Engineering Plan - Malda

Rev. No.
0
Grain Storage Silo Complex of 125000 MT @ FSD BORIVALI
Date 10/08/2023
Concessionaire KCC Agri Logistics Pvt Ltd
Technical Support ASHISH DUBEY Page 1 of 14
Engineering and Design plan
For all heads of
Grain Storage Silo Complex of 50000 MT
in
Malda, WB
Rev. No. 0
Date 10/08/2023
Table of Contents
1.0 Introduction
1.0.1 Layout Of Silo Complex
1.1 System And Facilities Proposed At The Silo Complex
1.1.1 Grain Storage And Handling System
1.1.2 Railway Siding And Wagon Unloading System
1.1.3 Administration And Other Ancillary Buildings / Facilities
1.1.4 Utilities I.E. Electrical, Fire Hydrant System Etc.
1.2 Design Methodology, Codes And References
1.2.1 Design Methodology & Sequence :
1.2.2 Codes & Standards
1.3 List Of Drawings and Design To Be Submitted
1.3.1 Silos Complex – Grain Storage And Handling System
1.3.2 Civil Structure Drawings
1.3.3 Electrical System & Automation / Control System
1.3.4 Fire Hydrant System
1.3.5 Drains And Rain Water Harvesting System
1.3.6 Key Plans
1.4 Engineering Time Lines Including Execution Plan

Rev. No. 0
Date 10/08/2023
1.0 INTRODUCTION:
A concessionaire agreement was signed between FCI and WEST BENGAL LOGISTICS PVT
LTD on 23rd Feb 2017. As per the provisions of Concessionaire agreement WEST BENGAL
LOGISTICS PVT LTD (WBLPL) has proposed to develop Grain Storage Silo Complex of
50000 MT at Malda, West Bengal.
This document is to briefly define the Engineering and Design methodology. All the system and
project components are to be designed as per applicable Indian and International Codes /
standards.
The document includes the design philosophy of the facility.
Layout of Silo Complex 50000 MT Capacity (Long Term Storage Silos)
Based on the availability of land parcel available with WBLPL the layout of the 50000 MT Silo
complexes is finalized incorporating all the systems and the facilities to be developed as per
the Concessionaire agreement.
Rev. No. 0
Date 10/08/2023
Fig. 1 Layout of Silo Complex
The layout finalized has all the facilities as mentioned in the Concessionary Agreement. The
details of the provisions made in the silo complex is shared herein this document.
Rev. No. 0
Date 10/08/2023
1.1 SYSTEM AND FACILITIES PROPOSED AT THE SILO COMPLEX
1.1.1 Grain Storage and Handling system :
The silo complex is being designed and detailed our as per the OPTION 2 Provisions of
FCI Concessionaire agreement. The OPTION-2 is for consuming region for Food Grain
i.e. Wheat.
Following facilities, as per the Schedule B : Project Facilities, related to Silo and
Material handling system will be designed and implemented at the silo complex :
Silo Complex
Silo Complex 50000 MT Malda WB by WBLPL
Configuration
Long Term  Numbers of flat bottom sheet metal silos, each of 12,500
Storage Silos Metric Ton as per Standards and Specifications totaling to a
Capacity of 50,000 Metric Ton
 Each of the Long Term Storage Silo shall be fitted with

stationary vents and mechanical ventilators, aeration fans and
aeration floors and temperature monitoring system
 The Long Term Storage Silos are to be top loading and bottom
discharge.
 The intake capacity of the conveying system : 150 TPH
 The discharge / reclaim of the long term storage silos including

that of the sweep augur : 60 Tons Per Hour (TPH)
Grain intake system  Grain intake system comprising of unloading station with dump pits
arrangement comprising of four (04) hopper bins covered with MS
grating suitably connected through a conveyor to Pre-Storage Silos.
 Truck Unloading shed : Min 22 X 16 Mtrs
 Hydraulic Tippler ( 9 MTRS x 3 Mtrs ) : 1 No
 Drag Chain Conveyor : 150 TPH
 Dust suppression system
Process Tower  Pre Cleaner System : 150 TPH
 Online Weigher : 150 TPH
 Suitably designed Bag filter & Dust Collection system
Bulk Truck Loading  50 MT Hopper Bottom Silo : 1 Nos

System  60 TPH Drag Chain Conveyor : 1 Set (as per actual requirement)
Rev. No. 0
Date 10/08/2023
Bagging system  Semiautomatic weigher and bagger mechanism – 30 TPH : 2 Nos

(Total Capacity 60 TPH)
 50 MT Hopper Bottom Silo : 2 Nos
Bulk Rake Unloading  Dump pit 50 MT : 2 Nos

System  Drag Chain Conveyor : 2 Nos X 350 TPH = 700 TPH
 Bucket Elevators : 2 Nos X 350 TPH = 700 TPH
 The Receiving Silo - Flat bottom silo of 4000 MT Complete with
aeration floor, aeration fans and provision of fumigation : 1 Set
Bag Storage  Covered Warehouse as per FCI / CWC Specifications / norms : 200
Warehouse MT Capacity with suitable place to store Empty Bags – Approx Size
of Covered Shed : 405 SQM
 CAP storage capacity of 500 MT : 345 SQM
 The proposed warehouse will have good cross ventilation and have
the requisite plinth level and should be rodent and fire proof.
 A closed loop fumigation system, either from the Silos’
Fumigation aeration fans or separate centrifugal fan or a separate
system phosphine generator
 Temperature monitoring system : Min 13 Temperature Cables

Silo Grain for 12500 MT Silos and Min 9 Temperature Cables for 4000
Temperature MT Silos – Total Min 61 Temperature cables with centralized
Monitoring and temperature monitoring and control system
Silo Complex
 Motor Control Center (MCC)
Automation
 PLC Panel
system
 SCADA with required interface facility and display
 Weather station
1.1.2 RAILWAY Siding and Wagon Loading system :
As per the concessionaire agreement provisions are made to receive food grains
through railways through wagons in bulk or in bags. During procurement of the land for
the Silo Complex, it was ensured by WBLPL that required land parcel is aligned
suitably along the railway line is available. The terminal with the railway track will be
as per the Private Freight Terminal Policy of Indian Railway.
WBLPL planned the layout confirming to the requirements of the railway authorities.
The railway siding design approval, from appropriate authorities in Indian Railways, and
construction of railway siding at Silo Complex Malda@WB will be done in following
steps:
(1) Apply for Approval in Principle (AIP)

(2) Approval of Detailed Project Report (DPR) & Engineering Scale Plan (ESP) from
railway authorities
(3) Detailed Engineering
(4) Construction
Rev. No. 0
Date 10/08/2023
Following facilities to be created on the railway siding:
Silo Complex
Configuration
Railway Siding  Railway siding confirming requirements by Indian Railways as per

approved layout and provisions
 In-motion railway track Weighbridge
 Cabin for In Motion Weighbridge
Bulk Rake Unloading  Dump pit 50 MT : 2 Nos – Planned at the entry of the railway siding
System in WBLPL Premises
 Drag Chain Conveyor : 2 Nos X 350 TPH = 700 TPH
 Bucket Elevators : 2 Nos X 350 TPH = 700 TPH
 The Receiving Silo - Flat bottom silo of 4000 MT Complete with
aeration floor, aeration fans and provision of fumigation : 1 Set
1.1.3 Administration and other ancillary Buildings / facilities
Silo Complex
Configuration
Parking Lots  Lorry / Truck Parking (3 Axle Truck) - 20 (twenty)

 Car Parking : 4 (four) cars
 Two Wheelers : 24 (twenty four)
Lorry Weighbridge  Pit less Type steel Weighbridge – 60 MT (16 x 9 mtrs) – 2 Nos
Laboratory for quality  Integrated Quality Testing Lab : Area 40 SQM Approx
testing  Lab Equipment / Testing facilities to test at least 40 samples per hour as
per Quality parameters defined by FCI
 Pneumatic truck probe sampling system
 WBLPL has planned to connect the road from the national
Road highways through a paved road with a width of not less than 7
connectivity meters
 Administration office with meeting Room & Rest House : 180 sqm Approx
Administration office
 Integrated facility for Drivers and Working staff : 75 SQM Approx

Drivers’ Rest Room
& Cafeteria
 Engineering workshop : 40 SQM Approx
WORKSHOP
 Engineering spare Store : 15 SQM Approx
Rev. No. 0
Date 10/08/2023
 Fumigation Material Store : 15 SQM

Fumigation Material
Store
1.1.4 Utilities i.e. Electrical, Fire hydrant System etc.
Silo Complex
Configuration
 Meter Room : 10 SQM (at Suitable locations)

Electrical Substation
 Compact Substation of required capacity – Open to sky *
 Main DG Set : > 250 KVA DG Set (as Power Back-up)*
 Stand-by DG Set : > 63 KVA DG Set (as stand by Power Back up)*
 UPS (for Critical Power) : 10 KVA *
Fire Hydrant  10000 Ltrs UGT for Fire Hydrant System
System  Fire Hydrant System including suitably designed Main fire Pump and
Jockey Pump with Fire hydrant line and hose pipes
 Diesel Engine Powered Fire Hydrant Pumps
Rain Water  Suitably designed rain water harvesting system with ground water recharge
Harvesting system bores
 WBLPL has planned to connect the road from the national

Road highways through a paved road with a width of not less than 7
connectivity meters
 Administration office with meeting Room & Rest House : 180 sqm
Administration office
 Integrated facility for Drivers and Working staff : 75 SQM

Drivers’ Rest Room
& Cafeteria
Rev. No. 0
Date 10/08/2023
1.2 DESIGN METHODOLOGY, CODES & REFERENCE
1.2.1 Design Methodology & sequence :
• Land Demarcation
• Contour Surveying & area surveying
• Silo Complex facility Layout incorporating all facilities
• Finalization of process Flow
• Finalization of Elevation of Silos and Material Handling systems
and facilities
• Silo Finished Level to kept at Min + 1000 mm
above High flood Level(HFL) RECORDED
• Roads Level within the complex + 300 mm
HFL
• Truck Unloading hopper Top Level + 600 mm
HFL
• Process Tower and Other Elevator Pits Wall +
600 mm HFL
• Finalization of Silo and Material Handling system reaction loads
• Civil Structure Design of Silos, Material Handling system and
Process Tower
• Finalization of Roads & Railway Siding design and per relevant
Codes and practices
• Finalization of Electrical Load Data Sheets
• Designing of Electrical Substation and Power Backup System
• Structure Designing and material selection for all ancillary
buildings
1.2.2 Major Design Codes and Standards to be followed :
• Civil and Structure Design
Code/StandardTitle
IS:456-2000 Code of Practice for Plain and Reinforced Concrete

IS 1904 -1986 Code of practice for design & construction of foundations
in soil general requirements
IS 2950, Part 1 -1981 Code of practice for design & construction of raft
Foundations, Part I - Design
IS : 269-2015 Ordinary Portland cement, 33 Grade -
Specification IS: 455-1989 Portland slag cement - specification
IS: 1489 (Part I)-1991 Portland Pozzolana cement - specification (Fly ash based)
IS: 1786-2008 Specification for high strength deformed steel bars and
wires for concrete reinforcement
IS: 383-2016 Specification for coarse and fine aggregates from natural
sources for concrete
IS: 9103-1999 Concrete admixtures – Specification
IS: 1905-1987 Code of Practice for Structural use of unreinforced Masonry
Rev. No. 0
Date 10/08/2023
IS: 11089-1984 Code of Practice for Design & Construction of Ring Foundation
• Material Specifications
Materials Unit Weight (kN/m3)
Steel 78.50
Plain Cement Concrete (PCC) 24.00
Reinforced Cement Concrete (RCC) 25.00
Soil 18.00
Water 10.00
• Electrical System
Code/StandardTitle
 National Building Code of India – 2016

 Energy Conservation Building Codes
 Relevant codes of National fire Codes
 Relevant codes of Bureau of Indian Standards
 Institute of Electrical & Electronic Engineers
 NEC – NFPA 70, National Electric Code
 NFPA 101, Life safety code
 NEC, National Electric Code of India.
• Fire Hydrant System
Code/StandardTitle
 National Building Code - 2016: Part IV, Fire and Life Safety.
 BIS and IS Codes; IS: 3044, IS: 5290, IS: 5312, IS: 908, IS: 2190, IS: 3844 etc.
 Local Bye – Laws and Guidelines of Local Fire Authority.
 NFPA & TAC Manual (for reference and guideline).
 Consultation with local (CFO) Chief Fire Officer.
Rev. No. 0
Date 10/08/2023
• General System Design
Code/StandardTitle
The silo complex will be designed in accordance with the prevailing standards as applicable to the job.
 FCI (Food Corporation of India) Norms defined n Concessionaire agreement
 Indian Electricity Rules
 State Electricity Board (SEB) regulations West Bengal
 Chief Electrical Inspectorate requirements of State of West Bengal
 Indian Factory Act
 Indian Weights & Measures Act
 Any other applicable Indian Act
Rev. No. 0
Date 10/08/2023
1.3 List of Drawing to be submitted
1.3.1 Silo Complex : Grain Handling and Storage system
• Design basis for all Silo Complex system

• Process Flow Diagram
• Silo Complex layout
• Silo Complex Equipment and system Elevation Drawing
• GA Drawings Silos
• Silo Base GA Drawing
• GA Drawings Conveyors and Elevators
• GA Drawings Truck Unloading Hoppers
• GA Drawings Cleaning system
• GA Drawings Dust Suppressions and Collection system
• GA Drawings Aeration system
1.3.2 Silo Civil Structure Drawings – Architectural, Structure and GA Drawings
• Structure Design basis report

• Time & Security office
• Pile drawing
• Metering & PCC room
• Electrical Panel room
• Weighing office
• Warehouse
• Road - Internal
• Approach Road
• Main Silos
• Bagging Silo
• Water tank & Pump room including Shed
• Truck Intake Pit
• Process Tower with connecting tunnel
• Bulk loading Silo with ramp
• Receiving Silo
• Elevator Pit
• Dust collector support structure
• Impurity Bin Plinth
• Wagon Unloading Pit
• Rest room/ Toilet Block
• Septic tank & Soak Pit
• Catwalk support structure foundation
• Aeration fan foundation
• Weigh Bridge foundation
• Transformer Plinth
• DG Plinth
• Street light foundation
• High mast light foundation
• Truck & 2/4 wheeler Parking
• Cable Chambers
• Rain water harvesting Pit
• Admin Building
• Warehouse Structural
• Truck intake pit shed
• Main entry & Exit gate
Rev. No. 0
Date 10/08/2023
• Watch Tower
1.3.3 Electrical system & Automation / Control System
• Design Basis report including Electrical Load Data

• Single Line Diagram
• Compact Substation sizing (CSS)
• DG Set Sizing
• Ups Sizing
• Cable Tray - Route layout
• Temperature Monitoring, Automation and Grain Management
Software Architecture
1.3.4 Fire Hydrant System
• Fire Hydrant Line with complete mountings, Pipes and Fittings

• Pump Room Drawings – Mechanical
1.3.5 Drains and Rain Water Harvesting system
• Design basis for Rain Water Harvesting system

• Slope Calculations and sizing of Storm Water Drains
1.3.6 Key Plans
• Complete Silo Complex with levels / elevation

• Connectivity – Road and Railway
• Land Utilization
Rev. No. 0
Date 10/08/2023
1.4 Engineering Timelines with execution schedule

DEVELOPMENT OF BULK FOOD GRAINS STORAGE SILO PROJECT , MALDA - 50000 MT -OPTION 2
MILESTONE SCHEDULE
2023
Activity - WBS JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC
1FN 2 FN 1FN 2 FN 1FN 2 FN 1FN 2 FN 1FN 2 FN 1FN 2 FN 1FN 2 FN 1FN 2 FN 1FN 2 FN 1FN 2 FN 1FN 2 FN 1FN 2 FN
PACKAGE I (Silo Construction)
Land Demarcation and surveying - COMPLETED

Geotechnical & Countour Surveying
Civil Design ALL SILOS COMPLETED
Piling Column-Storage Silo SILO 1 SILO 1

SILO 2 SILO 1
SILO 3 SILO 1
SILO 4 SILO 1
SILO 4 K SILO 4 K
PT PT
RECEIVING RCV
BOS BOS
Foundation-Storage Silo SILO 1 SILO 1

SILO 2 SILO 2
SILO 3 SILO 3
SILO 4 SILO 4
SILO 4 K SILO 4K
PT PT
RECEIVING RCV
BOS BOS
Procurement - SILO & CLEANING ALL SILOS ALL SILOS

PT PT
RECEIVING RCV
BOS
Installation, Testing SILO 1 SILO 1

SILO 2 SILO 1
SILO 3 SILO 1
SILO 4 SILO 1
SILO 4 K SILO 4K
PT PT
RECEIVING RCV
BOS BOS
PACKAGE II A (Conveyor and Material Handling)
Engineering COMPLEX
Piling-Receiving Tunnel, Rail Unloading Pit COMPLEX
Foundation and Civil Works COMPLEX
Procurement COMPLEX
Erection COMPLEX
PACKAGE II B (Equipments)
Design (Functional specifications) COMPLEX
Foundation COMPLEX
Procurement COMPLEX
Erection COMPLEX
PACKAGE III (Railway siding)
Civil Design COMPLEX
Procurement COMPLEX
Construction COMPLEX
Install, testing COMPLEX
PACKAGE IV (Roads and Parking)
PACKAGE V (Buildings and Boundary Wall
Construction (Major Building) COMPLEX
PACKAGE VI (Electrical substation)
Engineering COMPLEX
Procurement COMPLEX
Receipt and Install, testing COMPLEX
INTERFACE COMMISSIONING
Precommissioning of Silo, MHS COMPLEX

and SCADA & BMS System
INSTALLTION AND Commissioning
Commissioning trials with wheat shipment
Arrangement of trial shipment COMPLEX
Commissioning, FCI inspection COMPLEX
Commencent of operation COMPLEX

Engineering Plan - Malda

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Engineering Plan - Malda

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Rev. No.

Engineering and Design plan

For all heads of

Grain Storage Silo Complex of 50000 MT

1.0.1 Layout Of Silo Complex

1.1 System And Facilities Proposed At The Silo Complex

1.1.1 Grain Storage And Handling System

1.1.2 Railway Siding And Wagon Unloading System

1.1.3 Administration And Other Ancillary Buildings / Facilities

1.1.4 Utilities I.E. Electrical, Fire Hydrant System Etc.

1.2 Design Methodology, Codes And References

1.2.1 Design Methodology & Sequence :

1.2.2 Codes & Standards

1.3 List Of Drawings and Design To Be Submitted

1.3.1 Silos Complex – Grain Storage And Handling System

1.3.2 Civil Structure Drawings

1.3.3 Electrical System & Automation / Control System

1.3.4 Fire Hydrant System

1.3.5 Drains And Rain Water Harvesting System

1.3.6 Key Plans

1.4 Engineering Time Lines Including Execution Plan

Layout of Silo Complex 50000 MT Capacity (Long Term Storage Silos)

Fig. 1 Layout of Silo Complex

1.1 SYSTEM AND FACILITIES PROPOSED AT THE SILO COMPLEX

1.1.1 Grain Storage and Handling system :

 Each of the Long Term Storage Silo shall be fitted with

 The intake capacity of the conveying system : 150 TPH

 The discharge / reclaim of the long term storage silos including

Bulk Truck Loading  50 MT Hopper Bottom Silo : 1 Nos

Bagging system  Semiautomatic weigher and bagger mechanism – 30 TPH : 2 Nos

Bulk Rake Unloading  Dump pit 50 MT : 2 Nos

 Temperature monitoring system : Min 13 Temperature Cables

1.1.2 RAILWAY Siding and Wagon Loading system :

(1) Apply for Approval in Principle (AIP)

Following facilities to be created on the railway siding:

Railway Siding  Railway siding confirming requirements by Indian Railways as per

1.1.3 Administration and other ancillary Buildings / facilities

Parking Lots  Lorry / Truck Parking (3 Axle Truck) - 20 (twenty)

 Integrated facility for Drivers and Working staff : 75 SQM Approx

 Fumigation Material Store : 15 SQM

1.1.4 Utilities i.e. Electrical, Fire hydrant System etc.

 Meter Room : 10 SQM (at Suitable locations)

 WBLPL has planned to connect the road from the national

 Integrated facility for Drivers and Working staff : 75 SQM

1.2 DESIGN METHODOLOGY, CODES & REFERENCE

1.2.1 Design Methodology & sequence :

1.2.2 Major Design Codes and Standards to be followed :

• Civil and Structure Design

IS:456-2000 Code of Practice for Plain and Reinforced Concrete

Materials Unit Weight (kN/m3)

Plain Cement Concrete (PCC) 24.00

Reinforced Cement Concrete (RCC) 25.00

 National Building Code of India – 2016

• Fire Hydrant System

• General System Design

1.3 List of Drawing to be submitted

1.3.1 Silo Complex : Grain Handling and Storage system

• Design basis for all Silo Complex system

1.3.2 Silo Civil Structure Drawings – Architectural, Structure and GA Drawings

• Structure Design basis report

1.3.3 Electrical system & Automation / Control System

• Design Basis report including Electrical Load Data

1.3.4 Fire Hydrant System