TA-143-D00-G-TD006_0_Annex I, Specificarion and Data Sheets.pdf

National Iranian Steel Co.

Baft Steel Complex

DDRR aanndd MMaatteerriiaall HHaannddlliinngg PPllaanntt

PPrroojjeecctt

“Annex I to Employer’s Requirements”

Specification and Data Sheets

Table of Contents Doc No.: TA-143-D00-G-TD006 16-Sep-07 Rev 0

TARA TARH Engineering & Technological Co.

DR & Material Handling Plant Project

Plant Specification and Data Sheets Baft Steel Complex Page 1 of 1

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Table of Contents

Contents Page

1- General 1

1.1- Safety 2

1.2- Standardization of Equipment 2

1.3- Quality Control, Inspection and Testing 2

1.4- Training 6

1.5- Recommended Spares 7

1.6- Special Tools 8

1.7- Manning 8

1.8- Weights of Plant, Equipment and Materials 8

1.9- Manufacturers 9

1.10- Supervision of Erection 10

1.11- Time Schedule 11

2- Direct Reduction Plant Specification 14

3- Raw Material Handling Plant Specification 40

4- Process and Process Equipment Data Sheets 47

5- Material Handling System Data Sheets 71

6- Fluid System Data Sheets 83

7- Electrical Equipment Data Sheets 105

8- Instrumentation and Control Data Sheets 123

Section 1 Doc No.: TA-143-D00-G-TD006 16-Sep-07 Rev 0




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1- GENERAL

The Employer intends to construct a direct reduction and a material handling plant in Baft

steel company located near Baft city, in Kerman province.

For this propose, implementation of a direct reduction module with nominal capacity of

800,000 TPY-DRI (+5 mm) and raw material handling plant with nominal capacity of

2,500,000 tonne pellet and lump ore per year shall be in the scope of obligations of the

Contractor for the present Project.

The direct reduction plant and raw material handling plant shall be complete in all respects

and any devices which is not included in the specification but is necessary for proper

operation of equipment and process, shall be considered as included within the specification

whether specifically mentioned in this “Specification and Data sheets” or not.





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1.1- SAFETY

The Contractor shall ensure that the supplied Plant and Material, equipment, machinery

and apparatus are designed in conformity with all those codes and regulations in normal

usage for the type of equipment and machinery being offered.

The Contractor shall list the steps and special design features included in the design of

the Plant, equipment, machinery and apparatus to ensure that all the safety requirements

has been taken into account.

1.2- STANDARDIZATION OF EQUIPMENT

To reduce the quantity of spares that must be held and to simplify maintenance, the

Contractor shall wherever possible use similar components and sub- assemblies throughout

the Plant supplied under this Contract.

1.3- QUALITY CONTROL, INSPECTION AND TESTING

The Contractor required supplying information to enable the Employer to make assessment

of quality control, inspection and testing policies of the Contractor. Also certain minimum

requirements in this respect have been laid down here.

1.3.1- Tender Information

The Contractor shall submit with his tender a description of the quality control, inspection

and testing procedure currently in use in the Contractor's manufacturing works and those

of his principal Sub- Contractors. This description shall include non-destructive testing

(NDT) facilities, material testing, control of critical welding operations, material

classifications and identification and all test facilities. The Contractor shall submit with

his tender a description of the quality assurance procedure which he intends to adopt for

the Contract Works.





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1.3.2- Draft Quality Control Procedure

Within one month of the effectiveness of Contract, the Contractor shall submit to the

Employer’s Representative for approval a draft procedure of quality control, inspection

and testing activities which he proposes to perform, together with a program indicating

when these activities are to be carried out. The program of inspection and testing shall be

related to the preliminary program of plant design, manufacture, erection and start-up.

Individual quality assurance procedures shall be proposed for any specialized item of

Plant but standardized procedures may be proposed for common items such as castings,

forging, fabrications, structural steel, fans, pumps, pipe work, valves, tanks, drive units,

ducting, compressors, couplings, bearings, motors, conveyors, switchgear, control gear,

batteries, transformers and instruments. The Employer’s Representative will have the

right to modify or complete the draft quality control procedure whenever the

modifications are supported by the Employer specifications except welding which shall be

according to applicable international standards i.e. UNI, DIN, B.S and applicable

American standards.

1.3.3- Detailed Quality Control Procedure

Within three months of effectiveness of Contract and following approval of the draft

procedure by the Employer’s Representative , the Contractor shall submit to the

Employer’s Representative four copies of the agreed detailed quality assurance

procedure and a detailed program of the inspections and testing to be carried out. This

program shall conform to general Time Schedule of the Contract. In order to achieve a

uniformity of quality assurance procedures, inspection and testing throughout all aspects

of the Contract Works from design to commissioning, the procedure shall be issued by

the Contractor to all members of his quality assurance organization, to all Sub-

Contractors and to all supervising engineers. The document shall also be issued by the

Contractor to the Employer or Employer’s Representatives carrying out inspection

surveillance. The procedure shall not be altered without prior agreement by the

Employer’s Representative but the Contractor shall maintain a complete list of





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recipients of all issues of the procedure, in order to ensure correct updating by

revisions, which may be so approved.

1.3.4- Reports

The Contractor shall provide reports of all visits made by his quality assurance personnel

and any other inspecting engineers appointed and acting on his behalf. The Contractor

shall fully document all quality assurance checks, inspections and tests carried out in his

own works and those of all Sub-Contractors. Four copies of all such reports and

certificates shall be forwarded to the Employer’s Representative within one week of

testing. Inspections or tests resulting in the discovery of defects, damage or rejections

shall be labeled prominently with a capital 'D' in the top right-hand corner of the first page.

Any discovered damage, defects or rejections which in the Contractor’s view may prevent

satisfactory completion of the Contract Works, or cause delays to program shall be

advised to the Employer by telex or facsimile and be confirmed by written report within

one week. The Contractor shall submit to the Employer, at intervals of not more than four

weeks, a summary of all quality control, inspection and testing activities which have taken

place in the previous four weeks.

1.3.5- Tests at Manufacturers' Works

1.3.5.1- Materials

Materials test and analysis certificates shall be supplied as required by the Employer’s

Representative.

1.3.5.2- Inspection and Witnessed tests

The following shall be witnessed or inspected by the Contractor and as required by the

Employer or the Employer’s Representative:

(a) Check material tests and chemical analysis of each cast or batch of material.

(b) All dimensions.





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(c) Protective coating when applicable

(d) Joint edge preparation

(e) Weld tests as selected by the Employer’s Representative with magnetic crack or

dye penetrate tests of up to 100% of attachment fillet welds

(f) Plant and equipment performance tests

(g) Transformer, switchgear and electrical equipment tests

(h) Protection for transport and storage.

1.3.5.3. Mechanical Tests & Chemical Analysis

Test pieces shall be branded in the presence of the Contractor and the Employer’s

Representative and for important forgings and castings the position of the pieces

shall be to approval of the Employer’s Representative . Where heat treatment of the

casting or forging is necessary the test piece shall not be removed before the treatment is

carried out.

1.3.5.4. Castings and Forgings

The type and extent of non-destructive examination of castings and forgings at relevant

stages of manufacture will be suggested by the Contractor and approved by the

Employer’s Representative taking into account the service for which the component is

intended.

1.3.5.5. Welding

Welding procedures and tests shall conform to the appropriate A.W.S. Standard. Where

specified welds shall be subjected to an approved crack detection test, for example

dye penetrate or magnetic particle test , the Employer’s Representative may ask for

additional tests at its discretion.





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1.3.6. Plant and Equipment

Items of Plant and equipment having a definite performance specified either in the

relevant Standard or in the Specifications shall be tested for such performance in the

presence of the Contractor and the Employer’s Representative. Pressure tests shall be

carried out on all pressure-containing components. Where practicable items of associated

equipment which together comprise a complete assembly shall be assembled at the

manufacturer's works and tested to prove the combined performance. Test certificates

shall be supplied for all such tests.

1.3.7. Electrical Plant and Equipment

All electric power, control, supervisory, alarm and communication equipment such

as transformers, switchgear, control gear, motors, batteries, rectifiers, thyristors, electronic

apparatus, telephones and radio equipment (if any), cables and associated materials shall

be tested in accordance with the Employer Specifications particularly in relation to

correct operational functioning, safety and clearances. Type, routine, insulation,

temperature rise and performance tests shall be fully documented and four copies of all

test records and certificates submitted to the Employer’s Representative within one week

of test. Where thyristor control systems (if any) are used the performance tests of the

complete system up to and including the motors shall be witnessed by the Contractor

and the Employer and /or the Employer’s Representative.

1.3.8. Utilities

All Plant, equipment and pipe work shall be tested in accordance with appropriate

ANSI standards, which will be proposed by the Employer’s Representative .

1.4. TRAINING

In order to enable the Employer to properly operate and maintain the Plant, it is necessary to

train the Employer personnel. Training package shall include training of personnel for





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proper operation and maintenance of equipment .In addition in order to specialize and

familiarize the Employer personnel with the supplied equipment and machinery, the

Contractor shall ensure for the Employer 's personnel a suitable period of staying at his

and/or Sub- Contractor's design and fabrication installations during the relevant stages

of progress of work, in order that they may be made fully aware of design and

construction details to ensure an effective maintenance and operation of the Plant.

Tenderers are required to provide with their offer the proposed training program showing

the extent and periods of training to be provided, places where training will be carried out,

the number, grades of personnel, expected previous experience and educational standard

of the personnel to be trained, etc. Language of training shall be English.

1.5. RECOMMENDED SPARES

The Contractor shall submit with his tender the recommended list for all spare parts relevant

to equipment of the Plant. The spare parts shall be subdivided by the tenderer into the

following categories:

1.5.1. Commissioning Spares

The commissioning spares shall include the spares that according to the experience and

judgment of the tenderer must be available at the Site before commencement of the

commissioning period. These spares will be available for use by the Contractor during this

period, but the Contractor shall replace them at the earliest opportunity at his own expense.

1.5.2. Capital Spares

The capital spares shall include the spares that the tenderer recommends to be kept in

stock at all times because, in the event of the breakage or failure of such item, the time of

repair or replacement would incur serious deterioration of performance.





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1.5.3. Operating Spares

The operating spares shall include the spares that the tenderer recommends to be kept in

stock to permit systematic replacement in order to maintain the plant in good operating

condition for a period of two years, in normal operation. These spares will not be available

for use by the Contractor during commissioning period. After completion of detailed

design, the Contractor shall furnish to the Employer complete fabrication drawings and

specification for spare parts to enable the Employer to manufacture or procure all the spare

parts from all possible suppliers. The Contractor shall also give the name of the supplier’s

of each and every spare part and shall indicate clearly the single-supplier items (if any).

1.6. SPECIAL TOOLS

The tenderer shall submit with his tender the recommended list for special tools required

for erection, maintenance and operation of the supplied equipment. These tools shall be

provided by the Contractor and will be available for use by the Contractor during erection

and commissioning periods.

1.7. MANNING

The tenderer shall submit with his tender the recommended manning requirements for

staffing all shifts of the Plant. This manning requirement should be given under different

categories such as, maintenance, operation, management, etc. The tenderer shall also specify

the required qualifications, of the personnel and their brief job description.

1.8. WEIGHTS OF PLANT, EQUIPMENT AND MATERIALS

The Contractor shall insert in the table below or any extension required to it a breakdown

of the total weight of the Plant, to be supplied. The breakdown shall conform in general to

the sub-divisions in the Schedule of Prices. Items of plant and equipment such as

miscellaneous motors, pumps, instrumentation and cabling for which it is not practical

to give itemized weights, shall be listed in the table and the overall weight inserted in





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order to arrive at the total weight of the Plant.

Reference

NumberDescription Weight

1.9. MANUFACTURERS

The Contractor shall insert in the table below and required extensions to it, the names of

the manufacturers of the principal items of equipment which shall include the name of

associated companies and divisions within the Contractor's organization. The table shall

also include the location where the items will be manufactured and tested.





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ItemName of Supplier, Sub-Supplier

or Associated Firm

Place of Manufacture

and Testing

1.10. SUPERVISION OF ERECTION

The Contractor for fulfilling properly it’s erection obligation shall provide a sufficient

number of competent engineers thoroughly experienced in the erection, operation and

maintenance of apparatus similar to that which will be utilized in this Contract who will

supervise the, erection, carry out Site quality assurance, report on erection progress and

make the tests on completion of erection of the Plant and the subsequent commissioning

and setting to work. The Contractor shall prepare erection instruction manuals giving

detailed instructions for the handling, erection, alignment, tolerances and the subsequent

commissioning and setting to work of all items of the Plant. An adequate number of copies

of these instruction manuals shall be made available to the Contractor's erection supervisors

and six copies shall be supplied to the Employer’s Representative . All levelling, aligning

and bedding onto concrete and walls before grouting shall be carefully checked by

Contractor’s supervisors.





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1.11- TIME SCHEDULE

1.11.1. Introduction

Contractor shall submit with his tender a program which adequately describes the Contract

Works. As a minimum this program shall comprise the complete time schedule together

with a bar chart, or a network drawn to time scale, which shall show the periods proposed

for basic design, detailed design, material procurement, main stages of manufacture,

assembly and tests in the manufacturer's works, packing and delivery, civil construction

works, erection, testing and commissioning of major items of the Plant, both for Local

Supply and Foreign Supply.

In preparation of time schedule Contractor shall take into account the following:

From Contract Coming into Force up to issuance of take over certificate shall not be more

than 30 months.

1.11.2. Preliminary Program

Within four weeks of Coming into Force of the Contract, the Contractor shall provide the

Employer’s Representative with two CDs and three copies of the following items in draft

proposal form:

- an equipment list

- a program of drawing and data submission which shall conform to the requirements of

relevant specifications and Contract Documents

- a program of supply and erection

- a program of civil construction works

- a program of inspection and testing

- a progress report

The information supplied shall be sufficiently detailed to enable the Employer’s

Representative to ascertain the Contractor's compliance with the dates given in tender

program.





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It will be used to form a basis for production by the Contractor of an agreed detailed

program for the Contract Works. It will be used to relate the Contract Works to program

of work of others involved in the Contract and the timing of any inspection, progress

control, verification and expediting functions to be carried out by the Employer and/ or the

Employer’s Representative.

1.11.3. Detailed Contract Program

Within eight weeks of Coming into Force of the Contract following discussion and

approval by the Employer’s Representative of preliminary program information, the

Contractor shall provide the Employer’s Representative with two CDs and three copies of

the following items in agreed final form:

- master plant list

- sub-order schedule

- detailed program of supply and erection

-detailed program of drawing and data submission which shall conform to the

requirements of relevant specifications and Contract Documents.

- detailed civil construction program.

- program of inspection and testing

- progress report

Subsequently this information, suitably updated, extended and revised as agreed by the

Employer’s Representative will be provided by the Contractor at regular two-months

intervals throughout the period of the Contract Works.

1.11.4. Shipping Information

Ninety days before dispatch of the first consignment to Site, the Contractor shall provide

a schedule of shipments setting out details of all consignments, weights and sizes,

packaging, markings, number and identification, port of delivery. This information,





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suitably updated, extended and revised as agreed by the Employer , will be provided by

the Contractor at intervals of not more than four weeks, from the initial issue until

completion of D.D.U Site delivery of all Foreign Supply and D.D.P Site delivery of all

Local Supply items included in the Contract Works.





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2- DIRECT REDUCTION PLANT SPECIFICATION

2.1- GENERAL DESCRIPTION

In this section a preliminary description of the direct reduction plant will be brought

forward, the plant set-up objective, main, auxiliary, and support systems and their

functions.

The module objective is to produce metallic iron (direct reduced iron, DRI) from iron oxide

material through a gas-based direct reduction process, and then delivering the DRI as feed

material to the steel making plant. The process of iron oxide reduction will be done by

means of reducing gas (CO&H2), which is produced by the so-called reforming of natural

gas (NG, mainly CH4), either by a mixture of carbon dioxide (CO2), and water vapor

(H2O) in a reformer.

The DR. module will be set up with the following general specifications:

- One module with nominal capacity 800,000 TPY-DRI (+5 mm). Pellet coating system is

in the scope of Work in this Project but this module shall be capable to produce the

nominal capacity of 800,000 TPY-DRI (+5 mm) without using coated oxide pellet

- Operating time of the module shall be 8000 hours per year, with 100 t/hr production rate.

As a whole, the DR. module will include but not limited to the following main parts:

1- Oxide material handling system: for transferring iron oxide material in the form of

oxide pellets to the shaft furnaces as specified in Sub Clause 2.3 of this “Specification

and Data sheets”.

2- Product material handling system: for transferring the DRI from the shaft furnace to the

storage bins as specified in Sub Clause 2.4 of this “Specification and Data sheets”.

3- Main part of direct reduction module: in which the direct reduction process will be

performed. In connection with DR module, the units and systems which are

incorporated in which the direct reduction process takes place, may be classified as

follows:





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- Shaft Furnace: where iron oxide is reduced to metallic iron by high temperature

reducing gas.

- Reformer: where the reducing gas is produced.

- Recuperator: a heat recovery unit where the hot exiting flue gas is utilized for

preheating various gas flows including process gas, natural gas, and combustion air.

- Process Gas System: for transferring the gas flow containing oxidized gas

(CO2&H2O) and natural gas for reforming and recycling back to the reduction shaft

furnace.

- Cooling Gas System: for providing the cooled gas required for cooling zone of the

shaft furnace.

- Combustion/dilution Air System: where the combustion and dilution air required in

the reformer is provided by a series of air blowers.

- Flue Gas System: where the combustion exit gases from the reformer, after being heat

recovered and cleaned, is ejected to the atmosphere through the ejector stack.

4- Civil, Building and Infrastructure: including all buildings with their related

infrastructures and HVAC (Heating, Ventilation and Air-Conditioning) systems.

In addition to the main systems as mentioned above, the following auxiliary systems is

considered in connection with the DR plant.

- Seal gas generation and distribution system.

- Utility and water treatment system including cooling water in top gas scrubber and

cooling gas scrubber, clarification and recycling.

- Dust collection systems.

- Compressed air generation (including both plant air and instrument air) and

distribution system.

- Sewage collection and treatment system.

- Fire detection and fighting system.

- Electrical system (including telecommunication system)





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- Instrumentation and control system.

- Repair shop

- Laboratory

- Warehouse

- Offices

- Lockers and showers to serve DR and material handling plants.

Cold Briquetting Plant

Due to DRI fine production in DR plant and for making it useable in the arc furnace a cold

briquetting plant shall also be in the Contractor scope of Works.

The capacity of this plant shall be 33,000 tonnes/year and 12 t/h . A screening station shall

be installed after DRI silos and DRI fines shall be handled to briquetting plant by a belt conveyor

by Contractor and necessary bins for fines and binders (such as molasses, hydrated lime, etc.)

storage is in the Contractor's scope of Work in this Project.

The briquettes will be handled to melt shop by truck but necessary stock pile for briquettes

storage is in the Contractor's scope of Work.

Fine particle size will be 0-8 mm and briquette dimensions shall be approximately

44mm

x38mm

x20mm

.

2.2- DIRECT REDUCTION PROCESS DESCRIPTION

Direct reduction process converts iron oxide, in the form of oxide pellets, to highly reduced

product in order to be used in steel making. To accomplish this, the reduction process

utilizes a continuous flow of reducing gas to remove the oxygen from the iron oxide and to

carburize the reduced product.

The reduction process is carried out below the fusion temperature of the feed material. The

reducing gas, a mixture of H2 & CO is produced in the reformer and introduced into the

reduction furnace at controlled temperature and composition. This gas flows up the





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furnace, heating the descending iron oxide to the reduction temperature. Hydrogen and

carbon monoxide remove the oxygen from the feed, yielding a highly reduced product.

The most significant features of the process are:

1- A steady- state process and uninterrupted flow of reducing gas for the removal of

oxygen from the feed and for carburizing the reduced iron.

2- A gas reforming system, which either uses CO2 and water vapor contained in top gas

and natural gas to produce CO & H2 rich reducing gas without formation of soot.

3- Maximum gas utilization by recycling the top gas from the shaft furnace to the process.

The principal components of plant are the gas reformer for the production of the reducing

gas, and the shaft furnace in which the reduction process takes place. In addition, there are

transportation systems for oxide feed material, and metallized product automatically

controlled from control room and water, gas and other utilities circulation systems.

The shaft furnace is divided into two zones with separate gas systems. The upper zone for

reduction and the lower zone for cooling. The iron oxide material descends from the

reduction furnace charge hopper by gravity through a dynamic gas seal system into

distribution pipes which feed the material into the reduction furnace, thereby maintaining a

uniform profile of material in the furnace. The feed rate to the charge hopper is controlled

by the discharge rate of the product from the bottom of the furnace.

The distribution feed pipes and the furnace geometry must be specifically designed to

maintain a uniform flow of material downward through the refractory-lined furnace. The

shape of the oxide material is not changed during the reduction, as most oxide materials are

normally free of swelling. The metallized material is highly porous, as oxygen is removed

from the ore, and tends to reoxidate. Therefore, the hot metallized material must be cooled

before exposure to the atmosphere to prevent any reoxidation. Most chemical constituents

of the raw material are not affected by direct reduction and remain in the metallized

material, however the gangue constituents will show a percentage increase due to oxygen





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removal during the reduction process. The final product analysis will therefore depend on

the iron oxide analysis.

The principal part of reforming equipment is the gas reformer which mainly consists of

radiation fire boxes, in which reforming takes place in the reformer tubes.

The gas reformer generates reformed gas. The reformed gas containing hydrogen, carbon

monoxide and some other gases at a controlled temperature and ratio.

The vertical reformer tubes shall be filled of catalysts. These tubes shall be made of high

quality alloy (heat resistant) with spring supports.

The reformer boxes shall be provided gas tight to avoid cold air leakage into the fire boxes.

Two different systems of burners shall be installed in the reformer that are main burners

and auxiliary burners. The task of the auxiliary burners are as follows:

- They are used as pilot burners.

- During start-up, the reformer will be heated up to nearly operating temperature by them.

- The idling condition: these burners keep the reformer at a temperature slightly below

operating temperature. In idling condition, it is necessary to stop gas flow through

reformer tubes and shaft furnace.

In case the tenderer willing to propose an other process (rather than described above) for

DR-module process it should be proposed as an option.

2.3- OXIDE MATERIAL HANDLING SYSTEM

Oxide pellets and lump ore shall be delivered by a belt conveyor to the D.R. module day

bin. A day bin with the capacity of 1800 m3 shall be considered and equipped by two

discharge feeders. Oxide pellets shall be discharged by these feeders to belt conveyors with

the rated capacity of 250 ht and transported to the screening stations for separation of

fines and oversizes. The screened pellets after passing through coating station shall be

transported to D.R. shaft furnance hopper by belt conveyors.

Oxide fine bin elevation shall be suitable for loading the fines to trucks.





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The Contractor shall construct suitable open storage area for stacking the fines.

The oxide materials belt weighers shall be installed on conveyors at proper places.

A complete remet handling system shall be installed for direct reduction plant. For this

propose, a belt conveyor with the capacity of 170 ht shall handle remet to day bin

discharge conveyor.

A remet hopper and relevant feeder shall be installed in suitable place for remet charging.

2.4- PRODUCT MATERIAL HANDLING SYSTEM

The output from direct reduction furnace shall be transported by a conveyor that includes a

weighing system to measure the outgoing rated capacity 170ht . In emergency situations

DRI shall be piled in an emergency pile. After separation of oversize material in grating

feeder, a diverter gate shall transfer the material to a discharge belt conveyor or to remet

belt conveyor. Belt conveyors shall handle DRI to silos.

The silos consist of four bins with the capacity of 2200 m3 each, totally 8800 m

3. These bins

shall be equipped by two discharging feeders with the capacity of 2x200 ht for each bin.

The reduced materials in silos shall be passivated by inert gas for prevention of explosion

and sticking so the silos shall be equipped with inert gas distribution system.

A storage area shall be constructed for passivation of DRI in case of the operators can't send

DRI to silos. The dimensions of this area shall be approximately 30m

x100m

. All the

necessary equipment and facilities for transferring DRI to this storage area and charging

DRI to product material handling system is in the scope of Work. The silos discharge

material shall be handled to the screen station where the fine is separated and stored in the

bin. The fine shall be handled to the cold briquetting plant by conveyors. The fine bin

discharge chute shall be so designed to have the capability to discharge material on belt

conveyor or in truck.





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2.5- DEDUSTING SYSTEM OF MATERIAL HANDLING SYSTEM & GAS CLEANING

The Contractor shall provide dedusting system for material handling system of DR plant to

reduce dust emission to a level acceptable to Iranian Environmental Protection Organization

(IEPO) and reduce fire and explosion hazards.

The dedusting system shall be provided at any point dust may be produced during operation

of plant i.e. silos, day bin, transferring points between belt conveyors and screening station.

Provisions shall be made to collect and remove such dust from the operating area and to

clean them before they are discharged into the atmosphere considering high importance of

safety in DR plant.

Contractor shall clearly describe the steps taken to ensure safety of operation of dust

collection and cleaning systems offered.

In addition, a gas cleaning system shall be provided to clean the emission from fume ejector

stack to the level required by IEPO.

The Contractor shall provide disposal facilities for fines captured by the dedusting & gas

cleaning equipment.

2.6- WATER TREATMENT PLANT AND WATER RECIRCULATION SYSTEM

The direct reduction plant water treatment unit and cooling water system shall include, but

not limited to the following systems.

1- Indirect cooling system serving machinery cooling systems.

2- Direct cooling system mainly serving top gas scrubbers, cooling gas scrubbers,

dedusting system, and etc. (contaminated process water cycle equipped with

contaminated cooling tower)

3- Direct cooling system mainly serving reformed gas cooler, seal gas cooler, plate heat

exchangers of machinery cooling water system and etc. (clean process water cycle

equipped with clean cooling tower)

4- Make up water treatment and softening systems.





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1- Indirect cooling system

Warm water from machine water basin is pumped toward the plate heat exchangers

where warm water is cooled by means of cold water which is prepared in the open loop

cooling system to cool machinery and equipment.

Note: Chlorine content of make up water for machinery process water shall not be higher

than 30 ppm.

2- Direct cooling system (contaminated process water cycle)

Contaminated warm water returning from top gas scrubber and cooling gas scrubber is

routed by gravity toward a clarifier.

Other contaminated warm water such as compressor spray system, drainage from seal

system and slurry from all dedusting systems are collected in the basin and pumped to

the clarifier.

The settled sludge will partially re-circulated while excess sludge will be pumped to the

mud settling pond.

Clarifier overflow is conducted by gravity into hot water basin of contaminated cooling

tower and then pumped to the scrubbers and dedusting systems.

Cold water is collected into cold water basin and pumped to consumers.

Note: Max TSS in clarifier effluent shall be 50 ppm.

3- Direct cooling system (clean process water cycle)

The warm water returning from reformed gas cooler, seal gas cooler and seal gas after

cooler and plate heat exchangers is routed to clean process water cooling tower.

4- Make up water treatment and softening system

Industrial water which is characterized in Employer’s Requirements will be delivered to

the Contractor in battery limits.

Appropriate water shall be produced by water treatment systems from industrial water.

Any water treatment systems supply shall be in the scope of work of the Contractor.





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Water with appropriate specifications will be used as make up water in the open and

close loop cooling water systems.

Industrial water shall be conducted to Industrial water reservoir and then pumped to the

softeners.

2.7. Electrical Distribution System

2.7.1- MV/MV Transformers

Main characteristics:

Transformer shall be three phase, core type design, oil immersed and outdoor type.

o Standard for design, manufacturing

and test IEC 76

o Standard for loading and guaranteed

overload IEC 354

o Rated power to be defined by tenderer

o Ratio 33± 2x2.5% / 6.9kV

o Tap changer type off load

o Impedance Max. 10%

o Vector Group Dyn11

o Cooling system ONAN / ONAF

o Insulation class A

o Protection of 33 and 6.6 kV terminals IP54

o Accessories IEC standard

2.7.2- 6.6kV switchgear


o Type metal clad

o Insulation voltage 7.2 kV

o Duty voltage 6.6 kV

o Short circuit current 31.5 kA – 1sec

o CB’s breaking capacity 31.5 kA





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o Feeder type for > 1MW SF6/Vacuum-Withdrawable CB

o Feeder type for 1MW Vacuum Contactor withdrawable

type equipt with HRC type fuse

o Rated lightning impulse withstand voltage 60 kV

o Power frequency voltage test (60 sec) 20 kV

o Aux. and control rated voltage 110 V DC

o Degree of protection IP 42

o Complete with digital Multifunction

devices yes (protection, measuring, monitoring)

o Protection function 86, 50, 51, 51N, 27 & others

o Measuring function V, I, F, P, Q, Ph, Qh, PF

2.7.3- MV/LV Transformers (6.6/0.42 kV Transformer)


o Ratio 6.6/0.40kV

o Manual off load tap changer ±2 x 2.5%

o Impedance about 6%

o Vector group Dyn11

o Secondary winding neutral Solidly grounded

o Placing Out door


o Rating By Tenderer

2.7.4- 400 V Power Center Board

The low voltage distribution switchboard , power center type will be foreseen with metal clad

design, single busbar system, with short circuit and over current trips, complete and fully wired

up to the terminals and with the following operating characteristics :

o Rated voltage 400 V

o Insulating voltage 1000 V

o Short circuit current 50 kA, 1sec





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o Main bus bar rated current By Tenderer

o CB’s breaking capacity 50 kA

o Installation Indoor

o Protection degree IP42

2.7.5- Low Voltage Motor Control Center (M.C.C.’s)

Refer to Annex III item 3.5.

2.7.6- LV/LV Transformers (Lighting Transformer 400/400-230 V)


o Insulating liquid Dry type

o Rating To be defined by tenderer

o Primary voltage 400 V

o Rated secondary voltage 400 V – 230 V

o Impedance about 4%

o Vector group Dyn11

o Secondary winding neutral Solidly grounded

o Manual off load tap changer on Primary

side ± 2 x 2.5%

o Placing Indoor


2.7.7- 400 Volt Induction Motors


2.7.8- 6 kV Induction Motors


2.7.9- Neutral grounding resistors (6.6 kV)

For the control of over voltages and earth fault protection of the 6.6kV system, the star point of

secondary side of the 33 / 6.9 kV transformers is grounded via neutral grounding resistor.





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o Rated voltage 6.6/ 3 kV

o Rated current / time By tenderer

o Material stainless steel AISI 304

o Degree of protection IP54

o External surface temperature rise after a

fault to ground 30 °C

General features:

The panel will be divided in a resistor part and a switchboard part.

The switchboard parts consist of:

o A single pole disconnector

o A current transformer, 5P5

2.7.10- 6.6 kV cables and terminals


o Cables

Conductor Copper

Insulation type XLPE

Jacket type PVC

Shield Yes

No cracking, UV resistant, No carbon

black, red colored Outer sleeves yes

o Terminals

Type Heat shrinkable

Insulation voltage >7.2 kV

2.7.11- Low voltage and auxiliary cables







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o Conductor copper

o Insulation type XLPE / PVC

o Jacket type PVC

2.7.12- Stand by Diesel Generators


o Generators

Rated voltage 400V

Power factor 0.8

Rated voltage 400V

Standard IEC 34-1

Excitation Brushless

Enclosure IP23

Cooling Self ventilated

Speed 750~1500 rpm

Over speed 1.25 rated speed

Winding Star

Heater For winding & Bearing

Insulation class F

Temperature class B

Auto start/stop Yes

o Diesels:

Number of strokes 4

Starter DC motor





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2.7.13- UPS


o Input voltage 400/230 V ± 10%

o Input frequency 50 Hz ± 5%

o Out put voltage 400/230 V ± 2%

o Out put frequency 50 Hz ± 0.5%

o Harmonic content of output 3%

o Efficiency> 90%

o StandardIEC

o With by pass transformer Yes


o Batteries Ni/Cd, sealed type

o Battery duration 30 minutes

2.7.14- 6.6 kV Bus Ducts


o Type Air insulation type

o Conductor material copper

o Enclosure material Steel

o Insulators porcelain brown glazed

o Short circuit 31.5 kA, 1sec

o Degree of protection IP 54

o Rated voltage 7.2 kV

o Peak dynamic current 80 kA

o Ventilation Natural

o Anti vibration facilities Yes





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2.7.15- Telecom


o Back up battery for central unit of

Intercom. System 2 hours duration

o Min. protection degree for peripheral units IP50/IP54

o Paging system shall be included Yes

o Type of mounting Desk/wall mounted

o Load speaker type for paging High watt/volume control

2.7.16-PFC


o Rated voltage 6.6 KV, 400V, 3Ph, 50Hz

o Power withstand voltage 7.2 KV, 2.5 KV

o Short circuit current 31.5 KA, 50 KA, 1Sec.

o Control voltage 110V DC

o Standard IEC

o Discharge device <50V, 1min.

o Protection (S.C. and O.C.) H.R.C. Fuses, thermal relay, Unbalance

protection (If needed), etc.


o Insulation Dry type

2.7.17-Lightning protection and earthing system


o Earthing grid resistance 2

o Conductor size (main mesh, bare, buried) 185 mm2

o Conductor type Standard, soft drawn, annealed

copper

o Step & touch voltage Acc. To IEEE80

o Earthing rod size 16mm 3m





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o Conductor to conductor connection Cad weld

o Above ground conductor PVC insulated

o Testing links shall be provided Yes

o Buildings/structures (Non metallic and high) Lightning rod

o Lighting protection for ordinary non metallic

buildings Faraday cage Method

o Lightning protection conductor Copper belt 5 30 mm

2.8- INSTRUMENTATION AND CONTROL SYSTEM

2.8.1- General

This specification should apply for the instrumentation and control system togetherness

with Engineering Standard, Instrumentation And Control (Annex IV) whether specifically

mentioned or not; and any control device, field equipment and other requirements

concerning the design, material selection, erection, commissioning, etc. should comply

with it.

2.8.2- Scope

Contractor should install an advanced DCS control system, all field instrumentation,

cabling and all necessary accessories for direct reduction plant.

2.8.3- Design Criteria

2.8.3.1- Automation System’s Features

The main general features requested to the automation system, are the following:

High availability (the availability is defined as the ratio between the up-time and the

total operating time)

High reliability (the reliability is defined as the probability that a device will function

without failure over a specified time period or amount of usage)





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Scalability (the scalability is defined as the possibility to add new part of system or to

increase the performance of the existent systems to comply with the new

requirements)

and from the Hardware point of view are:

High similarity

High redundancy

The design and the implementation of the automation systems for this project should

consider all the above mentioned features.

2.8.3.2- Automation Levels

A complete plant automation system is a sequence of layers, organized into a pyramid

shape, where each level is superimposed to the lower one, starting from the field

instrumentation:

a) Field Instrumentation (level 0)

b) Basic automation and supervision (level 1)

including:

- Reformer control

- Furnace control

- Logic sequences, interlocks, alarms, events

- Closed loop control

- Field signals collection

- MMI mimics, event logging, trends

- Material tracking

c) Process control and optimization (level 2)

including:





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- Data exchange with basic automation

- Quality tracking and supervision

- Mathematical models calculations

- Technical standard management

- Operating procedures managements

- Production reports

d) Production control (level 3)

- Connection to MIS system

including:

- Production planning

- Production control

- Quality management

- Quality control

- Material management

- Maintenance management

2.8.4- Control system configuration

The proposed control system should be selected according to the section 2 of Engineering

Standard, Instrumentation and Control (Annex IV).

2.8.5- Field Instrumentation And Control Cables

All necessary field instrumentation and cabling should be according to section 6 and 7

of Engineering Standard, Instrumentation And Control (Annex IV).





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2.9- REPAIR SHOP

2.9.1- Design basis

This section is a typical description of the direct reduction and raw material handling

plants maintenance shop, which has the repair and maintenance facilities to support

operation.

The facilities indicated in this section are selected to carry out most of the normal and

routine maintenance work inside the direct reduction and raw material handling plants.

The tenderers shall complete or revise the list and supply according to their experience

for above mentioned purposes.

The tenderer shall submit specification, type, quantity, and manufacturer of the facilities.

The repair shop consists of the following:

- Mechanical repair shop equipped by 8 tones overhead traveling crane.

- Electrical & instrument workshop

2.9.2- Planning basis

1- Mechanical repair shop:

Assembling and disassembling of equipment, repair of mechanical, hydraulic and

pneumatic components and related piping, fitting, etc.

2- Electrical & instrument workshop:

Repair, inspection and test of electrical and instrumentation equipment.

2.9.3- Equipment list

Mechanical repair shop facilities

- Horizontal hydraulic press

- Hoists





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- Ratchet lever hoist

- Hydraulic jack

- AC welder

- Hand pallet truck

- Hydraulic equipment

- Upright drilling machine

- Electric floor grinder

- Bench drilling machine

- Jib crane

- One lathe machine

- One hack saw machine

- One heavy duty tube bender

- One TIG and one MIG-MAG welding machine

- One portable vulcanizing device

- One grinding machine

- Set of wrenches, screw drives, pliers, etc

Electrical & instrument workshop facilities

The electrical and instrument workshop is mainly planned to repair, inspect and test

electrical and instrumentation equipment. It’s a totally convened workshop with clean and

controlled atmosphere.

- Cable repair facilities

- Calibration room

Typical test and calibration equipment for onsite instrument testing, and pre-

commissioning. Test and calibration equipment shall be calibrated in the units of





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measurement selected for the project. All test equipment shall be approved by the

Employer’s Representative.

General Equipment

1) Workbench for Instrument repairing and calibration

2) Printed circuit board check device

3) Combined pneumatic/electronic portable tester

4) Control valve test bench or test rig.

General Electronic/Electrical Test and Calibration Equipment

5) Digital voltmeters (DVM) portable (minimum 3 portable types) with an accuracy of

+/-0.1% of range or better and with a discrimination of 10 uv or better, incorporating an

internal calibration, standardizing feature and 0.1% calibration resistors.

6) Precision milli volt, volt and milliamp, source measuring device.

7) Portable multi meters (analogue).

8) Insulation resistance testers.

9) Stop-watch and relay contact timing device.

10) Dual beam oscilloscope.

11) Portable, variable mA power supply unit (0 to 50 mA Max.).

12) Portable multi meters (digital).

13) Signal generator.

Pressure Testing and Calibration Equipment

14) Portable manually operated hydraulic pump (bucket pump).

15) Low pressure, hand-held pressure pump (range up to 1 bar).

16) Vacuum pump manually operated.

17) Dead weight tester. (Oil, different ranges from 0 ~ 700 kg/Cm2).

18) Dead weight tester. (Air, different ranges from 0 ~ 700 kg/Cm2).

19) Pressure gage comparison test pump.

20) Precision air filter/regulator sets.

21) Glass thermometers (different ranges from -10 ~ 300 bar).

22) Digital pressure calibrator (0 ~ 400 bar).





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23) Liquid filled manometer (ranges below 10 mbar).

24) U-tube manometer (ranges approx. +/-25 mbar).

25) Precision-inclined manometer (ranges below 10 mbar).

26) Precision-sealed mercury manometer (ranges up to approximately 1000 mbar).

27) Certified test gauges, 0.25% accuracy or better.

28) Portable pneumatic digital calibrator (different ranges from -1 ~ 20 bar).

29) Portable air compressor (If air supply is not available).

Temperature Test and Calibration Equipment

30) Thermostatically controlled temperature bath(s) (oil and antifreeze liquid).

31) Thermostatically controlled oven, for checking cold junction compensation.

32) Sets of standard (precision) mercury in glass thermometers.

33) Precision potentiometer and milli volt generator.

34) Precision Whetstone Bridge incorporating a detachable resistance box where

resistance thermometers will be installed. Accuracy 0.05% on any resistance value.

35) Decade resistance box 0.1% accuracy.

36) Thermocouple simulator

Note:

All test instruments shall be provided with test leads complete with test probes, clips and

distribution terminals.

Electrical workshop facilities, including but not limited to the following:

1- Digital multi meter 3

2- AC/DC clamp on current meter 3

3- Meger (250 ~ 5000 VDC) 2

4- Ground resistance meter 1

5- Phase sequence indicator 2

6- Tacho meter 2

7- Frequency meter 2

8- Cable fault locator 1





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9- Oil insulation tester 1

10-Soldering 2

11- Schering bridge 1

12- Manual earth (perch) 2

13- General tools 1

2.10- LABORATORY

Contractor shall construct and supply a complete laboratory with all laboratory equipment

for carrying out all required analysis and tests in direct reduction and raw material handling

plants.

The facilities indicated in this section are selected to carry out most of the normal analysis

and tests inside the direct reduction and raw material handling plants.

The tenderer shall complete or revise the list according to his experience for above

mentioned purposes.

The tenderer shall submit specification, type, quantity and manufacturer of the laboratory

equipment.

2.10.1- Laboratory equipment

- Atomic absorption

- Spectrophotometer

- Gas chromatograph

- C. & S. analyzers

- Chamber furnace

- Balances

- Oven





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- Jaw crusher

- Grinding mill

- Cross beating mill

- Crusher

- Automatic press (compression test for DRI)

- Size analysis device (granulometer laser type)

- Grave and crush tests (for DRI)

- Fast DRI metallization measurement device

- Equipment for DRI characterization (drop number and resistance, bulk density)

2.11- WAREHOUSE

The warehouses of DRP shall be constructed by Contractor.

These warehouses shall have necessary equipment, hardware and software for servicing to

the plant in maintenance and operation time. These warehouses are for storing spare parts,

equipment, chemicals and refractories. Warehouses shall be equipped with shelves, ladders,

railing, platforms, lifts, etc which in a modern warehouses for easy handling is required. At

least one three ton capacity fork lift for general purpose shall be provided. Required No. of

hardware (computers, printers, copy machine, etc) and powerful software for handling the

duty shall be provided. The provide system shall be capable of communication with steel

complex MIS/ERP which in future will be provide by Employer.

2.12- HVAC SYSTEM

2.12.1- General

Outdoor design conditions will be determined according to the operation and climatic condition

at site.

2.12.2- Air conditioning system

Air conditioning system with cooling and heating system shall be used to serve control room,

electrical room, gas analyzer room, laboratory, offices, etc.





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The equipment shall be capable of maintaining internal conditions according to the ASHRAE

standard for offices and specification of equipment from manufacturer for electric equipment in

control and electrical rooms.

Suitable internal conditions for control room, electrical room and laboratory are 22±2oc and

relative humidity equal 45 to 50%.

The air cooling system, without humidity control for the electrical room and air conditioning

system with humidity control for the control room for PLC equipment shall be considered.

Air systems shall be balanced to the conditions set forth in drawings and specifications and

following items shall be performed:

- Balancing air supply, return and exhaust system.

- Balancing chilled water system.

2.12.3- Heating and ventilation

Heating and ventilation shall be used for warehouses, workshop, locker, shower and suitable

ventilation system shall be provided for all of these spaces are according to ASHRAE or relevant

standard. In heating system for the piping material and flange rating, DIN or equivalent code

shall be applied.

For fans, performance curve showing air volume shall be delivered at various pressure drops.

2.12.4- Specification for HVAC system

Air conditioning equipment should included the following data and specifications.

- Cooling and heating data

- Fresh air rate

- Motor power

- Total heat rejection





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2.13- FIRE DETECTION AND FIGHTING SYSTEM

2.13.1- Specifications of fire detection and fighting system

Complete fire detection system including fire alarm panel, detectors (fire, smoke, heat, and

explosion), manual fire call, available and visual alarms shall be provided. A complete fire

hazard study shall be done to classify area’s of plant. For more information for fire alarm can

refer to following specification and engineering standards Annex III item 3.18.

Detectors Hydrocarbon gas, Heat, Smoke, Fire,

Explosion

Detectors pilot light Yes

Detectors signal 4~20 mA DC

Detectors calibration 25% and 50% of LEL (lower explosion limit)

Fire alarm panel Generates 24 VDC

Protection degree IP54

Horn silence button Yes

Horn silence for testing & calibration Yes

I/O fault alarm Yes

Panel input 220VAC from UPS

Cables Fire resistant, shielded

Alarm type Audible and Visual

Alarm location Field, fire alarm Panel, Operator console in

control room

Fire alarm panel with battery back up Yes





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3- RAW MATERIAL HANDLING PLANT SPECIFICATION

3.1- GENERAL DESCRIPTION

For feeding DR plant, pellet as a charging material is required.

For this propose, provision of a raw material handling plant with the capacity of 2,500,000

tonne per year pellet and lump ore (by consideration of future expansion) is one of the

Contractor's obligations.

This plant shall be designed for 7500 hours working time per year with handling rate of

600ht .

The Employer will use oxide pellet and lump ore produced from indigenous ore and some

imported pellets and lump ore, therefore Contractor shall provide truck unloading stations

for unloading pellet and lump ore. Train unloading station isn’t in the scope of Work but

the Contractor shall foreseen suitable location for car tippler in material handling plant

layout , meanwhile the Contractor shall foreseen an optimum manner for pellet conveying

from car tippler to MHP in material handling plant design for future stage.

After trucks unloading, belt conveyors shall handle pellet and lump ore to pellet storage

area.

A combined stacker reclaimer shall be installed in pellet storage area for raw material

stacking and reclaiming.

When the trucks are unloading, the belt conveyors system shall be able to handle raw

material directly to direct reduction module day bin, as well.

As a whole, the raw material handling plant will include but not limited to the following

main parts:

A- Truck unloading station

B- Pellet open storage area equipped with combined stacker reclaimer and yard

conveyor

C- Belt conveyors system

D- Screen, Feeders, Silos, Chutes, Bins and whatever similar equipment





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In addition to the main systems as mentioned above, the following auxiliary systems shall

be considered in connection with this plant and shall be designed, supplied, erected and

tested by the Contractor:

- Civil, building and infrastructure including all buildings such as substation, control room,

ware house, office, etc. with their related infrastructures and HVAC (Heating, Ventilation

and Air-Conditioning) systems.

- Potable water distribution system.

- Industrial water for spraying over the belt conveyors at conveyor loading and at dust

return in train unloading station and truck unloading station. (if required), based on

Contractor's design.

- Dust collection systems.

- Compressed air generation (including both plant air and instrument air) and distribution

system based on Contractor's design.

- Sewage collection and treatment system.

- Fire detection and fighting system.

- Electrical system(including communication system).

- Instrumentation and control system.

- Warehouse.

3.2- RAW MATERIAL HANDLING PLANT DESCRIPTION

3.2.1- TRUCK UNLOADING STATION

The different kinds of trucks in size and type containing pellets, lump ore, and lime shall

be unloaded in truck unloading station.

The unloading station consists of five substations. Two for flatbed trucks or articulated

lorries and three for dumper trucks (jack bodies). Each of these substations shall have one

unloading unit, in such a way that five trucks can unload their contents simultaneously.





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For the articulated Lorry or flatbed, two hydraulic truck unloaders shall be installed by

the Contractor. Each of these units shall have unloading hoppers.

The hoppers shall be designed to accept both unloading trucks by hydraulic truck

unloader and trucks with flatbeds. These hoppers shall be equipped with grating network

for avoiding oversize entrance to hoppers.

The Contractor shall provide five hoppers , each hopper capacity 100 cubic meters and

five feeders with the capacity of 300 t/h .

Raw material shall be transferred to storage area by belt conveyors.

The truck road, truck weigher, provision the suitable parking for the trucks and other

relevant facilities are in the Contractor's scope of Work.

3.2.2- PELLET STORAGE AREA EQUIPPED WITH COMBINED STACKER RECLAIMER

A pellet storage area with two piles shall be considered. Dimensions of this area is

350mx96m and maximum height of the piles will be approximately 13m.

Any necessary civil works for construction of pellet storage area is in the Contractor's

scope of Work.

A combined stacker reclaimer with stacking capacity of 1500ht and reclaiming capacity

of 600ht shall be installed in this storage area. The combined stacker reclaimer shall be

able to stacking in and reclaiming from two piles.

3.2.3- BELT CONVEYOR SYSTEM

Raw material shall be transferred from truck unloading station to direct reduction plant

day bin by belt conveyors. Belt conveyor capacity from truck unloading station to stack

piles shall be 1500 t/h and from stack piles to DRP day bin shall be 600 t/h.

Weighers shall be installed on the conveyors where it is necessary.

All necessary cranes and hoists for erection, dismantling and maintenance of equipment

shall be installed.





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3.3- DEDUSTING SYSTEM OF MATERIAL HANDLING SYSTEM

Industrial dedusting systems to maintain compliance with the laws and regulations of

Iranian Environmental Protection Organization shall be provided for raw material handling

plant.

Dedusting system shall be provided everywhere dust may be produced during operation of

the plant i.e. truck unloading station, transferring points between belt conveyors and

screening station, considering plant operation, dust concentration and particle size.

Safety requirements in collection & cleaning of dust shall be considered and the step taken

to ensure safety of the operation of dedusting system shall be described by the Contractor.

The Contractor shall also provide disposal facilities for dusts collected by the dedusting

system.

3.4- ELECTRICAL DISTRIBUTION

Refer to item 2.7

3.5- INSTRUMENTATION AND CONTROL SYSTEM

3.5.1- General

This specification should apply for the instrumentation and control system togetherness

with Engineering Standard, Instrumentation And Control (Annex IV) whether specifically

mentioned or not; and any control device, field equipment and other requirements

concerning the design, material selection, erection, commissioning, etc. should comply

with it.

3.5.2- Scope

Contractor should install an advanced control system, all field instrumentation, cabling and

all necessary accessories for raw material handling plant.

The control system shall be capable of controlling a car tippler which may be added in

future and necessary installed spares shall be provided in control system.





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The control system shall be connected to DR plant control system as well.


3.5.3.1- Automation System’s Features

The main general features requested to the automation system, are the following:

High availability (the availability is defined as the ratio between the up-time and the

total operating time)

High reliability (the reliability is defined as the probability that a device will function

without failure over a specified time period or amount of usage)

Scalability (the scalability is defined as the possibility to add new part of system or to

increase the performance of the existent systems to comply with the new

requirements)

and from the Hardware point of view are:

High similarity

High redundancy

The design and the implementation of the automation systems for this Project should

consider all the above mentioned features.

3.5.3.2- Automation Levels

A complete plant automation system is a sequence of layers, organized into a pyramid

shape, where each level is superimposed to the lower one, starting from the field

instrumentation:

e) Field Instrumentation (level 0)

f) Basic automation and supervision (level 1)

g) Process control and optimization (level 2)

h) Production control (level 3)





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- Connection to MIS system

including:

- Production planning

- Production control

- Quality management

- Quality control

- Material management

- Maintenance management

3.5.4- Control system configuration

The proposed control system should be selected according to the section 2 of Engineering

Standard, Instrumentation and Control (Annex IV).

3.5.5- Field Instrumentation and Control Cables

All necessary field instrumentation and cabling should be according to section 6 and 7 of

Engineering Standard, Instrumentation and Control (Annex IV).

3.6- WAREHOUSE

The Contractor shall construct a suitable warehouse for the raw material handling plant.

This warehouse shall have necessary equipment, hardware and software to serve the plant in

maintenance and operation period. Warehouses shall be equipped with shelves, ladders,

railing, platforms, lifts, etc which in a modern warehouses for easy handling is required. At

least one three ton capacity fork lift for general purpose shall be provided. Required No. of

hardware (computers, printers, copy machine, etc) and powerful software for handling the

duty shall be provided. The provide system shall be capable of communication with steel

complex MIS/ERP which in future will be provide by Employer.





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3.7- HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

3.7.1- Air conditioning system

Air conditioning system shall be used to serve control room (material handling pulpit), electrical

room, and offices.

The equipment shall be capable of maintaining internal conditions according to the ASHRAE

standard for offices and specification of equipment from manufacturer for electric equipment in

control and electrical room.

Suitable internal conditions for these spaces is 22±2oc and relative humidity equal 45 to 50%.

The air cooling system, without humidity control for the electrical room and air conditioning

system with humidity control for the control room for PLC equipment shall be considered.

3.7.2- Heating and ventilation

Heating and ventilation shall be used for spare part storage and suitable ventilation system and

minimum quantity of outside air shall be provided according to ASHRAE or relevant standard.

For fans, performance curves showing air volume shall be delivered at various pressure drops.

3.7.3- Specification for HVAC system

For Specification of HVAC system can refer to 2.12.4.

3.8- FIRE DETECTION AND FIGHTING SYSTEM

3.8.1- Specification

For specification of fire detection and fighting system can refer to 2.13.1.





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4- PROCESS AND PROCESS EQUIPMENT DATA SHEETS

Tenderer shall fill out process data in process data sheets.

Tenderer shall fill out data of offered equipment in data sheets provided hereinafter.

Tenderer shall complete one data sheet for each type of equipment.

Consumptions Data Sheet

The tenderer shall fill out the consumptions table for DR module.

No. Item Unit Tenderer Proposal

1 Oxide pellet t/t DRI (+5mm sponge iron)

2 Natural gas Nm3/hr

3 Nitrogen Nm3/hr

4 Electric power consumption kWh/t DRI (+5mm sponge

iron)

5 Make up water M3/hr

6 Service (plant) comp. air Nm3/hr

7 Instrument Comp. air Nm3/hr





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Shaft Furnace Data Sheet

- Total weight of reduction furnace excluding

refractories (tonne) ..……...……………………………….…….

- Estimated weights of required refractories

(tonne) …...…..……………………………….…….

- Inside dimension of reduction zone (m)

Height x Diameter …...…..……………………………….…….

- Effective volume of reduction zone (m3) ...…..…………...…………………….…….

- Shell plate thickness (mm) ...…..…………...…………………….…….

- Shell plate material ...…..…………...…………………….…….

- Input rate (tonne/h) ...…..…………...…………………….…….

- Output rate (tonne/h) ...…..…………...…………………….…….

- Temperature of sponge iron at discharge (˚c) ...…..…………...…………………….…….

- Operating temperature (furnace bed) approx.

(˚c) ...…..…………...…………………….…….

- Pressure of reduction gas at entry to the

furnace (ata) ...…..…………...…………………….…….

- Pressure of reduction gas at exit of the furnace

(ata) ...…..…………...…………………….…….

- Temperature of reduction gas at entry to the

furnace (˚c) ...…..…………...…………………….…….

- Gas composition (bustle & top) Approx. (vol

%) ..…..… bustle gas ….…… top gas ………

- H2 ...…..…………...…………………….…….





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- CO ...…..…………...…………………….…….

- CO2 ...…..…………...…………………….…….

- H2O ...…..…………...…………………….…….

- CH4 ...…..…………...…………………….…….

- N2 ...…..…………...…………………….…….

- Natural gas requirement per tonne of product

(Nm3/tonn) ...…..…………...…………………….…….

- Reduction gas requirement per tonne of

product (Nm3/tonn)

...…..…………...…………………….…….

- Number of reducing gas tuyeres ...…..…………...…………………….…….

- Retention time (reduction and cooling) (hour) ...…..…………...…………………….…….

- Cooling gas system ...…..…………...…………………….…….

...…..…………...…………………….…….

...…..…………...…………………….…….

- Charging system ...…..…………...…………………….…….

...…..…………...…………………….…….

...…..…………...…………………….…….

- Discharging system ...…..…………...…………………….…….

...…..…………...…………………….…….

...…..…………...…………………….…….

- Method of sealing ...…..…………...…………………….…….

...…..…………...…………………….…….





NISCO

...…..…………...…………………….…….

- Level of carbon content (%) ...…..…………...…………………….…….

...…..…………...…………………….…….

...…..…………...…………………….…….

- Method of carbon content control ...…..…………...…………………….…….

...…..…………...…………………….…….

...…..…………...…………………….…….

- Bruden feeder equipment ...…..…………...…………………….…….

...…..…………...…………………….…….

...…..…………...…………………….…….

- Lubrication system type and description ...…..…………...…………………….…….

...…..…………...…………………….…….

...…..…………...…………………….…….





NISCO

Gas Reformer Data Sheet

- Number of reformers per module ...…..…………...…………………….…….

- Total weight excluding refractories (kg) ...…..…………...…………………….…….

- Estimated weight of required refractories (kg) ...…..…………...…………………….…….

- Length (m) x width (m) ...…..…………...…………………….…….

- Reformed gas capacity (Nm3/h) ...…..…………...…………………….…….

- Natural gas consumption for reforming

(Nm3/h) ...…..…………...…………………….…….

- Natural gas consumption for fuel (Nm3/h) ...…..…………...…………………….…….

- Reforming method ...…..…………...…………………….…….

- Feed gas ...…..…………...…………………….…….

- Reformer type ...…..…………...…………………….…….

- Gas flow direction ...…..…………...…………………….…….

- Composition of the reformed gas at exit

approx. (vol%) ...…..…………...…………………….…….

- CO ...…..…………...…………………….…….

- H2 ...…..…………...…………………….…….

- CO2 ...…..…………...…………………….…….

- H2O ...…..…………...…………………….…….

- CH4 ...…..…………...…………………….…….





NISCO

- N2 ...…..…………...…………………….…….

- Operating temperature (˚c) ...…..…………...…………………….…….

- Temperature of preheated feed gas before

reforming (˚c) ...…..…………...…………………….…….

- Temperature of reformed gas at exit (˚c) ...…..…………...…………………….…….

- Pressure of feed gas before reforming (ata) ...…..…………...…………………….…….

- Pressure of reformed gas at exit (ata) ...…..…………...…………………….…….

- Permissible sulphur in feed gas (ppm) ...…..…………...…………………….…….

- Reformer burners fuel ...…..…………...…………………….…….

- Fuel gas mixer type ...…..…………...…………………….…….

- Number and type of burners ...…..…………...…………………….…….

- Main burners ...…..…………...…………………….…….

- Auxiliary burners ...…..…………...…………………….…….

- Capacity of each burner (Gcal/h) ...…..…………...…………………….…….

- Gas consumption of each burner (Nm3/h)

Natural gas + top gas ...…..…………...…………………….…….

- Air consumption of each burner (Nm3/h) ...…..…………...…………………….…….

- Total heat input in normal working condition

(Gcal/h) ...…..…………...…………………….…….

- Number of catalyst tubes ...…..…………...…………………….…….





NISCO

- Material of tubes ...…..…………...…………………….…….

Method of construction ...…..…………...…………………….…….

- Internal diameter of tubes (mm) ...…..…………...…………………….…….

- External diameter of tubes (mm) ...…..…………...…………………….…….

- Tube length (m) ...…..…………...…………………….…….

- Tube life (years) ...…..…………...…………………….…….

- Provision for thermal expansion of tubes ...…..…………...…………………….…….

- Catalyst tubes fixed end ...…..…………...…………………….…….

- Weight of catalyst (kg) ...…..…………...…………………….…….

- Temperature distribution along the tube ...…..…………...…………………….…….

- length (˚c) ...…..…………...…………………….…….

Bottom ...…..…………...…………………….…….

Middle ...…..…………...…………………….…….

Top ...…..…………...…………………….…….

- Catalyst temperature at the tube center line

(˚c) ...…..…………...…………………….…….

Bottom ...…..…………...…………………….…….

Middle ...…..…………...…………………….…….

Top ...…..…………...…………………….…….

- Reformed gas cooler type ...…..…………...…………………….…….





NISCO

- Reformed gas cooler capacity (Nm3/hr) ...…..…………...…………………….…….





NISCO

Fuel Gas Mixer Data Sheet

- Type ……...………………………………………..

- Natural gas input rate ……………………………………….….…...

- Top gas input rate ……...………………………………………..

- Output rate ……...………………………………………..

- Manufacturer ……………………………………….….…...

- Place of manufacture ……...………………………………….…….





NISCO

Recuperator Data Sheet

- Total weight excluding refractories

- Estimated weight of required refractories

- Geometry and dimension

- Heating media

- Preheated gases

- Heating media rate (Nm3/h)

- Preheated gases rate (Nm3/h)

- Heating media temperature (˚c)

Input & Output

- Preheated gases temperature (˚c)

Input & Output

- Number of tubes

- Material of tubes

- Method of construction

- Internal diameter of tubes (mm)

- External diameter of tubes (mm)

- Total tube length (for each type) (m)

- Tube life (year)

- Provision for thermal expansion of tubes

- Shell plate material

- Shell plate thickness

………………………………………………

………………………………………………

………………………………………………

………………………………………………

………………………………………………

………………………………………………

………………………………………….……

………………………………………………

………………………………………………

………………………………………………

………………………………………………

………………………………………………

………………………………………………

………………………………………………

………………………………………………

………………………………………………

………………………………………………

………………………………………………

………………………………………………





NISCO

Top Gas & Cooling Gas System

- Top gas scrubber type …………………………………………….…

- Top gas scrubber capacity (Nm3/hr) ……………………………………….….…...

- Top gas scrubber water quantity (m3/hr) …………………………………………….…

- Top gas scrubber operating pressure (ata) …………………………………………….…

- Top gas scrubber dimension …………………………………………….…

- Top gas scrubber shell thickness (mm) …………………………………………….…

- Process gas mixer type ……...………………………………….…….

- Process gas mist eliminator type ……...………………………………………..

- Process gas mist eliminator capacity

(Nm3/hr)

……………………………………….….…...

- Cooling gas scrubber type ……...………………………………….…….

- Cooling gas scrubber capacity (Nm3/hr) ……...………………………………………..

- Cooling gas scrubber water quantity (m3/hr) ……...………………………………….…….

- Cooling gas scrubber operating pressure

(ata)

……...………………………………………..

- Cooling gas scrubber dimensions ……...………………………………….…….

- Cooling gas scrubber shell thickness (mm) ……...………………………………………..

- Cooling gas mist eliminator type ……………………………………….….…...

- Cooling gas mist eliminator capacity

(Nm3/hr)

……...………………………………….…….





NISCO

Seal, Inert and Purge Gas System

- Brief description of seal, inert, purge gas

system ………….…………………………………….

-Total generated seal gas (Nm3/h) ……………………………………………….

- Total necessary seal gas flow (Nm3/h) …………………………………………….…

- Seal gas cooler capacity (Nm3/h)

- Seal gas cooler water quantity (Nm3/h)

- Seal gas cooler dimensions

……………………………………….….…...

……...………………………………….…….

……...………………………………………..

- Seal gas dryer capacity (Nm3/h) ……………………………………………….

- Seal gas dryer operating pressure (ata) …………………………………………….…

- Seal gas dryer shell thickness (mm) ………………………………………….……

- Number of purge gas tank

- Purge gas tank dimensions …………………………………………….…

- Purge gas tank shell thickness (mm) ……………………………………….….…...

- Number of gas generators …………………………………………….…

- Capacity of each generator (Nm3/h) …………………………………………….…

- Number of inert gas storage tank ……………………………………………..…

- Total capacity of inert storage tank (Nm3) …………………………………………….…





NISCO

Dust Collectors

- Item number …………………………………………..……

- Type and function description …………………………………………..……

- Quantity of dust collected (kg/hr) …………………………………………..……

- Fan rating (Nm3/min) ……………………………………….….…...

- Duct air velocity (m/sec) ……...………………………………….…….

- Unit weight ……...………………………………………..

- Motor rating (kW) ……………………………………….….…...

- Assumed dust load (mg/Nm3) ……...………………………………….…….

- Collected dust discharge and removal

system ……...………………………………………..

- Dust content of exhaust air (mg/Nm3) ……………………………………….….…...

- Type and quantity of nozzles (if any exist) ……………………………………….….…...

- Manufacturer ……...………………………………….…….

- Place of manufacture ……...………………………………………..

- Other details and technical particulars ……………………………………….….…...





NISCO

Bag Filter

- Number of bag filter/system .………………………………………………

- Number of compartments per bag filter .………………………………………………

- Number of bags per compartment .………………………………………………

- Bag diameter (mm) .………………………………………………

- Bag effective length (mm) .………………………………………………

- Over all dimensions of bag filter

a) Length (m)

b) Width (m)

c) Height (m)

.………………………………………………

……………………………………………….

……………………………………………….

- Cladding material .………………………………………………

- Material of filter .………………………………………………

- Max, safe operation temperature )( C .………………………………………………

- Outlet air specification )( 3Nmmg .………………………………………………

- Guaranteed life of bags (years) .………………………………………………

- Number of dust hoppers .………………………………………………

- Slope of sides

(referred to horizontal) (degree) .………………………………………………

- Type of dampers .………………………………………………

- Number of dampers .………………………………………………





NISCO

- Bag cleaning method .………………………………………………

- Describe cycle of cleaning .………………………………………………

- Manufacturer .………………………………………………

- Place of manufacture .………………………………………………





NISCO

Dust Collection Duct System

- Duct diameter (mm) .………………………………………………

- Steel plate quality .………………………………………………

- Plate thickness (mm) .………………………………………………

- Type of dampers .………………………………………………

- Size of dampers ……………………………………….………

-Volume of air entrained when fully

open )(3

hNm .………………………………………………

- Manufacturer .………………………………………………


- Type of temperature detector .………………………………………………

- Temperature of actuation .………………………………………………





NISCO

Fans of Dust Collection Systems

- No. of fans/system ………………..…………………………..

- Type of fan …………………………………………….

- Manufacturer …………………………………………….

- Place of manufacture …………………………………………….

- Capacity per fan )(3

hNm …………………………………………….

- Working temperature (max.) )( C …………………………………………….

- Static pressure (kpa.gauge) …………………………………………….

- Power required (kW) …………………………………………….

- Fan motor rating (kW) …………………………………………….

- Motor type and speed (rpm) …………………………………………….

- Motor manufacturer …………………………………………….

- Place of manufacturer of motor …………………………………………….

- Weights …………………………………………….

- Noise level (dB) …………………………………………….





NISCO

Dust Conveying System

- Brief description of dust conveying

System …………………………………………….

…………………………………………….

…………………………………………….

…………………………………………….

- Type of dust discharge valves ………………………………………….….

- Capacity of valves )(3

hm ………………………………………….….

- Manufacturer ………………………………………….….

- Place of manufacture …………………………………………….





NISCO

Compressors Data Sheet

- Item No. …………………………………………….…

General:

- Function

No. of units:

In operation

Stand by

……………………………………….….…...

……...………………………………….…….

……...………………………………………..

- Manufacturer ……………………………………………….

- Place of manufacture ………………………………………………

Compressor Characteristics:

- Type ………………………………………………

- No. of stages ………………………………………………

- Fluid handled ………………………………………………

- Suction pressure (kg/cm2) ………………………………………………

- Delivery pressure (kg/cm2) ………………………………………………

- Suction temperature (˚c) ………………………………………………

- Delivery temperature (˚c) ………………………………………………

- Rated capacity (Nm3/hr) ………………………………………………

- Nature of cooling fluid ………………………………………………

- Cooling fluid requirements (Nm3/hr) ………………………………………………





NISCO

- Bearing type ……………………………………….….…...

- Lubrication system ……...………………………………….…….

- Coupling type ……...………………………………………..

- Efficiency at normal operating condition (%) ……………………………………….….…...

- Speed (rpm) ……...………………………………….…….

- Motor power (kW) ……...………………………………………..

Material:

- Casing ……...………………………………………..

- Impeller ……………………………………….….…...

- Shaft ……...………………………………….…….

- Bed plate ……...………………………………………..





NISCO

Fans and Blowers Data Sheet

- Item No. ……...………………………………………..

General: ……………………………………….….…...

- Function ……...………………………………….…….

- No. of units:

In operation

Stand by

……...………………………………………..

……………………………………………….

- Manufacturer ……...………………………………………..

- Place of manufacture ……………………………………….….…...

Characteristics: ……...………………………………….…….

- Type ……...………………………………………..

- Fluid handled ……...………………………………………..

- Total pressure (mm H2O) ……………………………………….….…...

- Suction pressure (mm H2O) ……...………………………………….…….

- Efficiency at rated capacity (%) ……...………………………………………..

- Capacity (Nm3/h) ……...………………………………………..

- Fan speed (rpm) ……………………………………….….…...

- Absorbed power at rated capacity (kW) ……...………………………………….…….

- Noise level (at a distance of one meter from

perimeter of the fan) ……...………………………………………..

- Motor power (kW) ……...………………………………………..





NISCO

Stack Data Sheet

- Dimension .………………………………………………

- Material .………………………………………………

- Total weight excluding refractories .………………………………………………

- Weight of required refractory .………………………………………………





NISCO

Cranes and Hoists Data Sheet

- I.D. No. .………………………………………………

- Function/Location .………………………………………………

- Type .………………………………………………

- Quantity .………………………………………………

- Capacity .………………………………………………

- Manufacturer .………………………………………………






NISCO

Shaft Furnaces Passenger and Goods Elevators Data Sheet

- Quantity .………………………………………………

- Carrying capacity (kg) .………………………………………………

- Inside cabinet dimensions (m) .………………………………………………

- Power of elevator motor (kW) .………………………………………………

- Speed (m/s) ……………………………………….………

- Lift (m) .………………………………………………

- Number of stops .………………………………………………

- Manufacturer .………………………………………………






NISCO

5- MATERIAL HANDLING SYSTEM DATA SHEETS

Tenderer shall fill in data of offered equipment in data sheets provided hereinafter.

Tenderer shall complete one datasheet for each type of equipment for raw material handling





NISCO

Combined Stacker Reclaimer Data Sheet

- Design stacking capacity (t/h) ………………………………………………

- Design reclaiming capacity (t/h) ………………………………………………

- Boom length (m) ………………………………………………

- Total weight(t) ……………………………………………....

- Pile ……………………………………………...

- Width

- Height

……………………………………………...

……………………………………………...

Belt Conveyor

- Width (mm) ………………………………………………

- Speed (m/s) ………………………………………………

- Power (kW) ………………………………………………

- Length (m) ………………………………………………

Travel

- Traveling speed (working speed) (m/min) ………………………………………………

- Out of operation traveling speed (m/min) ………………………………………………

- Rail type ………………………………………………

- Wheels diameter (mm) ………………………………………………

- Machine wheels Nr. ………………………………………………





NISCO

- Drive power (kW) ………………………………………………

- Operating wind pressure (kg/m2) ………………………………………………

Bucket Wheel

Type :

- Diameter (mm) ………………………………………………

- Speed (rpm) ………………………………………………

- Power (kW) ………………………………………………





NISCO

Truck Hydraulic Unloader Data Sheet

- Brief description of the system ………………………………………………

………………………………………………

………………………………………………

- Dimensions ………………………………………………

- Capacity (t) ………………………………………………

- Angle of rotation (o) ………………………………………………

- Hydraulic jack pressure ………………………………………………

- Hydraulic cylinder diameter ………………………………………………

- Hydraulic motor power

………………………………………………

- Tipping cycle time

………………………………………………

- Manufacturer

………………………………………………

- Other infromation

………………………………………………





NISCO

Belt Conveyors Data Sheet

- I.D. No.

- Center distance of end pulleys (m)

- Lift (mm)

- Belt width (mm)

- Belt speed (m/s)

- Handling rate (MT/h)

- Material handled

- Drive system and its components type

- Power consumption of conveyors

(including 15% extra power requested by

THE EMPLOYER ) (kW)

- Power installed of conveyors (kW)

- Type of take-up device

- Size of tail and drive pulleys

- Type of belt

- Belt material

……………………………….…………..…

….…………………………….………….…

………………………………...……………

………………………………...……………

………………………….……..……………

……………………………..…………….…

……………………………..…………….…

….………………………..…………………

…………………………………………...…

……………………………………..………

……………………………………...………

…………………………………….…..…...

……...……………………………….….….

……...………………………………….…..





NISCO

Oxide Pellet Coating System Data Sheet

Coating material ………………………………………………

Amount of coating material (kg/t) ………………………………………………

Brief description of coating system ………………………………………………





NISCO

Screen Stations Data Sheet

- I.D. No.

- Function & description of unit

- Type

- Rating (MT/h)

- Method of suspension & vibration

- No. of decks

- Mesh opening & screening area for each

deck

- Drive system type

- Power consumption of screen (kW)

- Time between deck replacements

- Specific materials used (e.g. for wear,

corrosion protection, etc. If any).

…….…………………………………..…...…

………………………………………………..

……….…………………….…………………

……………………………………………….

……………………………………………….

……………………………………………….

……………………………………………….

……………………………………….….…...

……...………………………………….…….

……...………………………………………..

……………………………………….….…...





NISCO

Belt Scales (Weighing System) Data Sheet

- I.D. No

- Function and description of unit

- Capacity & accuracy

- Other technical data

………………………………………………

………………………………………………

………………………………………………

………………………………………………





NISCO

Feeders Data Sheet

- I.D. No.

- Function & description of unit

- No. of units

- Type

- Rating (MT/h)

- Method of suspension

- Feed motion mechanism and particulars, e.g.

stroke length & rate, vibration, amplitude &

frequency, etc. Depending on the design

-Flow rate regulation system

-Installed drive power (kW)

-Manufacturer

-Place of manufacture

………………………………………………

………………………………………………

………………………………………………

……………………………………………….

……………………………………….….…...

……...………………………………….…….

……...………………………………………..

……………………………………….….…...

……...………………………………….…….

……...………………………………………..

……...………………………………………..

……...………………………………………..

……...………………………………………..

……………………………………………….





NISCO

Transfer Towers Data Sheet

- I.D. No. ……………………………………………..…

- Dimensions: base area x height. Approx. (m) ……………………………………………..…

- No. of platforms ……………………………………………..…

- Covers, grating, etc. ……………………………………………..…





NISCO

Diverters Data Sheet

- I.D. No. .………………………………………………

- Function & description of unit .………………………………………………

- Method of actuation


corrosion protection, etc. if any)

.………………………………………………

……………………………………….….…...





NISCO

Bins and Hoppers Data Sheet

- I.D. No. .………………………………………………

- Function & description of unit .………………………………………………

- Geometry

- Dimensions & capacity


corrosion protection, etc. if any)

.………………………………………………

……………………………………….….…...

……...………………………………….…….





NISCO

6- FLUID SYSTEM DATA SHEET

Design, selection and installation of fluid systems and equipment shall be in accordance with

standards and specification which have been specified in these tender documents. Tenderer shall

fill in data of offered system and equipment in the data sheets provided hereinafter.

Technical specification for the equipment which has not been specified here and is necessary for

reliability of the system shall be specified by the tenderer.





NISCO

Plate heat exchangers

- Manufacturer ………...………………………………...

- Place of manufacturer …………………………………………..

- Number …………………………………………..

- Flow rate of cooling water (m3/hr) …………………………………………..

- Flow rate of cold water (m3/hr) …………………………………………..

- Cooling water inlet/outlet temperature (ºC) …………………………………………..

- Cold water inlet/outlet temperature (ºC) …………………………………………..

- Cooling water pressure drop (kpa) …………………………………………..

- Cold water pressure drop (kpa) …………………………………………..

- Overall heat transfer coefficient (kcal/m2. ºc.h) …………………………………………..

- Overall heat transfer Area (m2) …………………………………………..

- Heat transferred (kW) …………………………………………..

- Fouling factor ..(2

hm ckcal) …………………………………………..

- Surface margin (%) …………………………………………..

- Material

a ) Plate …………………………………………..

b) Gasket ……………………………………….….

c) Frame …………………………………………..





NISCO

Clarifier

- Number of tanks ..................................................................

- Type of tank circular rectangular

- Capacity (m3/h) ..................................................................

- Detention time ..................................................................

- Tank Net volume (m3) ..................................................................

- Design surface load (m3/m

2.h) ..................................................................

- Tank Dimensions (m) ..................................................................

- Slope of Bottom (%) ..................................................................

- Expected effluent suspended solid

concentration (in maximum inlet

suspended solid condition) (mg/l) ..................................................................

- Bridge traveling velocity (m/min) ..................................................................

- Manufacture and place of manufacture ..................................................................

a) bridge structure ..................................................................

b) gear ..................................................................

c) motor ..................................................................

d) scraper ..................................................................

e) wheels ..................................................................

f) weir ..................................................................

g) power transfer system ..................................................................

- bridge length (m) ..................................................................

- width of bridge walk way (cm) ..................................................................

- weir length ..................................................................





NISCO

- time interval between each blow off in

maximum inlet suspended solids (min) ..................................................................

- material ..................................................................

a) tank ..................................................................

b) bridge structure ..................................................................

c) scraper and wheels ..................................................................

d) weir ..................................................................

- protective treatment ..................................................................

a) shot blasting ..................................................................

b) coating ..................................................................

d) description ..................................................................

- Chemical used & quantity ..................................................................





NISCO

Cooling Circuit

- Cooling circuit denomination ..........................................................................

- Acceptable cooling water analysis ..........................................................................

- Water flow rate (m3/h) ..........................................................................

- Water volume in the circuit (m3) ..........................................................................

- Supply water temperature (oC) ..........................................................................

- return water temperature (oC) ..........................................................................

- Supply water pressure (kpa) ..........................................................................

- Expected corrosion rate (mpy) ..........................................................................

- Chemical conditioning system description

for circulation water ………………………………………………..





NISCO

Cooling Towers

- Manufacturer ..........................................................................

- place of manufacturer ..........................................................................

- Preliminary duty of tower (Design condition) ..........................................................................

a) Water flow (m3/h) ..........................................................................

b) Inlet water temperature (oC) ..........................................................................

c) Outlet water temperature (oC) ..........................................................................

- Type of tower ..........................................................................

- Number of cells ..........................................................................

- Lifetime of cooling tower and its auxiliaries ..........................................................................

- Maximum size of largest section ..........................................................................

a) Length ..........................................................................

b) Width ..........................................................................

c) Height ..........................................................................

- Preliminary proposed packing ..........................................................................

a) Type ..........................................................................

b) Material ..........................................................................

c) Depth ..........................................................................

- Casing ..........................................................................





NISCO

a) Material ..........................................................................

b) Protective material ..........................................................................

- Fans ..........................................................................

a) Type ..........................................................................

b) Number of fans ..........................................................................

c) Fan static pressure (mm H2O) ..........................................................................

d) Fan speed (rpm) ..........................................................................

e) Blade material ..........................................................................

- Motors ..........................................................................

a) Manufacturer ..........................................................................

b) Number ..........................................................................

c) Absorbed power (kW) ..........................................................................

d) Rated power (kW) ..........................................................................

e) Speed (rpm) ..........................................................................

f) Electrical supply ..........................................................................

Voltage (V) ..........................................................................

Phase ..........................................................................

Frequency (Hz) ..........................................................................

Frame size ..........................................................................





NISCO

Enclosure ..........................................................................

- Drift eliminators ..........................................................................

a) Material ..........................................................................

b) Expected drift loss (%) ..........................................................................

- Make up water ..........................................................................

a) type ..........................................................................

b) temperature (oC) ..........................................................................

c) pressure (kpa) ..........................................................................

d) expected maximum flow rate (m3/h) ..........................................................................

e) analysis ..........................................................................

- Noise level and spectrum with all fans

working ratio dB(A) ..........................................................................





NISCO

Centrifugal Pumps

- Manufacturer ..........................................................................

- place of manufacturer ..........................................................................

- Type of pump ..........................................................................

- Number of pumps (operating, stand by) ..........................................................................

- Function ..........................................................................

- Liquid ..........................................................................

- Capacity (m3/h) ..........................................................................

- Differential head (m.W.c) ..........................................................................

- Efficiency (%) ..........................................................................

- Absorbed power (kW) ..........................................................................

- Rotating speed (rpm) ..........................................................................

- Motor power and speed (kW, rpm) ..........................................................................

- Impeller type ..........................................................................

- Impeller diameter (min/rated/max) (mm) ..........................................................................

- Seal type ..........................................................................

- Material ..........................................................................

a) Casing ..........................................................................

b) Impeller ..........................................................................

c) Shaft ..........................................................................





NISCO

Chemical Dosing Units

- Manufacturer ..........................................................................

- Place of manufacturer ..........................................................................

- Function ..........................................................................

- Chemical solution preparation tank ..........................................................................

a) Material ..........................................................................

b) Type ..........................................................................

c) Dimensions (m) ..........................................................................

- Mixer ..........................................................................

a) Manufacturer ..........................................................................

b) Mixer type ..........................................................................

c) Absorbed power (kW) ..........................................................................

d) Rotating speed (rpm) ..........................................................................

e) Motor power and speed (kW, rpm) ..........................................................................

f) Propeller/Impeller type, material

& diameter

..........................................................................

g) Shaft and coupling material ..........................................................................

- Dosing pumps ..........................................................................

a) Manufacturer ..........................................................................

b) Place of manufacturer ..........................................................................





NISCO

c) Type ..........................................................................

d) Number (operating , Stand by) ..........................................................................

e) Maximum capacity (lit/hr) ..........................................................................

f) Discharge pressure (kpa) ..........................................................................

g) Motor speed and power (rpm, kW) ..........................................................................

h) Instrument included: Relief valve:

……….. Pressure gage: …………other:

…….….

- Material

Liquid end ..........................................................................

Plunger/Diaphragm ..........................................................................

Packing/Seal ..........................................................................





NISCO

Air Compressors

Manufacturer ………………………………………………..

Place of manufacturer ………………………………………………..

Type ………………………………………………..

Number of compressor (operation, standby) ………………………………………………..

Function ………………………………………………...

Number of stages ………………………………………………..

Capacity (Nm3/h) ………………………………………………..

Working pressure (bar)

Min/Max pressure (bar)

………………………………………………..

………………………………………………...

Efficiency (%) ………………………………………………..

Rotating speed (rpm) ………………………………………………..

Motor

o power and speed (kW, rpm)

o Manufacturer

o Place of manufacturer

o Protection insulation

………………………………………………...

………………………………………………...

………………………………………………...

………………………………………………...

Compression: Oil free, Dry Oil free, liquid injected Oil injected

Cooling type

water cooled Air cooled

Noise level (in 1 m distance)

Material

………………………………………………..

o Air end casing ………………………………………………..

o Rotor ………………………………………………..





NISCO

Air Dryers

Manufacturer ……………………………………………….

Place of manufacturer ……………………………………………….

Air dryer type ……………………………………………….

Number of air dryer (operation, stand by) ……………………………………………….

Function ……………………………………………….

Capacity (Nm3/hr) ……………………………………………….

Min / Max working pressure (bar)

Test pressure (bar)

Dew point of air at the dryer exit (ºC) ……………………………………………….

Regeneration type ( for adsorption type ) ……………………………………………….

Change over cycle ( for adsorption type ) ……………………………………………….

Material ……………………………………………….

o Vessel ……………………………………………….

o Desicant (for adsorption type) ……………………………………………….





NISCO

Air Receivers

Item No. ……………………………………………….

Manufacturer ……………………………………………….

Place of manufacturer ……………………………………………….

Type ……………………………………………….

Number ……………………………………………….

Function ……………………………………………….

Net capacity (m3) ……………………………………………….

Working pressure (bar) ……………………………………………….

Design pressure (bar) ……………………………………………….

Test pressure (bar) ……………………………………………….

Design code ……………………………………………….

Head thickness ……………………………………………….

Shell thickness ……………………………………………….

Dimension

o Height ……………………………………………….

o Diameter ……………………………………………….

Internal lining ……………………………………………….

External coating ……………………………………………….

Insulation type and thickness ……………………………………………….

Material of construction ……………………………………………….





NISCO

Filters

Manufacturer ………………………………………………..

Place of manufacturer ………………………………………………..

Type ………………………………………………..

QTY ………………………………………………..

Function ………………………………………………..

Number of stages ………………………………………………..

Capacity (Nm3/h) ………………………………………………..

Working pressure (bar)

Max pressure (bar)

Drain method (automatic, manual)

Particle removal

………………………………………………..

………………………………………………..

………………………………………………..

………………………………………………..





NISCO

Heating, Ventilation and Air Conditioning System

Data sheet

Contractor shall submit a complete description of heating, ventilation and air conditioning

system offered for the direct reduction plant and raw material handling plant specification of

equipment. Catalogue of equipment shall also be enclosed.





NISCO

Air Conditioning Unit

Location ……………………………………………….

Item number (s) ……………………………………………….

Number of units:

o In operation ……………………………………………….

o Stand-by ……………………………………………….

Type ……………………………………………….

Air Conditioning Unit Characteristics

Heating data ……………………………………………….

o Heating load ……………………………………………….

o Fresh air rate ……………………………………………….

Cooling data ……………………………………………….

o Total cooling load ……………………………………………….

o Fresh air rate ……………………………………………….

Fan data

Capacity ……………………………………………….

Motor power ……………………………………………….

Compressor data

Number ……………………………………………….

Total power of compressors ……………………………………………….

Remote Condenser Characteristics

Total heat rejection ……………………………………………….

Ambient air temp. ……………………………………………….

Condensing temp. ……………………………………………….

Refrigerant ……………………………………………….

Number of fan motor ……………………………………………….

Power of each motor ……………………………………………….





NISCO

Fire Fighting, Detection and Alarm System

Data Sheets

Contractor shall submit a complete description of fire detection, alarm and fighting system

offered for the direct reduction plant and raw material handling plant including specification of

equipment. Catalogue of equipment shall also be enclosed.





NISCO

Fire Alarm

Manufacturer’s name and country:

o Type designation ………………………………………………..

o Detector type ………………………………………………..

o Calibration level of LEL ………………………………………………..

o Fire alarm panel generated voltage ………………………………………………..

o Input voltage ………………………………………………..

o Protection degree ………………………………………………..

o Number of loops ………………………………………………..

o Cable type ………………………………………………..

o Audible alarm type ………………………………………………..

o Visual alarm type ………………………………………………..

o Back up battery duration ………………………………………………..

o Quality ………………………………………………..





NISCO

Fixed fire extinguishing CO2 Cylinder Specifications

Location ………………………………………………..

Number of cylinders ………………………………………………..

Capacity ………………………………………………..

Height ………………………………………………..

Diameter ………………………………………………..

CO2 pressure at 20 °C ………………………………………………..

Test pressure ………………………………………………..





NISCO

Portable Fire Extinguishing (CO2 System)

Item No. ………………………………………………..

Number of unit ………………………………………………..

Gas weight ………………………………………………..

Total weight ………………………………………………..

Cylinder material ………………………………………………..

Hose material ………………………………………………..

Working pressure ………………………………………………..

Discharge duration ………………………………………………..

Discharge distance ………………………………………………..





NISCO

Portable Fire Extinguishing (chemical dry powder)

Item No. ………………………………………………..

Number of unit ………………………………………………..

Total weight ………………………………………………..

Cylinder material ………………………………………………..

Hose material ………………………………………………..

Working pressure ………………………………………………..

Discharge duration ………………………………………………..

Discharge distance ………………………………………………..





NISCO

7. Electrical Equpment Data Sheet

7.1- Medium Voltage Switchgear Cubicle

Plant Unit Number (P.U No.) ………...……………………………………...

Manufacturer’s name and country ………...……………………………………...

Manufacturer’s type designation ………...……………………………………...

GIS or conventional ………...……………………………………...

Indoor or outdoor installation ………...……………………………………...

Number of phases ………...……………………………………...

Number of busbars ………...……………………………………...

Rated voltages …………………………………… kV (r.m.s)

Rated insulation level (at IEC service

conditions): ………………………………………………..

o Rated 1 min. power frequency withstand

voltage …………………………………… kV (r.m.s)

o Rated lightning impulse withstand voltage …………………………………… kV (r.m.s)

Rated normal current of circuits:

o Busbar & bus-section feeder …………………………………… A (r.m.s)

o Trafo feeder …………………………………… A (r.m.s)

o Outgoing feeder …………………………………… A (r.m.s)

o Rated short-time withstand current …………………………………… kA (r.m.s)

Rated duration of short circuit ………………..……..……………………(S)

Rated peak withstand current ……………………………………..kV (peak)

Current transformer type and manufacturer ………...……………………………………...

Current transformer burden and accuracy ………...……………………………………...

Current transformer ratio ………...……………………………………...

Voltage transformer type and manufacturer ………...……………………………………...

Voltage transformer burden and accuracy ………...……………………………………...

Voltage transformer ratio ………...……………………………………...

Ground switch type and manufacturer ………...……………………………………...





NISCO

Ground switch type of mechanism ………...……………………………………...

Ground switch type of interlock ………...……………………………………...

Ground switch number and type of

auxiliary switch ………...……………………………………...

Ground switch type of blade ………...……………………………………...

Type and rating of fuses for voltage ………...……………………………………...

Transformer circuits:

o Primary H.V. fuses ……………….…………………………(A)

o Secondary L.V. fuses ……………….…………………………(A)

Degree of protection for the enclosure and

partitions ………………………………………………..

o For the enclosure ………...……………………………………...

o Between LV+HV compartments ………...……………………………………...

Cubicle weight

o Incoming …………………..………………………(kg)

o Bus-section …………………..………………………(kg)

o Outgoing …………………..………………………(kg)

Cubicle shipping weight including circuit

breaker …………………..………………………(kg)

o Cubicle dimensions (L × W × H) ……………………...……………….….(cm3)

o Earthquake protection (coefficient of g) ………...……………………………………...

Type of metal enclosed switchgear ………...……………………………………...

SF6 gas filling pressure (abs) ………...……………………………………...

Minimum SF6 gas operation pressure (abs) ………...……………………………………...

Gas pressure for alarm ………...……………………………………...

Gas pressure for trip ………...……………………………………...

NOTE: For each type of Switchgear an individual data sheet shall be prepared.





NISCO

7.2- Circuit Breakers & Contactor

Circuit breakers:

Current brekers ………...……………………………………...

Plant Unit Number (P.U No.) ………...……………………………………...

Manufacturer’s name and country ………...……………………………………...

Manufacturer’s designation (Type) ………...……………………………………...

Applicable technical ………...……………………………………...

standards ………...……………………………………...

Type of circuit breaker (SF6 or vacuum) ………...……………………………………...

Mass of complete circuit breaker ………...……………………………………...

Creepage to earth over insulation ………...……………………………………...

Minimum clearances: ………...……………………………………...

o Between phases ………………………………………….(mm)

o Between live parts to earth ………………………………………….(mm)

Overall dimension of the installation ………...……………………………………...

Indoor or outdoor installation ………...……………………………………...

Number of phases ………...……………………………………...

Number of poles ………...……………………………………...

Rated Voltages …………………………...………..kV (r.m.s)

Rated frequency …………………………………………(Hz)

Rated insulation level (at IEC service

conditions): ………...……………………………………...

o Rated 1 min. power frequency withstand

voltage ……………………………...……..kV (r.m.s)

o Rated lightning impulse withstand voltage ……………………………………..kV (peak)

Rated normal current (at IEC service

conditions): ………………………..…………… A (r.m.s)

Rated short-circuit breaking current …………………………………… kA (r.m.s)

Rated duration of short circuit ………………….…………………………(S)





NISCO

Rated line-charging breaking current …………………………………… A (r.m.s)

Rated cable-charging breaking current …………………………………… A (r.m.s)

Rated small- indactive breaking current

First pole to clear factor ………………………………………………..

Rated transient recovery voltage (TRV) for

terminal faults …………………………………… kV (r.m.s)

Rated characteristics for short-line faults …………………………………… kA (r.m.s)

Rated short-circuit making current …………………………………… kA (r.m.s)

Rated out-of- phase breaking current …………………………………… kA (r.m.s)

Rated operating sequence ………...……………………………………...

Rated time quantities: ………...……………………………………...

o Rated opening time ……………………………………..……(ms)

o Rated break time ……………………………………..……(ms)

o Rated closing time ……………………………………..……(ms)

o Rated make time ……………………………………..……(ms)

o Max. Time interval between opening of

first and last phase of three phase circuit-

breaker ……………………………………..……(ms)

o Closing time from energize of close coil

to latching of circuit breaker in fully

closed position ……………………………………..……(ms)

Max. Temperature rise under rated load

condition …………………………………...………(ºC)

Max. Peak value of switching over voltage

when interrupting rated line charging current …………………………………………(kV)

Voltages drop across terminals of a phase at

100 A DC ………………………………………… (mV)

Breaking current (Asymmetrical) ………………………………….………...(A)

Number of NO & NC auxiliary contacts ………...……………………………………...





NISCO

Contactors

Fuse type ………...……………………………………...

Fuse rated voltage ………...……………………………………...

Fuse rated current ………...……………………………………...

Contactor type ………...……………………………………...

Contactor rated voltage ………...……………………………………...

Contactor rated current ………...……………………………………...

NOTE: For each type of Circuit Breaker and contractors an individual data sheet shall be

prepared.

7.3- Transformers

Plant Unit Number (P.U No.) ………….………….…………………………

Manufacture’s name and country ………….………….…………………………

Type and designation ………….………….…………………………

Rated capacity ………….………….…………………………

Number of phases ………….………….…………………………

Frequency ………….………….…………………………

Voltage ratio ………….………….…………………………

Cooling ………….………….…………………………

Temperature Rise at rated capacity ………….………….…………………………

Windings ………….………….…………………………

o H.V.

Rated capacity ………….………….…………………………

Voltage rating ………….………….…………………………

Connection ………….………….…………………………

o L.V.

Voltage rating ………….………….…………………………

Connection ………….………….…………………………

(i) Insulation Levels





NISCO

Power frequency test voltage for 60 Sec.

o On windings:

H.V. Neutral ………….………….…………………………

L.V. Winding ………….………….…………………………

o On bushings:

H.V. Winding ………….………….…………………………

H.V. Neutral ………….………….…………………………

L.V. Winding ………….………….…………………………

Impulses withstand voltage, wave 1.2/50 s

o On windings:

H.V. Winding ………….………….…………………………

L.V. Winding ………….………….…………………………

o On bushings:

H.V. Winding end ………….………….…………………………

H.V. Neutral end ………….………….…………………………

L.V. Winding end ………….………….…………………………

(ii) On load tap changer

Tapping Range ………….………….…………………………

Number of tap steps ………….………….…………………………

(iii) Current transformers installed in the H.V.

Bushings

Number for each phase ………….………….…………………………

Number in the neutral ………….………….…………………………

Current Ratios ………….………….…………………………

Standard ………….………….…………………………

(iv) Item fault level ………….………….…………………………

(v) Vacuum Requirements ………….………….…………………………

(vi)Terminations ………….………….…………………………

H.V. ………….………….…………………………

L.V. ………….………….…………………………





NISCO

(vii) Vector group ………….………….…………………………

NOTE: For each type of transformer an individual data sheet shall be prepared.

7.4- DC Supplies and Equipment Battery


Manufacturer name/country of origin ………….………….…………………………

Rating of system:

o Nominal supply voltage of system (V) ………….………….…………………………

o Float voltage of battery (V) ………….………….…………………………

o Battery voltage after 10 hour discharge

period (at 25A discharge rating) (V) ………….………….…………………………

Rated discharge capacity:

o Discharge current (250m sec. impulse) ………….………….…………………………

o At 1 hr. rate (Ah) ………….………….…………………………

o At 10 hr. rate (Ah) ………….………….…………………………

Type of cell (i.e.: Lead acid or alkaline) and

designation ………….………….…………………………

Particulars of cells:

o Voltage per cell when float charged (V) ………….………….…………………………

o Voltage per cell at end of 1 hr. discharged

period (V) ………….………….…………………………

o Voltage per cell at end of 10 hr. discharge

period (V) ………….………….…………………………

o Charging current:

Initial (A) ………….………….…………………………

Starting (Max.) (A) ………….………….…………………………

Continuous (A) ………….………….…………………………

o Final voltage per cell when boost

charged (V) ………….………….…………………………





NISCO

o Maximum permissible instant current at

one minute(A) ………….………….…………………………

o Total resistance of battery (Ohm) ………….………….…………………………

Battery and cell arrangement:

o Number of cells ………….………….…………………………

o Number of tiers and cells per tier ………….………….…………………………

o Type of container (plastic, glass or steel) ………….………….…………………………

o Number of cells and method of assembly

per group (Alkaline batteries only) ………….………….…………………………

o Mass of cell complete with electrolyte (kg) ………….………….…………………………

o Maximum mass of largest transportation (state

item if cell not transported complete) (kg) ………….………….…………………………

o Mass of battery and stands as in service (kg) ………….………….…………………………

o Type of positive plate ………….………….…………………………

o Type of negative plate ………….………….…………………………

o Electrolyte specific gravity at 25ºC, when

the cells are fully charged (gr/cm3) ………….………….…………………………

o Complete battery dimension H×W×H ………….………….…………………………

o Expected life of battery (Year) ………….………….…………………………

Battery fuse: (A) ………….………….…………………………

o Manufacturer and type designation ………….………….…………………………

o Rating- amps. (Ah) ………….………….…………………………

7.5- Battery Charger


Manufacturer name/country of origin ………….………….…………………………

Standard ………….………….…………………………

Input voltage/frequency ………….………….…………………………

Tolerances of input voltage/frequency ………….………….…………………………

Output voltage ………….………….…………………………





NISCO

Output regulation ………….………….…………………………

Output ripple ………….………….…………………………

Protection degree ………….………….…………………………

Max. Charging current ………….………….…………………………

Power rating ………….………….…………………………

Transformer type ………….………….…………………………

Thyristor type ………….………….…………………………

Cooling system ………….………….…………………………

7.6- Lighting


Manufacture’s name and country ………….………….…………………………

Min. Illumination level (Name of area’s) ………….………….…………………………

Max. Illumination level (Name of area’s) ………….………….…………………………

Protection degree of Indoor/outdoor fixture ………….………….…………………………

Indoor fixture type/Lamp type/rating ………….………….…………………………

Outdoor fixture type/Lamp type/rating ………….………….…………………………

Fixture with capacitor ………….………….…………………………

Power factor of lighting ………….………….…………………………

Max. Noise level of lighting ………….………….…………………………

Fluorescent start system ………….………….…………………………

Socket out let type and rating ………….………….…………………………

Switch type and rating ………….………….…………………………

7.7- Low Voltage AC Switchgear

Plant Unit Number (P.U No.) ………………………………………………

Manufacturer name/country and type

designation ………………………………………………





NISCO

Degree of protection (IEC 144) for indoor/

outdoor boards ………………………………………………

Normal current rating of Busbars ……………….….………………………(A)

Short time current rating of Busbars and

connections ………………………………..(1sec.) (kA)

Short time current rating of outgoing fuse

protected connections ……………...…….……………………(kA)

Type of insulation provided on Busbars and

connections ………..………….……………………(kA)

Whether busbar cross section is graded? ………………………………………………

Method of earthing incoming supply circuit ………………………………………………

Type of protection provided within cubicles

(shutters, insulation cover, etc.) ………………………………………………

Are Busbars sectionalized between

cubicles? ………………………………………………

Are down dropper connections segregated

from incoming/outgoing connections? ………………………………………………

Maximum temperature rise and location

within switch-board, any unit when carrying

rated current. ………………………………………………

Type of insulation or material subjected to

this temperature rise ………………………………………………

Method of neutral earthing ………………………………………………

Applicable technical standard ………………………………………………

Nominal service voltage …………………….………………V (r.m.s)

Rated dynamic current of incomer C.B ………………..….………………kA (peak)

Type and designation ………………………………………………

Rated continuous current of incomer C.B …………………….………………A (r.m.s)

Max. Breaking capacity (symmetrical) of …………………..….……………kA (r.m.s)





NISCO

incomer C.B

7.8- Low Voltage Motor Control Center (MCC)

Plant Unit Number (P.U No.) ………………………………………………

Manufacturer name/country and type

designation ………………………………………………

Degree of protection (IEC 144) for indoor/

outdoor boards ………………………………………………

Normal current rating of Busbars ………………….………………………(A)

Short time current rating of Busbars and

connections ………………………………..(1sec.) (kA)

Short time current rating of outgoing fuse

protected connections ………………….………………………(kA)

Type of insulation provided on Busbars and

connections ………………….…………..…………(kA)

Maximum temperature rise and location

within switch-board, any unit when carrying

rated current. ………………………………………………

Type of insulation or material subjected to

this temperature rise ………………………………………………

Method of neutral earthing ………………………………………………

Applicable technical standard ………………………………………………

Nominal service voltage ………………….….………………V (r.m.s)

Rated dynamic current of incomer C.B …………………....………………kA (peak)

Type and designation ………………………………………………

Rated continuous current of incomer C.B ………………….….………………A (r.m.s)

Max. Breaking capacity (symmetrical) of

incomer C.B ………………….….……………kA (r.m.s)

Type of MCB/MCCB’s ………………………………………………

Type of fuses ………………………………………………





NISCO

Type of contactors ………………………………………………

Type of Bimetal thermal relays ………………………………………………

Type of residual current relays ………………………………………………

Type of motor starters: ………………………………………………

o Direct on line ………………………………………………

o Star/delta ………………………………………………

o Soft start ………………………………………………

7.9- Standby Diesel Generator


Diesel:

o Manufacturer’s name and country ………….………….…………………………

o Type designation ………….………….…………………………

o Number of cylinders ………….………….…………………………

o Speed ………….………….…………………………

o Type of cooling ………….………….…………………………

o Coupling ………….………….…………………………

o Start-up time from initiation until circuit

breaker closes ………….………….…………………………

o Number of strokes ………….………….…………………………

o Compression ratio ………….………….…………………………

o Efficiency at rated load ………….………….…………………………

o Fuel injection system ………….………….…………………………

o Specific fuel consumption at: (Based on

generator output) ………….………….…………………………

110% of rated output (lit/kWh) ………….………….…………………………

100% of rated output (lit/ kWh) ………….………….…………………………







NISCO

o Aspiration (Natural or supercharger) ………….………….…………………………

o Type of fuel ………….………….…………………………

Generator:

o Manufacturers name & country ………….………….…………………………

o Type of Generator ………….………….…………………………

o Apparent power (kVA) ………….………….…………………………

o Rated voltage (kV) ………….………….…………………………

o Rated frequency (Hz) ………….………….…………………………

o Power factor ………….………….…………………………

o Number of poles ………….………….…………………………

o Insulation class ………….………….…………………………

o Temperature rise class ………….………….…………………………

o Winding Connection ………….………… star ……………………

o Star point grounding ………….………….…………………………

o Excitation system ………….………….…………………………

o Auto start ………….………….…………………………

o Auto atop ………….………….…………………………

o Protection system ………….………….…………………………

o Cooling system ………….………….…………………………

o Heating system voltage ………….………….…………………………

o Heating system Monitoring ………….………….…………………………

7.10- Low Voltage Electrical Motors

Plant Unit Number (P.U No.) ……………………………………………..…

Driven equipment ……………………………………………..…

Equipment reference number ……………………………………………..…

Manufacturer ……………………………………………..…

Type ……………………………………………..…

Model number ……………………………………………..…

Frame size ……………………………………………..…





NISCO

Horsepower/kW output(HP/kW) ……………………………………………..…

Confirming standards ……………………………………………..…

Voltage (V) ……………………………………………..…

Frequency(Hz) ……………………………………………..…

Max. Voltage(V) ……………………………………………..…

Min. Voltage(V) ……………………………………………..…

Max. frequency(Hz) ……………………………………………..…

Min. frequency(Hz) ……………………………………………..…

Min. volts for starting(V) ……………………………………………..…

Phases ……………………………………………..…

Starting current not to exceed (%) ……………………………………………..…

Service factor (%) ……………………………………………..…

Full load current (A) ……………………………………………..…

Normal continuous duty (%) ……………………………………………..…

o Short time duty (%) ……………………………………………..…

o Peak duty (30s) (%) ……………………………………………..…

Power frequency withstands (1 min.)(kV) ……………………………………………..…

Insulation class ……………………………………………..…

Temperature rise limited to class ……………………………………………..…

Enclosures ……………………………………………..…

Over speed test for 2 min. (%) ……………………………………………..…

Noise levels(IEC 34-9) ……………………………………………..…

o Indoor(dBA) ……………………………………………..…

o Outdoor (dBA) ……………………………………………..…

Heaters ……………………………………………..…

o Voltage (V) ……………………………………………..…

o Wattage (W) ……………………………………………..…

o Power frequency 1 min. test (V) ……………………………………………..…

NOTE: Individual sheet to be provided for each motor





NISCO

7.11- Medium Voltage Electrical Motors

Plant Unit Number (P.U No.) ……………………………………………..…

Driven Equipment ……………………………………………..…

o Equipment Reference Number ……………………………………………..…

Manufacturer ……………………………………………..…

Type ……………………………………………..…

Model Number ……………………………………………..…

Frame size ……………………………………………..…

Conforming standards ……………………………………………..…

o IEC ……………………………………………..…

o NEMA ……………………………………………..…

o ANS I ……………………………………………..…

Voltage (kV) ……………………………………………..…

Frequency (Hz) ……………………………………………..…

Max. Voltage (V) ……………………………………………..…

Min. Voltage (V) ……………………………………………..…

Max. Frequency (HZ) ……………………………………………..…

Min. Frequency (Hz) ……………………………………………..…

Min. Volts for Starting (V) ……………………………………………..…

Phases ……………………………………………..…

Starting Current not to exceed % of FLC (%) ……………………………………………..…

Rated Output (kW) ……………………………………………..…

Service Factor ……………………………………………..…

Short time duty (%) ……………………………………………..…

Peak duty (%) ……………………………………………..…

Full Load Current (A) ……………………………………………..…

Insulation ……………………………………………..…

o Insulation Class ……………………………………………..…

o Temperature rise Limited to class ……………………………………………..…

Enclosures ……………………………………………..…





NISCO

o (TEFC) ……………………………………………..…

Water-to-Air Coolers ……………………………………………..…

o Water velocity in tubes not to exceed

(m/sec) ……………………………………………..…

o Cooler material with clean fresh water: ……………………………………………..…

Type 1: tube material

tube plate material

header material

……………………………………………..…

……………………………………………..…

Type 2: tube material

tube plate material

header material

……………………………………………..…

……………………………………………..…

Air-to-Air Coolers ……………………………………………..…

Over speed test for 2 min. ……………………………………………..…

Noise Levels (IEC 34-9) ……………………………………………..…

o 250 kW-1.5MW-indoor (dBA)

outdoor (dBA)

……………………………………………..…

……………………………………………..…

o 1.5 MW to 10 MW-indoor (dBA)

outdoor (dBA)

……………………………………………..…

……………………………………………..…

Heaters ……………………………………………..…

o Voltage (V) ……………………………………………..…

o Wattage (W) ……………………………………………..…

o Power Frequency 1 min. test (V) ……………………………………………..…

Requirement for neutral connections for

differential protection ……………………………………………..…

14. Sub transient reactance dX (%) ……………………………………………..…

NOTE: Individual sheet to be provided for each motor

7.12- UPS

Plant Unit Number (P.U No.) ………………………………………………..

Manufacturer / country ………………………………………………..





NISCO

Type designation / Version ………………………………………………..

Rating at Cos =0.8 ………………………………………………..

Input voltage and tolerance ………………………………………………..

Output voltage and tolerance ………………………………………………..

Input frequency and tolerance ………………………………………………..

Output frequency and tolerance ………………………………………………..

Harmonic content of output ………………………………………………..

Efficiency ………………………………………………..

Standard ………………………………………………..

Bay pass transformer ………………………………………………..

Protection degree ………………………………………………..

Batteries type ………………………………………………..

Batteries sealed type ………………………………………………..

Batteries work duration ………………………………………………..

7.13- Tele Communication

Plant Unit Number (P.U No.) ……………………………………………….

Manufacturer’s name and country ……………………………………………….

Type designation ……………………………………………….

Protection degree ……………………………………………….

Mounting type ……………………………………………….

Backup battery duration ……………………………………………….

Paging system load speaker ……………………………………………….

Volume control ……………………………………………….

7.14- PFC


Manufacturer’s name and country ……………………………………………….

Type ……………………………………………….

Voltage ……………………………………………….





NISCO

Power withstand voltage ……………………………………………….

Short circuit current ……………………………………………….

Rated MVAR ……………………………………………….

Control voltage ……………………………………………….

Insulation liquid ……………………………………………….

Regulator system ……………………………………………….

Discharge device residual voltage ……………………………………………….

Protection for short circuit and over current ……………………………………………….

Protection degree ……………………………………………….

7.15- Lightning Protection and earthing system


Max. Earthing grid resistance ……………………………………………….

Max. Earthing rod resistance ……………………………………………….

Max. Step voltage ……………………………………………….

Max. Touch voltage ……………………………………………….

Connection type ……………………………………………….

Conductor burying depth ……………………………………………….

Earthing rod specifications ……………………………………………….

Lightning rod specifications ……………………………………………….

Earthing pit specifications ……………………………………………….

Lighting protection for high non metallic ……………………………………………….

Buildings/structures ……………………………………………….

Lightning protection for ordinary non metallic

Buildings……………………………………………….

Lightning protection conductor ……………………………………………….

Main mesh conductor specifications ……………………………………………….

Branch conductor specifications ……………………………………………….





NISCO

8- INSTRUMENTATION AND CONTROL DATA SHEETS

The following data sheets should be filled in for both direct reduction plant and raw material

handling plant and tenderer should prepare and fill enough datasheets for each type of

instrument and control device for both a.m. plants separately.

8.1- GENERAL


- How many years the proposed control

system had been in used in direct

reduction plants

………………………………………………

- Manufacturer of control system ………………………………………………

- System redundancy:

- Central processing unit

- Process interface

- Communication components & BUS

- Power supply

……………………………….………Yes/No

……………………………….………Yes/No

……………………………….………Yes/No

……………………………….………Yes/No

- Degree of automation

(Possibility to run in automatic mode)

………………………………………………

……………………………….………Yes/No

- Component selection, individual testing,

worst-case design.

…………………………………….…Yes/No

- Protection against over voltage ……………………………….………Yes/No

- Passive & active protection for

equipments and systems.

…………………………………….…Yes/No

- Low number of contact point, short

circuit proof output.

……………………………………….Yes/No





NISCO

8.1.2- Plant Control and Supervision

- CRT or LCD based control/Eng. Station ………………………………………………

- Diagnostics system:

- Degree of diagnostics (short

explanation)

………………………………………Yes/No

………………………………………………

- Sequence of event recorder: ………………………………………Yes/No

- Resolution

- Number of input signals

………………………………………………

………………………………………………

- Number of control locations

- Local control room

- Remote central control room

………………………………………………

………………………………………………

………………………………………………

- Provision of proper space and

arrangement for future expansion in

the central control room and building

………………………………………Yes/No

8.1.2.1- Remote and Local Control

- CRT/LCD based local control HMI ………………………………………Yes/No

- CRT/LCD based central control HMI ………………………………………Yes/No

- HMI control facilities:

- Start up/shut down

- Mixed operation possibility

- Lube oil and seal oil control facilities

- Alarm handling

………………………………………Yes/No

………………………………………Yes/No

………………………………………Yes/No

………………………………………Yes/No





NISCO

8.1.3- Plant Protection and Safeguarding

- The following consideration for

instruments:

- Dust weather proof

- Flame proof (if necessary)

- Explosion proof (if necessary)

- IP30 for inside the cabin, buildings

- IP54 for indoor installation

- IP65 for outdoor installation

………………………………………Yes/No

………………………………………Yes/No

………………………………………Yes/No

………………………………………Yes/No

………………………………………Yes/No

………………………………………Yes/No

8.1.4- Availability

- Independent manual control facilities

for all automatic systems.

………………………………………Yes/No

- All drives can be operated from at least

two places

………………………………………Yes/No

- Automatic change over facilities for

duplicate drives.

………………………………………Yes/No

- Redundant power supply from two

sources

………………………………………Yes/No

- Self monitoring and self diagnostic

feature

………………………………………Yes/No

- Equipment testing can be carried out on

load

………………………………………Yes/No

- Distributed automation structure ………………………………………Yes/No





NISCO

- Hierarchical subsystem structure

(processing all the functions of the

individual control level in the I/O

section).

………………………………………Yes/No

- Redundant automation functions ………………………………………Yes/No

- Redundant signal distribution ………………………………………Yes/No

- Redundant monitoring & operation ………………………………………Yes/No

- Redundant structure ………………………………………Yes/No

8.2- Field Instrumentation & Alarm System

8.2.1- Instrumentation

- Instrument vendor list is attached ………………………………………Yes/No

- Separation of control and monitoring

field instruments from protection field

instruments

………………………………………Yes/No

- Uniform type, model and manufacturer

of instruments which perform similar

duties

………………………………………Yes/No

8.2.1.1- Temperature Instruments

- Manufacturer ………………………………………………

- Country of origin ………………………………………………

- Type of thermocouples (double,

single, …)

………………………………………………

- Type of thermocouples (K/T/…) ………………………………………………





NISCO

- Suitable protective sheath /well is

provided

………………………………………Yes/No

- Type of local measurements ………………………………………………

- Accuracy ……………………………………………%

- Protection class of indicators and

transmitters

…………………………………………..….

8.2.1.2- Pressure Instrument

- Manufacturer ……………………………………….………


- Types of pressure instruments .………………………………………………

- Material of sensor .………………………………………………

- Accuracy .………………………………………………

- Protection class of

indicators/transmitters

.………………………………………………

8.2.1.3- Flow Instrument

- Manufacturer ………………………………………………


- Types of flow measurement ………………………………………………

- Material ………………………………………………

- Thickness of orifice edge ………………………………………………

- Accuracy ………………………………………………





NISCO


indicator/transmitters

………………………………………………

8.2.1.4- Level Instruments

- Manufacturer ………………………………………………


- Types of level instruments ………………………………………………

- Material ………………………………………………

- Accuracy ………………………………………………


indicator/transmitters

………………………………………………

8.2.1.5- Control Valve

- Manufacturer ………………………………………………


- Material of valve body ………………………………………………

- Control valve actuators are selected so

that on failure of the operating

medium the valve will automatically

take a safe position

………………………………………Yes/No

- Type of actuator ………………………………………………

- Valve position indication is provided ………………………………………Yes/No





NISCO

- Actuators are sized for positioning the

valve against 1.20 times the Max.

differential pressure

………………………………………………

- Positioner ………………………………………Yes/No

- Limit switch ………………………………………Yes/No

- Torque switch ………………………………………Yes/No

- Hand operated facilities ………………………………………Yes/No

- Control valves are sized for 120% of

normal operating design flow rate

………………………………………Yes/No

- 150% of normal operating design

pressure and temperature

………………………………………Yes/No

- Normal operating point of valve is

60% valve opening position

………………………………………Yes/No

Following tests will be performed:

- Chemical analysis and mechanical test

- Magnetic particle inspection on each body

- Random radiographic inspection on body

- 100% radiographic inspection on welds

- Hydraulic test

- Leak test

- Noise level

………………………………………Yes/No

………………………………………Yes/No

………………………………………Yes/No

………………………………………Yes/No

………………………………………Yes/No

………………………………………Yes/No

………………………………………Yes/No





NISCO

8.2.1.6- Position transducers (encoders)

a- Absolute rotating encoders

- Manufacturer ….…………………………………….…

- Country of origin …………………………………………..

- Resolution …………………………………………..

- Frequency range …………………………………………..

- Rated speed ………………………………..................

- Frequency range …………………………………………..

- Output format …………………………………………..

- Power supply …………………………………………..

b- Incremental encoders

- Manufacturer …………………………………….…….


- Resolution …………………………………………..

- Number of pulse …………………………………………..

- Rated speed …………………………………………..

- Frequency range ……..…………………………….….......

- Output format ……………………………………….….

- Power supply …………………………………………..

8.2.1.7- Load cell

- Application …………………………………………..

- Manufacturer …………………………………………..


- Type …………………………………………..

- Quantity …………………………………………..





NISCO

- Nominal load …………………………………………..

- Max overload without change of

characteristics …………………………………………..

- Max overload without mechanical damage …………………………………………..

- Class …………………………………………….

- Linearity error in full scale output ……………………………………..……...

- Hysteresis in full scale output ………………………………………….....

- Repeatability in full scale output …………………………………………….

- Calibration accuracy …………………………………………….

- Operating temperature …………………………………………….

- All fittings and accessories

are provided ………………………………….…Yes/No

8.2.1.8- Flame & flammable gas monitoring system

- Complete system for continuous

detection and alarming of combustible

and toxic gases is provided ………………..…………….………Yes/No

- Type of sensor ……………………………………………..

8.2.1.9- Instruments Accessories

- Material …………………………………………..…

- Where conditions for steady

instruments reading are unobtainable

on pressure lines due to pulsations, a

snuffer or pulsation damper is

provided

………………..……………………Yes/No





NISCO

- Where instruments are used for the

measurement of fluids which are

corrosive, seal pots are used.

…………………………………..…Yes/No

- Where in piping containing liquid

with considerable amounts of

entrained solids which may block

lines settling chambers are used.

…….………………………………Yes/No

- Instrument valves:

- Isolating valves

- Test and drain valves

……………………………………Yes/No

……………………………………Yes/No

8.2.1.10- Temp monitoring

Reduction gas temp at furnace entry

Reduction gas temp at furnace exit

Cooling gas temp at furnace entry

Cooling gas temp at furnace exit

Top gas temp at fuel gas mixer entry

Combustion air temp at reformer

entry

Heating media temp at recuperator

entry

Exhaust gas temp from recuperator

………………………………………Yes/No

………………………………………Yes/No

………………………………………Yes/No

………………………………………Yes/No

………………………………………Yes/No

………………………………………Yes/No

………………………………………Yes/No

………………………………………Yes/No

8.2.1.11- Vibration Monitoring

a. Type and location of pick-up

b. No. of pick-up

………………………………………………

………………………………………………





NISCO

8.2.2- Instrument Installation

- Applicable standard for instrument

installation

………………………………………………

8.2.3- Cabling

- Adaptable box between flexible cables

of field devices and permanent armored

cables

………………………………………Yes/No

8.2.4- Measuring Points

a. Analog measuring points:

- Number of pressure measuring point ………………………………………………

- Number of temperature measuring point ………………………………………………

- Number of level measuring point ………………………………………………

- Number of flow measuring point ………………………………………………

b. Number of Discrete measuring points ………………………………………………

8.3- CONTROL SYSTEM

8.3.1- General

- Type of main control system ……………………………………..DCS/PLC

- Type of Aux. plant control system ……………………………………..DCS/PLC

(if different from main)





NISCO

a. Programmable Logic Controller (PLC)

- Manufacturer of PLC ………………………………………………

- Type & model of PLC ………………………………………………

- Type & model of CPU ………………………………………………

- For which main or Aux. plants PLC

has been proposed ………………………………………………

- Modular design of PLC ……………………………………... Yes/No

- CPU and BUS redundancy ……………………………………... Yes/No

- Self diagnostic capability ……………………………………... Yes/No

- CPU functions, all function

according to part 2.3.2.2, of

engineering standard (Annex IV)

……………………………………... Yes/No

- Memory capacity ………………………………………………

- I/O units general features ………………………………………………

- Type of input signals ………………………………………………

- HMI of PLC (CRT/LCD or

conventional panel)

………………………………………………

- Programming device ……………………………………... Yes/No

b. Distributed control system (DCS)

- Manufacturer of DCS ………………………………………………

- Type and model of DCS ………………………………………………

- Number of operator stations ………………………………………………





NISCO

- Number of shift engineer stations ………………………………………………

- Number of engineer and diagnostic

stations

………………………………………………

- Programming device …………………………….…………Yes/No

- Redundancy:

- Main control system

- Data communication system

- HMI parallel redundancy

- Power supply

……………………………….………Yes/No

……………………………….……... Yes/No

……………………………….………Yes/No

…………………………….………... Yes/No

…………………………….…………Yes/No

- Capability of DCS of being

expanded for control and

monitoring of future expansion

…………………………….…………Yes/No

- Spare I/O capacity ………………………………………………

- Installed I/O capacity ………………………………………………

- Diagnostic for hardware and

software

- Operating temperature range

…………..……………………………Yes/No

……………………….…….…………………

- Operating humidity range ………………………..………………………

- Facilities for emergency shut down

of the plant

…………………..……………………Yes/No

- Facilities for monitoring station

common auxiliaries in remote

…………………..……………………Yes/No





NISCO

8.3.2- System Hardware:

a. Data communication

- Data communication standard ……………….………………………………

- Reliable communication by data

protection methods and

acknowledgement of individual

message

……………….………………………Yes/No

- Redundancy of data communication

system

…………………..……………………Yes/No

b. Control stations:

- Independence of control modules

from each other

………………..………………………Yes/No

- Set point and output ramping speeds

to be adjustable through engineering

station or portable maintenance tools

……………..…………………………Yes/No

- Final element fail safe position in case

of control station failure

………………………..………………Yes/No

- Control stations redundancy …………………………………..……Yes/No

- Variety of used control modules (No.

of different types to be used).

………………………………..………………

c. I/O modules variety and functions:

- 4-20 mA inputs/output ……………………………….….……Yes/No

- 1-5 V inputs/outputs ……………………………………..…Yes/No





NISCO

- Thermocouple input with cold

junction compensation

………………………………….……Yes/No

- RTD input …………………………………..……Yes/No

- Pulse input …………………………………..……Yes/No

- Dry contact …………………………………..……Yes/No

- BCD signal ………………………………..………Yes/No

- Direct digital signals from smart

transmitters

…………………………………..……Yes/No

- Serial I/O link & type of them …………………………………..……Yes/No

- Square root extracting …………………………………..……Yes/No

- Noise suppression filtering …………………………………..……Yes/No

- Open or grounded thermocouple

detection

…………………………………..……Yes/No

- Wire break monitoring …………………………………..……Yes/No

- Short circuit proof …………………………………..……Yes/No

- Valid-invalid input ………………………………..………Yes/No

- Over range protection …………………………………..……Yes/No

- Electrical isolation …………………………………..……Yes/No

- Independent interface modules for serial

link, with MIS & other systems

…………………………………..……Yes/No

- Analogue input scan time …………………………………..….….… ms

- Digital input scan time …………………………………..……..… ms

d. HMI:





NISCO

Operator stations (OS): ………………………………………………

- CRT/LCD resolution ………………………………………………

- Type of OS ………………………………………………

- Number of OS/unit ………………………………………………

- Data storage type and capacity ………………………………………………

e. Engineering station (ES):

- CRT/LCD resolution ………………………………………………

- Access to all modules of the system by

engineering work station

……………………………………... Yes/No

- Type of ES ………………………………………………

- No. of engineering stations ………………………………………………

- Modifying configuration data, creating

new video pages or modifying old ones

……………………………………... Yes/No

- Portable configuration device is also

available

………………………………………………

-VCD/DVD writer for E.S. are provided …………………………….………... Yes/No

- Printer type ………………………………………………

- Color graphic capabilities of printers ………………………………………………

- Printers manufacturer and model No. ………………………………………………

- No. of hard copiers ………………………………………………





NISCO

- Type of hard copiers

f. Computers and monitors (for HMI & ES)

- Manufacturer

- Country of origin

- CPU type & speed

- Hard disk, RAM and video RAM type

& size

- Mouse or track ball provided

- CD-ROM /DVD-ROM provided

- Monitor type & size

………………………………………………

……………………………………………….

……………………………………………….

……………………………………………….

……………………………………………….

……………………………………………….

……………………………………………….

………………………………………Yes/No

………………………………………Yes/No

……………………………………………….

g. Alarm system:

- Standard of alarm system sequence

h. Power supply:

…………………………………………….…

- Power supply redundancy ……………………………………... Yes/No

- Monitoring of breakers and failure

alarm

……………………………………... Yes/No

8.3.3- System Software:

- Modular software ……………………………………... Yes/No

- Management and diagnostic routines ……………………………………... Yes/No





NISCO

- Real time operating system and data

base

……………………………………... Yes/No

- HMI operating system ……………………………………...............

- ES operating system ……………………………………...............

8.3.3.1- Control software:

- Mathematical functions ……………………………………... Yes/No

- Logic functions ……………………………………... Yes/No

- Continues control ……………………………………... Yes/No

- PID algorithm modification ……………………………………... Yes/No

- Control loop modes and cascade test

and set

……………………………………... Yes/No

- Automatic adjusting of set points ……………………………………... Yes/No

8.3.4- Monitoring and DAS Functions:

- Indication of analog and digital

controlled or non controlled variables

……………………………………... Yes/No

- Manipulation of control set point and

alarm setting values

……………………………………... Yes/No

- Performing hourly, shift end, daily and

monthly average and historical trends

and logs

……………………………………... Yes/No

- System diagnostic reporting ……………………………………... Yes/No

- Menu display ……………………………………... Yes/No





NISCO

- Over view display ……………………………………... Yes/No

- Group display ……………………………………... Yes/No

- Detail display ……………………………………... Yes/No

- Trend group display ……………………………………... Yes/No

- Single trend display ……………………………………... Yes/No

- Interactive color dynamic control

configuration, process and logic

graphic display

……………………………………... Yes/No

- Alarm summary display ……………………………………... Yes/No

- Alarm processing and display ……………………………………... Yes/No

- System self diagnostic display ……………………………………... Yes/No

- System hardware status display ……………………………………... Yes/No

- Real time trend and curve display ……………………………………... Yes/No

- Report display ……………………………………... Yes/No

- Log sheet display ……………………………………... Yes/No

- Guide message display ……………………………………... Yes/No

- Help message display ……………………………………... Yes/No

- Logs and reports ……………………………………... Yes/No

- The graphic display of variables by bar-

graph which shows deviation value

……………………………………... Yes/No

- Presenting the alarm signals for each

variable at the bottom side of the screen

and showing deviation indication

……………………………………... Yes/No





NISCO

- Measured value for each analog

variable on graphic display

……………………………………... Yes/No

- Status of equipment such as pumps,

on/off valves on graphic display

……………………………………... Yes/No

- Analog and discrete variable alarm on

graphic display

……………………………………... Yes/No

- Commands for turning ON or OFF the

pumps, valves, etc. in operator display

……………………………………... Yes/No

- Setting controller set points and

manipulating of process variables in

manual mode in operator display

……………………………………... Yes/No

- The graphic is programmed based on an

international standard such as ISA

S5.1,S5.3,S5.5 for instrument and

equipment symbols

……………………………………... Yes/No

- Alarm message with tag identification

and time tag and description

……………………………………... Yes/No

- No of different alarm priorities ……………………………………... Yes/No

- Alarm summary display provided ……………………………………... Yes/No

- Group printing ……………………………………... Yes/No

- Event printing ……………………………………... Yes/No

- Sequence reporting ……………………………………... Yes/No

- Sequence of events reporting ……………………………………... Yes/No

- Periodic logging ……………………………………... Yes/No





NISCO

- Shift engineer station functions same as

operator station

……………………………………... Yes/No

- Modifying the scaling and tuning

parameters of controllers by

engineering station

……………………………………... Yes/No

- Modifying configuration during system

operation without interference to other

device or loops by engineering station

……………………………………... Yes/No

8.4- ANALYZER SYSTEM

- Manufacturer ……………………………………………….

- Type ……………………………………………….

- Sensitivity ……………………………………………….

- Accuracy ……………………………………………….

- Time of analysis ……………………………………………….

- Auto calibration facility ……………………………….………Yes/No

8.5- TV CAMERA SYSTEM

- Manufacturer

- Type

- Focus

- Zoom

- Water cooling jacket and air purge are

provided

……………………………………………….

……………………………………….………

……………………………………………….

……………………………………………….

………………………….……………Yes/No





NISCO

8.6- COMMUNICATION TO MANAGEMENT INFORMATION SYSTEM

- All Hardware and software requirements for

communication to MIS system are provided …………………………..………… Yes/No

8.7- OTHER REQUIREMENTS

8.7.1- Documentation

- List of documentation is attached ……………………………………... Yes/No

8.7.2- Test and repair requirements

- Complete set of special tools shall be

submitted for engineer approval

………………………………………. Yes/No

8.7.3- Test

- Factory test shall be done and test report

will be delivered for engineer approvals

……………………………………... Yes/No

8.7.4- Training

-According to section 11.4 of engineering

standards, instrumentation and control

(Annex IV)

……………………………………... Yes/No