Ducon Technical Proposal - Rev00 - 15.01.2018

Alumina Unloading & Transportation System
for Smelter Plant, Angul Odisha
Proposal No.: DTIPL/NALCO-AHS/Rev00 Date: 15.01.2018

Reference: NIT No. NBC/MM/PR 3000002927/AUT/2017/PT/77 Page 1 of 24
1. Preface:
M/s NALCO (National Aluminium Company Limited), Nalco Bhavan, Bhubaneswar, Odisha, has
floated Notice Inviting Tender wide Reference no. – NBC/MM/PR 3000002927/AUT/2017/PT/77
Dtd 10/11/2017 for proposed package of Alumina Unloading and Transportation System at
Smelter Plant at Angul, Odisha.
The complete proposal comprises, Design, Engineering, Manufacturing, Shop fabrication,

Assembly, Testing and Inspection at supplier work, Packing, Dispatch, Shipping, Inland
transportation to Job site, import of equipment, Insurance, Delivery at site, installation, Testing,
Commissioning, handing over and PG test of Alumina Unloading and Transportation System as
specified in NIT document.
2. Design Basis:
Site Data:
Job location Angul, Orissa.

Geographical location of reference Latitude - 21.21ᵒ North
Point of the site (S-E corner) Longitude - 86.11ᵒ East
Record max. temperature : 50.9 Degree. C
Average daily max. temperature : 30.00 Degree. C
Average daily minimum. Temperature : 18.00 Degree. C
Record minimum Temperature : 5.00 Degree. C
Annual Average rainfall : 1421 mm (mid-June to mid-Sept)
Maximum rainfall recorded in one hour : 100mm (Design)
Maximum relative humidity : 68.3 %
Prevalent direction of wind from : southwest and northwest
Prevalent wind speed : 50 m/s
Seismic Zone : Zone III
Material Characteristic:
Material Alumina
Type Sandy
Maximum density after Compression under 1.1 T/m3.
4 bar
Angle of repose during reclaiming and during 35 degree & 23 degree respectively

loading
Internal angle of friction 27 degree to 36 degree
Angle of friction on steel 25 degree
Granulometry + 125 micron max. 15%
- 45 micron max. 12%,Typical 10%
Hardness 9 on Mohs’ Scale
Chemical Specification of Alumina:
Item Unit Typical Limit (max)

SiO2 Wt % 0.01 0.025
Fe2O3 Wt % 0.01 0.0015
TiO2 Wt % 0.003 0.004
Na2O Wt % 0.39 0.5
P2O5 Wt % 0.001 0.002
V2O5 Wt % 0.0015 0.002
CaO Wt % 0.025 0.06
Alpha Wt % <2.0 10.0
-45 micron Wt % 8.0 20 (Max corresponds to CA 15
grade Alumina)
+125 micron Wt % 10 - 12 15
LOI (300- 1000o C) Wt % 0.6 - 0.7 1.0
BET 60-70 m2/g (Typical)
40 m2/g (Min) & 80 m2/g (max)
Bulk Density 0.95 to 1 t/m3

System requirement:
No. of operation shift / week : 18 (max)

Effective operating hours / day : 24
Hours/shift : 8
Capacity : 900000 T per annum
Alumina unloading : 8 nos. wagons simultaneously from rake
: (4 nos. wagon from each track).
Rake capacity : 2700 ton
No. of wagons in a rake : 52
No. of track : Track 1, track 2 + Engine escape line
No. of wagon on each track : 26
Rate of unloading from individual wagon : ~ 2 t / min
Wagon unloading and conveying capacity to : 1000 TPH
silo
3. System and Process Description:
Existing System Description:
The requirement of fresh alumina for the smelter plant after expansion will be approximately
9,00,000 TPY. The additional requirement of fresh alumina for the phase-2 expansion is
approximately 2, 42,350 TPY.
In the existing NALCO Smelter Plant, requirement of alumina is being catered by transporting
alumina from Damanjodi to Angul in specially designed pneumatically operated wagons. These
wagons have a payload capacity of approx 55 T each. Total alumina payload in a rake comprising
48 to 52 wagons i.e. approximately 2700 T.
The residence time of rake is at present 8 hrs as maximum. The unloading time of one rake is
approximately 5 hrs. During unloading, a group of wagons are placed in position and each wagon
is connected to compressed air inlet. Flexible hoses are connected with one end to wagon
evacuation points and other end to the fixed pipes leading to air slides. The rate of unloading for
individual wagon is 2 T/min. The extracted alumina is conveyed through air slide for feeding to
intermediate bin (15 T capacity). From the intermediate bin (having fluidized bottom) alumina
comes to belt conveyor TR1 that conveys alumina to existing silos 1, 2, 3, 4, 5, 6, 7 & 8 through
number of belt conveyors/air slides at the rate of 1000TPH.

The main conveyor TR1 is integrated with weigh scale of load cell type to meter the quantity of
alumina to be conveyed to the silos. In the existing unloading system an outlet has been provided
from the distribution box located over silo No. 1 to feed to air slide HA-AL-001. The air slide HA-
AL-001 conveys alumina to the belt conveyor HC-BL-002.The belt conveyor transports alumina to
pot line 3 areas for feeding to Silo No.5 (TI-AL-020) or to Silo No. 7 (TI-AL-021), through air
slides and belt conveyor HC-BL-012.
Proposed System Description:
The plant will have a yearly Aluminium production capacity of 4,60,000 T after phase-2
expansion, which approximately corresponds to a yearly requirement of 9,00,000 T of alumina. To
achieve such alumina requirement a new system with wagon unloading facility by gravity and
alumina conveying to the silo 5 & 6 and silo 1 & 2 (separately) have been envisaged.
From silo1 & silo 5 the alumina can be diverted to silo 3 & 4 and silo 7 & 8 respectively through
existing conveying path (conveyor / air slides).Similar to existing system, alumina will arrive at
the plant in specially designed pneumatically operated wagons. Each rake is grouped in 52 wagons
corresponding to a service capacity of approx. 2700 ton. This new system has been envisaged to
facilitate to convey alumina to each silo @1000 TPH through pipe conveyors (for silos 1, 2&5, 6)
independently to all the silos during shut down of existing main conveyor TR1 & also conveyor
(HC-BL-002) which is conveying alumina from silo1 to silo 5. Afterwards alumina transportation
facility has been connected to existing belt conveyor TR2 & BL012 (both conveyors having
1400mm belt width) for filling of silos 3, 4 & 7, 8 respectively.
Unloading of alumina from wagon for this new system shall be done in between proposed
expansion railway tracks1 &2 (12m apart), located at east side of Rolling Plant (RP). Suitable rope
winch systems (2nos.) for hauling 12 BTAP wagons has been envisaged. The unloading of 8
wagons shall be done at a time (4 nos. Wagon from each track).The drive units and automatic rope
tensioning arrangements of the winch systems shall be located in a common shed / house. 2 nos.
Rope winch system (reversible type) have been provided for wagon hauling, positioning for
unloading and also operate haulage winch to move the wagons from the unloading zone and again
set for the position for next 8 wagons. By adopting the suitable connecting / removing of hitch
ropes / round link chain sling to the near side rope / far side rope, the optimization of unloading
cycle are to be obtained.
A dedicated operator cabin shall be provided over the unloading area at the starting point to
precisely control the placement of rake in the unloading stations.

Unloading of alumina from each BTAP wagon is to be connected to compressed air inlet and also
flexible hoses to be connected with one end to wagon discharge points and other end to fixed pipes
for gravity discharge (for quick unloading and lesser energy consumption) to the air slides placed
in an underground pit (i.e. in between two railway tracks). Unloaded alumina shall be conveyed by
air slides (3 nos.) to pipe conveyor PC-100 partly underground and partly over ground which in
turn feed alumina either to pipe conveyor PC-200 or another pipe conveyor PC-300 through 2-
way chutes at transfer point TP-1 located above ground. Underground tunnel shall have the sump
with pumping (1w +1s) facility to drain out water from the sump. The pipe conveyor (PC-100)
shall be provided with integrated Belt weigh scale of load cell type for metering amount of
Alumina conveyed to the silos. The pipe conveyors PC-200 & PC-300 shall carry same alumina
from TP-1 to silo-1&2 and silo-5 &6 respectively through air slides (4 nos.). Two nos. transfer
points (TP-2 & TP-3) shall be provided, one near silo 1 &2 and other transfer point near to silo5 &
6 to convey alumina to silo1& 2 and silo5&6.
One rack and pinion type passenger cum goods lift of capacity 1Ton (16 passengers) with one side
collapsible gate shall be provided near the transfer point (TP-3) of silo 5&6.
Five nos. de-dusting units with measurement system of DP, Inlet pressure, outlet pressure and
pulsing pressure etc, one at unloading area, one at feeding area of pipe conveyor PC-100 from air
slide (AS-300) and three nos. at different transfer houses shall be installed. The dust emission level
from the de-dusting units shall be limited to 10 mg/Nm3.
One new control room, MCC room, Blower room & VVVF room shall be suitably installed. No
disturbance to the existing system while erection and commissioning will be allowed except during
hook-up. During construction and erection, proper care shall be taken for existing equipment at the
interface.
4. Operation & Control Philosophy:
The operation and control of the proposed Alumina Unloading from Wagons Loading into existing
silos will be carried out from PC-PLC based control system to be located in PLC room interface
with Client’s existing control room. The PC-PLC based system will be a stand-alone system and
will be provided with the necessary programming software for logic and graphic development. The
PC-PLC based system will display the operator action, following status, indication for each drive /
equipment –

START / STOP commands

ON/ OFF status indication
Interlock activate/deactivate switch (if required)
Drive healthy status, running indication
Motor trip alarms
Necessary start permissive, level of Chute /silo etc will be taken care by PLC system for smooth and
safe operation. Availability / readiness of other systems like de-dusting bag filters, Conveying air &
Instrument air, etc. will be monitored by PLC system.
Wagon Unloading and Transportation System:
An auto start request for this area to be obtained from Operator PC at Wagon shed control tower
station. The request will also come from the main control room for Start routine. The request shall be
handled the same way in all cases.
The equipment within this area is started in the sequence shown in the table below. Eachof the
equipment shall be started according to its individual Auto Start Sequence and Auto Mode
Interlocks, as described in the table below.
Once the area is ‘Running OK’ each of the equipment continues to run according to its individual
Auto Mode Interlocks, as described.
If the Silo High Level switch is activated, divert gate shall become operational & get diverted in
other Pipe conveyor. An Automatic Shutdown will occur in this Area if all Silos showing high level,
then auto stop sequence shall be initiated.

Automatic Start-up Routine for Wagon Unloading and Silo Filling:

Step Action
Step 0 Preconditions:
Verify readiness of Existing system to receive alumina (Alumina Silos
and related equipment)and dust extraction system.
Verify Pipe Conveyor PC#200 or PC#300 is ready to operate then verify
PC#100 is ready to operate (MCC isolator on, overload and
thermistor not tripped, conveyor selected for Auto Mode).
Step 1 Area Auto Start request received from wagan unloading shed area from
watch tower after placing of wagon, fitting hoses material hoses and air
hoses)
Step 2 Run Auto Start Sequence for Air slide blower of respective silo with Dust
Collector for PC#200 or PC# 300.
Step 3 Run Auto Start Sequence for Dust Collector DE#1A and DE#1B
Step 4 Run Auto Start Sequence for Dust Collector PC#100.
Step 5 Run Auto Start Sequence for Pipe Conveyor PC#200 or PC#300.
Step 6 Run Auto Start Sequence for pressurizing fan in compressor / blower
room.
Step 7 Run Auto Start Sequence for blowers for air slide AS#100, AS#200 and
AS#300.
Step 8 Run Auto Start Sequence for Compressors KA100 to KA107/ 108 (SB).
Step 9 Check proper pressure achieved in wagon approx 2 bar then slowly open
Material valve and adjust air valve accordingly.
Step 10 Once pressure of wagon drops down to very low stop compressor one by
one as required for all 8 nos. from Local operator Station.
Step 11 Stop fluidizing blower for AS#100,AS#200,AS#300.
Step 12 Wait for delay programmed in PLC Conveyor PC#100 and respective dust
extraction stop. Similarly PC#200 or PC#300.
Step 13 Again wait for delay to stop blowers for air slides and respective de-
dusting systems.
Step 14 Move wagon and place at desired location for next cycle of unloading.
Step 15 Sequence will repeat as mentioned in above.
Note : Selection of Divert gate, Pneumatic isolation gate and other accessories
shall be programmed as per requirement. The system may also be
programmed for continuous operation during wagons replacement at
every cycle.

5. Scope of Supply – Main Package:
Sl. No. Description Quantity
1. Pneumatic Conveying system for unloading of Alumina from 1 Lot

BTAP wagons and gravity discharge to the air slides.
2. Wagon Hauling, placement &movement of wagons by Rope- 1 Lot
Winch System with reversible rope.
3. All Air Slides and Air Blowers/Fans for fluidization complete 1 Lot
system, as required.
4. Ventilation and pressurization system for Blower Room and 1 Lot
Substation, MCC, Switchgear and VVVF panel & auxiliaries.
5. All staircase, ladder, platforms as required. 1 Lot
6. All transfer points and galleries of pipe convey or shall be 1 Lot

covered.
7. Air conditioning of Control room, VVVFD room and Battery 1 Lot
Room.
8. Tunnel, Pent House, Operator’s Cabin at Watch Tower and also 1 Lot
Winch Drive Room as required.
9. Gates at rail crossing the road near the tail of the rail siding. 2 Nos.
10. Pipe conveyors including belt scale at pipe conveyor PC-100 1 Lot
complete with de-dusting systems/ bag filters, technological
structure, drive system, Safety equipment/instruments, take-up
arrangement, docking system at tail and head side, transfer towers
& supporting structures including & safety
barriers.
11. Compressed air & water supply system located within the plant 1 Lot
with compressors, pumps and all accessories including pipes &
piping/support.
12. Power Receiving and Distribution System. 1 Lot
13. Control & Instrumentation System including Control Room. 1 Lot
14. Contour survey of the wagon unloading area, spot level fixing of 1 Lot
the support location and support structures, Soil Investigation,
Area Grading, Roads, Drainage etc. as required.
15. Fire fighting system connection with the existing firefighting 1 Lot
network.
16. Fire detection, protection, alarm and fire extinguisher as required. 1 Lot

17. Passenger-cum-goods elevator near transfer point (TP3) of silo 5 1 Lot

& 6.
18. Electric and manual hoists including monorail as required. 1 Lot
19. All civil & structural, architectural, process/mechanical, 1 Lot

environmental,electrical and control & instrumentation works
pertaining to Alumina Unloading & Transportation System shall
be under the scope of bidder.
20. Approach road for smooth & uninterrupted movement of traffic 1 Lot
shall be provided from main approach road of the plant to the
proposed wagon unloading area keeping in view the traffic and
personal movement a road of width 7.5 m shall be considered.
21. Design, supply and construction of outdoor paving and roads of 1 Lot
the proposed installation.
22. Design, manufacture, planning, fabrication, assembly, shop testing 1 Lot
and shop painting including procurement and supply of all
materials, labour, supervision and necessary quality assurance
testing.
23. Receiving/unloading, storage at site, handling at site till take over. 1 Lot
24. Site fabrication, construction and final assembly. 1 Lot
25. Layout and Civil & Structural construction. 1 Lot
26. Erection and Final painting. 1 Lot
27. Mechanical and Electrical No Load Tests, Interlock Tests. 1 Lot
28. Pre-commissioning, Checkup, No Load run, Trial Run and 1 Lot

Commissioning.
29. To provide training at site to O&M personnel before 1 Lot
commissioning. The no of participants and duration will be
mutually discussed and agreed upon.
30. Performance Guarantee Tests. 1 Lot
31. Maintenance till handing over. 1 Lot
32. All the software loaded on the hardware installed for the project 1 Lot
shall be procured in the name of NALCO. The license key of the
software shall be handed over to NALCO after commissioning for
any modification in future.

33. The supplier of the hardware and software shall extend their 1 Lot
service support at least for a period of six years from date of
commissioning at site. The LSTK vendor shall arrange the
agreement for the same from the supplier and submit to NALCO.
34. Two nos. of PC ( i8/latest,16 GB RAM, 1TB HDD, DVD writer, 1 Lot
Graphics Card, 24” monitor etc) with two nos. of A4 size laser
color printers before the start of engineering. The same shall be on
non-returnable basis.
6. Scope of Supply – Spares:
A. Mandatory Spares:
Mechanical
1. List not provided in NIT
Electrical
1. HT&LT motors as per annexure-a page no 99 of 774. 1 Lot
2. HT switch board as per annexure-d page no 125 of 1 Lot

774.
3. PMCC, ACDB, LIS, LPBS, NSPB spares as per 1 Lot
annexure-e page no 159 & 160 of 774.
4. Transformers spares as per annexure- c page no 175 of 1 Lot
774.
5. 11/0.690kv transformer. 1 Lot
6. 11/0.433kv transformer. 1 Lot
7. Battery & battery charger spares as per annexure-d page 1 Lot

no 195 & 196 of 774.
8. VFD panel spares as per annexure-b page no 253 of 1 Lot
774.

9. A complete VFD unit. 1 No.
10. A dedicated desktop & laptop with preinstalled vvfd 1 Set

programming communication software with printer also
in cd media with license key.
11. Communication cable & other hardware 1 Set
C&I
1. Pulse Air Valves (Solenoid Operated) 6 Nos.
B. Recommended 2 years of O&M Spares:
Mechanical
1. Oil Free Screw Compressor

(KA-100 – KA-108)
Air filter 2 Nos.
Oil filter 2 Nos.
Air oil separator 2 Nos.
Coupling(compressor and motor) 2 Nos.
Bearing for both compressor & motors 2 Nos.
2. Blower (BL100-1600m3/hr, BL300-2500m3/hr, BL400 -

5500m3/hr)
Bearing 2 Nos.
Oil Seal 2 Nos.
V-Belt 4 Nos.
3. Centrifugal Fan (EF100A-11000 m3/hr,EF200
14400m3/hr,EF300-11850m3/hr ,EF400-
7200m3/hr,EF500-8800m3/hr)

Bearing 2 Nos.
Oil Seal 2 Nos.
V-Belt 4 Nos.
4. Fabric for Air Slide
For 500 TPH Air Slide (700w x 1050L)

-2 Nos.
For 1000 TPH Air Slide (1000w X 1050L)
– 5 Nos.
5. De-Dusting System(Bag Filter)
Bags with fixing clamps 60 Nos.

(160mm
dia.x4000mm long)
6. Electric Hoist(EH-1,EH-2,EH-3,EH-4)
Brake liners 4 sets
Rope guide and rope tighter 2 Nos
7. Fire Fighting System
Fire Hydrant Valve 5 Nos.

Fire Hose(15m long) 10 Nos.
Hose Reel Box 2 Nos.
Butterfly Valve
i) 80mm 3 Nos.
ii) 150mm 2 Nos.
Ball Valve 2 Nos.
Non-Return Valve 2 Nos.
Portable CO2 Type Fire Extinguishers(4.5Kg) 4 Nos.
8. Air-Conditioning & Ventilation System

Expansion joint 1 set(Each type)
Gravity louver 1 set(Each type)
9. Pipe Conveyor and Accessories
A Spares -Rollers & Frames. 5 % of Installed
1 Pipe conv. Belt 10 % of Installed
2 Special Pipe forming Idlers 20 % of Installed

3 Impact idler roll. 10 % of Installed

4 Pipe conveyor idler rolls (PSK) 10 % of Installed
5 Pipe conveyor idler mounting brackets. 10 % of Installed
B Drive Component.
Gearbox (Note - Each of one type means with respect to
1 1 One of each type
model, Size, rating , handing etc)
2 sets of Oil seal,1 set of hold back for each type of
2 1 Lot
gearbox.
Motor (Note - Each type of one means with respect to
3 1 One of each type
frame size , model , rating etc)
4 Low speed coupling (Coupling in pilot bore) 1 One of each type
5 High speed coupling. 1 One of each type
6 Spring for coupling 2 Set of each type.
C Pulley
1 Plummer block for Drive pulley 1 One of each type
2 Plummer block for Non drive pulley 1 One of each type
D Safety switches.
Zero speed switch.(1 set consisting of 1 controller and
1 2 Set
1sensor)
2 Belt sway switch. 10 % of Installed
3 Pull cord switch. 10 % of Installed
E Belt Cleaner
1 Skirt seal rubber assembly 20 % of Installed
2 Primary scrapper complete with all accessories. 1 set of each type
3 Secondary scrapper complete with all accessories. 1 set of each type
4 V-Plough internal scrapper complete with all accessories. 1 set of each type
F Belt Scale
1 Load cell for belt scale 1 Set of each type.
2 Electronics controller for belt scale 1 One of each type
G Diverter gate Gate
1 Nos. of each type
2 Oil seals of Actuator
& rating
1 No. of each type &
3 Diverter gate shaft
rating
H Miscellaneous Electrical Items
1 Indication Lamp 2 Nos. of each type
2 MCCB/SFU 1 Nos. of each type
3 Aux Contactor 2 Nos.
4 Power Contactor 1 Nos. of each type
5 O/L relay 1 Nos. of each type

6 Push Button 2 Nos. of each type

7 BSS./PCS Sensor 5 Nos.
Electrical
1. Since the list of mandatory spares is very exhaustive -

hence we do not recommended any additional 2 years
O & M spares.
C&I
Field instruments and accessories

1. 1 No.
Dist. Box Level Switch (Vibrating Type)
2. Pressure Switch 1No.
3. Pressure Gauge 2 Nos.
4. Differential Pressure Transmitter 1No.
5. Air Regulator Filter 1No.
6. Pulse Jet Solenoid Valve 5 Nos.
PLC System and accessories
7.
Digital Input Module 1No.
8. Digital Output Module 1No.
9. Analog Input Module 1No.
10. Analog Input Module (RTD / TC) 1 No.
11.
Analog Output Module 1No.

12. MCB's 3 Nos.

13. Power Module 1No.
14.
Communication Modules 1No.
C. Commissioning Spare:
1. Ducon shall supply all Commissioning spares for its

supplied equipment as required during commissioning of
the system for this project. Separate list is not envisaged by
us.
D. Insurance Spare:
1. We have not envisaged any insurance spares -
E. Special Tools and Tackles:
1. No Special Tools & Tackles are required for this package -


7. Electrical Feeder List:
Motor Total
Sl. No.-of Motor Power Motor
No. Equipment Equipment Description per in Power
No. Equipment in Remarks
KW
/Total qty. (each) KW
Rope Winch System for wagon Hauling ( 2 24 48
1 .a 2-Nos)
Automatic Rope Tensioning
1 .b Arrangement (2 Nos.)
Pneumatic Unloading System from wagons 2 22 44
2 to Underground pit through Air Slides
(1set)
Screw Compressors ( For 8 Nos. 9 55 495
3.a KA100 to 108
working + 1 sand by)
BL100 , 2 7.5 70
3.b 200& 300 Blower for air slides (For 3nos.)
1 55
Pressurization Fan for Blower Room. (2 2 7.5 15
3.c FN100 &200 nos.)
4 P-1 & 2 Sump Pump (1w +1s) 2 5.5 11
Goods cum passenger lift (Rack and Pinion 1 45 45
4 EL-01 type, located near silo no. 5)
5 PC-100 Pipe Conveyor (1 No.) 1 315 315
De-dusting system complete unit near 2 22 44
7 DE-1 unloading station (1 No.)
De-dusting system complete unit in 1 22 22
8 DE-2 Transfer House TP-1(1 No.)
9 DE-3 Transfer
House TP-2(1 No.)
10 DE-4 Transfer
House TP-3(1 No.)
11 BL- Blower for air slide 4 22 88
400,401,500
12 EH-1,2,3,4 &5 Electric Hoist (5 nos.) 5 7.5 37.5
&501
13 RV-100-800 Rotary Air Lock Valve 8 2.2 17.6

14 MD-100 TO Motorized Dampers 9 7.5 67.5

15 FN-100 To 600 Pressurization Ventilation Fan (3W+3S) 6 7.5 45
16 NLF-100 & 200 Lighting Transformer 2 80 160

17 AUX./PSB Aux. Power Supply Board 1 145 145
18 E/PSDB Emergency PSDB 1 145 145
19 ELT-100 Lighting Transformer for Emergency 1 40 40
lighting
20 BW-1 Belt weigher (1 no.) - - -
8. Technical Specifications of major items:

Details provided in Data Sheets enclosed with proposal.
9. Scope of Services:
Detail Design and Engineering of entire package, within battery limit.

Civil works for entire package within battery limits.
Procurement & supply of sub-packages.
Site fabrication as per package requirement.
Shop inspection & testing.
Packing & transportation to site.
Receipt at site and storage.
Intra site handling.
Erection, installation and hook-up.
Tools & tackles for erection work.
Skilled & unskilled labor for erection work.
Painting, including supply of paints.
Mechanical completion and commissioning.
Performance testing of the complete plant at site.
“On-site” training to Owner’s personnel on operation and maintenance.
First fill of lubricants required at the time of commissioning.
Handing over the system to client.
Supply of spares as applicable / agreed.
Adherence to contract safety requirements.
Fulfilling warranty obligations
Statutory clearance related to site execution.

10. Exclusions:
Owner’s cost of inspection.
Supply of consumables during the construction period (potable water, industrialwater,

firefighting water, electrical energy etc. up to the battery limits)
Supply of consumables during the construction period (potable water, industrialwater,

firefighting water, electrical energy etc. up to the battery limits)
Maintenance of access roads during the construction period as shown in thelayout only.
No new roads will be constructed for the project by the owner.
Operational and maintenance staff during commissioning and start-up. M/s Ducon’s
personnel shall be deployed for commissioning. Owner shall extend technical support.
The system shall be designed to conform to the prevailing safety and statutory
requirements as applicable. LSTK vendor shall arrange for the inspections and approvals
from the statutory authorities as required. The statutory fee for the inspection and
approval shall be borne by the owner. Statutory approval in original shall be submitted to
Owner for records.
Utility lines beyond interface points.
Compressed air for instruments @ 5 kg/cm2 , if it is designed to be drawn from utilities.

If dedicated compressors are included in the design, the same shall be in M/s Ducon’s
scope.
All mobile equipment and special handling equipment, such as fork lift truck etc. for
normal operation of the plant. The cranes and other equipment required for erection,
commissioning and testing shall be in the scope of the M/s Ducon.
Supply of maintenance tools. But Special tools and tackles shall be in M/s Ducon’s
scope.
Stack sampling and sample analysis
Power factor improvement capacitor banks.
Wagon rail, sleepers & accessories such as clamps fish plate etc at unloading zone not is
considered in our scope.

Fire fighting pump, pump house and accessories is not considered in our scope.
List of Mandatory Spares considered only for Electrical items. As list of Mandatory
Spare for Mechanical & Instrumentation items are not specified in the Tender
specification, hence same has not been considered.
Automatic self-cleaning electronic air cleaning unit not considered in our scope.
Belt Sway Switch shall be provided on Both Side of the conveyor only in the transition
length of the pipe conveyor.
In absence of description, we have considered cable operated belt rip or tear detection
switch.
11. Owner’s obligations:
This offer is based on the fulfilment of following obligations by the Owner:
Allotment of levelled open area for construction of offices, stores, workshops etc. and area for
disposal of waste materials as applicable.
Providing reference survey grid pillars and bench marks.
Uninterrupted supply of construction water and construction power at agreed battery limit for our
scope of work.
Access roads with proper lighting and drainage.
Supply of raw materials, operating supplies and utilities etc. as may be required for the given
scope of work.
Co-ordination of supplied system with respect to facilities, scope of supply, coordination with
suppliers of other related packages.
To furnish all interface data and relevant information connected with other packages.
To supply design drawings & documents for existing facilities as per the tender documents in
requisite copies, transparency and floppies for reproduction. It should be preferably in AutoCAD
R-14 version. The drawings and floppies should be furnished along with LOI for starting the
work without losing any time.
To sort out the queries on the drawings and other technical queries raised by Bidder within a
week on receipt of the queries to approve or otherwise, the drawings / documents submitted by
Bidder within one week of receipt of the same.
To depute inspectors from Owner/Consultant/Inspecting Authority for inspection within 7 days
notice by the Bidder.
Timely payment to Bidder as per the agreed terms of the contract including advance.

To release the dispatch clearance & various acceptance / clearance certificates as per the contract
within a week of completing the respective activity.
To provide all government clearances, documentation required for execution of contract like
waybill, C-form etc.
Approval & Issuance of entry and exit permits of equipment’s materials, personnel etc. to and
from work site round the clock during the project tenure.
Supply of energy, in-process materials, consumables and utilities for testing, commissioning &
Guarantees Test as per technical specifications.
Provision of intercom, P&T telephones and fax facilities, on chargeable basis.
Assistance in obtaining permits, clearance certificates, required from statutory authorities.
Assistance in obtaining Visas & other related documents for foreign personnel.
Test Loads for testing the plant and equipment.
Carrying out regular operating & Preventive maintenance of system after testing and
commissioning.
Owner to make available work site and existing facilities with proper shutdown as required for
the site work.
Deputing personnel in adequate batches as per training programme provided by the Bidder, if
agreed specifically in the offer and providing the required class room with necessary equipment.
Ensuring finalization of all spares in time so as to make them available during commissioning
and operation of the plant.
Timely finalization of any additional legitimate claim of Bidder.
Deputing trained skilled and adequate persons for testing, commissioning and operation of the
plant.
Keeping all the interfaces and existing facilities which have effect on performance of the systems
covered in this offer, healthy and operative at full capacity.
Providing handling equipment’s, cranes etc. as required at site on chargeable basis.
Providing erection fronts as per schedule for electrical, instrumentation and automation.
12. Battery Limits:
Conveying of Alumina : From discharge flange of BTAP Wagons
Discharge of Alumina : (1) pipe conveyor (PC-100) through 3 nos. air slides
(AS-100, As-200 & AS-300) and then feed to silos 2 &
1 and 6 & 5 through another two (2) pipe conveyors
(PC-200 & PC-300) and 4 nos. air slides (AS-400, 401
& As-500 & 501) to inlet of silo-5, Silo-6, Silo-2 &
Silo-1.

13. Performance Guarantee Parameters:
Pipe conveyor :
Equipment Number PC-100/200/300
Capacity 1000 TPH
Accuracy ± 5%
Type Horizontal with slope
Air slides
Equipment Number AS-100/200
Average Capacity 480 TPH
Design Capacity 500 TPH
Equipment Number AS-300

Average Capacity 960 TPH
Equipment Number AS-400/401/500/501

Dust Emission
Equipment Number DC-100/200/300/400
Type Bag Filter type Bag Filter type
Location On top of On top of each Transfer
&Transfer
Hopper Points.
Function Filter the air loaded with alumina dust
before venting it to the atmosphere.
Stack emission shall be limited to 10 mg/Nm3 shall be limited to 10 mg/Nm3

14. Utilities:
Power Consumption – Please see Electrical Load List enclosed with proposal.
15. Project Schedule:

Details provided in Bar Chart enclosed with proposal.
16. Proposed Additional Make List:
Sl. Equipment / System Vendor

No.
MECHANICAL EQUIPMENT
1. Centrifugal Blower 1.Chicago Blowers

2. Kay Blowers.
3. Boldrocchi.
2. Fans for De-Dusting 1.Chicago Blowers.

2. C.B .Doctor.
3. Boldrocchi, International
3. Elevator/Lift 1. Universal Construction Machinery
2. Alikraft.
3. Avon Cranes.
4. Mekaster
4. Electric Hoist 1.CHPL
2.Meeka
3.VME Cranes
4.Eddy Cranes
5. Manual Hoist 1. Hercules
2.Tractel
3. W.H.Brady
6. Rotary Air Lock Valve 1.Rotolock,
2.Hyquip.
3.Anval

7. Fire Fighting System 1. Star Safety Concepts

2. Agnice
3. PragatiEngg.
8. Ventilation System 1. Voltas.
2. Aerovent
9. Centrifugal & Vertical Pump 1.Sam Turbo

No.
MECHANICAL EQUIPMENT
A.
1. Pipe conveyor system 1. BTL EPC LTD.
2. Pipe conveyor belt 1. Oriental,
2. Forech
3. Belt cleaners (sprung type) / modular type 1. BTL EPC LTD.

skirt sealing
4. Pneumatic diverter gate 1. BTL EPC LTD.
5. Resilient couplings 1. Fenner
6. Elevator / lift 1. Alikraft
7. Gear Box 1. Premium
2. Elecon
8. Paint 1. Shalimar Paints
B. Electrical
1. MV Motor 1. MARATHON
2. ABB
2. VFDs 1. Siemens (or its system house)
3. Belt Scale 1. IPA
2. Transweigh
3. Sartorious
4. PULL CORD, ZERO SPEED 1. Ag associates, mumbai
2. Jayshree, pune


No.
3. Telemechanique
5. Electrical Hoist 1. Tractel

2. Brady &Moris
3. Elequip
4. Centrury crane

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Alumina Unloading & Transportation System

for Smelter Plant, Angul Odisha

Proposal No.: DTIPL/NALCO-AHS/Rev00 Date: 15.01.2018

The complete proposal comprises, Design, Engineering, Manufacturing, Shop fabrication,

Job location Angul, Orissa.

Proposal No.: DTIPL/NALCO-AHS/Rev00 Date: 15.01.2018

Chemical Specification of Alumina:

Item Unit Typical Limit (max)

Proposal No.: DTIPL/NALCO-AHS/Rev00 Date: 15.01.2018

No. of operation shift / week : 18 (max)

3. System and Process Description:

Existing System Description:

Proposal No.: DTIPL/NALCO-AHS/Rev00 Date: 15.01.2018

Proposed System Description:

Proposal No.: DTIPL/NALCO-AHS/Rev00 Date: 15.01.2018

4. Operation & Control Philosophy:

Proposal No.: DTIPL/NALCO-AHS/Rev00 Date: 15.01.2018

START / STOP commands

Wagon Unloading and Transportation System:

Proposal No.: DTIPL/NALCO-AHS/Rev00 Date: 15.01.2018

Automatic Start-up Routine for Wagon Unloading and Silo Filling:

Proposal No.: DTIPL/NALCO-AHS/Rev00 Date: 15.01.2018

5. Scope of Supply – Main Package:

Sl. No. Description Quantity

1. Pneumatic Conveying system for unloading of Alumina from 1 Lot

6. All transfer points and galleries of pipe convey or shall be 1 Lot

13. Control & Instrumentation System including Control Room. 1 Lot

Proposal No.: DTIPL/NALCO-AHS/Rev00 Date: 15.01.2018

17. Passenger-cum-goods elevator near transfer point (TP3) of silo 5 1 Lot

19. All civil & structural, architectural, process/mechanical, 1 Lot

24. Site fabrication, construction and final assembly. 1 Lot

25. Layout and Civil & Structural construction. 1 Lot

26. Erection and Final painting. 1 Lot

27. Mechanical and Electrical No Load Tests, Interlock Tests. 1 Lot

28. Pre-commissioning, Checkup, No Load run, Trial Run and 1 Lot

30. Performance Guarantee Tests. 1 Lot

31. Maintenance till handing over. 1 Lot

Proposal No.: DTIPL/NALCO-AHS/Rev00 Date: 15.01.2018

6. Scope of Supply – Spares:

Sl. No. Description Quantity

1. List not provided in NIT

Sl. No. Description Quantity

1. HT&LT motors as per annexure-a page no 99 of 774. 1 Lot

2. HT switch board as per annexure-d page no 125 of 1 Lot

6. 11/0.433kv transformer. 1 Lot

7. Battery & battery charger spares as per annexure-d page 1 Lot

Proposal No.: DTIPL/NALCO-AHS/Rev00 Date: 15.01.2018

9. A complete VFD unit. 1 No.

10. A dedicated desktop & laptop with preinstalled vvfd 1 Set

Sl. No. Description Quantity

1. Pulse Air Valves (Solenoid Operated) 6 Nos.

B. Recommended 2 years of O&M Spares:

Sl. No. Description Quantity

1. Oil Free Screw Compressor

Oil filter 2 Nos.

Air oil separator 2 Nos.

Coupling(compressor and motor) 2 Nos.

Bearing for both compressor & motors 2 Nos.

2. Blower (BL100-1600m3/hr, BL300-2500m3/hr, BL400 -

Proposal No.: DTIPL/NALCO-AHS/Rev00 Date: 15.01.2018

4. Fabric for Air Slide

For 500 TPH Air Slide (700w x 1050L)

Bags with fixing clamps 60 Nos.

Brake liners 4 sets