
otherwise for technical reasons. However, only spherical roller
self-aligning bearings shall be used for LT & CT wheel
assemblies.
12.3.10 Rope Drum
Rope drum shall be of cast steel Gr.ll of IS 1030 or fabricated

out of rolled steel plates. Fabricated drums shall be stress
relieved before machining. The grooves of the drum shall be
smooth finished. Rope drum shall be flanged at both ends.
The drum shall be mounted on antifriction ball/roller bearings.
The end of the rope shall be anchored to the drum with at
least two (2) rope clamps for each and they shall be readily
accessible.
Seamless pipe is acceptable for Electric hoist.
12.3.11 Rope Sheaves
Rope sheaves shall be of cast steel or fabricated out of rolled

steel plates. Fabricated sheaves shall be stress relieved. The
diameter of the sheaves used for bottom block shall not be
less than drum diameter.
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12.3.12 Wire Rope
Fibre core wire rope having 6 x 36 construction, best plough

steel having tensile strength of not less than
160-180 kg/mm2 and conforming to IS:2266 shall be
provided. Six falls of rope shall be avoided. Factor of safety
for wire rope shall not be less than 6. The rope reeving
arrangement shall be such that there shall not be lateral
movement of hook block parallel to rope drum during
lifting/lowering operation.
12.3.13 Hook
Drop forged “C” type swivelling hook conforming to

IS : 15560-2005 supported on thrust bearing. All hooks shall
be provided with closing finger and swivel lock arrangement.
12.3.14 Buffers
Double Girder EOT crane: Spring buffers for cross travel and
long travel motions
Single Girder EOT crane : Spring buffer for long travel

motion and rubber buffer for
Hoist CT motion.
Under Slung EOT crane : Rubber buffer for long travel

motion and Hoist CT motion.
12.3.15 Platform
For double Girder EOT crane, full length chequered plate

platforms shall be provided along both sides of the Crane in
order to ensure easy access to the Crane Crab, long travel
wheels, drive units and other parts of the Crane like panels,
cross conductors etc. Safety railings shall be provided on
Crane bridges and crab frame. Minimum clearance in front of
panels and LT machinery shall be 500mm.
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For Single Girder EOT crane, walkway shall be provided on

one side of the girder for the entire length and on the other
side platform shall be provided to facilitate maintenance of
the wheels and LT drive assembly.
For Under Slung EOT crane, platforms shall be provided on all

4 corners in the building to facilitate maintenance of LT wheel
drive / LT wheel assembly and electric hoist.
12.3.16 Lubrication
Grouped grease lubrication system shall be used. Lubrication

of the gears and pinions in the gearboxes shall be splash fed
from the sump. In case of vertical gearboxes having center
distance exceeding 400 mm an oil pump shall be fitted to
ensure lubrication of all gears. All equipment shall be
provided with proper lubrication of all parts and fittings.
Inaccessible grease locations shall be piped to accessible
locations and terminated with grease nipples. Group
lubrication shall be provided for LT & CT wheels and for
bottom block pulleys. Grease lubrication facility shall be
provided wherever oil lubrication cannot be provided.
12.4 STRUCTURAL
12.4.1 The box girder shall meet the following requirements in

addition to Indian Standards.
i) Web plate thickness shall not be less than 8mm.
ii) Bottom (tension) flange thickness and top

(compression) flange thickness shall not be less than
8mm and 10mm respectively.
iii) Depth of the box girder shall not be less than 1 / 18 of

the span of the crane.
12.4.2 Cross travel rail shall be fixed to the bridge girders by

clamping only and not by welding.
NMDC LIMITED MECON
LIMITED

12.4.3 Transverse fillet welding on load carrying members shall be

avoided. All butt welds in tensile zone shall be x-rayed and a
certificate to this effect shall be submitted.
12.4.4 Full length chequered plate (minimum 6 mm thick) platforms

shall be provided along both sides of the crane to ensure easy
access to crane crab, long travel wheels, drive units and other
parts of crane like panels cross conductors etc. Safety railings
shall be provided on crane bridges and crab frame. Platforms
to facilitate inspection and dismantling of long travel wheels
and main current collectors shall be provided. Crossover
facility shall be provided by chequered plate over both in the
carriages with handrails on outer face of the carriage,
Minimum width of chequered plates platform shall be 750mm
for maintenance of crab. Easy entry in the crab shall be
provided at 4 corners by entry ladders. DSL cage shall be
provided wherever applicable. A clear walking / maintenance
space of 600mm shall be provided on the platform
everywhere. Near motor, brake and gearboxes of LT
mechanism this may be reduced to 450mm. Also there shall
be at least 500mm space in front of panels and resistors.
12.4.5 Black bolts shall not be used in the main structure of the
crane.
12.4.6 For welded construction such as that of bridge girders, end –

carriages, rope drums, gearboxes etc., steel shall be as per
IS: 2062 – 1992 quality. For welding these members low
hydrogen electrodes shall be used.
NMDC LIMITED MECON
LIMITED

12.5 ELECTRICAL
12.5.1 Limit switch
Roller lever operated, self resetting limit switches shall be

provided for all travel motions. For each hoist motion, a
rotary cam type over hoist and over lower self-resetting limit
switch shall be provided. This limit switch shall have
independently adjustable cams for hoisting and lowering
motion. The cams shall have adjustability such that end limit
can be set to within 100 mm of hoisting or lowering motion.
In addition to this, a back up ultimate limit switch of series
gravity type shall be provided to prevent over hoist.
`
12.5.2 Type & Make of Motor
Motors shall be of heavy duty reversible type and selected for

the specific crane duty service and conditions specified. All
motors shall be totally enclosed fan cooled wound rotor
motors. However, motors having less than 3 kW may be
squirrel cage motors. All motors shall conform to latest
edition of IS: 325. Class insulation shall be F/F
(Stator/Rotor) with temperature raise for ‘F’ also limited to
that for ‘B’. Pullout torque to be not less than 275% of full
load torque corresponding to 40% CDF & 150 starts/ hour, S4
duty rating. All the motors shall be suitable for crane duty
rating of not less than 40% CDF and shall be designed for
high starting torque and frequency intervals (S4 duty – 150
starts per hour). RPM of motors shall not be more than 1000.
The motors shall have IP-55 degree of protection.
12.5.3 Type of Brake
Double Girder EOT Crane:
- Electro hydraulic thruster type brake for all motions.
Single Girder EOT Crane:
- Electro hydraulic thruster type brake for Hoist & LT

motions.
- ACEM disc type brake for CT motion.
NMDC LIMITED MECON
LIMITED

Under slung EOT crane:
- Electro hydraulic thruster type brake for Hoist motion.

- ACEM disc type brake for CT & LT motions.
Electric Hoists:
- Electro hydraulic thruster type brake for Hoist motion.

- ACEM disc type brake for CT motion.
Braking capacity shall be minimum 150% of motor torque in

respect of hoisting mechanism and minimum 100% motor
torque in respect of other mechanisms.
12.5.4 Protective Panel & Control Panels for the various drives
i) The crane protective panel and other panels shall be

Dust & Vermin Proof with IP 55 protection and consist
of MCCB, Control Switches, MCB’s, contactors, relays,
HRC fuses, control transformers, Voltmeters for
Incomer & Control Voltage, 3 Nos. Ammeters for 3
phases and LED type Indication Lamps to indicate
Control – ON/OFF & incomer MCCB – ON/OFF/individual
trip indicators. All the items shall be adequately rated
considering the maximum current. Contactors shall be
of AC 4 duty & reversible contactors shall be
interlocked both electrically and mechanically.
Approved panel wiring diagram shall be embossed on
tin metal sheet of minimum 16-guage thicknesses and
fixed on the door of panel (inside), for reference during
attending faults/maintenance. Plugging of squirrel cage
motors shall be avoided. The hoist motion shall have
counter torque, single phase and regenerative braking
during lowering. At least rotor steps shall be provided
for hoist motion and three for travel motion. Antidrop
feature shall be provided for hoist motion. For travel,
rotor resistance control with the plugging shall be
provided and plugging current shall be limited to full
load current.
NMDC LIMITED MECON
LIMITED

ii) Main Power Contactors in the protective panel shall

close only when: (a) none of the directional contactors
are in closed position initially (b) emergency switches
not operated (c) door/gate switch, gravity limit switch
for hoist motion not operated. Each motion shall have
its independent panel on crane.
12.5.5 Resistance Box
Air-cooled, rustless, unbreakable stainless steel (AISI-406)

grid type of 10 minutes rated resistance suitable for operation
in conjunction with pendent push button station or master
controller to be provided. Other details of resistance box shall
be as indicated in the electrical part of the specification.
12.5.6 Identification of circuits and cables
Labels of permanent nature shall be provided on supports of

all switches, fuses, contactors relays etc. to facilitate
identification of circuits and replacement. All panels, resistors
etc are to be properly marked for each motion. All power,
control, lighting and other cables are to be tagged at both
ends as per cable number indicated in the supplier’s drawing.
All equipment terminals are also to be marked.
12.5.7 Earthing
A ring earthing system shall be provided on the Crane and

interconnected to shop earthing network. Each & every
electrical equipment shall be connected to this earthing at
least at two points. The earthing shall be connected to the
Crane rails on either side through a set of two earth collector
brushes on each side. An earth core shall be provided in
flexible cable in case of power supply though festooned cable
system.
NMDC LIMITED MECON
LIMITED

12.5.8 Lighting, Socket outlets & Bells etc.
2 Nos. 250W high pressure sodium vapour flood lights shall

be provided below crane platforms which shall be so fixed
that they can be approached from the crane platforms for
maintenance. The lights shall he equally spaced (under crane
girders) amid they shall be provided with shock absorbing and
anti-Swing suspension arrangements. Adequate number of
hand lamp socket outlets and power socket outlets shall be
provided along with switches. A hand lamp with-sufficient
length of cable with a plug shall also be provided. An alarm
bell shall also be provided on Crane. All light fittings shall be
of dust tight type.
12.5.9 Power Feeding System
i) Power Supply for LT Motion:
a) Crane power supply feed system shall be

through galvanised steel shrouded bus bar
system.
b) Encapsulated/shrouded galvanised steel bar
conductor system shall comprise of 4 wires
suitable for single power feed to mid point. The
conductor system shall be complete with all
accessories like power feeding sections,
expansion section, standard sections, clamps,
joint/end covers, joint couplers, current
collectors (tandem type), danger boards, etc.
The material of shroud shall be PVC suitable for
70 deg.C. The continuous current rating of the
conductors shall be so chosen that the voltage
drop from load break switch to the motor
terminal is restricted to 3 % based on maximum
derated and 10% based on peak current. The
Tenderer shall furnish detailed technical
catalogues for the crane feed system proposed
to be supplied by him along with the Bid.
NMDC LIMITED MECON
LIMITED

ii) Power Supply for CT Motion:
Flexible trailing cable systems mounted on retracting

supporting system shall be used. The system shall
consist of insulated multi conductor or several single
conductor cables with permanent termination on the
bridge and on the trolley. The flexible trailing cables
shall have ample length and shall be supported by
means of properly designed movable clamps. These
clamps shall be fitted with rollers and shall run freely
on a guide beam of minimum size ISMB 100 allowing
relative movement of bridge and trolley without undue
stress on wear on the suspended cable. Provision shall
be made for the inclusion of space cables at a later
stage in case of necessity. The flexible cable shall be
EPR insulated CSP sheathed type
12.5.10 Power Distribution on Crane:
One adequately rated load break switch with locking facility

shall be provided immediately after current collectors on
incoming line on the crane. The switch shall be capable of
carrying current of three largest motors. Power from the
switch shall be taken to the MCCB in protective panel.
12.5.11 EQUIPMENT IN PENDANT UNIT (with Die cast Aluminium

enclosure)
The following shall be included on the pendant unit:
Push buttons for : Hoist, lower, left cross traverse, right cross
traverse, forward Long travel, backward
Long travel, mushroom headed emergency
stop, lockable OFF, Main supply ON, Main
supply OFF. Push buttons for gravity limit
switch, bell operation.
Switch for : Flood lights
Lamps for : Power "ON" indication, Control “ON” and
gravity switch operation. (LED lamps to be
used)
NMDC LIMITED MECON
LIMITED

Pendant shall be of independently movable type.
13.0 ELECTRIC & MANUAL HOISTS
Electric and manual hoists shall be provided at various

locations for maintenance of conveyor drives, pulleys, EOT
crane, etc.
13.1 ELECTRIC HOIST
i) Electric hoist with electrically movable trolley shall be

provided wherever required, for the maintenance of
equipment. The capacity of the hoist shall be decided
based on the heaviest item to be lifted.
ii) The Electric hoist wherever provided shall be designed

in accordance with IS 3938-1983. The outdoor hoists,
motors, brakes & other equipment shall be covered to
suit outdoor operations.
iii) Hoist shall have minimum 4/2 fall of wire rope.
iv) Electric hoists shall conform to class-II as per IS:3938.
v) All flexible-trailing cables shall be clamped with PVC or

non-metallic clamps.
vi) The wheels shall be mounted on antifriction ball / roller

bearings & shall be easily removable for repair &
replacement. The wheel dia shall be selected such that
skidding does not take place even under unloaded
condition.
vii) Electro hydraulic thrustor brake shall be provided for
hoist motion. The brakes shall be DCEM disc type for
travel motion. Limit switches shall be provided for each
motion. Hoisting motion shall be provided with two
limit switches.
viii) Electric hoists shall be provided with drop stop plates to

prevent falling of hoist block in the case of travel wheel
failure.
NMDC LIMITED MECON
LIMITED

ix) Hooks shall have closing fingers and lock against

swiveling. Suitable thrust bearings shall be provided for
swivel.
x) Shrouded bus bar type power supply arrangement shall

be considered for hoist CT power supply.
xi) Hoist block shall be provided with rubber buffer for CT

motion along with buffer stop on the girder / monorail.
13.2 MANUAL HOIST
(i) Chain pulley shall be complete with geared traveling

trolley.
(ii) Chain Pulley blocks shall conform to class-2 as per

IS: 3832-2005.
(iii) Only triple spur geared type shall be considered.
(iv) Swiveling type standard shank hook mounted on

grease lubricated anti-friction thrust bearing shall be
used.
(v) Only ball and roller anti-friction bearing shall be used.
NMDC LIMITED MECON
LIMITED

CHAPTER-Q2
ENVIRONMENTAL
TECHNICAL SPECIFICATION FOR AIR CONDITIONING,

VENTILATION & DUST SUPPRESSION SYSTEMS
1.0 SCOPE OF WORK:
1.1 The scope of work involves design, engineering, inspection, supply,

erection, testing, commissioning and Performance guarantee of Air-
conditioning, Pressurised Ventilation and Dust Suppression Systems
for the premises indicated as below:
Sl.
Premises Equipment Description
No.
Air-Conditioning facility with

associated equipments
Compressor, Condenser,
Evaporator, Refrigerant
Control Room, VFD Room, piping, Cooling Towers,
1
Shift-In charge Room. Water Pumps, Piping,
Ducting, Volume control
damper, Fire damper and
Electrics including MCC,
Earthing, Controls etc.
Pressurised Ventilation
system comprising of TA
Fans, Filters, Fire damper,
Switchgear Room/ Electrical Volume control damper,
2
Room/ MCC Room. Relief dampers / Gravity
open louvers, Rain
protection Cowl and Bird
Screen, starter as required.
Exhaust Ventilation with

Cable Cellars, Battery room,
Tube Axial Fan provided
3 HT Capacitor Bank room,
with bird screen and rain
Pump House.
protection cowl.
MEC/01/Q6DH/KIOP/PKG-II/TD Rev. 0
NMDC LIMITED MECON
LIMITED

Sl.
Premises Equipment Description
No.
a) Discharge point of Dry Fog Dust Suppression

Conveyor no. 718 at TH-1. System.
b) Receiving point &
Discharge point of
Conveyor no. 719 at TH-1
& RCC SILO respectively.
c) Discharge point of Belt
Feeder no. 720 at TH2.
d) Receiving point &
Discharge point of
Conveyor no. 721 at TH-2
& TH-2A respectively.
e) Receiving point &
Discharge point of Downhill
4 Conveyor no. 723 at TH-2A
& TH-3 respectively.
f) Discharge point of Belt
Feeder no. 725 at TH-3.
g) Receiving point &
Discharge point of
Reversible Conveyor no.
727 at TH-3.
h) Discharge point of Belt
Feeder (Future) at TH-3.
i) Receiving points of
Conveyor to New
Screening Plant (Future)
from Reversible Conveyor
no.727 & Belt Feeder
(Future) at TH-3.
1.2 Requirements specified above are the minimum. Tenderer to work

out the same and submit the data.
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1.3 All exposed carbon steel surfaces should receive acid resistant
primer and finish coat with epoxy painting after shot blasting as per
the approved painting procedure, which shall be submitted by the
successful tenderer.
1.4 The system shall be complete with all the items essential for the
efficient operation of the systems, including those items, which are
not specifically included in the specifications, but are required to
complete the erection and foolproof commissioning of Air-
conditioning, Ventilation and Dust Suppression Systems in all
respects.
2.0 DESIGN CRITERIA
2.1 OUTSIDE DESIGN CONDITIONS
Pl. Refer site climatic conditions.
2.2 INSIDE DESIGN CONDITIONS:
2.2.1 AIR-CONDITIONING SYSTEM:
Temperature (0C) : 23 + 2
Relative humidity (%) : 55 + 5
Filtration (microns) : Min. 90 % down to 10 microns
2.2.2 PRESSURISED VENTILATION SYSTEM:
Inside Temperature not to

exceed more than 5°C over and
Temperature :
above the prevailing ambient
temp.
Positive Pressure of minimum
Pressure : 3 mmWc shall be maintained
inside the premises.
Pre-Filtration : Min. 90 % down to 10 microns.
NMDC LIMITED MECON
LIMITED

2.2.3 EXHAUST VENTILATION SYSTEM:
Not more than 20 C rise above

Temperature : ambient temperature (maximum)
shall be maintained.
2.2.4 DRY FOG DUST SUPPRESSION SYSTEM:
The respirable dust at 1m to 10m from source shall be within

threshold limit value of 3 mg/m3.
2.3 RAW WATER QUALITY:
The available quality of Raw Water shall be Potable.
3.0 TECHNICAL SPECIFICATIONS
3.1 GENERAL
3.1.1 AIR-CONDITIONING SYSTEM.
The Variable Frequency Drive room (VFD), Control room and Shift-
in charge Room of the Electrical building shall be provided with
Water cooled Air-Conditioning facilities with associated equipments
such as Compressor, Condenser, Evaporator, Refrigerant piping,
Cooling Towers, Water Pumps, Water Piping, Valves, Ducting,
Volume control damper, Fire damper and Electrics including MCC,
Earthing, Controls etc.
The Bidder shall provide the required AC facilities to maintain the

desired temperature of 23±2ºC at RH 55±5% inside VFD room,
Control room & shift-incharge room for continuous operation of
various panels. The bidders are requested to indicate the capacity
and type of AC facilities in their offer for maintaining the above
environment.
The Bidder shall submit the detailed heat load calculation for AC
facilities for technical scrutiny.
NMDC LIMITED MECON
LIMITED

3.1.2 PRESSURISED VENTILATION SYSTEM:
Pressurised Ventilation System shall be envisaged to remove excess

heat from Switchgear room / Electrical room / MCC room by
maintaining the rooms at a temperature not exceeding 5°C over
and above the ambient temperature. Positive Pressure of 3 mmWc
shall be maintained inside Switchgear room / Electrical room / MCC
room to avoid ingress of outside air. The ventilation system shall be
sized based on the equipment heat loads and other loads or a
minimum of 15 air changes per hour whichever is higher.
Pressurised Ventilation system for Switchgear room / Electrical

room / MCC room shall consist of Tube Axial (TA) Fans, Filters
provided with connection box, Fire damper, Volume control damper,
Relief dampers / Gravity open louvers, Rain protection Cowls, Bird
Screens & electrics as required.
3.1.3 EXHAUST VENTILATION SYSTEM:
Exhaust Ventilation Systems comprising of Tube Axial fans provided

with Rain protection Cowls and Bird Screens shall be considered for
Cable cellar, Battery room, HT Capacitor bank room, Pump house
and any other rooms which require Exhaust Ventilation.
The Exhaust Ventilation Systems shall be designed on the basis of

20 air changes per hour or equipment heat loads whichever is
higher.
3.1.4.1 The Dry Fog Dust Suppression System (DFDS) is envisaged to

suppress the dust generated in conveyor transfer points. The DFDS
is intended to maintain the working environment clean and dust
free.
3.1.4.2 The Dust Suppression System shall be designed based on 2000 TPH
capacity of the system.
3.1.4.3 Dry fog Dust Suppression System shall be considered at the

following minimum locations:
a) Discharge point of Conveyor no. 718 at TH-1.
NMDC LIMITED MECON
LIMITED

b) Receiving point & Discharge point of Conveyor no. 719 at TH

- 1 & RCC SILO respectively.
c) Discharge point of Belt Feeder no. 720 at TH-2.
d) Receiving point & Discharge point of Conveyor no. 721 at TH
- 2 & TH-2A respectively.
e) Receiving point & Discharge point of Downhill Conveyor no.
723 at TH-2A & TH-3 respectively.
f) Discharge point of Belt Feeder no. 725 at TH-3.
g) Receiving point & Discharge point of Reversible Conveyor no.
727 at TH-3.
h) Discharge point of Belt Feeder (Future) at TH-3.
i) Receiving points of Conveyor to New Screening Plant (Future)
from Reversible Conveyor no.727 & Belt Feeder (Future) at
TH-3.
3.2 SPECIFICATION OF COMPONENTS
3.2.1 AIR CONDITIONING SYSTEM
Design and Engineering the complete Air-Conditioning facility for

VFD room, Control room & Shift Incharge room shall be done
considering the following:
• Air Conditioning units shall be selected based on the Heat Loads,

Area, Occupancy & other factors related to the premises.
However 50% stand-by units shall be considered for AC
facilities.
• Under deck insulation with Thermocole/PUF/Rockloyd wools shall

be provided wherever the roofs are exposed to Sun radiation.
• The Air-conditioning facilities shall include refrigerant piping,

power and control wiring, earthing, etc.
• Incidental civil works such as making of openings in walls/

floors/ ceilings for taking out cables/ piping/ supports/ ducting
etc and making them better by providing and fixing framework
for the grilles/ diffusers etc.
NMDC LIMITED MECON
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• The cooling capacity shall be decided on the basis of heat

dissipated by equipment, building heat radiation, illumination
heat, occupancy heat, make up air heat etc. in the premises.
• System shall be suitable for un-interrupted continuous

operation.
• The Air Conditioning facilities shall be provided with a circuit,

which shall include thermostat, expansion valve, distributor,
liquid strainer, dehydrator & liquid line shut-off valve. The circuit
shall be protected by Hi-Lo pressure stat.
• Air filter shall be provided for the fresh air as well as total air.
The air filter shall be dry panel type. The cleaning efficiency of
the filter shall be more than 90% down to 10 microns. The filter
shall be easily replaceable type.
• Air Conditioning unit shall be provided with suitable openings

with flanges for fresh & re-circulated air ducts with hand
operated control dampers. Thermostat and humidistat shall be
provided for control of temperature & humidity as per the inside
design conditions.
3.2.1.1 Evaporator
The evaporator coil shall be of direct expansion type with copper

tubes of minimum 4 rows and mechanically bonded aluminum fins
of min15-16 fins per inch. It shall be sufficiently deep and well
proportioned to match the airflow and ensure perfect cooling. Tubes
shall be arranged in staggered design for best air contact giving low
by-pass. If required Evaporator shall be thermally insulated with
polyurethane of 50 mm thick & density 32 kg/m3.
3.2.1.2 Compressor
The refrigerant compressor shall be Hermetically / Semi-

hermetically sealed reciprocating / rotary / scroll type operating on
Low GHG / ODP refrigerant. The Compressor shall have an Energy
Efficiency Ratio (EER) of not less than 10.0 under designed
operating conditions. It shall be capable of operating continuously
in an industrial atmosphere.
NMDC LIMITED MECON
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3.2.1.3 Condenser
The condenser shall be water-cooled copper coil of minimum 3 rows,

12-14 fins/inch, aluminium fins with ample condensing surface.
Tubes shall be arranged in a staggering manner for better
efficiency.
3.2.1.4 Cooling Towers
Induced draft type, FRP cooling tower shall be provided for the
cooling of condenser water.
Cooling tower shall be designed, manufactured and performance
tested as per CTI codes.
The capacity of the cooling tower basin shall be adequate to take

care of the entire cooling water required for the air conditioning
systems. Only make-up water will be made available from the plant
network.
The cold-water basin shall be of FRP construction. Cooling tower

basin shall have accessories and connections for make up, quick fill,
drain and overflow. Ball and float valve is to be provided for make
up water line. The makeup water supply pipe shall be positioned at
least 2 diameters above the maximum level in the basin.
The structural framework of the tower including all members and

connections shall be designed for operating loads and prevailing
wind pressure. Steel members shall be of hot dipped galvanized
steel and of sufficient sizes to safely withstand all imposed loads.
Framework, bolts, nuts and washers shall be non-corrosive type.
All the fasteners shall be of stainless steel. Rubber/neoprene

gaskets must be used on all bolted joints as a seal against water
leakage.
Motor of induced draft fan shall be of weather-proof construction.
3.2.1.5 Water Pump Sets
Pump sets are required for the service of condenser water re-
circulation.
NMDC LIMITED MECON
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Type of pump set is horizontal split casing, unless otherwise stated

in the specification. Flexible coupling should be used to connect
pump shaft with motor. Pump motor assembly shall be mounted on
a common base frame.
Pump head capacity characteristic shall be gradually rising from

operating to shut-off point without any zone of instability. The
pump BHP - flow characteristic shall preferably be non-overloading
type beyond rated capacity point. Pumps shall be rated for
continuous operation. Operating speed of the pumps should not be
more than 1500 RPM.
Pump shall be provided with suitable bearings, sized adequately to

take maximum imbalance.
Pump and drive motor shall be directly coupled through a flexible

coupling. Suitable coupling guard shall be provided for each pump.
Each pump shall be complete with pressure gauge at the suction

and discharge complete with isolating valve. All integral piping
required for sealing, cooling, etc. shall be supplied with the pump.
Condenser water pump set will handle water having temperature

35ºC.
The pumps shall be designed, manufactured and performance

tested as per IS: 9542 - 1980.
The impeller and shaft assembly should be statically and

dynamically balanced. Dial type pressure and temperature gauges
should be provided for suction and discharge side
Each pump set should be subjected to mechanical running for

minimum 4 hours.
3.2.1.6 Water Piping Network
Heavy class piping is to be used as per IS: 1239 for interconnecting

water-piping network.
Copper alloy gate and globe valves are to be used up to pipe sizes
50mm and CI valves are to be used above these pipe sizes.
NMDC LIMITED MECON
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Pipe fittings like bends, elbows, flanges, sockets, nipples, etc shall
be as per relevant IS/BS standards.
Drain piping network is to be included as required for condenser
water system, plant room drain, cooling tower drain etc., with
isolation valves at proper places.
Pipe supports shall be of steel, adjustable for height and coated
with rust preventive primer and finish coated with Aluminium paint.
When pipe and clamp are of dissimilar material, a gasket shall be
provided in between.
Spacing of pipe supports shall not exceed the following:
Pipe dia (mm) Spacing (m)

Up to 25 1.85
32 to 150 2.50
150 and above 3.00
All piping shall be tested to hydrostatic test pressure of at least one

and half times the maximum of operating pressure but not less
than 7 kg/sq.cm for a period of not less than 4 hours. System may
be tested in sections and such section shall be securely capped.
No insulation shall be applied to piping until the completion of
pressure testing to the satisfaction of the Purchaser/Consultant.
The Bidder shall provide all materials, tools, equipment,
instruments, services and labour required to perform the tests and
to remove waste materials resulting from cleaning and/after
testing.
3.2.1.7 Duct work for Air Conditioning Systems
a) Air duct for air conditioning systems shall be fabricated as per

latest revision of IS: 655 /ASHRAE standards.
b) All longitudinal joints shall have double 'S' seam joint and
circumferential joint will be lap joint. All joints are to be
airtight. Ducting shall be fabricated at site from GI sheets.
c) Flanges of sheet metal duct will be of angle iron type riveted
with G.I sheet rivet on duct perimeter. Flanged joints should
be made air tight with use of felt gaskets. Spacing of duct
flanges will be about 3 meters.
NMDC LIMITED MECON
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d) Overhead ductwork shall have ceiling suspended type duct

hangers comprising rod suspenders threaded at either ends or
angle iron horizontal support for duct. There will be no
provision of insert plates. The Bidder is required to fix anchor
fasteners in the slab to hook up the rod hangers. Spacing for
duct supports should be about 2 to 3 meters.
e) Turning guide vanes are to be provided inside the duct

wherever change of direction occurs, to minimise eddy
formation.
f) Bends/ elbows, wherever used, in ductwork shall have radius
not less than the depth of ductwork in change of direction.
g) Manually operated volume control damper is to be provided at
each supply air diffuser outlet. Collar piece is to be provided
to duct bottom to connect with throat of diffuser. The diffuser
should flush with false ceiling.
h) Sheet metal duct shall be acoustically and thermally insulated.
i) The space between false ceiling and roof slab shall be used for
return air. Return air grill should be provided in false ceiling.
Ductwork shall be complete with flanges, stiffeners, fasteners
& hangers.
j) The recommended air velocities in the plenum system are as
given below:
Main ducts : 6 to 8 m/sec

Branch ducts : 4 to 5 m/sec
Branch risers : 4 m/sec
k) Motor operated fire dampers shall be provided in the air ducts
at the supply end. Design of diffusers, grills etc. shall be made
by the Bidder matching the lighting fittings and interior
decorator of the area to be conditioned.
3.2.1.8 Inter-connecting Refrigerant Piping, Fittings & Valves
a) Refrigerant piping is required to interconnect the compressor,

condenser & Evaporator into a closed network.
NMDC LIMITED MECON
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b) Suction & Discharge lines shall be thermally insulated with

polyurethane of 50 mm thick & density 32 kg/m3. The piping
design shall be carried out in conformity with the (ANSI – B
31.5 1962) codes applicable and sound engineering practice.
Heavy-duty seamless steel pipe shall be used for pipe
network. Seamless solid drawn copper tubes shall be used for
refrigerant liquid line.
c) The piping network shall be adequately supported to ensure

rigidity and strength and isolated by means of suitable
isolators.
d) The Bidder shall furnish complete piping and instrumentation

diagrams showing the arrangement of piping inclusive of all
materials, instruments & controls proposed to be included in
the bid. The entire piping network shall be pressure-tested,
leak tested, dried, evacuated and charged with the refrigerant
after erection.
e) All bolts and nuts shall be of black hexagonal carbon steel

type as per IS: 1363 (1992) & with the material & other
requirements as per IS: 1367- 1992.
f) Velocity in the discharge and suction pipe of the refrigerant

shall be such that no undue vibration and noise are
generated.
g) The piping network shall incorporate loops in the circuit to
efficiently separate oil and liquid refrigerant from hot gas and
suction vapour respectively.
h) All horizontal lines shall be pitched to 12 mm for every 3.0 m

in the direction of refrigerant flow. All necessary loops and
bends shall be provided to ensure proper return of oil to the
compressor.
i) Each refrigerant circuit shall be suitable for operation and

include the following items:
- Thermostatic expansion valve with pressure
equalization
- Removable liquid line drier / strainer
- Liquid line sight glass with moisture indicator.
NMDC LIMITED MECON
LIMITED

- Hand shut off valves

- Liquid to suction heat exchanger
3.2.1.9 Supply Air Diffusers / Grilles
a) Supply air diffusers / grilles shall be used for distribution of air in

the premises and shall be mounted on the duct collars extending
from the duct.
b) The diffuser should be flushed with the false ceiling.
c) Manually operated volume control and direction control dampers

shall be provided along with the supply air diffusers / grilles.
The volume and direction control dampers shall be designed for
smooth operation.
3.2.1.10 Thermal Insulation Of Ducting
Thermal insulation of Air Conditioning duct shall be carried out

by the Tenderer as per the following description:-
i. Clean the external surface of duct & apply a coat of Bitumen

primer.
ii. Apply a coat of bituminous cold adhesive on to duct surface.
iii. Fix PUF / PHENOTHERM / Rockwool Slab / wools (48kg/m3

density) of 50mm thick insulation laminated with Aluminium
foil on one side & seal the joints by means of aluminium foil
self adhesive tape.
iv. Finish the surface with GI wire netting / aluminium band of

size 20 mm x 24 swg.
3.2.1.11 Acoustic Insulation
Acoustic insulation of 12mm thick rigid fibre glass board

48kg/m3 density covered with 1mm thick fibre glass cloth or
kraft paper shall be provided on the inside of supply ducting
upto 6m from each air handling units / indoor units.
NMDC LIMITED MECON
LIMITED

3.2.1.12 Underdeck Thermal Insulation
Under deck insulation of the areas to be air-conditioned shall be

carried out with TF quality Thermocole / PUF / Rockloyd wools
48kg/m3, 50 mm thick with Aluminium foil 0.03mm laminated
on one side on to the open bed made out of 22 swg GI wire with
Aluminium foil lamination facing the floor. GI wire netting of size
½” x 22 swg shall be fixed on to the MS cleats ensuring proper
contact of insulation with ceiling.
3.2.2 PRESSURISED VENTILATION SYSTEM
3.2.2.1 Equipments Envisaged:
3.2.2.2 Tube Axial flow fan:
i. Fan impeller shall be of aerofoil section. The speed of the TA

fan shall be preferably within 1000 rpm and outlet velocity shall
be within 12 m/sec.
ii. The impeller shall be directly mounted on the motor shaft and
the assembly shall be mounted inside rigid tubular casing.
iii. The TA fan with Pre-filter shall be provided with Rain protection
Cowl & Bird screen / wire mesh at the suction side of the TA fan
for protection against physical & climatic encounters.
iv. Terminal box shall also be provided outside the tubular casing
for ease of electrical connections.
v. The connecting flanges shall be provided at both ends of tube.
vi. Fan to be installed in fire hazardous/acid area shall be spark

proof construction and painted with acid resistant paint/anti
corrosive lining.
vii. The impeller shall be of cast aluminium alloy construction of

high efficiency aerofoil section blades. The fan impellers shall be
cast in one piece, finished all over and carefully balanced both
NMDC LIMITED MECON
LIMITED

statically and dynamically as per AMCA Standard. Finally the

assembled rotor shall be dynamically balanced.
viii. Axial flow fan casings for wall mounted/roof mounted fans and
their components shall be suitable for outdoor installation. The
casing shall be minimum 2 mm thick. The casings shall be
provided with flanges at inlet and outlet. All nuts & bolts
associated with it shall be of zinc or cadmium plated. Easily
removable inspection cover having galvanised fly nut shall be
provided. The covers shall be located such that the grease
nipple for all bearings, and also motor terminals are easily
accessible through the cover.
3.2.2.3 Relief Damper / Gravity Open Louver
Suitable number of Relief Dampers / Gravity open louvers shall be

provided for exhausting the supply air for maintaining a positive
pressure of 3mmWc in the ventilated premises.
3.2.3 Pre-Filters
a) Pre-filters shall be provided at the inlet of TA Fan & Fresh Air

intake in the AC plant room.
b) Size of filters shall be of standard size 610x610x150/50 mm

thick.
c) Velocity of air across the filter shall be in the range of 2 m/sec.
d) Filter panel shall be cleanable and washable type for reuse.
e) Magnahelic gauge shall be provided for measuring pressure

drop across the filter.
f) Cleaning efficiency of the pre filter element shall be 90% down

to 10-micron size of dust particles.
NMDC LIMITED MECON
LIMITED

g) Filter material shall be enclosed in a sheet metal framework.

Filter frame shall be fabricated from 16G M.S sheet in welded
construction. All leakage areas shall be sealed with suitable
sealing compound.
h) Proper sealing shall be ensured to prevent leakage of air

between mounting frame and filter panels.
3.2.4 Volume Control Dampers
i) Volume control damper shall be provided to regulate the

airflow to the desired capacity.
ii) The volume control damper shall be multi leaf, opposed

acting, aerofoil blade type with external operating link and
operating mechanism.
iii) Size of the volume control damper shall be as per the outlet
size of TA Fan / AC ducts.
iv) Volume control damper shall have flanges at both ends for its
connection.
3.2.5 Fire Damper
The fire acting dampers shall be provided at out-let of the TA Fan /

AC indoor unit to isolate the served premises in case of fire
occurrence. These shall be electrically operated & interlocked with
plant's fire protection system.
3.2.6 EXHAUST VENTILATION SYSTEM
i. Fan impeller shall be of aerofoil section. The speed of the TA fan

shall be preferably within 1000 rpm and outlet velocity shall be
within 12 m/sec.
ii. The impeller shall be directly mounted on the motor shaft and
the assembly shall be mounted inside rigid tubular casing.
NMDC LIMITED MECON
LIMITED

iii. The TA fan shall be provided with Rain protection Cowl & Bird
screen / wire mesh at the suction side of the TA fan for
protection against physical & climatic encounters.
iv. Terminal box shall also be provided outside the tubular casing
for ease of electrical connections.
v. The connecting flanges shall be provided at both ends of tube.
vi. Fan to be installed in fire hazardous/acid area shall be spark

proof construction and painted with acid resistant paint/anti
corrosive lining.
vii. The impeller shall be of cast aluminium alloy construction of high

efficiency aerofoil section blades. The fan impellers shall be cast
in one piece, finished all over and carefully balanced both
statically and dynamically as per AMCA Standard. Finally the
assembled rotor shall be dynamically balanced.
viii. Axial flow fan casings for wall mounted/roof mounted fans and
their components shall be suitable for outdoor installation. The
casing shall be minimum 2 mm thick. The casings shall be
provided with flanges at inlet and outlet. All nuts & bolts
associated with it shall be of zinc or cadmium plated. Easily
removable inspection cover having galvanised fly nut shall be
provided. The covers shall be located such that the grease
nipple for all bearings, and also motor terminals are easily
accessible through the cover.
3.2.7 DRY FOG DUST SUPPRESSION SYSTEM
The Dry Fog Dust Suppression System shall be designed to

suppress the fugitive air borne dust generated at various transfer
points of the conveyors.
The system shall develop superfine atomisation of water droplets

with the help of compressed air to form a blanket of extremely fine
fog to entrap the fugitive air borne dust such that the suppression
NMDC LIMITED MECON
LIMITED

is achieved due to agglomeration by impact of dust particles with

water droplets until mass becomes heavy enough to cause the
particle to settle on the main material without wetting the product
being handled.
3.2.7.1 Main Equipments
The main equipments shall comprise of Spray Bar Assemblies fitted

with dual fluid “Dry Fog” Atomizing Nozzles, Pressure Regulating
Units, Flow Activation Stations for ON/OFF control of the system
and Instrumentation for auto operation. The detailed specifications
of the main equipments are given in the following paragraphs.
3.2.7.2 Spray Bar Assemblies
The atomizing nozzle shall be dual phase, self-cleaning and non-

clogging type with in-built filters made of brass. The nozzle
configuration shall be designed to provide consistent quality of
atomization over a wide range of flow. The nozzle housing shall be
made of cast aluminium alloy and the tip shall be Stainless Steel
conforming to AISI-410 or SS-304 with SS strainer.
The spray bars shall be made of SS-304 and the same are to be
provided with mounting clips, supporting brackets and braided
flexible hoses for air & water line connections.
The number of nozzles shall be provided according to the

application and these shall be suitably mounted on top and sides of
skirt board/hoods depending upon the site conditions. Any
modifications required for proper mounting shall be carried out by
the tenderer.
3.2.7.3 Pressure Regulating Units
Spray Circuit should be provided with Pressure Regulating Unit

comprising of independently operated manual regulator with gauge
isolation valve etc. in air and water line to obtain the desired air
and water pressure for maintaining required water droplet size in
consonance with size of dust particles for optimum dust
suppression.
NMDC LIMITED MECON
LIMITED

3.2.7.4 Flow Activation Stations
The Flow Activation Stations should be provided for ON/OFF

operation of the system and shall be provided with the following
minimum options:
a. ON/OFF/AUTO select switch.
b. Indicating Lights.
- For system tripping due to insufficient air pressure.
- For system in operation.
3.2.7.5 Automation and Instrumentation
The system shall be equipped with auto-operation in addition to

manual mode operation with the provision of sensors located at
suitable locations. The automation and instrumentation shall be
provided for the system to operate only when: -
a. Sufficient air pressure to the nozzle is available so as to eliminate

pouring of un-atomized water into dust source.
b. Conveyor/ Belt is in motion and loaded with the material.
3.2.7.6 Auxiliary Equipments
The auxiliary equipments shall comprise of 2 sets of Air Compressors

& 1 set of Air Receiver, 2 sets of Water Pumping Unit, Air & Water
Pipelines along with hoses up to Pressure Regulating Units, Electrical
Cabling etc.
The design of auxiliary equipments shall be based on the

consideration of 2 nos. centralized air compressors (1W+1S)
working in conjunction with 2 nos. centralized water-pumping units
(1W+1S) of required capacities.
The various equipments covered under the auxiliary equipments and

their specifications are described below:
3.2.7.7 Air Compressor
The Air Compressor (1W + 1S) shall be heavy duty industrial type,
directly coupled, electric motor driven, air cooled, oil injected screw
compressor having self contained lubrication and cooling console,
suction filter, silencer, oil separator, pressure gauges board etc.
NMDC LIMITED MECON
LIMITED

Acoustic housing shall be provided to control sound level within

85dB(A) at 1 metre distance.
3.2.7.8 Water Pumping Unit
The Water Pumping unit (1W + 1S) shall consist of Duplex Filter of
adequate size to remove all suspended particles above 100 microns,
Water Storage Tank of adequate size with provision of low level
switch, float valve, vent, drain etc and centrifugal water pumps to
cater to the water requirement of the dust control system.
3.2.7.9 Air and Water Pipeline System
Air and Water pipelines from air compressor and water pump
respectively to various flow activation stations, pressure regulating
units and spray bar assemblies shall be provided along with
necessary fittings and valves. Design pressure of pipelines shall be
minimum 1.5 times the maximum expected pressure.
3.2.7.10 Electrical Works
Electrical Panels, power and control cabling shall be included as per

the requirements.
4.0 PERFORMANCE GUARANTEE
4.1 Performance guarantee parameters for Air Conditioning, Ventilation

& Dust Suppression Systems are as follows:
4.1.1 AIR-CONDITIONING SYSTEMS:
Temperature (0C) : 23 + 2
Relative humidity (%) : 55 + 5
Filtration (microns) : Min. 90 % down to 10 microns
NMDC LIMITED MECON
LIMITED

4.1.2 PRESSURISED VENTILATION SYSTEMS:
Inside Temperature not to exceed

Temperature : more than 5°C over and above the
prevailing ambient temp.
Positive Pressure of minimum

Pressure : 3 mmWC shall be maintained inside
the premises.
Pre-Filtration : Min. 90 % down to 10 microns.
4.1.3 EXHAUST VENTILATION SYSTEMS:
Not more than 20 C rise above ambient

Temperature : temperature (maximum) shall be
maintained.
The respirable dust at 1m to 10m from source shall be within

threshold limit value of 3 mg/m3.
FORM No. 11.20(DQM) F-9 REV. 0
CONTRACTOR NMDC LIMITED

QUALITY ASSURANCE PLAN PROJECT
ORDER No. & DATE
FOR
SUB-CONTRACTOR - STRUCTURAL & MECHANICAL PACKAGE No. PKG-II
EQUIPMENT
ORDER No. & DATE - PACKAGE NAME DOWNHILL CONVEYOR SYSTEM
INSTRUCTIONS FOR FILLING UP: CODES FOR EXTENT OF INSPECTION, TESTS, TEST CERTIFICATES & DOCUMENTS:
1. QAP shall be submitted for each of the equipment separately with break-up of assembly / sub-assembly
& part / component or for group of equipment having the same specification. Code Description Code Description Code Description DOCUMENTS
2. Use numerical codes as indicated for extent of inspection & tests and submission of test certificates &
documents. Additional codes & description for extent of inspection & tests may be added as applicable 1. Visual ( Welding etc. ) 15. Leakage Test 30. Proving Test D1. Approved GA drawings
for the plant & equipment. 2. Dimensional 16. Balancingt 31. Surface preparation / Painting D2. Information and other
3. Fitment & Alignment 17. Vibration Test 32. Manufacturer’s Test Certificates reference drg. / stamped drgs.
3. Separate identification number with quantity for equipment shall be indicated wherever equipment 4. Physical Test (sample) 18. Amplitude Test For bought out items released for mfg.
having same specifications belonging to different facilities are grouped together. 5. Chemical Test (sample) 19. Sponge Test 33. IBR / Other Statutory agencies D3. Relevant catalogues
6. Ultrasonic Test 20. Dust / Water Ingress Test Compliance certificate D4. Bill of matl. / Item No. /
4. Weight in tonnes (T) must be indicated under column 5 for each item. Estimated weights may be
indicated wherever actual weights are not available. 7. Magnetic Particle Test (MPI) 21. Friction Factor Test 34. Internal Inspection Report by Identification Relevant
8. Radiography Test 22. Adhesion Test Contractor catalogues
9. Dye Penetration Tes 23. Performance Test / 35. Hardness Test D5. Match mark details
10. Metallographic Exam Characteristic curve 36. Spark Test for Lining D6. Line / Layout diagram
ABBREVIATIONS USED :
11. Welder”s Qualification & 24. No Load / Free Test 37. Calibration D7. Approved Erection procedures
weld procedure Test 25. Load / overload Test 38. Safety Device Test D8. Un priced sub P. O. with
CONTR : CONTRACTOR 12. Approval of Test and Repair 26. Measurement of speeds 39. Ease of Maintenance specification and amendments,
MFR : MANUFACTURER procedure 27. Accoustical Test 40. Bearing temperature rise test if any.
13. Heat Treatment 28. Geometrical Accuracy 41. Out of roundness of roller D9. Calibration Certificates of all
14. PressureTest 29. Repeatabiliity & Positioning IS : 8598-1987 measuring Instruments and
Accuracy gauges
EQUIPMENT DETAILS I N S P E C T I O N AND T E S T S

Acceptance Criteria
Test Certificates &
Description (with Expected Raw Material and inprocess Standards/IS/ BS/ REMARKS/
Quantity Final Inspection / Test by documents to be
Sl. equipment heading,place Identification Manufacturer’s Schedule stage inspection ASME/ Norms and SAMPLING PLAN
submitted to Mecon
No. of use & brief No. Name & address of Final Documents
specifications) No. T Inspn. MFR CONTR. MECON MFR CONTR. MECON
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
(QAP No. TO BE ALLOTED BY MECON)
QAP No. MEC / 01 / Q6DH / KIOP / /QAP

For CONTRACTOR / SUB-CONTRACTOR REV. 0
For MECON (Stamp & Signature) (Stamp & Signature) SHEET 1 OF 2
ANNEXURE - A
CONTINUATION SHEET FORM No. 11.20(DQM) F-9 REV. 0
EQUIPMENT DETAILS INSPECTION AND TESTS

Acceptance Criteria
Test Certificates & REMARKS/
Description (with Expected Raw Material and inprocess Standards/IS/ BS/
Quantity Final Inspection / Test by Documents to be SAMPLING
Sl. equipment heading,place Identification Manufacturer’s Schedule stage inspection ASME/ Norms and
submitted to Mecon PLAN
specifications) No. T MFR CONTR. MECON MFR CONTR. MECON
Inspn.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

REV. 0
For CONTRACTOR / SUB-CONTRACTOR
FORM No. 11.20(DQM) F-10 REV. 0
CONTRACTOR
PROJECT
NMDC LIMITED
ORDER No. & DATE QUALITY ASSURANCE PLAN KUMARASWAMY IRON ORE PROJECT
FOR
SUB-CONTRACTOR
ELECTRICAL EQUIPMENT
PACKAGE No. PKG-II
ORDER No. & DATE PACKAGE NAME DOWNHILL CONVEYOR SYSTEM
INSTRUCTIONS FOR FILLING UP: CODES FOR EXTENT OF INSPECTION, TESTS, TEST CERTIFICATES & DOCUMENTS :
1. QAP shall be submitted for each of the equipment separately with break-up of assembly / sub-
assembly & part / component or for group of equipment having the same specification. Code Description Code Description Code Description DOCUMENTS
2. Use numerical codes as indicated for extent of inspection & tests and submission of test
certificates & documents. Additional codes & description for extent of inspection & tests may be 1. Visual 12. Routine test as per relevant 23. Short time rating D1. Approved GA drawings
added as applicable for the plant & equipment. 2. Dimensional IS / other standard 24. Operational & functional D2. Approved single line /
3. Fitment & Alignment 13. Type tests as per relevant IS / 25. check schematic diagram
3. Separate identification number with quantity for equipment shall be indicated wherever 4. Physical Test (sample) other standard 26. Over speed Test D3. Catalogues / Approved
equipment having same specifications belonging to different facilities are grouped together. 5. Chemical Test (sample) 14. Impulse Test 27. Flame proof Test data sheet
6. Ultrasonic Test 15. Partial Discharge Test 28 Clearance & creepage D4. Approved bill of materials
4. Weight in tonnes (T) must be indicated under column 5 for each item. Estimated weights may be
indicated wherever actual weights are not available. 7. Magnetic Particle Test (MPI) 16. Heat run test / tempr. Rise Test distance D5. Unpriced P.O. copy
8. Radiography Test 17. Enclosure protection Test D6. Calibration Certificates of
9. Dye Penetration Test 18. Calibration all measuring instruments
10. Measurement of IR value : 19. Noise & Vibration and gauges
ABBREVIATIONS USED :
a) Before HV Test 20. Test certificates for bought out
b) After HV Test components
CONTR : CONTRACOR 11. High Voltage test / 21. Tank pressure Test
MFR : MANUFACTURER Dielectric test 22. Paint shade verification
EQUIPMENT DETAILS I N S P E C T I O N AND T E S T S

Acceptance Criteria
Test Certificates &
Sl. equipment heading,place Identification Manufacturer’s Schedule stage inspection ASME/ Norms and SAMPLING PLAN
submitted to Mecon
No./M T MFR CONTR. MECON MFR CONTR. MECON
specifications) Inspn.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

ANNEXURE - B
CONTINUATION SHEET FORM No. 11.20(DQM) F-10 REV. 0
EQUIPMENT DETAILS INSPECTION AND TESTS

Acceptance Criteria
Test Certificates &
Sl. equipment heading, place Identification Manufacturer’s Schedule stage inspection ASME/ Norms and SAMPLING PLAN
submitted to Mecon
specifications) No./M T MFR CONTR. MECON MFR CONTR. MECON
Inspn.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

MECON LIMITED
BANGALORE
IS
O
Y
90
01 AN
CO M P
PAGE : 1 OF 1
INSPECTION CALL DOCUMENT No
TITLE
PROFORMA 11.20(DQM) F – 05/2 REVISION - 1
INSPECTION CALL No : DATE :
NMDC
PROJECT PURCHASER NMDC Limited.
Kumaraswamy Iron Ore Project
CONTRACTOR ‘S
CONTRACTOR
ORDER No & DATE
PLACE OF
SUB – CONTRACTOR
INSPECTION
Phone No./ Fax No
Phone No./ Fax No.
PROPOSED DATE OF
NAME &
INSPECTION
DESIGNATION
OF CONTACT PERSON
MANUFACTURER’S WITH PHONE No
OFF DAY
LIST OF ITEMS OFFERED FOR INSPECTION :
ITEM QAP &DRG

QUANTITY ( No / T/M )
IDENTIFI- ITEM QAP & DRG No . APPR
CATION No DESCRIPTION With Revision STATUS Total Total Offered
(A/AAN/INF) ordered accepted now
---
Legend : A= Approved AAN = Approved As Noted : INF = Information category
LIST OF DOCUMENTS & TEST CERTIFICATES ENCLOSED IN 4 SETS

DESCRIPTION REF No & DATE DESCRIPTION REF No & DATE
----------------------------------------------------------------
( FOR CONTRACTOR / SUB – CONTRACTOR)

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NMDC LIMITED

KUMARASWAMY IRON ORE PROJECT

MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD REV. 0 JANUARY 2010

KUMARASWAMY IRON ORE PROJECT

Preamble, Summary of Prices, Price for exemptions / variations

KUMARASWAMY IRON ORE PROJECT

N Documents /drawings to be submitted by successful Tenderer

1. Tender drawings as per the list under chapter-L

1. Soft copy of Questionnaire and design data sheet – Chapter-M (Part-2 of 2)

KUMARASWAMY IRON ORE PROJECT

BRIEF ON THE PROJECT AND INTENT OF

1.1 NMDC Limited, a premier iron ore producer in the public

1.2 Now, NMDC proposes to develop Kumaraswamy Iron Ore

1.3 Brief Description of the System under Package-II

KUMARASWAMY IRON ORE PROJECT

Reversible conveyor no. 727 will feed the material at the

1.3.2 Iron Ore from the existing Donimalai tripper conveyor

2.0 IMPLEMENTATION METHOD

2.1 MECON Limited has been appointed as CONSULTANT for

MECON has associated with Conveyor Dynamics, Inc. USA for

2.2 NMDC is proposing to implement the Kumaraswamy Iron Ore

2.3 The details of these six packages are as follows:

2.3.1 Package – I: CRUSHING PLANT

Major facilities / units included under this package are:

• Primary crushing Plant

KUMARASWAMY IRON ORE PROJECT

• Service road from PWD Road to PCH and SCH office

Package shall also include associated technological

Package shall further include earth cutting & leveling of the

2.3.2 Package – II: DOWNHILL CONVEYOR SYSTEM

Major facilities / units included under this package are:

• Conveyor No. 718

KUMARASWAMY IRON ORE PROJECT

• Electrical, control cum office buildings

Package shall also include associated technological

Package shall further include earth cutting & leveling of the

2.3.3 Package – III: ELECTRICAL WORKS

Major facilities / units included under this package are:

• Mains receiving sub-station

Package shall also include earth cutting & leveling, civil

KUMARASWAMY IRON ORE PROJECT

2.3.4 Package – IV: TELECOMMUNICATION WORKS

Major facilities / units included under this package are:

• Telecommunication facilities between various units of

Package shall also include civil works, structural works, etc.

2.3.5 Package – V: HILL TOP FACILITIES

Major facilities / units included under this package are:

• Package V-A : Civil, structural Works & Water Supply

The above packages shall include earth cutting & leveling,

2.3.6 Package – VI: ROADS

Widening and asphalting of the following roads:

• Kacha road developed by NMDC from Ranjitpura village to

3.0 INTENT OF TENDER

The intent of this Tender document is to enable the Tenderer

KUMARASWAMY IRON ORE PROJECT

GENERAL TECHNICAL CONDITIONS

1.1 This part covers technical conditions pursuant to the Contract

1.2 The Tenderer shall carefully go through the entire tender

1.3 The Bidder shall be deemed to have exhaustively examined the

KUMARASWAMY IRON ORE PROJECT

responsibility for deductions and conclusions as to the nature

2.0 LIMIT OF CONTRACT

2.1 Equipment furnished shall be complete in every respect with all