Project : Nagpur Grinding Unit

Part : Technical Specification For

Laboratory Equipments

16/12/2011
Rev - 0

CONTENTS
1.0

INTRODUCTION

2.0

BASIS OF DESIGN

3.0

DESIGN STANDARDS

4.0

SCOPE OF SUPPLY

5.0

DESIGN DATA & TECHNICAL SPECIFICATION

5.1. LABORATORY AUTOMATION
5.1.1.

X-RAY ANALYSER

5.1.2.

ON-LINE PARTICAL SIZE ANALYSER

6.0

INSPECTION AND TESTING SCHEDULE AT MANUFACTURER'S WORKS

7.0

SUBMITTAL OF DRAWINGS/DOCUMENTS AND ENGINEERING ACTIVITIES

8.0

TRAINING OF PLANT PERSONNEL

9.0

PERFORMANCE GUARANTEES AND PENALTIES

10.0

DELIVERY SCHEDULE

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Part : Technical Specification For

Laboratory Equipments

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1.0 INTRODUCTION
M/s Abhijeet New India Cement Pvt.Limited, are setting up a 1.5 MTPA Green Field Cement
grinding Plant at Nagpur (Maharashtra). For Site Conditions & other information General
Conditions of Supply shall be referred. General condition shall be furnished to selected Bidder.

2.0 BASIS OF DESIGN

2.1 CONTINUITY OF POWER SUPPLY FACILITIES FOR INSPECTION, TESTING, MAINTENANCE, CLEANING

AND GENERAL REPAIRS WILL BE OF PRIME IMPORTANCE IN THE DESIGN.

2.2 STANDARDISATION OF EQUIPMENT AND ITS COMPONENTS TO REDUCE THE NECESSARY STOCK OF

SPARE PARTS.

2.3 ALL ELECTRICAL EQUIPMENT SHALL BE DESIGNED FOR OPERATION AT THE REQUIRED CAPACITY IN

AMBIENT AIR TEMPERATURES (49 C) IN A DUSTY PLANT ENVIRONMENT.

2.4 THE DESIGN SHALL INCLUDE THE NECESSARY PROVISIONS FOR THE SAFETY OF MAN, MACHINE AND

ENVIRONMENT.

2.5 THE VOLTAGE, FREQUENCY AND SYMMETRICAL SHORT CIRCUIT LEVELS FOR SUPPLY AND

DISTRIBUTION SHALL BE AS FOLLOWS: 2.5.1

INCOMING POWER (GRID POWER)

3 PH, 220 KV 10%, 50 HZ 3%

2.5.2

MEDIUM DISTRIBUTION VOLTAGE

3 PH, 11 KV 10%, 50 HZ 3%

2.5.3

MV FAULT LEVEL

40 KA AT 11KV

2.5.4

MV SYSTEM OF EARTHING

NON-EFFECTIVELY EARTHED

2.5.5

LV DISTRIBUTION VOLTAGE (TN-S)

3 PH, 415 V 10%, 50 HZ, 3%,

50 KA MIN.

2.5.6

LIGHTING, PLUGS SOCKET AND AUX. EQPT. : 230V, 1 PH + E + N , 50 HZ

2.5.7

WELDING OUTLETS

415 V, 3PH + E + N, 50 HZ

2.5.8

EMERGENCY POWER

415V, 3 PH +E + N, 50HZ

2.6 AUXILIARY CONTROL VOLTAGE

2.6.1 HV & MV SWITCHGEARS

2.6.2 MCC

110 V-DC & 220 V-AC + E + N, 50HZ

220 V AC 1 PH. + E + N, 50HZ

2.6.3 CONTROL SUPPLY

2.6.4 (ACTUATORS, SOLENOIDS, AND PROXIMITY ETC):

220 V AC, 1PH. + E + N, 50HZ

2.6.5 AUTOMATION CONTROL

2.6.6 DIGITAL INPUT / OUTPUT

220 V AC 1 PH. + E + N, 50HZ

2.6.7 DIGITAL INPUT / OUTPUT

220 V AC 1 PH. + E + N, 50HZ

2.6.8 ANALOGUE INPUT / OUTPUT

4-20MA

2.6.9 UNINTERRUPTIBLE VOLTAGE

220 V, 1 PH, 50 HZ.

2.6.10 ALL VARIABLE SPEED MOTORS SHALL BE SQUIRREL CAGE WITH VVVF DRIVE.

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Part : Technical Specification For

Laboratory Equipments
2.7

ENVIRONMENT CONDITIONS

2.7.1

DESIGN TEMPERATURE FOR INDOOR EQUIPMENT

Rev - 0

MIN. 06C
Max. 49C

DESIGN TEMPERATURE FOR OUTDOOR EQUIPMENT

2.7.2

MIN. 06C
MAX. 49 C

2.7.3

DEGREE OF PROTECTION FOR INDOOR EQUIPMENT

IP4X

2.7.4

DEGREE OF PROTECTION FOR OUTDOOR EQUIPMENT :

IP55

2.7.5

DEGREE OF PROTECTION FOR FIELD INSTRUMENTS :

IP65

2.7.6

DEGREE OF PROTECTION FOR PUSH BUTTON STATIONS:

IP65

2.8

SIGNAL COMMUNICATION AND INTERFACE WITH PLANT PLC

1.1.1. MV Switchgear Meters & Relays : Profibus/Field Bus (Profibus is preferred)

1.1.2. Switchgear Meters & Relays : Profibus/Field Bus (Profibus is preferred)
1.1.3. LV Switchgear (PCC) Controls

Hardwire/ Profibus

1.1.4. Motor Control Centre (MCC) Controls :

Profibus

1.1.5. Process Monitoring Instruments

Profibus/ Hardwire

1.1.6. Machine Safety Instruments

Hardwire

1.1.7.

Profibus/ Hardwire

3.0

Sub Control Systems

DESIGN STANDARDS:

In general, the equipment/components shall conform to the latest edition of relevant

Standards of the Indian Standards Institution.
Wherever the Indian Standards do not exist, the equipment/ components shall be designed,
assembled and tested in accordance with the latest editions of the Standards of the
International Standard Institutions, Institution of Electrical & Electronics Engineers, USA
(IEEE), National Electrical Manufacturers Association, USA (NEMA), International ElectroTechnical Commission (IEC) or National Standards Institution of the country where they are
manufactured.
The equipment shall also conform to the latest International Standard Institutions as regards
safety, earthing and other essential provisions specified therein for installation and operation
of electrical plants.
4.0

SCOPE OF WORK
The scope of supply and services shall include design, engineering, manufacturing, software
development, testing, documentation and handing over the complete Laboratory Equipments.
The detailed scope of work is as per Annex-IV-B-4 enclosed with the specifications.

ANICPL

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Laboratory Equipments

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5.0 TECHNICAL CONCEPT & FUNCTIONAL REQUIREMENT OF LAB EQUIPMENTS

GENERAL
01

The System shall include suitable compact instruments, incorporating latest technology
with solid-state modular plug-in construction.

02

The Scope shall include necessary companion flanges and other accessories to make the
system complete and operational. Any device not included in the specification but
considered necessary for proper erection, mounting and operation of the equipment shall
be deemed to be within the scope of supply under this specification.

03

To reduce inventory, as far as possible, standard equipment in standard sizes and ratings
shall be supplied. The purchaser reserves the right to select the equipment of a particular
manufacturer and the Supplier shall supply equipment of that particular make, if so
required.

04

The openings for ventilation and forced draft etc. shall be suitably protected with screens.
When screens are provided on top of the equipment, means shall be provided to protect
them from falling objects.

05

The equipment should be designed so as to ensure safety of operating and maintenance

personnel. Aspect of ease of maintenance, testing and repair should be given due
consideration while designing the equipment.

06

The equipment shall be sturdy and continuous duty type. The instruments must retain
their guaranteed accuracy / sensitivity / repeatability under the conditions existing in a
cement plant.

07

The equipment shall be tropicalised and given protective dips to prevent any damage due
to fungus, mildew etc.

08

Power shall be made available at 415V + 10%, 3 phase, 50 Hz + 5%. For other voltages,
adequately rated step down transformers / power supply units shall be provided by the
supplier. 220 V AC UPS supply for Electronics & other critical items shall be provided at
one point.

5.1 TECHNICAL FEATURES

5.1.1

X-RAY ANALYSER
01

The X-Ray fluorescence spectrometer will be applied for off-line chemical analysis of raw
materials like fly ash, gypsum, clinker, cement etc.

02

The facilities for sample preparation, pressed powder tablets shall be included

03 X-Ray Fluorescence Spectrometer

ANICPL

.A high standard of accuracy is required.

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Part : Technical Specification For
Laboratory Equipments

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Multi channel spectrometer for simultaneous determination of following key elements

Si, Al, Fe, Ca, Mg, S, K, Na, (8 elements) with one Goneometer.

Optionally Multi channel spectrometer for simultaneous determination of following

key elements Si, Al, Fe, Ca, Mg, S, K, Na, Cl & C (10 elements) with one Goneometer.

X-ray tube of suitable wattage, without sacrificing sensitivity of detection

preferably X-ray Tube wattage should be 2.2 to 2.5 KW.
-

External air/water or water/water cooler system for close circuit water cooling Xray spectrometer.

Spare part kits for spectrometer and cooler.

Operational supplies such as counter gas, sample rings etc. for approximately 2
years.

04 Standard samples for calibration for X-ray analyser shall be the part of the supply.
5.1.2

ON-LINE PARTICLE ANALYSER

The system shall be based on Laser diffraction principle for rapid reproducible means of measuring
the whole particle size distribution i.e. both size by size classification as well as average diameters
& surface area.
Measuring principle

: Laser Diffraction

Particle size range

0.3 to 300-1000 micron (dry) without changing the calibration or

optic system

The resolution of the results to be divided in > 30 classes

Dry

Suitable to operate in air suspension. Compressor air will be

supplied by ANICPL necessary moisture separator to be
considered by supplier.

Calibration

Suitable for automatic calibration and must use international

standards. An option should exist to use any other standards in
case of any specific need

The particle analyser shall be applied for particle size analysis of cement.
The particle size range analysed with the instrument shall be 0.3 micron to 300-1000 micron. The
instrument shall be fully automatic. The switchover shall be in less than a minute.
The measurement shall be displayed on a computer. The computer shall be with the following
minimum configuration:

Intel Pentium IV processor 2.66 GHz. or better

512 MB RAM

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Project : Nagpur Grinding Unit

Part : Technical Specification For

Laboratory Equipments

256 KB cache memory

80 GB HDD

SVGA graphics

Ethernet adapter

Keyboard with mouse

Windows 2000/ XP operating system

22 TFT colour monitor

All related system software

DVD writer

Laser printer with auto sheet feeder

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The measurement time shall be less than 1 min.

The results of the analysis shall be displayed on the computer screen in the following ways:

Curves of percentage by weight, cumulative undersize or oversize

Graphically by weight, Area, no. of particles

Possibility of processing measurements for values of any diameters as specified

Possibility of processing by different proven laws

by user

Software configuration
The software shall be Windows2000/XP based to be compatible with plant DCS. The complete
instrument operation and control should be simple along with full range of analysis and data
interpretation facilities. The system software shall have compatibility to integrate with QCX Lab
Automation system.
The software measurement control should have operator alarms of incorrect actions/conditions. It
should have controlled access providing the security of operation.
Sampler

5.1.3

Auto sampler for fully automatic sampler to measure samples online.

Automatic cleaning of lens assemblies.

DCS

A suitable designed process controller shall be provided for operation and control of X-ray analyser,
particle size analyser. The process controller shall be modular and open in architecture. The details of
process controller shall be furnished
6.0

INSPECTION AND TESTING SCHEDULE AT MANUFACTURER'S WORKS

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Laboratory Equipments

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The equipment shall be Inspected/Tested which may be witnessed by the Purchaser/Purchaser's

representatives. The Supplier shall be responsible for providing instruments of correct accuracy that
may be required for carrying out these tests. All tests shall be carried out as per relevant Indian
Standard Specifications or other approved International Standard Specifications.
7.0

SUBMITTAL OF DRAWINGS/DOCUMENTS AND ENGINEERING CTIVITIES:

The drawings/documents in six (6) sets shall be submitted for scrutiny /approval. Six sets of final
approved drgs./documents including up dated and as built shall be provided to the purchaser.
Three sets of complete documentation as mentioned above including as built drawings and
documents should be provided as soft copy. All drawings, GA, circuits, loop diagrams, system
architecture etc. shall be in Auto cad format and other documents in PDF/ HTML / XML as
applicable
8.0 TRAINING OF PLANT PERSONNEL:
The Supplier shall provide the following training to the two engineers for trouble free operation
and maintenance of the equipment.

8.1

AT MANUFACTURER'S WORKS/DESIGN OFFICE

01 Acquaintance with the inner details of system being supplied.
02 Acquaintance with the hardware and software used
03 Programming, incorporating changes in the programme, optimisation of control loop
etc.
04 System and component faultfinding
05 Minor repairing of the defective equipment/components at site.
06 Erection and commissioning procedures
07 Preventive maintenance of the equipment supplied.
08 Also refer to section 2.5 above regarding training

8.2

ON JOB TRAINING AT PLANT SITE

1 Plant personnel will be associated actively with software
Development erection and commissioning
2 All the pre-commissioning and commissioning tests and the set
Values will be made available to the plant personnel.
3 All the commissioning problems will be discussed and explained to the plant personnel.

8.3

TRAINING SCHEDULE
The training at the Manufacturer's Works/design office / OEMs works shall be arranged for two
engineers.

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Laboratory Equipments

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The training schedule shall be worked out in consultation with the purchaser's representative that
the personnel are mobilised for training at the appropriate stage of manufacturing and design.
9.0

PERFORMANCE GUARANTEES AND PENALTIES:

The successful Bidder shall guarantee the performance of. In case of trouble/ problem with the
equipment, the Bidder shall have to make suitable modifications, repairs, replacement at his cost as
may be called for to bring the equipment up to the desired/specified level of performance, failing
which the equipment shall be deemed to have failed to perform and is liable for rejection and the
Purchaser shall have the right to modify/replace the equipment at the risk and cost of the Supplier.

10.0 DELIVERY SCHEDULE

In order to maintain the overall time schedule for the project implementation, the Bidders shall
confirm to supply and complete the erection, testing, commissioning and handing over of the x-Ray
analyser within 8 months from the date of issue of Letter of Intent.

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