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M/S.

RUNGTA MINES LIMITED


DHENKANAL, ODISHA, INDIA

SPECIFICATION NO.: 1174/RMLD/TS/MECH-01

FOR

DESIGN, ENGINEERING, SUPPLY, SUPERVISION OF


ERECTION & COMMISSIONING

OF

INDUCTION FURNACE

IN

STEELMELT SHOP

AT

M/S. RUNGTA MINES LIMITED,

DHENKANAL STEEL PLANT, DHENKANAL, ODISHA

JUNE, 2018

MAKNAN CONSULTANCY PVT LTD


AE 767, SECTOR-1, SALT LAKE
KOLKATA – 700 064

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TECHNICAL SPECIFICATION
OF
INDUCTION FURNACE
M/S. RUNGTA MINES LTD. DHENKANAL STEEL PLANT

1.0 INTRODUCTION

M/s. Rungta Mines Limited (RML) is setting up a mini steel plant at


Dhenkanal, Odisha, which will comprise DR Plant, Steelmelt Shop and
Rolling Mill for production of TMT construction rebars.
The steel plant will be built in phases. A DR plant of 1 x 500 tpd
capacity is now under construction. Initially, the Steelmelt Shop will
comprise 4 x 20-ton capacity Induction Furnaces (IF) and 1 x 6/11 m
radius Billet Caster for production of concast billets.
A Ladle Treatment Station for dephosphorisation and refining of liquid
steel will be built in the Steelmelt shop at a later stage. Rolling Mill also
is planned in future.

This Technical Specification is issued for design, manufacture, supply,


supervision of erection and commissioning of 4 x 20-ton Induction
Furnaces at Dhenkanal plant. General Layout Drawing no. 1174-RMLD-
LAY-001 (Rev-03) indicating the preliminary layout of Steelmelt Shop is
enclosed for information.

Plant and equipment for the Induction Furnace will be provided with
state-of-the-art features which will enable operational and maintenance
flexibility, assist in increased output and ensure maximum availability
of the furnace.

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2.0 TECHNICAL SPECIFICATION OF INDUCTION FURNACE

No. of Induction Furnace Three (24 Pulse) to be located in 1


block of 3 X IF
No. of crucibles 2 per IF (Heavy Steel frame)
Nominal liquid steel capacity 25 MT
Maximum tap weight 27.5 MT
Furnace charge-mix 80% DRI with 84% recovery,
10% scrap with 96% recovery,
10% pig iron with 93% recovery.
Overall average yield 86.1%.
Melt temperature 1600 – 1625 0 C
Estimated No. of heats per day/furnace 10 (average), 12 (maximum)
Rated converter capacity of Furnace 7500 Kw.
Tenderer to check and confirm.
Maximum capacity for melting 7500 Kw.
Tenderer to check and
confirm.
Line power factor Above 0.98
KVA required at input of converter To be specified by Tenderer
Sintering panel 2 x 600 Kw, 12 pulse. To feed 3
furnaces. Tenderer to
check and confirm
Melt rate with above charge-mix To be specified by Tenderer
Energy consumption/ton liquid steel To be specified by Tenderer
with above charge-mix
Expected no. of heats/day/IF To be specified by Tenderer
Furnace availability To be specified by Tenderer
Fume Extraction System (FES) The Tenderer shall indicate the
gas volume, temperature and
dust load for design of the FES
by others.

2.1 Reference copy of Layout must be submitted in soft copy in 3IF,1C


basis (including sinter panel)
2.2 Tenderer shall furnish break-up of expected tap to tap time of a heat
considering the given charge-mix and indicate overall yearly availability
of IF.

RML D: Induction Furnace June 2018 2|Page


2.3 Hydraulic unit for tilting of furnace shall consist of pump with motor,
reservoir, direction control valve, pressure relief valve, pressure gauge,
return line filter with breather valve etc and the total unit shall be
mounted on common frame with seamless pipes and fittings. The
hydraulic pumps shall be of (1W+1S) configuration.
2.4 Tenderer shall indicate the in-built measures considered in the system
to empty full crucible in case of failure of motor of hydraulic power pack
and power failure.
2.5 Tenderer shall recommended refractory for crucible along with expected
life considering intermediate patching

3.0 UTILITIES AND SERVICES

The following utilities will be provided by the Purchaser at the


battery limit at the nearest shop column to be mutually agreed
upon:
3.1 Electric Power

 Electric power available at the plant is as follows:

a) 33kV, 3-phase, 50 Hz power supply for furnace


transformer.
b) 415V, 3-phase, 4-wire, 50 Hz for all other equipment
including motors up to 200 kW rating.
c) Control Voltage: 220V, 1-phase, 50Hz
d) The expected voltage and frequency variation will be in
the range of 10% and 3% respectively.
 If any equipment is designed for a voltage different from
the above, necessary transformer and conversion
equipment shall be included in the tender.
 Power supply to LT MCC will be made available at 415 V
from the shop load-Centre substation.

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 The tenderer shall furnish drive list of connected load
along with the emergency load requirement for operation
during power failure for safety of equipment.
 The tenderer shall furnish bus duct sizes for
interconnection between furnace transformer and furnace
panel along with Sintering transformer and Sinter Panel.
 The Tenderer shall indicate the possibilities of Harmonic
generation in the system, and indicate whether Harmonic filters
are recommended to maintain Power factor 0.98.
 Tenderer to include Ground Leak Detector system and
indicate details of the same

3.2 Instrumentation & Automation


The followings are to be included in the offer and details to be
provided:
 The relevant P&I diagram in Autocad Format must accompany
the offer
 List of field instruments as considered
 Micro PLC based interlocking for each Electrical Panel
operation.
 Interface requirement with the Purchaser’s Utility Systems, if
any.
 Annunciator panel
 Fault detector for individual component
 UPS to have minimum 30 min backup
 Optional price for overall PLC based SCADA System

3.3 Compressed Air


 Tenderer to indicate the requirement of plant grade
compressed air for general purpose and instrument
grade air, (if required).
 Compressed air shall be supplied by the Purchaser at
the battery limit at desired pressure.

RML D: Induction Furnace June 2018 4|Page


3.4 Cooling Water
 Tenderer to indicate the quantity and quality of water
required. The water shall be supplied at battery limit at
desired pressure and flow. Purchaser will receive the
return water at the same battery limit. Tenderer to
indicate the pressure at which water will be given at the
battery limit.
 The tenderer shall indicate the requirement and
duration of emergency water supply for operation
during power failure for safety of equipment.
 Tenderer must include 2 pumps (1W +1S) for DM water for
Electrical Panel Cooling.
 Tenderer must include 2 pumps (1W +1S) for Hydraulic
Panel Cooling.
 Tenderer shall include flow switches in place of pressure
switches in water circuit

3.5 Other Facilities

If any utility services other than those mentioned above


are required for the equipment, the tenderer shall indicate
the technical parameters (temperature, pressure, quality
etc.) and quantities required in their offer.

4.0 SCOPE OF WORK

4.1 The scope of work of the Tenderer will include design,


manufacture, supply, supervision of erection and
commissioning of the Induction Furnace.
4.2 Scope of supply shall be complete in all respects including
mechanical, electrical, instrumentation, automation, utility
and services equipment.

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4.3 Division list of scope of supply is broadly indicated in Annex-1.
It may be noted by that all equipment and accessories required
for safe and satisfactory operation of the furnace are to be
included in scope of supply, even if not specifically mentioned
in the Annex-1.

4.4 All commissioning spares, consumables and operating


supplies will be included in the main scope of supply.
An itemized list of 2 years’ spares along with price will be
submitted by the Tenderer.

5.0 PERFORMANCE GUARANTEE PARAMETERS


The following performance guarantee parameters shall be indicated by
the Tenderer:
- Power consumption per ton of liquid steel without the
auxiliary units considering the given charge-mix
- Tap to tap time, mins with break-up of activities
- Tap weight, ton – Nominal & maximum
- System efficiency

6.0 COMPLETION PERIOD


The offer shall include a bar chart showing all activities like design &
engineering, supply, erection, start up and commissioning, performance
guarantee tests etc.

7.0 DOCUMENTS TO BE SUBMITTED WITH OFFER


The offer shall contain the following information/documents:

RML D: Induction Furnace June 2018 6|Page


 Detail technical parameters of plant and equipment with a
brief write up on special features, operation highlights and
weight etc. including information sought in Item 2.0 above
 General arrangement drawings of Furnace (plan and
section) indicating transformer location and other details.
 General arrangement drawings for Power units and PLC
functions as offered.
 P&I/ Schematic water flow diagram
 Performance guarantee parameters
 Division list of supplies indicating scope of Tenderer and
Purchaser
 List of exclusions, if any
 Break-up of price for main items
 Supervision charges for Erection and Commissioning
 List of 2 years’ spares with item-wise price
 Delivery period and commercial terms and conditions
 Any other document considered relevant for the project

8.0 PRICES

The price shall be quoted for delivery duly packed F.O.R site basis.
Components of taxes, duties, freight, packing, insurance etc. shall be
shown separately. Commissioning spares price shall be included in the
main package and 2 years’ operating spares shall be quoted separately
item wise.

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