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PARADIP PORT TRUST

ELECTRICAL & MECHANICAL DEPARTMENT

E-TENDER CALL NOTICE NO: EM/MCHP-19/ 17

INSTRUCTION TO BIDDER [ITB],

&

GENERAL CONDITIONS OF CONTRACT [GCC]

VOLUME-1

Office of the MCHP Division,

E&M Department, Paradip Port Trust

Second Floor, Administrative Building,

Post: Paradip – 754 142, Dist: Jagatsinghpur (Odisha).

NAME OF WORK: OPERATION & MAINTENANCE OF

MECHNISED COAL HANDLING

PLANT

Paradip Port Trust Mechanised Coal Handling Plant

Page 2 of 286

PARADIP PORT TRUST


TENDER DOCUMENT FOR e-Tendering

VOLUME –I

Comprising of

Instruction to Bidder (ITB)

&

General Conditions of Contract (GCC)

INSTRUCTIONS TO BIDDERS

CLAUSE NO. DESCRIPTION

01.0 SCOPE

02.0 NOTICE INVITING BID AND OBTAINING BID DOCUMENTS

03.0 ELIGIBLE BIDDERS

04.0 COST OF BIDDING

05.0 SITE VISIT

06.0 CONTENTS OF BID DOCUMENTS

07.0 CLARIFICATION ON BIDDING DOCUMENTS

08.0 AMENDMENT TO BID DOCUMENTS

09.0 LANGUAGE OF BID

10.0 BID PRICES

11.0 BID VALIDITY

12.0 BID CURRENCIES

13.0 EMD

14.0 SECURITY DEPOSITS

15.0 DOCUMENTS COMPRISING THE BID

16.0 FORMAT AND SIGNING OF BID

17.0 PAYMENT OF EMD AND COST OF TENDER DOCUMENT

18.0 SECURITY OF BID SUBMISSION

19.0 DEADLINE FOR SUBMISSION OF THE BIDS

20.0 LATE BIDS

21.0 MODIFICATION AND WITHDRAWAL OF BIDS

22.0 OPENING OF BID

23.0 CLARIFICATION ON BIDS

24.0 CONVERSION TO SINGLE CURRENCY

25.0 EVALUATION AND COMPARISON OF BIDS

26.0 CONTACTING PARADIP PORT TRUST

27.0 AWARD CRITERIA

28.0 PURCHASER’S RIGHT TO ACCEPT OR REJECT ANY OR ALL THE

BIDS

29.0 NOTIFICATION OF AWARD

30.0 SIGNING OF CONTRACT

Instruction to Bidder


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31.0 BANK GURANTEE (BG)

32.0 MEMORANDUM OF SETTLEMENT

33.0 DESIGN CRITERIA

34.0 DRAWINGS

35.0 MANUALS

36.0 SITE SAFETY & ENVIRONMENT PROTECTION

37.0 QUALITY ASSURANCE PLAN, INSPECTION AND TESTING

38.0 THIRD PARTY INSPECTION

39.0 TIME IS THE ESSENCE OF THE CONTRACT

40.0 PURCHASER’S OBLIGATION

41.0 CONTRACTOR’S OBLIGATION

42.0 VENDOR LIST

43.0 SCRAP DISPOSAL

44.0 UNDERTAKING BY THE BIDDERS

45.0 DISCLOSURE BY THE BIDDER

46.0 CESS TO BE REMITTED TO THE ORISSA BUILDING AND OTHER

CONSTRUCTION WORKERS WELFARE BOARD

47.0 INTEGRITY PACT

INSTRUCTIONS TO BIDDERS (ITB)

1.0 SCOPE:

Paradip Port Trust (hereinafter referred to as the “Purchaser”) intends to receive Bids

online on the website eprocure.gov.in/eprocure/app from the interested eligible bidders for

the work as mentioned in the Tender call Notice (TCN). All Bids shall be completed and

submitted on line on the website eprocure.gov.in/eprocure/app in accordance with the

Instructions to the Bidders. No bid shall be accepted off-line.

2.0 NOTICE INVITING BID AND OBTAINING BID DOCUMENTS:

2.1 Executive Engineer is hereby nominated as “Officer inviting the Bid” who will deal with all

matters relating to the subject tender.

2.2 PARTICIPATING IN THE BID IN THE E-PROCUREMENT PORTAL: The

Contractor/Bidder intending to participate in the bid is required to register in the Portal with

some information about the firm/Contractor. This is a onetime activity for registering in

Portal. During registration, the contractor has to attach a Digital Signature Certificate (DSC)

to his / her unique user ID. The DSC used must be of appropriate class (Class II or Class III)

issued from a registered Certifying Authority such as n-Code, Sify, TCS, MTNL etc. If the

bidder is an individual person then he/she should register himself under “Individual” category

and if the bidder is a proprietorship firm/partnership firm /Joint venture or consortium/

Company then registration should be under “Corporate” category. The registration should be

in name of bidder, whereas DSC holder may be either bidder himself or his duly authorized

person.


https://eprocure.gov.in/eprocure/app



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2.2.1 To log on to the portal, the Bidder / Contractor is required to type his/her username and

password. The system will again ask to select the DSC and confirm it with the password of

DSC. For each login, a user’s DSC will be validated against its date of validity and also

against the Certificate Revocation List (CRL) of respective CAs stored in system database.

The system checks the unique ID, password and DSC combination and authenticates the login

process for use of portal.

2.2.2 Any prospective bidder can view or down load the bid documents from the web site

eprocure.gov.in/eprocure/app during the period as indicated in TCN/Contract Data.

2.2.3 In the case of any failure, malfunction or breakdown of the electronic system used during the

e-Procurement process, the tender inviting officer shall not accept any responsibility for

failures or breakdowns other than in those systems strictly within their own control.

2.2.4 Any third party/company/person under a service contract for operation of e-procurement

system in the PPT shall be ineligible to participate in the procurement processes that are

undertaken through the e-procurement system irrespective of who operates the system.

3.0 ELIGIBLE BIDDERS:

The invitation for bid is open to all bidders including an individual, proprietorship

firm, partnership firm, company or a Joint Venture/Consortium fulfilling all the requirements

as mentioned in the Tender Call Notice (TCN) and having Digital Signature Certificate

(DSC) issued from any agency authorized by Controller of Certifying Authority (CCA),

Govt. of India and which can be traced up to the chain of trust to the Root Certificate of CCA.

If the bidder himself is the DSC holder bidding on line then no document is required.

However, if the DSC holder bidding on-line on behalf of the bidder then the Power of

Attorney or any sort of legally acceptable document for the authority to bid on behalf of the

bidder is required.

Bidders should have (i) EPF registration certificate (ii) ESI / Mediclaim Policy/

Employment injury & Compensation. If the firm is having any type of Mediclaim Policy or

Employment injury & Compensation scheme other than ESI, then the firm has to submit an

undertaking that if the work is awarded in their favour then the firm would get registered

under the ESI Scheme.(iii) Permanent Account Number [PAN] (iv) Income Tax Return of

preceding three years, (v) Service Tax Registration Certificate and (vi) VAT/Sales Tax

Registration on works contract etc.

Bidders who have been debarred / blacklisted by any purchaser at the time of bidding

shall not be allowed to participate in this tender.

Successful execution and completion of “Similar Works” on or before the last day of

month previous to the one in which e- Tender has been invited (i.e. e-Publication date of

TCN) only shall be considered for evaluation of eligibility criteria. In case of continuation of

works such as Operation and Maintenance work, the work experience for the completed

period shall be considered only and if there is no discontinuity in the period of such work,

then the work shall be treated as one work. In case of work experience issued by Private

Organizations, the bidder has to submit the TDS certificate in addition to the work experience

certificate, failing which it shall not be considered.

Conditions for participation of Joint Venture (JV) Firms (Applicable to the tenders with

estimated cost put to tender is more than Rs.5.0 Crore.




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(1) Joint Venture (JV) firms are allowed to participate in the tenders having the cost of

work put to tender is more than Rs.5.00 Cr.

(2) No. of Joint Venture partners would be limited to three (including the lead partner) with

at least 26% equity holding by each member in case of a Company. In case a Joint

Venture is formed for the specific work only, each of the Joint Venture partner

including the lead partner shall have work experience of minimum value not less than

26% for atleast one single work of the estimated cost put to tender as indicated in TCN

to become eligible to be a member of Joint Venture. One of the partners shall be

nominated as Lead Partner for signing Agreement with Paradip Port Trust and shall be

authorized to incur liabilities and receive instructions for and on behalf of any and all

the partners of joint venture. This authorization shall be evidenced by submitting

registered power of attorney signed by all the partners.

(3) All partners of the Joint Venture shall be liable jointly and severally during the bidding

process and for the execution of the contract in accordance with the provisions of

contract and a statement to this effect shall be included in the authorization as above.

The bid shall be signed so as to legally bind all the partners jointly and severally.

Joint ventures must comply with the following requirements

The joint venture must satisfy collectively the eligibility criteria as described in this

section. For this purpose, the following information of each member of the joint

venture may be submitted which will be added together to assess the collective

eligibility criteria:

i) Average Annual Turnover

ii) Specific work Experience

iii) Capacity of key personnel

iv) Ability to own / lease relevant equipment

Each JV Partner including the lead partner shall meet not less than 26% of the

following criteria:

i) Average Annual Turnover

ii) Specific work Experience

All the partners together shall satisfy 100% of the criteria.

A copy of the joint venture agreement (JVA) specific to this work, if entered into by the

partners shall be submitted along with the Bid. Alternatively, the Memorandum of

Understanding (MoU) to execute a JVA in the event of successful bid shall be signed

by all partners and submitted with the bid. In any case, it is mandatory that a JV

agreement is entered into before the award of the work.

Pursuant to the foregoing, the Joint Venture Agreement shall include among other

things, the joint venture objectives, the proposed management structure, the

contribution of each partner in the Joint venture, the commitment of the partners to

joint and several liability for due performance, recourse / sanctions with in the joint

venture in the event of default or withdrawal of any partner and arrangements for

providing the required indemnities.

A. Similar Work Experience for Joint Venture (JV) Firm:

The partners of Joint venture shall individually or jointly meet the similar work

experience criteria and the relevant work experience documents shall be

furnished. Each JV partner including the lead partner shall have work



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experience of minimum value not less than 26% for atleast one single work of

the estimated cost put to tender as indicated in TCN. The single work/two

works/three works as indicated in the eligibility criteria shall not be split which

means in case of a single work one JV partner should have executed the single

work in full on his own as specified in Tender Call Notice and in case of two

works / three works, if JV partners proposed to collectively meet the

experience then they should have individually done each of the works in full on

their own as per example given below.

Example –

A joint venture is constituted by three firms namely A, B and C and the

estimated cost of the work put to tender is Rs. 10,00,000/-. Then the eligibility

criteria for meeting similar work experience shall be

i) Single work of value 80% equal to Rs. 8,00,000/-

ii) Two works of value 50% each equal to Rs. 5,00,000/-

iii) Three works of value 40% each equal to Rs. 4,00,000/-

JV may meet the similar work experience criteria either any of the following

categories.

(i) For Single work category of value Rs. 8,00,000/-

Any one Joint Venture Partner should have executed the Single work

of value Rs.8.00 lakh in full individually on his own.

(ii) For two works category of value Rs. 5,00,000/- each

Value of each work executed by JV Partner shall be Rs.5.00 lakh in

full individually on his own.

(iii) For three works category of value Rs. 4,00,000/- each

Value of each work executed by JV partner shall be Rs.4.00 lakh in

full individually on his own.

B. Financial Turnover : The average annual turnover of each partner of the JV

individually shall not be less than 26% of average annual turnover as indicated

in the eligibility criteria in TCN/ Tender Document. Turnover of individual

partner of the JV will be added together for each financial year to meet

eligibility of the Average Turn Over.

4.0 COST OF BIDDING:

The Bidder shall bear all costs associated with the preparation and submission of its

Bid and Paradip Port Trust will in no case be responsible or liable for those costs regardless

of the conduct or outcome of the bidding process.

5.0 SITE VISIT:

5.1 Paradip Port Trust may conduct joint site visit, pre-bid and/or post-bid meeting. The bidder

should attend the site visit as well as the pre-bid meetings, if any.

5.2 Bidders are strongly advised to inspect and assess the site conditions and its surroundings and

satisfy themselves before submitting their bids. In general, they shall themselves obtain all

necessary information as to risks, contingencies and other circumstances which may influence



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or affect their bid. A Bidder shall be deemed to have full knowledge of the site, whether he

inspects it or not and no extra charges arising out of any misunderstanding or otherwise shall

be allowed. Bidders shall submit a realistic offer for the execution of the work at their own

cost without any liability on Paradip Port Trust (PPT).

5.3 Submission of a bid by a bidder implies that he has read the Tender document and has made

himself aware of the terms & conditions and scope and specifications of the work to be done

and local conditions and other factors having a bearing on the execution of work.

BIDDING DOCUMENTS

6.0 CONTENTS OF BID DOCUMENTS:

6.1 The Notice Inviting Tender documents uploaded shall consists of

a) Tender Call Notice (TCN) and Contract Data

b) Technical (fee / (pre-qualification or eligibility) / technical) document

Volume-1 Instructions to Bidders (ITB),

General Conditions of Contract (GCC).

Appendices.

Appendix No. Description

01 Bill Entry Format

02 Techno – Commercial Information

03 Eligibility Information

04 Bank Guarantee Format for ISD

05 Bank Guarantee Format for PSD

06 Bank Guarantee Format for Advance

07 Corporate Performance Guarantee

08 LOI Format

09 Work Order Format

10 Format for Agreement.

11 Format for Integrity Pact Agreement.

12 Bank Guarantee format for stage Payment

13 Joint Venture / Consortium Agreement format

14 Mandate form for electronic fund transfer/RTGS Transfer

15 Format for Refund of EMD

Volume-2 Special Conditions of Contract (SCC),

Technical Specifications & drawings, if any

Scope of Work

c) Price Schedule [Bill of Quantity (BOQ)]

6.2 The bidder is required to down load all the documents including the drawings for preparation

of his bid. Any other drawings and documents if any pertaining to the works available with

“Officer inviting the Bid” will be provided for inspection by the bidders. The bidders are

strongly advised to examine all the instructions, forms, terms and specifications in the

Bidding documents. Failure to furnish all the information required by the Bidding Documents

or submission of a Bid not techno-commercially responsive, in every respect, will be at the

Bidder’s risk and shall result in the rejection of its Bid.



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7.0 CLARIFICATION ON BIDDING DOCUMENTS:

A prospective Bidder requiring any clarification (pre-bid queries) on the Bidding

Documents may request Paradip Port Trust online in the e-procurement portal using his DSC;

provided the questions are raised during the period as mentioned in the TCN / Contract

data/home page of portal. The identity of the bidder will not be disclosed by the system.

Reply to clarifications shall be sent by PPT only if the clarifications requested for, are

considered appropriate by PPT. The clarifications given by PPT will be visible to all the

bidders intending to participate in the tender. Also, on the request of the unsuccessful bidders,

the reasons for rejection of their offers shall be communicated to them by PPT.

8.0 AMENDMENT TO BID DOCUMENTS:

8.1 At any time prior to the deadline for submission of Bids, Paradip Port Trust may, for any

reason, whether at its own initiative or in response to a clarification sought by any

prospective bidder, modify the bidding documents by issuing Corrigendum and/or

Addendum.

8.2 Any addendum thus issued shall be part of bidding documents and shall be notified in the

website eprocure.gov.in/eprocure/app and through paper publication if required. Bidders

intending to participate in the tender shall be solely responsible to check the portal for the

amendment issued in shape of Corrigendum and/or Addendum.

8.3 In order to afford prospective bidders, reasonable time to take the amendment into account in

preparing their bids, Paradip Port Trust may at its discretion, extend the deadline for the

submission of bids.

PREPARATION OF BIDS

9.0 LANGUAGE OF BID:

The Bid prepared by the Bidder and all correspondences and documents relating to the

Bid exchanged by the Bidder and Paradip Port Trust shall be written in English language,

provided that any printed literature furnished by the Bidder may be written in another

language so long as it is accompanied by an English translation of its pertinent passages in

which case for purpose of interpretation of the Bid, the English translation shall be

considered. The English translation shall have to be certified to be the true copy by the bidder

or the person who has translated the same.

10.0 BID PRICES:

10.1 The Bidder shall indicate on the prescribed Bill of Quantity, the landed prices of all the

goods and services at Paradip Port Trust. It must include all the taxes (except Service Tax),

duties, fees, all types of Cess, insurance, transportation, packing, forwarding and all other

incidentals required for execution of the contract in all respect. Variation in taxes due to

change in Govt. Regulations only shall be considered, provided such change has taken

place within the period from 28 days prior to the last date of bid submission to the original

completion date of the Contract. The extended period of Contract shall only be considered

on merit.




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10.2 The Contractor shall have to submit the break-up prices of different items of the Bill of

Quantity in the following prescribed format within 30 days from the date of drawing

approval. In-case there is no provision of drawing approval in the contract; the break-up

prices shall be submitted by the contractor within 30 days of issue of Work Order. Where

the contractor expects to incur expenditure on unforeseen item, then the contractor may

keep a reasonable amount under “Miscellaneous Items”. In any case, the total of the

break-up prices shall not exceed the amount originally quoted in the Bill of Quantity. The

notional break-up prices given by the contractor are to be followed for making stage

payments. The contractor shall ensure that the break-up prices are rational, reasonable and

approved by the Port for effecting stage payments. In case the Contractor can not furnish

the break-up prices in the following format for all the items, the reasons must be clearly

mentioned by the contractor.

10.3 The break-up price and the price quoted in the BOQ format should match.

10.4 Paradip Port Trust does not have ‘C’ or ‘D’ form facility. The Contractor may arrange way

bill at his cost for inter-state transportation of all the materials required for successful

execution of the work.

11.0 BID VALIDITY:

11.1 The bids shall be valid for a period of 120 days from the last date of submission of bids. A

Bid valid for a shorter period shall be rejected as non-responsive.

11.2 In exceptional circumstances, prior to expiry of the original time limit, the “Officer inviting

the Bid” may request the bidders to extend the period of validity for a specified additional

period. The request and the bidders’ responses shall be made in writing or by cable or by e-

mail. A bidder may refuse the request without any risk of forfeiture of his Earnest Money

Deposit (EMD).

11.3 A bidder agreeing to the request will not be required or permitted to modify his bid but will be

required to extend the validity of his bid for the period of the extension.

12.0 BID CURRENCIES.

The prices shall be quoted in the currency of Indian Rupees only. The price quoted in

the currency of Indian rupees in the Bill of Quantity shall be firm and shall not be varied on

account of exchange rate fluctuation during the bid validity / contract period.

Sl.

No.

Description of

items

Base

price

All Taxes, Duties, Cess etc. Insurance,

Transport

Incidentals etc.

Total

Landing

Cost

ED CST Cess



Page 10 of 286

13.0 EARNEST MONEY DEPOSIT (EMD) :

The bidders shall furnish the prescribed EMD in accordance with the Clause No 17 of ITB.

The EMD shall be returned to all the unsuccessful bidders within 30 days of technical/

financial evaluation of the bid. The EMD shall be forfeited under the following circumstances:

1. If the Bidder withdraws its Bid during the period of bid validity, after bid opening or

2. If the bidder revises it’s price offer after opening of the price bid or

3. If the Bidder submits fraudulent documents and / or wrong information in support of

it’s eligibility / qualification or

4. If the Bidder, having been notified of the acceptance of its bid by Paradip Port Trust

during the period of bid validity,

a) fails to sign the Agreement or

b) fails to submit the required initial security deposit, Extra Additional Security

Deposit (EASD) if applicable, and /or does not agree to carry out the work as

per the tender conditions.

Refund of EMD and paper cost will be made to bidders who have not uploaded their bid

offers in the tender process at all.

EMD will be refunded to bidders who have deposited EMD & Paper cost, uploaded their bids

and has applied online for withdrawal of bid before stipulated time & date of opening bid.

Please refer Clause No.14.0 for returning of EMD to the successful bidder.

NB: Deposit of EMD is exempted for the bidder(s)/Firms(s) who are registered with the Central

Purchase Organisation, National Small Industries Corporation (NSIC) or the concerned

Ministry or Department. Documentary evidence in support of such registration must be

submitted by the bidder in Cover-A, Clause No ITB-15 failing which his/her bid shall be

rejected.

14.0 SECURITY DEPOSITS:

A sum of 10% of accepted value of the tender shall be deposited by the successful bidder

(Contractor) as Security Deposit (SD). This will be deposited initially 1% value of the

contract as initial security deposit (ISD) in shape of a Bank Guarantee or Demand Draft

(DD) / Banker’s Cheque drawn in favour of FA&CAO, Paradip Port Trust (DD/ Banker’s

cheque shall be payable at Paradip) within 15 days of issue of Letter of Intent (LOI). After

deducting the EMD and ISD from the stipulated security deposit, the balance amount will

be recovered in instalment through deduction at the rate of 10% of the value of each running

account bill subject to attaining the required amount by the last running bill. In case of

exemption of EMD, the successful bidder has to deposit initially 3% of the contract

value as ISD instead of 1% of contract value.

The Contractor may submit Bank Guarantee for the balance amount after deducting the

EMD and ISD from the stipulated security deposit in which case there will be no

deduction from the running bills towards security deposit.

EMD of the successful bidder may be refunded to the bidder after receiving an equivalent

amount of Bank Guarantee only after issue of work order and signing of agreement.



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The Contractor may also submit Bank Guarantee for a sum of 10% of accepted value of

tender as Security Deposit (SD) within 15 days of issue of Letter of Intent (LOI) in that

case (i) deposit of 1% ISD will not be required; (ii) there will be no deduction from the

running bills towards security deposit; and (iii) ‘EMD of the successful bidder will be

refunded to the bidder after issue of work order and signing of agreement.

The security deposits shall be returned to the Contractor within 45 days of successful

execution and acceptance of the work. The BG shall be as per Appendix-4 and valid till 45

days after the scheduled date of completion of the work.

14.1 PERFORMANCE SECURITY DEPOSIT (PSD):

The Contractor shall furnish PSD equivalent to 5% of the contract price in shape of a Bank

Guarantee as per Appendix-5 or Demand Draft (DD) / Banker’s Cheque drawn in favour of

FA&CAO, Paradip Port Trust (DD/ Banker’s cheque shall be payable at Paradip) on or

before date of completion of work. The PSD shall be retained by Paradip Port Trust till

successful completion of the warranty period. The PSD shall be released within 60 days of

successful completion of the warranty period. The BG shall be valid till 60 days after

completion of warranty period. In case the Contractor fails to furnish PSD on or before

scheduled date of completion of work, the PSD will be adjusted from the Security deposit and

the balance amount of security deposit will be returned to the Contractor.

15.0 DOCUMENTS COMPRISING THE BID:

15.1 All the volumes/documents of TD shall be provided in the portal by the “Officer inviting the

Bid”. The bidder shall carefully go through the document and prepare the list of required

documents those are asked for submission including cost of Tender document & EMD. The

bid shall be technical bid and financial bid. The bid shall be prepared as under and store in the

system for uploading the same through E-Procurement Portal online in three cover system and

digitally signed by the authorized representative of the bidder as follows:

Cover A--- “FEE” shall comprise

Self signed acknowledgements indicating e-TCN No. towards deposit of Cost of Tender

Document and EMD as per TCN, Clause No.13 and Clause No.17 of ITB.

Cover B--- “Technical Bid” shall comprise the documents for eligibility criteria for pre-

qualification as mentioned in the Tender Call Notice and the technical proposal

Pre-qualification Documents

1.0 EPF & ESI Registration Certificates.

2.0 Permanent Account Number [PAN]

3.0 Income Tax Return of preceding three years.

3.0 Service Tax Registration Certificate

4.0 VAT/Sales Tax Registration on works contract

5.0 Power of Attorney or any sort of legally acceptable document if the DSC holder

bidding on-line on behalf of the bidder

6.0 Eligibility information as per Appendix-3 filled in all respect.

a. The supporting documents (Work Orders, Completion Certificates, etc) of

details of works/projects executed to meet similar works experience as per the

eligibility criteria indicated in the Tender Call Notice.

b. In case of work experience issued by private organization, the bidder has to

submit the TDS certificate in addition to the work experience certificate.



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c. The supporting documents related with financial capabilities shall be affidavit /

certificate from CA mentioning turnover of last 3(three) years ending 31st

March of the previous financial year.

Technical Proposal document

7.0 Technical proposal comprising of the scope of work, detail specifications, the offered

equipment/system [wherever applicable] conforming to the technical requirements in

consonance with the tender document.

8.0 In addition, the following information as detailed below should also be submitted

a. Techno-commercial information as per Appendix-2 filled in all respects.

b. Preliminary project plan indicating the outlay and details of programme for

execution of the work, if applicable.

c. Details of Technical Manpower deployed or to be deployed by the firm for

execution of the said work if asked in Special Condition of Contract or Scope

of work.

d. Vendor list of the bidders/renderers, if any, in connection with the work.

e. Documents relating to Consortium or Joint Venture by the firm, if any.

f. An undertaking or declaration in any appropriate format regarding no

disputes/blacklisting/ban of business.

g. A declaration in any appropriate format regarding whether any of his relations

working under PPT or not.

h. An undertaking of not making any payment or illegal gratification to any

person / authority connected with the bid process so as to influence the bid

process and have not committed any offence under the Prevention of

Corruption Act (PC Act) in connection with the bid as per Clause No. 45 of

ITB.

i. The filled in & signed Integrity pact as per Appendix – 11 prepared in Non-

judicial stamp paper, if applicable as per Clause No.48 of ITB.

9.0 Any other information required for eligibility relating to the subject work or additional

information for improvising the work which the firm may provide for the benefit of

the organization.

NB: Please note that the bidder needs not to send any documents (Hard Copy) to the

Tender Inviting Authority before opening of tender.

Cover C----“Financial Bid “shall comprise

1.0 Priced Bill of Quantity

2.0 Break-up Price, if any.

15.2 PRICE PROPOSAL BY THE BIDDER:

i) In the E-Procurement Portal, an intelligent Bill of Quantity in Microsoft Excel format

shall be made available to the bidder.

ii) For Item rate tenders, the bidder shall fill in rates in figures and should not leave any

cell blank. The line item total in words and the total amount shall be calculated by the

system and shall be visible to the bidder. He has to only write the figures, the words

will be self generated.



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iii) In case of percentage tender, the bidder will only fill in the designated cell and activate

“less” or “excess” to indicate how much his/her price offer is excess or less than the

estimated amount.

iv) The bidder shall bid for the whole works as described in the Bill of Quantities.

v) If break up price is asked for along with BOQ then bidder shall upload scanned copies

of break-up price duly signed by authorized representative in PDF format at the

designated location “Finance” of the portal. The bidder shall ensure that grand total of

break-up should match with total price quoted in the BOQ. This break-up price may be

used as for reference or for evaluation if required.

vi) The contractor shall be deemed to have satisfied himself/herself as to the correctness

and sufficiency of the Tender and the rates and prices quoted in the Bill of Quantities,

all of which shall cover all his/her obligations under the Contract (including those in

respect of the supply of goods, materials, plant & services, etc) and all matters &

things necessary for the proper execution and completion of the work and the

remedying of any defects therein.

Note: Please ensure that the macros are enabled in the downloaded format of BOQ.

15.3 Bidders shall submit offers that fully comply with the requirements of the Tender documents.

Conditional offer or alternative offers will not be considered in the process of bid

evaluation.

15.4 The bidders are required to upload the documents in PDF format related to their fee / pre-

qualification or eligibility information/ Technical proposal and Price proposal duly filled in.

The bidders should upload only the documents those are asked in the preceding clauses.

Please note that it is not necessary for the part of the Bidder to upload the entire Tender

document while uploading his/her bid online and said documents will be deemed to be part of

the bid.

16.0 FORMAT AND SIGNING OF BID:

16.1 The bidder can undertake the necessary preparatory work of preparation of bids off-line.

Thereafter the bidder shall log on to the portal with his/her DSC and move to the desired

tender for up-loading the scanned documents one by one in Portable Document Format (PDF)

to the portal in the designated locations of Technical Bid simultaneously checking the

documents. The Bidder will fill up the rates of items or percentage in the BOQ down loaded

for the work in designated Cell and uploads the same in designated locations of Financial Bid.

Submission of document shall be effected by using DSC of appropriate class.

16.2 The protected BOQ uploaded by the Officer Inviting to Bid is the authentic BOQ. Any

alteration or deletion or manipulation in BOQ shall lead to cancellation of Bid.

16.3 The bidder shall upload the completed bid at his/her convenience within the final date and

time of submission. The bidder shall only submit single copy of the required documents and

Price Bid in the portal. The Bidders are advised to upload the completed Bid document well

ahead of bid closure time to avoid any last moment problem of power failures, failure of

network etc. for which PPT shall not be responsible in any manner.



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16.4 Tender cannot be pre-opened and cannot be submitted after due date and time. Therefore only

after satisfying that all the documents have been uploaded, the Bidder should activate

‘Submit’ button.

16.5 In the e-procurement, each process is time stamped as per server time. The system can

identify each individual who has entered in to the portal for any bid and the time of entering

in to the portal.

16.6 The bidder shall ensure correctness of the bid prior to uploading and take print out of the

system generated summary of submission to confirm successful submission/uploading of bid.

The Bidder should also ensure clarity/legibility of the document up loaded by him/her to the

portal especially the scanned documents by taking out sample printing. Non-submission of

legible documents may render the bid non-responsive. However, the Officer inviting the

Bid if so desires can ask for legible copies or original copies of scanned documents and

statements uploaded in the portal within specified period for verification provided such

document in no way alters the Bidder’s price bid. If the Bidder fails to submit the original

documents with in the stipulated date, his EMD shall be forfeited.

16.7 The online bidder shall digitally sign on all the statements, documents, certificates, uploaded

by him/her, owning responsibility for their correctness/ authenticity. The bidder must note

that misrepresentation of facts and/or submission of fraudulent documents or submission of

bid in an irresponsible manner may disqualify the bidder to participate in any tender of

Paradip Port Trust and result in forfeiture of the EMD and also, termination of any other on-

going contracts with forfeiture of the Security Deposit. Paradip Port Trust reserves the right

to verify the authenticity of the documents / information submitted by the bidder.

17.0 PAYMENT OF EMD AND COST OF TENDER DOCUMENT:

The bidder shall furnish as part of his/her bid, an EMD and cost of Tender Document for the

amounts mentioned in the TCN as per the following procedures.

17.1 The deposit of tender paper cost and EMD by the participating bidders will be made by

National Electronic Fund Transfer (NEFT) / Real Time Gross Settlement (RTGS), only to a

specific account of PPT, details of which are mentioned below.

Account No. : 34390705999

In favour of : Paradip Port Trust

Type of Account : Saving

Branch : State Bank of India, Bank Street, Paradip.

IFSC : SBIN0003945

For effecting any bid, the Bidder will deposit the Tender paper cost and EMD separately to

the above account number and obtain the acknowledgements of the above transactions on or

before last date & time of bid submission. A self signed copy of these acknowledgements

should be uploaded by the bidder to the portal in designated place Cover-A (Clause No.15 of

ITB) while submitting the tender in respect of documents regarding EMD and Tender paper

cost. Bidder is also requested to mention the e-TCN No in acknowledgements. If the Bidder

fails to upload scanned copy of self signed acknowledgement towards deposit tender paper

cost & EMD,his/her bid shall be declared as non-responsive and rejected. It is the

responsibility of the bidder to ensure that the cost of Tender Paper Cost and EMD is deposited



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into the account of the PPT before the scheduled last date and time of submission of bid. The

amount shall be credited into the account of PPT before the scheduled time and date of bid

submission.

The Bidder should ensure that the transaction will be within stipulated bidding period for that

tender. No previous dues of the bidder shall be adjusted towards the above transaction of

tender paper cost and EMD. The bidder shall not use the same transaction in more than one

tender; otherwise his bid will be rejected.

The account from which the tender paper cost and EMD will be deposited should be in the

name of the Firm/Contractor/authorized person of the firm who have digitally signed the bid.

In case the cost of tender paper and EMD is submitted from the account of any authorized

personnel the firm needs to submit an undertaking in Cover-A (Clause No.15 of ITB)

specifying that the account from which the cost of Tender paper and EMD transferred to PPT

account is of authorized person/Proprietor of the firm. Refund of EMD in respect of

unsuccessful bidders will also be made to that specific account of the bidder.

17.2 The self signed acknowledgement uploaded by the bidder in respect of tender paper cost and

EMD should be verified by the tender inviting authority and confirmation of the same may be

obtained from the Finance Department, PPT. This verified acknowledgement will be a part of

agreement in case of the successful bidder and will be used for refund of EMD in case of

unsuccessful bidders. Refund of EMD to unsuccessful bidders and successful bidders will be

made using a standard form as per Appendix-15.

NB: If the bidder is exempted from the deposit of EMD due to registered with the Central

Purchase Organisation, National Small Industries Corporation (NSIC) or the concerned

Ministry or Department, he/she shall upload the documentary evidence in support of such

registration in Cover A ,Clause No.15 of ITB.

17.3 If the Bidder fails to upload scanned copy of self signed acknowledgement towards deposit

tender paper cost & EMD, his/her bid shall be rejected. Also furnishing scanned copy of such

documents is mandatory failing which the bid shall be declared as non-responsive and

rejected.

NB: If exempted bidder fails to upload documentary evidence in support of exemption

of EMD (as mentioned in clause No. 17.2 & 13 of ITB) in Cover A , Clause No.15 of

ITB, his/her bid shall be rejected.

17.4 Extra Additional Security Deposit (EASD) wherever applicable will be collected from the

successful bidder along with the initial security deposit (ISD) after issuing the letter of intent.

Back out from the offer by the participating bidder after opening of technical bid (in case of

two bid system) or price bid (in case of single bid) OR non-deposit of EASD by the successful

bidder will liable for forfeiture of EMD and debarment of the bidder from participating in any

future tender of PPT. EASD may be accepted in form of Demand Draft, Bankers Cheque,

Bank Guarantee in favour of FA&CAO, Paradip Port Trust.

18.0 CONFIDENTIALITY & SECURITY OF BID:

18.1 Strict confidentiality is observed during bid processing. All bid data uploaded by the Bidder to

the portal will be encrypted by the DSC of the bidder(s). The system shall require all the



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mandatory forms and fields filled up by the bidder during the process of submission of the

bid/tender.

18.2 The Bid shall be received in encrypted format by the system which can only be decrypted /

opened by the authorized openers only on or after the due date and time.

18.3 The bidder must ensure that all the information required in the tender documents is furnished

appropriately, failing which the bid shall be rejected.

19.0 DEADLINE FOR SUBMISSION OF THE BIDS :

19.1 The online bidding will remain active till the last date and time of the bid submission. Once

the date and time (Server date and time) is over, the bidder will not be able to submit the bid.

The date & time of bid submission shall remain unaltered even if the specified date for the

submission of bids declared a holiday for the Officer inviting the Bid.

19.2 The officer inviting the bid may extend the deadline for submission of bids by issuing an

amendment in accordance with Clause No.8.0, in which case all rights and obligations of the

officer inviting the bid and the bidders previously subject to the original deadline will then be

subject to the new deadline. The new date after extension shall be available in the website.

20.0 LATE BIDS :

The system shall reject submission of any bid through portal after closure of the receipt time.

For all purpose the server time displayed in the e-procurement portal shall be the time to be

followed by the bidder and concerned officers.

21.0 MODIFICATION AND WITHDRAWAL OF BIDS :

21.1 In the E-Procurement Portal, it is allowed to modify the bid any number of times before the

final date and time of submission. The bidder shall have to log on to the system and resubmit

the documents as asked for by the system including the price bid. In doing so, the bids already

submitted by the bidder will be removed automatically from the system and the latest bid only

will be admitted. But the bidder should avoid modification of bid at the last moment to avoid

system failure or malfunction of internet or traffic jam or power failure etc. If the bidder fails

to submit his/her modified bids within the designated time of receipt, the bid already in the

system shall be taken for evaluation.

21.2 In the E-Procurement Portal, withdrawal of bid is allowed. But in such case the bidder has to

write a confidential letter with appropriate reasons for his/her withdrawal addressed to the

Officer inviting the bid and uploads the scanned document to portal in the respective bid

before the closure of submission / receipt of the bid. The system shall not allow any

withdrawal after expiry of the closure time of the bid.

OPENING AND EVALUATION

22.0 OPENING OF BID:

22.1 There should be at least one day gap between date & time of submission of bids and date &

time of opening of bids.

22.2 Bid opening dates are specified during publishing of tender or can be extended vide

corrigendum. These dates are available in TCN, tender document as well as the home page of

portal. The bids shall be opened on the specified date and time only. The bidders who



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participated in the on line bidding can witness opening of the bid from any system logging on

to the portal with the DSC away from opening place. Bidders are not required to be present

during the bid opening at the opening location if they so desire.

22.3 In the event of the specified date of bid opening being declared a holiday for Paradip Port

Trust, the bids shall be opened at the appointed time on the next working day.

22.4 The designated officers authorized to open the bid shall use their DSC and open the bids. The

Bid openers; who have been pre-defined shall log on to the portal with their respective DSC.

22.4.1 The Opening Officers will check the self signed acknowledgement uploaded by the bidder in

respect of tender paper cost and EMD. If found in order, they will continue opening of all

other documents in the system provided under Technical Bid.

22.4.2 The bids with appropriate tender document cost and EMD will be taken up for evaluation as

per the information furnished by the Bidders with respect to the eligibility/pre-qualification

Information and Techno-commercial & other information in accordance with Clause 14.0.But

evaluation of the bid does not exonerate the bidders from checking their original documents.

Paradip Port Trust reserves the right to verify the authenticity of the documents / information

submitted by the bidder.

As per Section-468 (Forgery for the purpose of Cheating) and Section – 471 (using as

genuine, a forged document) of IPC-1860, use of fraudulent/forged document for the purpose

of participating in any tender is a punishable offence. Hence, in such cases, PPT shall have no

other option than to take following actions against the firm, which has restored to use of

forged/fraudulent document in any tender. It is also applicable if at a later date the bidder is

found to have misled the evaluation through wrong information.

At the time of bidding stage

a) Forfeiture of the EMD and also, termination of any other on-going contracts with

forfeiture of the Security Deposits.

b) Black listing of firm under Prevention of Corruption Act, 1988 for a period of seven years

from the date of blacklisting.

At the time of contract execution

a) Termination of the contract with forfeiture of the Security Deposits.

b) Forfeiture of the EMD and also, termination of any other on-going contracts with

forfeiture of the Security Deposits.

c) Black listing of firm under Prevention of Corruption Act, 1988 for a period of seven years

from the date of blacklisting.

22.5 After technical evaluation of the bidders and selection of the qualified bidders offline, Officer

Inviting Bid will log on to the site with their DSC and record their comments on the Technical

evaluation page in the system. Upon acceptance of technical evaluations in the system, all the

bidders will get information regarding responsiveness of their bid along with date of opening

of Price bid on their personalized dash board and also by system generated e-mail.

22.5.1 The Officer inviting Bid shall ensure that all the Bidders are individually intimated about the

date, time & venue of opening of the financial bid along with the responsiveness of the

Technical Bid.



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22.6 The Financial Bid of the technically qualified bidders will be opened on the notified date &

time in the presence of bidders or their authorized representative who wish to be present.

22.6.1 Officers in charge of opening of bid (Bid openers) i.e. Members of the bid opening committee

log on to the system in sequence and open the financial bids for the technically qualified

bidders. The opening of financial bid by the opening officers using their DSC shall decrypt

the financial bids.

22.6.2 At the time of opening of “Financial Bid”, the names of the bidders whose bids were found

responsive will be announced. The bids of only those bidders will be opened. The remaining

bids will be rejected. The price offers of the technically qualified bidders shall be announced

after opening of the financial bid.

22.6.3 Special conditions and/or rebate/discount offer if any uploaded to the system shall be declared

and recorded first.

22.6.4 The Financial bid of the bidders shall be opened one by one by the bid Openers. The system

shall auto generate the Comparative statement.

22.7 The participating bidders can witness the principal activities and view the

documents/summary reports on line for that particular work by logging on to the portal with

his DSC from anywhere. The bidder will get the information regarding the status of their

financial bid and ranking of bidders on website.

23.0 CLARIFICATION ON BIDS:

23.1 To assist in the examination, evaluation and comparison of the technical bids, Paradip Port

Trust may, at its discretion, ask the Bidder for a clarification on its Bid documents and his

rates including breakdown of unit rates. The request for clarification and the response shall be

in writing and no change in price or substance of the Bid shall be sought, offered or

permitted. If required, the Purchaser reserves the right to ask the bidders to submit the

deficiency documents or required documents which are in possession with the bidder at

the time of bid submission only.

23.2 Paradip Port Trust reserves the right to conduct joint post bid discussion after opening the

technical bids, for clarification on techno-commercial offers and may amend the techno-

commercial requirements so as to bring all the bidders on to a common platform. In case of

any alteration in the techno-commercial requirements, all the bidders shall be given equal

opportunity to submit supplementary price offers for that item in which alterations have been

made. The supplementary offer must indicate the amount which shall be added to or

subtracted from the original price offered for that item. The supplementary price offer shall

be submitted in hand at the time of opening of bid or by registered post/speed post/courier

within the stipulated date and time. Both the original and the supplementary offer shall be

evaluated jointly.

24.0 CONVERSION TO SINGLE CURRENCY:

The payment shall be made to the Contractor only in Indian Rupees. In case of any expenses

which the bidder expects to make in any foreign currency, the same shall be converted to

Indian Rupees by the bidder and the rate of conversion shall be mentioned in the document

for reference purpose only.



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25.0 EVALUATION AND COMPARISON OF BIDS:

Conditional bids may be rejected by Paradip Port Trust. The technical evaluation shall be

made strictly on the basis of the documents submitted by the bidders in support of the

eligibility, the technical and commercial response. The financial evaluation shall be made on

the basis of the total price as indicated in the Bill of Quantity. Paradip Port Trust is not bound

to accept the lowest quoted offer. Conditions, if any, on any document enclosed with Price

Bid shall not be considered for any purpose.

26.0 CONTACTING PARADIP PORT TRUST:

Bidder shall not contact Paradip Port Trust on any matter relating to its Bid from the time of

the Bid Opening to the time the contract is awarded. Any effort by any Bidder to influence

Paradip Port Trust in the Bid Evaluation, Bid Comparison or Contract Award decision shall

result in disqualification of the bidder and forfeiture of the EMD.

AWARD OF CONTRACT

27.0 AWARD CRITERIA:

The officer inviting the bid on behalf of Paradip Port Trust will award the contract to the

bidder whose bid has been evaluated to be techno-commercial responsive and the lowest

evaluated Bid. A system generated e-mail will be communicated to the successful bidder &

un-successful bidder regarding their status. Paradip Port Trust, if so required, reserves the

right to:

i) split the work and award the work in favour of more than one firm,

ii) award the work separately as Supply, Execution, Operation & maintenance / operation

/ maintenance as applicable.

28.0 PURCHASER’S RIGHT TO ACCEPT OR REJECT ANY OR ALL THE BIDS:

Paradip Port Trust reserves the right to accept or reject any bid and to annul the bidding

process at any time prior to award of contract without thereby incurring any liability to the

affected Bidder or Bidders on the grounds of Paradip Port Trust’s action.

29.0 NOTIFICATION OF AWARD:

Prior to expiration of Bid Validity, in the E-Procurement Portal, the system shall generate the

template of award letter and the Officer Inviting the Bid shall mention the amount of Initial/

Performance Security and additional security required to be furnished in the letter and

intimate the successful bidder in his e-mail ID. The issue of the letter of acceptance shall be

treated as closure of the Bid process. However Paradip Port Trust will notify the Contractor

in writing by registered letter or by fax (to be confirmed in writing by registered letter) that its

Bid has been accepted (Letter of Intent - LOI). The communication by fax followed by

registered letter with any additional information/requirement will supersede the email through

E-Procurement Portal.

30.0 SIGNING OF CONTRACT:

Within 15days of issue of Letter of Intent (LOI), the Contractor shall furnish: i) Required

non-judicial stamp paper, ii) Initial Security Deposit (ISD) and iii) Bar Chart etc. as per the

Tender Conditions. Then the formal work order shall be issued and the Contract agreement

shall be signed.



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31.0 BANK GURANTEE (BG):

a) The bidder/ Contractor should furnish BG strictly in the prescribed format, from any of the

scheduled banks. The BG should bear the TCN No. and name of the work for future

references.

b) The Bank issuing the BG should send the same in original to Paradip Port Trust in the address

as given in the TCN so that it reaches Paradip Port Trust on or before the stipulated date.

However, in exceptional cases only, the Contractor may submit the required BG to Paradip

Port Trust and ensure that the issuing bank sends an un-stamped duplicate copy of the BG

directly to the beneficiary by Regd. Post / speed post / courier with A/D with a covering letter

requesting the beneficiary to compare the duplicate with the original received from the

Bidder/Contractor and confirm that it is in order. The duplicate BG should bear the stamp,

signature and specimen signature of the Branch Manager along with date and Branch seal.

This duplicate BG should also be superscripted with the words “Duplicate BG” on body of the

BG in red ink.

c) The Contractor shall make no attempt at any time to revoke the BG executed in favour of PPT

before completion of all the contractual obligations.

32.0 MEMORANDUM OF SETTLEMENT:

The Contractor shall not sign any memorandum of settlement with any agency such as Trade

Unions etc. in any form at any level without the prior approval of Paradip Port Trust in

relation to any work under taken by him in the Port premises.

33.0 DESIGN CRITERIA:

The bidder may please note that the specifications mentioned in the tender document are

indicative only.

All the material, equipment offered and used in the execution of the work shall be suitable

for sustained service in a marine atmosphere and cyclone prone environment.

In the event of repeated failure of any component or material or fitting, within the warranty

period , it shall be treated as failure on the part of the Contractor and the Contractor shall

have to promptly rectify the same at his own cost failing which Paradip Port Trust shall have

the right to recover the cost from any other outstanding amount of the Contractor lying with

PPT and / or any amount that may become due to the Contractor and the Contractor shall be

debarred to participate in any of the tender of PPT in future.

34.0 DRAWINGS:

Where the work requires submission of drawings, the Contractor shall adopt an agreed

system for numbering of the drawings and submission thereof. The Contractor shall submit a

numbering plan to Paradip Port Trust for acceptance. 4 sets of the General Arrangement (GA)

Drawings must be submitted to Paradip Port Trust for approval (3 for PPT + 1 to be returned

to the Contractor). The GA drawings must clearly indicate the location of important



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installations, important dimensions etc. and the execution shall be done strictly in accordance

with the approved drawing.

The construction drawings must be prepared prior to the commencement of

construction and it should be promptly supplied to Paradip Port Trust’s representative for

inspection of the work. On completion of the work, 6 sets of the “As Built” drawings, duly

incorporating all the changes made during the construction, shall be supplied to Paradip Port

Trust. A comprehensive list of the drawings shall be submitted along with the “As Built”

drawings.

The drawing sizes shall be as under:

GA Drawings – A0 (1189 x 841 mm).

Construction Drawings – Mechanical: A1(841 x 594 mm), Electrical: A3 (420 x 297 mm).

As Built Drawings – Mechanical: A1 (841 x 594 mm), Electrical: A3 (420 x 297 mm).

Data Sheets & Manuals: A4 (297 x 210 mm).

In addition to the above, the Contractor shall supply 2 sets of soft copies of all the

drawings and manuals in electronic forms in CDs.

35.0 MANUALS:

All the manuals shall be sufficiently informative so as to smoothly carry out operation and

maintenance after the work is completed and accepted by Paradip Port Trust. Two sets of

draft manuals shall be submitted by the Contractor, within 15 days of acceptance of the work,

for approval. Paradip Port Trust may make observations to improve the standard of the

manual and the Contractor, after incorporating the changes in the manuals, shall submit 4 sets

of the final copy for acceptance by Paradip Port Trust. Two set of soft copies of the accepted

version of the manuals shall be supplied by the Contractor in CDs. The following guide lines

may be followed by the Contractor for preparation of the manuals.

A) Operation Manual : The manual must cover, inter alia, the principal features of the machine

/ equipment / system, as applicable, the control philosophy used, pre-starting checks, starting

procedures, checks to be made during operation, stopping procedures, DOs and DONTs,

trouble shooting, emergency procedures, safety trips etc.

B) Maintenance Manual: The manual must include, inter alia, important maintenance

procedures, preventive maintenance schedule, Lubrication Chart, various tolerance limits and

list of special tools. The maintenance manual must contain dismantling and assembling

procedures of important components clearly showing positioning of special tools, fixtures,

measuring instruments etc. with diagrams.

C) Spare Parts Manual: The manual must contain, inter alia, spare parts details such as

drawing no., part no, specifications of all the assemblies. For bought out items, the cross

sectional drawings giving details of parts, dimensions etc. has to be supplied to Paradip Port

Trust. The bearing nos and oil seal nos of all the bearings and oil seals used in the work must

be listed clearly giving their make and the location where used.

36.0 SITE SAFETY & ENVIRONMENT PROTECTION:

The Contractor, during the execution of the work, shall be solely responsible for

complying all the statutory requirements of Government bodies or any statutory bodies with

respect to site health, safety and environment.



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37.0 QUALITY ASSURANCE PLAN, INSPECTION AND TESTING:

37.1 QUALITY ASSURANCE PLAN:

The Contractor shall submit a quality assurance plan (QAP) for acceptance by the Purchaser

before commencement of the work. The QAP shall, contain:

a) List of the tests and inspections proposed to be done to ensure quality.

b) List of the standards to be followed for execution of the work as well as tests and

inspections.

One set of the standards to be followed for the execution of the work / test and inspection

shall have to be submitted, by the Contractor along with the QAP for reference, to Paradip

Port Trust within 30 days of issue of LOI.

37.2 INSPECTION & TEST:

The Contractor shall submit an inspection plan compatible with the QAP. The test and

inspection report shall contain the description of the part / component / equipment, the date

and place of testing, the standard followed for conducting the test, the actual test result

recorded and the allowable limits, the name and designation and signature of the Contractor’s

representative, Paradip Port Trust’s representative and Third Party representative who

witnessed the test. The test report shall be forwarded to Paradip Port Trust within 15 days of

completion of the test for record and reference.

Paradip Port Trust reserves the right to subject any part / component / equipment for

re-test and on written instruction from Paradip Port Trust, the Contractor shall arrange for

the re-test and the cost shall be reimbursed by Paradip Port Trust as per actual, only if the

test results are satisfactory. In case of unsatisfactory test results, the part / component /

equipment shall be rejected and the Contractor shall be responsible for replacement of the

item at his own cost and also bear the cost of the re-test.

The Contractor shall inform Paradip Port Trust, at least 7 days in advance, about the

inspection / tests planned for and assist Paradip Port Trust in witnessing the same, if so

desired by Paradip Port Trust.

Paradip Port Trust’s right to inspect, test and, where necessary, reject the Goods after

the Goods’ arrival in Paradip Port Trust’s premises shall in no way be limited or waived by

reason of the Goods having previously been inspected, tested and passed by Paradip Port

Trust or its representative prior to the Goods’ shipment from the place of origin.

The Contractor shall submit an inspection and test plan (ITP) before commencement

of the work and it should inter-alia cover the following:

1. Identifications of tests/inspections to be conducted during execution of the Contract.

2. Hold points and witness points.

3. The list of records to be maintained.

Hold Points: Means a position in the execution beyond which work shall not proceed without

mandatory verification and acceptance by Paradip Port Trust or his representative.

Witness Points: Means a position in the execution where Paradip Port Trust may exercise it’s

option to witness some tests for acceptance.



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38.0 THIRD PARTY INSPECTION:

The Contractor shall avail the services of a third party, acceptable to Paradip Port

Trust, if required as per the contract, and bear the cost of the Third Party inspection. The

responsibility of the third party shall, inter alia, be to ensure and certify that the work is

being executed as per the relevant standards as given in the approved QAP. Paradip Port

Trust reserves the right to replace the Third party during the execution of the Contract if the

third party inspection is not satisfactory. Additional cost, if any, for such change shall have

to be borne by the Contractor.

In case of any technical dispute between the purchaser and the contractor in

connection with design, construction, erection, testing etc, the matter shall be referred to the

third party for a reasoned decision which shall be reviewed by Paradip Port Trust.

39.0 TIME IS THE ESSENCE OF THE CONTRACT:

Time is the essence of the contract and the Contractor shall ensure that all the

obligations under the contract are completed within the agreed time schedule. The

Contractor shall be solely responsible for all the delays including the delays caused by it’s

vendors. In case of delay in progress of the works, Paradip Port Trust reserves the right to

withhold the payment, cancel the contract unilaterally or complete the work departmentally

or by engaging another agency at the cost and risk of the contractor.

40.0 PURCHASER’S OBLIGATION : i) Electricity, water and land for execution of supply, installation, commissioning of the

system shall be provided to the contractor on payment of applicable tariff of PPT but

during operation and maintenance of the system, PPT shall provide free electricity and

water.

(ii) Upon request of the Contractor, PPT may provide Port Trust Quarters, during the

period of work, subject to availability and on payment of applicable Tariff.

(iii) Administrative support only, for obtaining clearance from any statutory authority,

shall be provided by Paradip Port Trust.

(iv) On successful completion of all the obligations under the contract and on the request

of the Contractor, Paradip Port shall issue a “ Work Done Certificate “ in the

prescribed format only and with the approval of the Chief Mechanical Engineer, PPT.

In case of association the work done certificate shall be issued in favour of the

association clearly indicating the names of it’s members.

41.0 CONTRACTOR’S OBLIGATION:

(i) All the materials and works, including labour, required to complete the work

satisfactorily is covered under the scope of the Contractor.

(ii) It shall be the responsibility of the Contractor to ensure that the persons engaged for

the work are clear from Security angle.

(iii) Contractor shall nominate an Authorized Representative for carrying out all the

transactions with PPT including receipt of payment.

(iv) The Contractor, at his own cost, shall be solely responsible for the following:

a) To pay all the taxes, duties, cess, fees, levies and all other dues imposed by any

authority in India or abroad as the case may be, except service taxes. Service Tax

shall be paid by Paradip Port Trust on claim and submission of Service tax

Registration Certificate.



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b) To execute the work with due diligence, efficiency and in conformity with sound

engineering, administrative and financial practices to protect the interest of the

Purchaser.

c) To follow metric system and follow the latest design criteria and ensure that the

design is suitable for the intended purpose, even though the GA Drawings are

approved by Paradip Port.

d) To co-ordinate with outside agencies for obtaining permission / approval /

clearances etc. that may be required to execute the work.

e) To extend all reasonable opportunities to other Contractors employed by the

Purchaser for carrying out their work.

f) To keep the work site free from obstruction.

g) To maintain site account of materials, including the departmental supply, clearly

indicating relevant information such as description of the material, source, date of

delivery at site, date of consumption at site. The Contractor shall forward a copy

of monthly site account of materials to the Engineer in Charge at the end of every

month. On completion of the work under the contract, the Contractor shall submit

to the Engineer in Charge a copy of the site account of the materials from the date

of commencement to date of acceptance. The Contractor shall also maintain

hindrance register, site instructions register, complaint register and daily progress

monitoring register and the EIC shall verify the registers as and when required and

sign the same, duly recording his remarks.

h) To arrange for transport, gate pass, accommodation, medical facility etc. for the

work men deployed under this contract at his own cost.

i) The Contractor shall include due percentage of SC/ST workers in outsourcing

work as laid down by the Government from time to time.

42.0 VENDOR LIST:

The Bidder, in it’s technical offer, must submit a vendor list of reputed makers for various

components / bought out items which is going to be followed for execution of the work. The

same shall be followed only after approval of Paradip Port Trust.

43.0 SCRAP DISPOSAL:

Unless otherwise specified, Scope of the contractor for the scrap disposal is as under:

(a) In case of one time repair and / or replacement and /or maintenance contracts scrap

generated during execution shall be the property of Paradip Port Trust.

(b) In case of operation and/or annual maintenance contracts, if the stores and spares

supply is included in the scope of the contractor, then the scrap generated during the

execution of the contract shall be the property of the contractor.

(c) In case of project works, scrap generated out of dismantled components /structures

during the execution of the work shall be the property of the PPT. Scrap generated out

of new materials supplied by the Contractor shall be the property of the contractor.

Scrap generated out of new materials supplied by Paradip Port Trust shall be the

property of Paradip Port Trust.

44.0 UNDERTAKING BY THE BIDDERS:

The bidders shall give an undertaking that they have not made any payment or illegal

gratification to any person / authority connected with the bid process so as to influence the bid



Page 25 of 286

process and have not committed any offence under the Prevention of Corruption Act (PC Act)

in connection with the bid.

45.0 DISCLOSURE BY THE BIDDER:

The bidder shall disclose any payment made or proposed to be made to any intermediaries

(agents etc.) in connection with the bid.

46.0 CESS TO BE REMITTED TO THE ORISSA BUILDING AND OTHER

CONSTRUCTION WORKERS WELFARE BOARD:

Govt. of Orissa vide Resolution No.12653 dt.15.12.08 have decided to collect a Cess of 1%

of the cost of construction incurred by the employer/ builder. The cost, however, would not

include the cost of land and other compensation paid or payable to a worker/his kin under the

Workmen’s Compensation Act, 1923.

The imposition of Cess would attract incase of construction, alteration, repairs,

maintenance or demolition interalia of/or in relation to the followings and such other works

as may be specified by the Government:-

1) Building 2) Streets 3) Roads

4) Railways 5) Air-fields 6) Irrigation

7) Drainage 8) Embankment 9) Navigation works

10) Flood Control works (including storm water drainage works, generation, transmission

and distribution of water)

11) Oil and gas installations 12) Electric lines

13) Wireless 14) Radio 15) Television

16) Telephone 17) Telegraph & Overseas communications

18) Dams 19) Canals 20) Reservoirs

21) Water courses 22) Tunnels 23) Bridges

24) Viaducts 25) Aqueducts 26) Pipelines

27) Towers 28) Cooling towers

29) Transmission towers

This, however, would further not include buildings or other constructions work to

which the Factories Act, 1948 and the Mines Act, 1952 apply.

The Act applies to every establishment, which employs 10 or more workers in all the

aforesaid works or has employed such number of workers on any day during the preceding 12

months.

47.0 INTEGRITY PACT:

For every work / procurement / contract the value of which is Rs. 5crores and above,

the integrity pact agreement format as given at Appendix – 11 shall form a part of the tender

document. The filled in & signed Integrity pact as per Appendix – 11 shall be prepared in

Non-judicial stamp paper and submitted in original along with Technical bid in case of

conventional tender by all the participating bidders . In case of e-tendering, scanned copy of

filled in & signed Integrity pact as per Appendix – 11 prepared in Non-judicial stamp paper

shall be uploaded along with technical bid and the original shall be submitted to Notice

Inviting Tender Authority within 7days of opening of tender by all the participating bidders.

The Integrity pact signed by the Purchaser and the bidder (successful bidder –Contractor)

shall be made part of contract agreement.



Page 26 of 286

GENERAL CONDITIONS OF CONTRACT ( GCC )

Clause No Description

1.0 Definitions

2.0 Use of Contract Document

3.0 Change Orders

4.0 Sub-Contracts

5.0 Payment to Sub-Contractors

6.0 Liquidated Damage

7.0 Acceptance

8.0 Warranty

9.0 Bar Chart

10.0 Payment Terms

11.0 Time Extensions

12.0 Termination for Default

13.0 Resolution of Dispute

14.0 Force Majeur

15.0 Insurance

16.0 Compliance with Statute, Regulations

17.0 Indemnification

18.0 Deduction

19.0 Variations in Conditions of Contract

20.0 Supply of Materials & Equipment

21.0 Idle Charges

22.0 Personal Protective Equipment

23.0 Conduct

24.0 Accident

25.0 Watch and Ward

26.0 Engineer – in – Charge

27.0 Agreement Copy

28.0 Undertaking by the Contractor

General Conditions of Contract


Page 27 of 286

GENERAL CONDITIONS OF CONTRACT(GCC)

1.0 DEFINITIONS:

In this contract, the following terms shall be interpreted as indicated.

(a) “The Contract” means the agreement entered into between Paradip Port Trust and the

Contractor as recorded in the Contract Form signed by the parties including all attachments

and appendices thereto and all documents incorporated by reference therein.

(b) “The Contract Price” means the sum stated in the Letter of intent / Work Order as payable to

the Contractor for the execution and completion of the works and the remedying of any

defects therein in accordance with the Contract.

(c) “The Goods” means all of the equipment, machine / equipment / system, as applicable, and/or

other materials including the design and drawings which the Contractor is required to supply

to Paradip Port Trust under the Contract.

(d) “Services” means services ancillary to the supply of the Goods, such as transportation and

insurance and any other incidental services such as installation, commissioning, provision of

technical assistance, training and other such obligations of the Contractor covered under the

Contract.

(e) The “Purchaser” is the Board of Trustees, Paradip Port Trust (PPT). Paradip Port Trust may,

from time to time, by notice in writing to the Contractor, nominate a representative or

representatives to perform specific duties of Paradip Port Trust under the Contract. The notice

shall specify the duties which the representative or representatives shall perform on behalf of

Paradip Port Trust.

(f) The Contractor is _________________ (Name of Contractor to be inserted at the time of

signing the Contract).

(g) (i) “Works” means the permanent Works and the Temporary Works or

either of them as appropriate.

(ii) “Permanent Works” means the permanent works to be executed including all the

goods and services in accordance with the Contract.

(iii) “Temporary Works” means all temporary works of every kind (other than Contractor’s

Equipment) required in or about the execution and completion of the Works and the

remedying of any defects therein.

(iv) “Plant” means machine / equipment / system, as applicable, apparatus and the like

intended to form or forming part of the Permanent Works.

(v) “Contractor’s Equipment” means all appliances and things of whatsoever nature (other

than Temporary Works) required for the execution and completion of the Works and

the remedying of any defects therein but does not include Plant materials or other

things intended to form or forming part of the Permanent Works.

(vi) “Section” means a part of the Works specifically identified in the Contract as a

Section.

(vii) “Site” means the places provided by Paradip Port Trust where the Works are to be

executed and any other places as may be specifically designated in the Contract as

forming part of the site.

(h) “Time for Completion” means the time for completing the execution of the Works or any

section or part thereof as stated in the Contract.



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(i) “Purchaser’s Representative” means the person appointed by Paradip Port Trust to act as the

Engineer for the purpose of the Contract and named as such in Special Conditions of

Contract.

(j) “Contract” means these Conditions, the Specification, the Drawings, the Schedule of Prices,

the Tender, the Notification of Award, the Contract Agreement (if completed) and all such

further documents as may be expressly incorporated in the Notification of Award or Contract

Agreement (if completed).

(k) “Commencement Date” means the date as recorded in the Letter of Intent / Work Order issued

by Paradip Port Trust.

(l) “Delivery Period” means the period elapsed between the commencement and completion date

as recorded in the Letter of Intent / Work Order issued by Paradip Port Trust.

(m) “Bill of Quantity” means any schedule included in the Tender and any subsequent schedule

requested during implementation of the Contract which, in respect of any section or item of

work to be carried out, shows the amount or respective rate of payment for the execution of

that work.

(n) “Drawings” means all drawings, designs and calculations and technical information of a like

nature provided by the Engineer to the Contractor under the Contract and all drawings,

calculations, samples, patterns, models, operation and maintenance manuals and other

technical information of a like nature submitted by the Contractor and approved by the

Engineer.

(o) “Tender” means the Contractor’s priced offer to Paradip Port Trust for the execution and

completion of the Works and the remedying of any defects therein in accordance with the

provisions of the Contract, as accepted by the Notification of Award.

2.0 USE OF CONTRACT DOCUMENT:

The Contractor shall not, without prior consent, make use of any document except for

the purpose of performing this contract.

3.0 CHANGE ORDERS:

At any time during the execution of the contract, by a written notice to the Contractor,

changes may be made in the general scope of contract. The Engineer In-charge (EIC), with

due approval of competent authority, may make any changes in the quality and/or quantity of

the work or any part thereof that may, in his/her opinion, be necessary and for that purpose

the Engineer In-charge shall have the power to order the Contractor to do and the Contractor

shall do any of the following:

a. Increase or decrease or split the quantity of work included in the contract,

b. Omit any such work,

c. Change the character, quality or kind of any such work,

d. Change the dimensions of any such work,

e. Execute additional work of any kind necessary for completion of the work under the

contract, and no such change shall in any way vitiate or invalidate the contract but the

cost, if any, arising out of all such changes shall be taken into account in ascertaining

the total amount of the contract price. Where the rate is available in the contract and

the same is applicable to the additional work, in the opinion of the EIC, the cost of the

additional work shall be determined as per this available rate. But, if the rate for

additional work is not available in the contract, the same shall be determined by the

EIC taking into account the market rate and labour cost at the site for similar works

and shall be final.



Page 29 of 286

f. Deviations from the specifications as contained in the tender agreement including

the make / model, shall not be accepted. In case of any such deviation, payment

shall not be made for that part of the work / item, even if it is meeting the functional

requirements and has been accepted by the purchaser. The payment for such

portion of the work / item can only be released if the contractor makes good the

deviations before the expiry of the warranty period so as to meet the specifications of

the tender agreement in all respects.

4.0 SUBCONTRACTS:

The Contractor shall not sub-contract all or any part of this contract without getting

PPT’s prior approval in writing and the Contractor shall guarantee that the Sub-Contractor,

for any part of the work under this contract will comply fully with the terms and conditions of

the contract. The Contractor shall clearly indicate the purpose for which the Sub-Contractor is

to be deployed. The Contractor shall ensure that:

a. The Sub-Contractor has not been de-barred to participate in any tender either by PPT

or any other Govt. Organisation and

b. The Sub-Contractor is competent to undertake the work assigned to him.

5.0 PAYMENT TO SUB-CONTRACTORS:

The Contractor shall ensure that timely payment is made to it’s sub-contractors. In

case of dispute between the Contractor and its sub-Contractor, PPT shall have the right to

withhold adequate money from the dues of the Contractor till the Contractor settles the

dispute with its sub-Contractor and submits documentary evidences in support of such

settlement. PPT shall also have the right to make payment to the sub-Contractor directly for

that part of the claim which has been certified for payment by the Contractor but not paid.

6.0 LIQUIDATED DAMAGE: (L. D.)

a. Unless otherwise specified, in case of delay in completing the work, liquidated damage shall

be charged to the Contractor at the rate 0.25% of the contract price for a delay of one week or

part thereof subject to a maximum of 5% of the contract price if the original execution period

is 90 days or more. Where the original execution period is less than 90 days, liquidated

damage shall be charged to the Contractor at the rate of 0.1% of the contract price for a delay

of one day or part thereof subject to a maximum of 5% of the contract value. Where the

Liquidated Damage amount exceeds the maximum limit, Paradip Port Trust reserves the

right to :-

i) Terminate the contract and / or ii) Forfeit the Initial Security Deposit (ISD).

b. In case of “substantial completion” of a section of work and subsequent taking over by the

purchaser within the scheduled date of completion, the liquidated damage shall be levied on

the cost of balance portion of the works which are completed after the scheduled date. “

Substantial Completion “ of a section shall mean that the section has been completed,

passed the tests, if any, to meet it’s intended purpose and can be used by the purchaser for

that purpose.



Page 30 of 286

7.0 ACCEPTANCE:

Upon completion of work under this contract, the Board may accept the works and/or

services after installation, if defects or shortcomings are not considered essential and, the

Contractor agrees to make good the deficiencies in confirmation with this contract. No work

shall be accepted before the Contractor clears the site of scraps, unused materials, work shed,

equipment and all such materials which were used for execution of the work and not required

any more at the work site. Also, the Contractor has to submit all the documents and final “as

built” drawings as per the contract agreement without which no work shall be treated as

complete.

8.0 WARRANTY:

8.1 The warranty period shall be valid up to six / twelve months (6 months for repairs and 12

months for new works including supplied items) with effect from the date of acceptance of

the work and/or services, unless otherwise specified in the scope of work / Special Conditions

of Contract (SCC).

8.2 The Contractor shall warrant the Board that the goods and services under this contract will

comply strictly with the contract, shall be first class in every particular case and, shall be free

from defects. The Contractor shall further warrant the Board that all materials, equipment and

the supplies furnished by him/her will be new and fit for their intended purposes.

8.3 The Board shall promptly notify the Contractor in writing of any claim arising under this

Warranty. Upon receipt of such notice, the Contractor shall promptly repair or replace the

defective goods and/or services at no cost to the Board.

8.4 If the Contractor, having been notified, fails to remedy the defects in accordance with the

contract, the Board may proceed to take such remedial action as may be necessary, at the

Contractor’s risk and cost.

9.0 BAR CHART:

The Contractor shall submit a bar chart, before signing the agreement, clearly indicating the

plan for timely execution of the work. The bar chart must indicate the individual activities

and commencement and completion dates of each activity. The bar chart shall be used for

monitoring the progress of the work.

10.0 PAYMENT TERMS:

10.1 Completed Bill Entry Format issued by the Engineer In-charge and the warranty certificate

issued by the Contractor shall be attached to the bills. Unless otherwise provided, payment

will be released after deduction of security deposit as per Clause No.14 of ITB within 30 days

of submission of bills for the works completed in all respects. The deduction amount towards

security deposit shall be released within 30 days after successful completion of the work.

The Contractor may submit Bank Guarantee for the balance amount after deducting the EMD

and ISD from the stipulated security deposit or BG for the stipulated security deposit as per

Clause No.14 of ITB in which case 100 % of the contract price shall be released for payment.

Payment shall be made only for the actual quantity executed. The payment to the Contractor

may be made through electronic payment, if the required data are given by the Contractor and

the e-payment mechanism is available in the local bank. Besides, the Contractor has to issue



Page 31 of 286

receipt confirmation immediately in writing for such payments. Payment can be made on

pro-rata basis.

10.2 STAGE PAYMENT:

Stage payment may be made, where not originally provided for, only when the work

has been delayed because of non-availability of work fronts and any other cause beyond the

reasonable control of the Contractor, up to 75% of the payment due to the Contractor for

completed portion of the work and for the goods which has been already delivered at the site

against BG of an equivalent amount with mutually agreed valid period as per Appendix-12.

10.3 ADVANCE PAYMENT:

Provision of Mobilization Advance should essentially be need-based. Paradip Port

Trust reserves the right to provide mobilization advance on case to case basis which will be

defined in Special Condition of Contract or clarifications issued to pre-bid queries. Otherwise

Advance payment will not be entertained.

The Mobilization advance limited to 10% of the contract amount (Excluding the

O&M component, if any in the BOQ) may be made as per the following terms and conditions

provided the Contractor

a. Makes a written request to avail advance payment with a refund plan.

b. Submits an irrevocable Bank Guarantee from a schedule bank at least of 110% of the

advance amount in the prescribed format valid till 30 days after the agreed date of

completion of the work. The Contractor may submit Part ‘Bank Guarantees’ (BGs)

against the mobilization advance in as many numbers as the proposed recovery

instalments and should be equivalent to the amount of each instalment. This would

ensure that at any point of time even if the contractor’s money on account of work

done is not available with the organization, recovery of such advance could be ensured

by encashing the BG for the work supposed to be completed within a particular period

of time.

c. Agrees to pay interest of 14% ( to be stipulated depending on the prevailing rate at the

time of issue of TCN). The interest on the advance shall be calculated from the date of

payment to the date of recovery, both days inclusive.

d. Agrees to receive advance in not less than two instalments.

e. Agrees to refund the advance amount as per the approved refund plan which will be

commenced after 10% of work is completed and the entire amount together with

interest shall be recovered by the time 80% of the work is completed.

f. Agrees to furnish utilization certificate for the mobilization advance. Subsequent

instalments should be released after getting satisfactory utilization certificate from the

contractor for the earlier instalment.

11.0 TIME EXTENSIONS:

The Contractor may claim extension of the time limits in case of:

a. Changes ordered by Paradip Port Trust.

b. Delay in supply of any materials or services which are to be provided by PPT.

c. Force Majeure;

d. Delay in performance of work caused by orders issued by Paradip Port Trust.



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The Contractor shall submit the claim, within 30 days of occurrence of such delay,

clearly indicating the justification for such extension and with necessary documentary

evidence.

12.0 TERMINATION FOR DEFAULT:

12.1 The Board may, without any prejudice to any other remedy for breach of contract, by written

notice of default sent to the Contractor, terminate the contract in whole or in part:

i) if the Contractor fails to execute the work within the period as specified in the

contract, or any extension granted by the Board;

ii) if the Contractor fails to perform any other obligation under the contract and if the

Contractor does not cure, after receipt of a notice of default, its failure within the time

specified in the notice. The notice of default shall specify the nature of default as well

as the time within which the default has to be cured by the Contractor.

12.2 In the event of Board’s termination of the contract in whole or in part, the Board may execute

the remaining work or procure goods similar to those undelivered by the Contractor, and the

Contractor shall remain liable to the Board for any excess cost for such works or goods and

risks, if any.

12.3 No payment shall be released in favour of the Contractor till all the balance works are

completed in all respects. After the balance works are completed, the Board may consider

payment for the items / goods that have been completed / supplied by the Contractor and

accepted by Paradip Port Trust after adjustment of any additional cost that have been incurred

for completing the balance works.

12.4 In case of termination of contract for default by the Contractor, the Board may forfeit the

initial security deposit and may not permit the Contractor to participate in any of the future

tender of Paradip Port Trust.

12.5 The contract may be terminated by either party by giving written notice to the other, at least

30 days in advance and neither party shall have any right of any claim on the other on

account of such termination.

13.0 RESOLUTION OF DISPUTE:

a) The Executing office and the Consultant shall make every effort to resolve any disagreement

or dispute arising between them in connection with the contract amicably as per terms

conditions of contract by direct informal negotiations. In case of non-resolve, the dispute

shall be referred to CME, PPT for amicable settlement. However, in case of failure of

negotiation between the CME and the Contractor, the parties shall refer their present and

future disputes relating to the contract itself or arising out of or concerning or in connection

with or in consequence of the contract to the Chairman, PPT whose decision shall be final

and binding on both the parties. The contract shall be governed by The Indian Contract Act,

1872.

b) JURISDICTION OF COURTS:

All disputes which could not be resolved at the intervention of Chairman, PPT shall be

subjected to exclusive jurisdiction of courts at Kujang only.



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14.0 FORCE MAJEURE:

14.1 In the event that the Contractor is delayed in performing its obligations in the contract, and

such delay is caused by force majeure including war, civil resurrection, strikes (other than the

strike solely by the Contractor’s men), fire, flood, epidemics, earthquakes, extremely adverse

climatic conditions, such delay may be excused and the period of such delay may be added to

the time of performance of the obligations without any addition to the contract price.

14.2.1 If a force majeure situation arises, the Contractor shall promptly notify the Board in writing of

such condition and the cause thereof, but not later than 7 days from it’s occurrence. Unless

otherwise directed by the Board in writing, the Contractor shall continue to perform its

obligations under the contract as far as reasonably practicable. The Contractor shall

demonstrate to the Board’s satisfaction that it has used its best endeavor to avoid or overcome

such causes of delay and the parties will mutually agree upon remedies to mitigate or

overcome such causes of delay without having any right to any claim on account of such force

majeure.

14.3 In any other situation, which is beyond the reasonable control of the Contractor in the opinion

of the Engineer In-charge, and where the Contractor has promptly notified the Board in

writing about such situation, it may be considered as “Force Majeure” situation.

15.0 INSURANCE:

15.1 All the men/women to be deployed by the Contractor for performing the contract shall be

insured against injury / accidents/death, by the Contractor at his own cost.

15.2 The Contractor shall indemnify Paradip Port Trust against all losses and claims in case of

death or injury caused to any person by him/her during the execution of the work.

16.0 COMPLIANCE WITH STATUTES, REGULATIONS:

16.1 The Contractor shall comply in all respects, with all statutes and regulations as may be

necessary, including clearance from State/Central Govt. authorities, Pollution Control Boards,

labour enforcement and local authorities. The Contractor shall, at all times during the

continuance of the contract, so far as it may be necessary, comply with all the existing

enactments including Central and State legislation as well as any by-laws of any local

authorities regarding labour, particularly the Minimum wages Act, Factories Act, Workmen’s

Compensation Act, Employees’ Provident Fund and Family Pension Fund Act, Employees’

State Insurance Act, Contract Labour (Regulation and Abolition) Act, Payment of Wages Act,

Maternity Benefit Act, National and Festival Holidays Act, Shop and Establishment Act, The

Apprentice Act and keep the Employer indemnified against any loss or claim arising out of

contravention of the provisions of the above said enactments by the Contractor. The price

quoted by the Contractor in the Bill of Quantity shall be deemed to include all expenses

whatsoever the Contractor may be required to incur for the compliance with the provisions of

the above said legislation. The Contractor shall make necessary arrangements for the

Employer to witness the payment made by the Contractor to his/her staff and labour.

The Contractor shall to cover all its workmen under EPF & ESI irrespective of the no.

of workmen engaged in the work. The Contractor shall produce documentary evidence in

support of the EPF & ESI coverage to its workers within 30days of induction of contractual

worker(s). This will also be applicable to the sub-contractor(s) appointed by the Contractor

for the subject work.



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The Contractor shall make payment of wages to its workmen deployed in the work

within 7th

day of the succeeding month positively. In case of failure to make payment by this

date , a deduction will be made from the monthly bill@2% of the monthly bill in case of

AMC & other contracts with a provision of monthly payment and Rs.25,000/- from the

Running Bill in case of other works in addition to the caution notice for such default. In case

of default by the Contractor for more than two times in a contract year then the Initial

Security Deposit (ISD) or any other security deposits will be forfeited and contract will be

terminated with immediate effect if the reason for default is attributable to the Contractor.

This will also be applicable to the sub-contractor(s) appointed by the Contractor for the

subject work. If the reason of default is not attributable to the Contractor in accordance with

“Force Majeure” clause of GCC, then no deduction/penalty will be imposed. This clause is

also applicable in case of default by the Contractor including in fulfilling its obligations for

all types of statutory rules & regulations mentioned in the contract including EPF, ESI &

Bonus.

16.2 OBSERVANCE BY SUB-CONTRACTORS

The Contractor shall be responsible for observance by his Sub-Contractors of the foregoing

provisions.

17.0 INDEMNIFICATION:

The Contractor shall indemnify, protect and defend at its own cost, Paradip Port Trust

and its agents and employees from and against any / all actions, claims, losses or damages

arising out of

a. any violation by the Contractor in course of its execution of the contract of any legal

provisions or any right of third parties;

b. Contractor’s failure to exercise the skill and care required for satisfactory execution of

the contract.

18.0 DEDUCTION:

18.1 Deduction of taxes at source shall be made from the bill of the Contractor in accordance with

the prevailing rules of Paradip Port Trust.

18.2 While performing under the contract, the damages caused by the Contractor or his/her

workmen to any of the Port Trust property shall be promptly made good by the Contractor at

his/her own cost. In case the Contractor fails to repair/replace the damage, Paradip Port Trust

shall have the right to take steps to make good the damages and all the cost on this account

shall be recovered from the bills of the Contractor or any money due to the Contractor from

this contract or any other contract or any other transaction. In determination of the damage,

the opinion of the Engineer In-charge (EIC) shall be conclusive.

18.3 Any dues arising out of failure on the part of the Contractor to carry out any obligation under

the contract shall be deducted from the bills of the Contractor or from any money due to the

Contractor from this contract or any other contract including Initial Security and Performance

Security.



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19.0 VARIATION IN CONDITIONS OF CONTRACT :

In case of any variation in Instructions to Bidders (ITB), General Conditions of

Contract (GCC) and Special Conditions of Contract (SCC), the Special Conditions of

Contract – if any, shall prevail. But in case of any requirement / condition specified in the

Scope of Work, it shall prevail over all other conditions. It may please be noted that at any

time prior to the dead line for submission of Bids, Paradip Port Trust may, for any reason,

whether at it’s own initiative or in response to a clarification requested by any prospective

bidder, modify the tender document by amendment / issue of addendum. In such cases,

Paradip Port Trust may, at it’s discretion, extend the dead line for submission of bid.

20.0 SUPPLY OF MATERIALS AND EQUIPMENT:

On request of the Contractor, Port Trust may supply materials and/or provide

equipment to the Contractor for the work subject to availability and Contractor’s acceptance

of the prevailing Port Trust conditions.

On request of Paradip Port Trust (PPT), to avoid delay, the Contractor shall supply

materials / spares which are not available with PPT and not included in the scope of the

Contractor and payment for such supply shall be made by PPT as per actual on the basis of

documentary evidences like purchase vouchers etc.

21.0 IDLE CHARGES:

All efforts shall be made for timely supply of materials and/or equipment where it is

included in the scope of Paradip Port. However, the Contractor shall not be entitled to any

idle charges for delay in supply of materials and/or equipment by the Port Trust. Further, in

case of any delay due to stoppage of work ordered by the Port Trust to avoid interruption in

other important activities of Port Trust, the Contractor shall not claim any idle charges.

22.0 PERSONAL PROTECTIVE EQUIPMENT: (PPE)

The Contractor shall be solely responsible, at his own cost, for the supply of required

PPE to his/her workers and staff and he/she shall also ensure the use of PPE such as helmets,

nose masks, hand gloves etc. by his/her staff at site.

23.0 CONDUCT:

The Contractor, at all times during execution of the contract, shall take all measures to

prevent any unlawful, riotous or disorderly conduct by or amongst his staff at the site and for

the preservation of peace and protection of persons and property at the work site as well as in

the neighbourhood of the works.

In case of any unlawful / riotous / disorderly conduct by any workman of the

Contractor, PPT reserves the right to direct the Contractor to disengage the worker

temporarily or permanently with a suitable replacement. If the Contractor does not take action

as directed, PPT may terminate the contract and / or forfeit the security deposit of the

Contractor.



Page 36 of 286

24.0 ACCIDENT:

The Contractor shall, within 24 hours of the occurrence of any accident, at or about the work

site or in connection with execution of the contract, report such accidents to the Engineer

Incharge giving all the details. He/She shall also provide additional information about the

accident as requested by the EIC.

25.0 WATCH AND WARD:

During the execution of the contract, it shall be the responsibility of the Contractor to arrange

watch and ward of the work including the raw materials, machine / equipment / system used

for the work at his/her own cost till the date of acceptance of the work by Paradip Port Trust.

26.0 ENGINEER INCHARGE: (EIC)

The EIC of this contract shall be as specified in the LoI / Work Order.

27.0 AGREEMENT COPY:

The agreement shall be made in two sets, one original and one copy. One copy of the

agreement shall be given to the Contractor. For each additional copy, the Contractor shall

have to pay the cost of the bid documents and 20% overhead charges.

28.0 UNDERTAKING BY THE CONTRACTOR:

Having understood all the terms and conditions of the tender document and having assessed

the site conditions, we hereby confirm that the price offered by us is a firm price and includes

all the taxes(excluding service tax), duties, fees, Cess etc. and all incidental charges.



Page 37 of 286

APPENDIX-01 (1 of 2)

BILL ENTRY FORMAT FOR E & M WORKS

(Vide F. C. no. 1534/FA dt. 09/06/03 & approval no. 2442/DCM dt. 17/06/03)

Name of the work :

Name of the Agency :

Work Order No. :

Head of Account : Capital / Revenue

Chargeable Head : _ _ _ / _ _ _ / _ _ _

Date of commencement :

Date of completion :

Sl.

No.

Description of works / materials as

per Bill of Quantity (BOQ)

Unit Qty. as

per BOQ

Qty.

Executed

Rate

(

R

s

.

)

Amount (Rs.)

(Use this format and submit the information in separate sheets.)

Additional items, if any, are to be indicated separately, but in the above format.

Accepted the above entries.

Signature of the EIC Signature of the Contractor

Certified that the Contractor has discharged all the obligations under the contract satisfactorily.

Remarks, if any, of EIC:

C/s by Executive Engineer Signature of the Engineer Incharge

Bill No.: ______________ Date: _________________

Gross Value of the Work: Rs. __________________

Less Recoveries:

a. Rs. ______________

b. Rs. ______________

c. Rs. ______________

Total Recoveries ( - ) Rs. _______________

Net amount payable: Rs. __________________

Passed for Rs.______________ (Rupees ______________________________________________)

Under Revenue / Capital Code No. _ _ _ _ / _ _ _ _ / _ _ _ _ .

Continued ----


Page 38 of 286

APPENDIX – 1 (2 of 2)

BILL ENTRY FORMAT FOR E&M WORKS

For making e-payment, the contractor shall have to furnish the following information in the

prescribed format along with each bill.

Name of the

contractor/firm/

supplier

Name of the Bank and

branch where payment

will be made with address.

Payee’s name Accounts

number [CBS]

Amount to be

released after

deduction.

All payments above Rupees Ten lakhs shall have to be made through e-payment only.

Payment below rupees ten lakhs shall also be made through e-payment in due course.

Signature of the D.D.O.


Page 39 of 286

APPENDIX -02

TECHNO-COMMERCIAL INFORMATION

Sl.No. Information required Bidders response

01. Name of the Bidder

02. Present address with at least two phone nos., fax nos,

email address and name of the contact person (s).

03. Do you accept all the Terms and Conditions of the

Tender

Yes / No

04. Joint Venture / Consortium Documents, if any

(Applicable for the works having estimated cost put to

tender more than Rs.5.0 Crores)

- Required/Not Required

- If required, please indicate

Enclosed as per Clause No.

2 of ITB

/ Not enclosed

05 An undertaking or declaration in any appropriate

format regarding no disputes/blacklisting/ban of

business.

- Enclosed/Not Enclosed

06 A declaration in any appropriate format regarding

whether any of his relations working under PPT or

not.


07. An undertaking in any appropriate format of not

making any payment or illegal gratification to any

person / authority connected with the bid process so

as to influence the bid process and have not

committed any offence under the Prevention of

Corruption Act (PC Act) in connection with the

bid.(ITB Cl-44)


08. Brief Technical information on major supply items

indicating the make, model, capacity etc, where

applicable.

Separate sheets may be used, if

required.

Signature of the Bidder


Page 40 of 286

APPENDIX - 03

ELIGIBILITY INFORMATION

1. SIMILAR EXPERIENCE:

Name of the work Work

Order no.

W. Order

value

Completion

Date

Completion

Certificate no.

(Fill up the above table & attach legible copies of the supporting documents i.e. Work orders and Completion

certificates)

N.B.: In case of work experience issued by private organization, the bidder has to submit the TDS certificate

in addition to the work experience certificate, failing which it shall not be considered.

2. FINANCIAL CAPABILITY: (Average Annual Turn Over)

Financial Year: Financial Year: Financial Year:

Average

Rs. Rs. Rs.

Rs.

(Fill up the above table and attach copy of affidavit / certificate from Chartered Accountant.)

3. OTHER ELIGIBILITY REQUIREMENTS, IF ANY, AS PER THE TCN:

Sl. No. Information required Bidders response

01 Bidder’s Permanent Account Number(PAN) a) Enclosed/Not enclosed

b) PAN No.___________

02 Bidder’s ESI Registration Certificate a) Enclosed/Not enclosed

b) Code No.__________

03. Bidder’s EPF Registration Certificate a) Enclosed/Not enclosed

b) Code No.__________

04. Bidder’s Income Tax Return of preceding three years, a) Enclosed for financial years

________,_________,________ /

Not enclosed

05. Bidder’s Service Tax Registration Certificate a) Enclosed/Not enclosed

b) Code No.___________

06. VAT/Sales Tax Registration certificate on works

contract.

a) Enclosed/Not enclosed.

b) Regd.No.__________

12. TDS Certificate, if any - Required/Not Required

- If required, Enclosed/Not enclosed

(Please strike out which is not applicable, fill up the blanks & attach legible copies of the supporting

documents)

4. The bidder must attach the eligibility documents as mentioned in Sl. No. 1, 2 and 3 above and clearly

mention the number of sheets attached.

We hereby confirm that copies of supporting documents for above are attached to this sheet (Total

nos. of pages including this sheet - ________). Originals shall be presented for verification, if

required by Paradip Port Trust.

Signature of the Bidder


Page 41 of 286

APPENDIX-04

BANK GUARANTEE FORMAT FOR INITIAL SECURITY DEPOSIT (ISD)

To : The Paradip Port Trust

Paradip Port – 754 142

ORISSA, INDIA.

Ref: Name of the Work : _______________________________________________________ .

LOI No. : ____________________________________ Date: _____________________ .

WHEREAS ____________________________________ (Name of Contractor) hereinafter called

“the Contractor” has undertaken, in pursuance of Letter of Intent No __________ dated __________

20 ___ to execute the work ( Name of the Work ) hereinafter called “the Contract”.

AND WHEREAS it has been stipulated by you in the said Contract that the Contractor shall furnish

you with a Bank Guarantee by a recognized bank for the sum specified therein as security for

compliance with the Contractor’s performance obligations during the execution in accordance

with the Contract AND WHEREAS we have agreed to give the Contractor a Guarantee :

THEREFORE WE hereby affirm that we are Guarantors and responsible to you, on behalf of the

Contractor, up to a total of ___________________________ (Amount of the Guarantee in Words

and Figures) and we undertake to pay you, upon your first written demand declaring the Contractor

to be in default under the Contract and without cavil or argument, any sum or sums within the limits

of Rs.__________ (Amount of Guarantee) as aforesaid, without your needing to prove or to show

grounds or reasons for your demand or the sum specified therein.

This Bank Guarantee shall be payable on submission of a request letter for revocation at

_______________Branch with code no __________ at Paradip in case there is a branch at Paradip

and in case there is no branch at Paradip, then at a branch nearest to Paradip strictly following the

guidelines issued by RBI from time to time.(The detailed postal address of the branch of the bank

where the BG can be encashed is to be mentioned.)

This guarantee is valid until the __________________ day of ___________ 20__

The above reference (LOI No.) must be used for all correspondences on this Bank Guarantee.

Authorised Signature of the Bank

Date: Name & Address:


Page 42 of 286

APPENDIX-05

BANK GUARANTEE FORMAT FOR PERFORMANCE SECURITY

DEPOSIT (PSD) DURING WARRANTY PERIOD.


Paradip Port – 754 142

ORISSA, INDIA.


Work Order No. : __________________________________ Date: _________________ .

WHEREAS ____________________________________ (Name of Contractor) hereinafter called

“the Contractor” has undertaken, in pursuance of Work Order No __________ dated __________ 20

___ to execute the work (Name of the Work) hereinafter called “the Contract”.

AND WHEREAS it has been stipulated by you in the said Contract that the Contractor shall furnish

you with a Bank Guarantee by a recognized bank for the sum specified therein as security for

compliance with the Contractor’s performance obligations during the WARRANTY PERIOD

in accordance with the Contract AND WHEREAS we have agreed to give the Contractor a

Guarantee : THEREFORE WE hereby affirm that we are Guarantors and responsible to you, on

behalf of the Contractor, up to a total of ___________________________ (Amount of the Guarantee

in Words and Figures) and we undertake to pay you, upon your first written demand declaring the

Contractor to be in default under the Contract and without cavil or argument, any sum or sums

within the limits of Rs.__________ (Amount of Guarantee) as aforesaid, without your needing to

prove or to show grounds or reasons for your demand or the sum specified therein.






This guarantee is valid until the __________________ day of ___________ 20__

The above reference (Work Order No.)must be used for all correspondences on this Bank Guarantee.

Authorised Signature of the Bank

Date: Name & Address:


Page 43 of 286

APPENDIX-06

BANK GUARANTEE FORMAT FOR ADVANCE PAYMENT

( To be used only where advance payment provision is there. )


Paradip Port – 754 142.

ORISSA, INDIA.


Work Order No. : ___________________________ Date: _______________________ .

Gentlemen:

In accordance with the provisions of the Contract for “Advance Payment” (Clause No. _______) ,

_______________________________ (Name and address of Contractor) (hereinafter called “the

Contractor”) shall deposit with The Paradip Port Trust a bank guarantee to guarantee his proper and

faithful performance under the said Clause of the Contract in an amount of

________________________________ (Amount of Guarantee in Words and Figures).

We, the ______________________________ (Bank), as instructed by the Contractor, agree

unconditionally and irrevocably to guarantee as primary obligator and not as Surety merely, the

payment to The Paradip Port Trust on his first demand without whatsoever right of objection on our

part and without his first claim to the Contractor, in the amount not exceeding

________________________ (Amount of Guarantee in Words and Figures).

We further agree that no change or addition to or any modification of the terms of the Contract to be

performed thereunder or of any of the Contract documents which may be made between The Paradip

Port Trust and the Contractor, shall in any way release us from any liability under this guarantee,

and we hereby waive notice of any such change, addition or modification.






This guarantee shall remain valid and in full effect from the date of the advance payment under the

Contract until The Paradip Port Trust receives full repayment of the same amount from the

Contractor.

The above reference (Work Order No.) must be used for all correspondences on this Bank

Guarantee.

Yours truly,

Signature and Seal _____________________

Name of Bank/

Date: _____________________________


Page 44 of 286

APPENDIX- 07

CORPORATE PERFORMANCE GUARANTEE


Work Order No. : _______________________________ Date: ___________________ .

(Name of the Firm), having their Head Office at ……………………, hereinafter called as

“the Contractor” do hereby offer guarantee to Paradip Port Trust, Paradip herein called Paradip Port

Trust for supply of goods and services as specified in the Purchase/Work Order No.………………..

for satisfactory performance for a period of ___years from the date of acceptance subject to the

following conditions in addition to the clauses/conditions mentioned in the above purchase/work

order and subsequent revision.

1. The Guarantors obligation under this guarantee shall be to repair all defects with material and

labor free of charge during the guarantee period of ___ years. “Defects” during the guarantee

period shall mean as under:

a)

b)

c)

2. The guarantee shall commence on the date of acceptance of the goods and services as

specified in the contract agreement.

3. The defects shall be rectified by appropriate as deemed necessary so as to meet the

specifications and/or instructions of the Engineer – in – Charge so that the repair work shall

not show any defects as defined above within guarantee period.

4. The guarantor shall rectify the defects within four weeks from the date of receipt of the

notice from the owner giving brief details of the nature of the defects, unless otherwise

specified.

5. If the guarantor fails to perform his obligation as per this guarantee, PPT reserves the right to

rectify the defects by another agency at guarantors risk and cost.

6. The guarantor shall have no liability under this guarantee for the following:

a) Damage caused by physical abuse, fire, explosion, accident.

7. Force Majeure: The Guarantor(s) obligations are automatically waived and void to the extent

that it becomes unreasonably difficult or impossible to carry out the claims procedure or

repair as a consequence of strikes, war, invasion, acts of terrorists or foreign enemies,

hostilities( whether war be declared or not), civil war, rebellion, revolution, insurrection,

military or power, confiscation or nationalization or requisition or destruction of damage to

property by or under the order of any Government or Authority and to the extent that loss or

damage is directly or indirectly caused by such circumstances.

The above reference (Work Order No.) must be used for all correspondences on this

Corporate Guarantee.

Corporate Seal: Authorised Signatory

Date:


Page 45 of 286

APPENDIX - 08

LETTER OF INTENT FORMAT No.: ___________________ Date: ________

To

M/s.____________________

____________________

Sub: ( Name of the Work.)

Dear Sir(s),

With reference to your above offer and subsequent correspondences on the subject, we are

pleased to inform you that your offer has been accepted by the competent authority and you are hereby

requested to initiate actions for fulfillment of all necessary formalities, as indicated in the tender

document for the above said work, at the earliest. The Engineer In-charge for this work shall be Mr.

________________.

Agreed Schedule date of commencement of the work is ____________ and Schedule date of completion

of the work is ________________ w.e.f the date of issue of Work Order, unless otherwise specified.

Total Contract Price is Rs. ______________ .

You are requested to sign the Agreement and fulfill other formalities as per the tender conditions.

Yours faithfully,

(Signature of the Controlling Officer)

****************************

APPENDIX - 09

WORK ORDER FORMAT W. O. No.: ___________________ Date: ____________ To

M/s.____________________

____________________

Sub: (Name of the Work)

Ref: Letter of Intent dtd. ________________ .

Dear Sir(s),

We are pleased to inform you that your offer for the above work has been approved by the

competent authority and you are requested to execute the work in accordance with the terms and

conditions of the contract and complete the work / services to the full satisfaction of the Engineer In-

charge (EIC) within the stipulated time period.

Agreed date of commencement

& completion of the Work/Services: ______________________________ w.e.f the date of issue of

Work Order, unless otherwise specified.

Total Contract Price : Rs. ________________

Payment: In accordance with the provisions of the Contract, the bills along with all the required

documents in triplicate shall be submitted to the EIC for certification and other processing for the

payment within thirty (30) days of submission of bills in full shape.

Warranty: The warranty period for this work shall be ________ from the date of acceptance of the

work / services.

Yours faithfully,

(Signature of the Controlling Officer)


Page 46 of 286

APPENDIX – 10

FORMAT FOR AGREEMENT

This Agreement made this Day of _______________________________ of Two Thousand

__________between the Board of Trustees of Paradip Port Trust, a body corporate under the Major

Port Trusts Act (38 of 1963) herein after called the Board which expression shall unless excluded by

or repugnant to the context be deemed to include their successors in office of the one part and

M/s___________________________________(hereinafter called the contractor) which expression

shall unless excluded by or repugnant to the context be deemed to include his surviving or other

partners and the persons entitled to share including his heirs, executors, administrators,

representatives and assignees of successors in the other part.

WHEREAS the Board is desirous of executing the work

“__________________________________________________” at _________________ and

WHEREAS the contractor______________________________________________ has offered to

execute, complete and maintain such work in perfect condition till handing over to Board and

whereas the Board has accepted tender of the contractor for an amount of

Rs.________________(Rupees ___________________________________________) only for

execution/supply/maintenance and WHEREAS the Contractor has agreed to take up the above work

in accordance with the conditions of contract and to the entire satisfaction of the Board of Trustees.

NOW THIS AGREEMENT WITNESSETH AS FOLLOWS:

1. In this agreement, words and expressions shall have the same meaning as are respectively

assigned to them in all the conditions of the contract herein after referred to.

2. The following documents consisting of __________pages shall be deemed to form and be

read and considered as part of the agreement.

i) The tender call notice

ii) The original Tender Document

iii) Bid document uploaded by the Bidder.

iv) Letter of Intent.

v) Letter of acceptance of letter of intent.

vi) Work Order.

vii) Any other letter(s) exchanged between Contractor & Paradip Port Trust in connection

with the relevant tender till issuance of work order.

3. The contractor hereby covenant with Board to execute, complete and maintain the work till

handing over to the Board in all respects.

4. The parties may refer their present or future dispute relating to the contract itself or arising

out of or concerning or in connection with or in consequence of the contract to the Chairman,

PPT and the decision of the Chairman, PPT will be final and binding on both the parties. The

contract shall be governed by the Indian Contract Act, 1872.

5. It is agreed that neither of the parties to the agreement shall be competent to resort to

Arbitration under the Arbitration and Conciliation Act, 1996 for adjudication of claim.


Page 47 of 286

6. All such disputes, present or future between the parties relating to the Contract, which could

not be settled at the intervention of Chairman, PPT can only be raised and adjudicated by the

courts situated within the jurisdiction of Kujang.

7. It is agreed by the contractor that the Board shall recover the ground rent towards

construction of site office / camp etc. as will be determined by the Sr. Asst. Estate Manager,

PPT from time to time from his dues recoverable under the agreement.

8. The structure of the site office / camp shall be temporary in nature and the final dues of the

contractor shall be settled only after handing over vacant possession of the work site to the

Board after demolition of the site office / camp by the contractor at his own cost.

9. The Board hereby covenant to pay the contractor in consideration of such execution,

completion and maintenance of the work “The Contract Price” at the time and manners

prescribed by the Contract.

In witnesseth where of the parties here unto have set their hands and seals the day and

year first above written.

Signature of the Contractor Chief Mechanical Engineer,

Paradip Port Trust.

For & on behalf of the Trust Board, PPT.

Witnesses: 1)

2)

Finance Vetting: UOI No.1958/FA dtd.06.10.2010

Legal Vetting: UOI No. 807/DS(law) dtd. 09.10.2010.

Admn. Approval: Approval dtd. 21.10.2010 vide UOR No. 4567/CD dtd. 11.10.2010.

File No.: EM/PD/08/2008


Page 48 of 286

APPENDIX – 11

INTEGRITY PACT

Paradip Port Trust (PPT) hereinafter referred to as “The Principal” , which includes Purchaser /

employer.

And

…………………………………………….……hereinafter referred to as “The Bidder / Contractor”

Preamble

The Principal intends to award , under laid down organizational procedures, a contract for < nature

of contract, in brief > . The Principal values full compliance with all relevant laws of the land,

rules, regulations, economic use of resources, and of fairness/ transparency in its relations with its

Bidder (s) and / or Contractor(s).

The Principal will nominate an Independent External Monitor (IEM) by name at the tender stage /

will appoint in case of receipt of any reference, from the panel of IEMs, for monitoring the tender

process and the execution of the contract in order to ensure compliance with the Integrity Pact by all

the parties concerned.

Section –1 Commitments of the Principal / Purchaser / Employer :

a. The Principal commits itself to take all measures necessary to prevent corruption and to

observe the following principles :-

(a) No employee of the Principal, personally or through family members, will in

connection with the tender for, or the execution of a contract, demand, take a promise

for or accept , for self or for third person, any material or non material benefit which

the person is not legally entitled to.

(b) The Principal will, during the tender process treat all bidders with equity and reason.

The Principal will in particular, before and during the tender process, provide to all

Bidders the same information and will not pride to any Bidder confidential /

additional information through which the Bidder (s) could obtain an advantage in

relation to the tender process or the contract execution.

(c) The Principal will exclude from the process all known prejudiced persons.

b. If the Principal obtains information on the conduct of any of its employees which is a

criminal offence under the IPC /PC Act, or if there be a substantive suspicion in this regard,

the Principal will inform Chief Vigilance Officer of PPT and in addition can initiate

disciplinary action.

Section 2 – Commitments of the Bidder(s) / Contractor (s) :

(1) The Bidder (s) / Contractor (s) commits to take all measure necessary to prevent corruption.

He commits to observe the following principles during his participation in the tender process

and during the contract execution.

(a) The Bidder (s)/ Contractor (s) will not, directly or through any other person or firm,

offer, promise or give to any of the Principal’s employees involved in the tender

process or the execution of the contract or to any third person any material or other


Page 49 of 286

benefit which he/she is not legally entitled to , in order to obtain in exchange any

advantage of any kind whatsoever during the tender process or during the execution

of the contract or to vitiate the Principal’s tender process or contract execution.

(b) The Bidder(s) / Contractor (s) will not enter with other Bidders into any undisclosed

agreement or understanding, whether formal or informal. This applies in particular to

prices, specifications, certifications, subsidiary contracts, submission or non-

submission of bids or any other actions to restrict competitiveness or to introduce

cartelization in the biding process or to vitiate the Principal’s tender process or

execution of the contract.

(c) The Bidder(s)/ Contractor(s) will not commit any offence under the IPC /PC Act;

further the Bidder (s) / Contractor(s) will not use improperly, for purposes of

competition of personal gain, or pass on to others, any information or document

provided by the Principal as part of the business relationship regarding plans,

technical proposal and business details including information contained or

transmitted electronically.

(d) The Bidder(s) / Contractor (s) of foreign origin shall disclose the name and address of

the Agent (s) / representative (s) in India, if any. Similarly, the Bidder(s) / Contractor

(s) of Indian nationality shall furnish the name and addresses of foreign supplier/

contract Agency, if any. Further details, as mentioned in the Guidelines on Indian

Agents of Foreign “Suppliers/Contract agencies”, shall be disclosed by the Bidder(s)

/ Contractor (s) wherever applicable. Further, as mentioned in the guidelines, all the

payments made to the Indian agent(s) / representative (s) have to be in Indian Rupees

only.

Copy of the guidelines on Indian Agents of Foreign “Suppliers / Contract

agencies” is enclosed.

(e) The Bidder(s) / Contractor(s) will, when presenting his bid, disclose any and all

payments he has made or committed to or intends to make to the agents, brokers or

any other intermediaries in connection with the award of the contract.

(2) The Bidder (s) / Contractor (s) will not instigate third person to commit offences outlined

above or be an accessory to such offences.

Section 3 - Disqualification from tender process and exclusion from future contracts :

(1) A transgression is considered to have occurred, if the principal after due consideration of the

available evidence, concludes that reasonable doubt is possible.

(2) If the Bidder(s) / Contractor (s), before award of contract or after award of contract has

committed a transgression through a violation of Section 2 above or in any other form such as

to put his reliability or credibility in question, the Principal is entitled to disqualify the

Bidder(s) from the tender process or to terminate the contract, if already awarded, for that

reason, without prejudice to other remedies available to the principal under the relevant GCC

of the tender / Contract.

(3) If the Bidder(s) / Contractor(s) has committed transgression through a violation of any of the

terms under Section 2 above or in any other form such as to put his reliability of credibility


Page 50 of 286

into question, the Principal is entitled also to exclude the bidder / contractor from future

tenders/ contract award processes. The imposition and duration of the exclusion will be

determined by the principal keeping in view the severity of the transgression. The severity

will be determined by the circumstances of the case, in particular the number of

transgression, the position of the transgressors within the company hierarchy of the bidder /

contractor and the amount of the damage.

(4) If it is observed after payment of final bill but before the expiry of validity of Integrity Pact

that the contractor has committed a transgression through a violation of any of the terms

under Section 2 above during the execution of contract, the Principal is entitled to exclude the

contractor from future tender/ contract award processes.

(5) The exclusion will be imposed for a minimum period of six (6) months and a maximum

period of three (3) years.

(6) If the Bidder/ contractor can prove that he has restored / recouped the damage to the Principal

caused by him and has installed a suitable corruption prevention system, the Principal may

revoke the exclusion before the expiry of the period of such exclusion.

Section 4 – Compensation for Damages :

(1) If the Principal has disqualified the bidder from the tender process prior to the award in

accordance with Section 3 above, the Earnest Money Deposit (EMD) furnished, if any, along

with the offer as per the terms of the Invitation to Tender (ITT) shall be forfeited. This is

apart from the disqualification of the Bidder as may be imposed by the Principal as brought

out at Section 3 above.

(2) If the Principal has terminated the contract in accordance with Section 3 above, or if the

Principal is entitled to terminate the contract in accordance with Section 3 above, the Security

Deposit / performance bank guarantee furnished by the contractor, if any, as per the terms of

the ITT / Contract shall be forfeited without prejudicing the rights and remedies available to

the principal under the relevant General Conditions of contract.

This is apart from the disqualification of the Bidder, as may be imposed by the Principal , as

brought out at Section 3 above.

Section 5 – Previous transgressions:-

(1) The Bidder declares that, to the best of his knowledge, no previous transgression occurred in

the last three (03) years with any other company in any country conforming to the anti-

corruption approach or with Government / any other public sector enterprise in India that

could justify his exclusion from the tender process.

(2) If the Bidder makes incorrect statement on this subject, he can be disqualified from the

tender process. The contract, if already awarded, can be terminated for such reason.

Section 6 – Equal treatment of all Bidders / Contractors / Subcontractors :-

(1) The Bidder (s) / Contractor (s) undertakes to demand from all his subcontractors a

commitment in conformity with this Integrity pact, and to submit it to the Principal before

seeking permission for such subcontracting.

(2) The Principal will enter into agreements with identical conditions as this one with all Bidders

and Contractors.

(3) The Principal will disqualify from the tender process all bidders who do not sign this Pact or

violate its provisions.


Page 51 of 286

Section 7– Criminal charges against violating Bidder(s) / Contractor (s) / Subcontractor(s)

If the Principal obtains knowledge of conduct of a Bidder, Contractor, Subcontractor or of

any employee or a representative or an associate of a Bidder/ Contractor/ Sub-contractor which

constitutes corruption, or if the Principal has substantive suspicion in this regard, the Principal will

inform the same to CVO of PPT.

Section 8 – Independent External Monitor(s) (IEMs)

(1) The Principal appoints competent and credible Independent External Monitor (s) (IEMs)

with clearance from Central Vigilance Commission and Transparency International (India) .

IEMs reviews independently, the cases referred to him/them to assess whether and to what

extent the parties concerned comply with the obligations under this Integrity Pact.

(2) In case of non compliance of the provisions of the Integrity Pact, the complaint/

noncompliance is to be lodged by the aggrieved party with the Nodal Officer only appointed

by Chairman, PPT. The Nodal Officer shall refer the complaint / non compliance so received

by him to the IEM, already appointed or to be appointed for that case.

(3) The IEM is not subject to instructions by both the parties and performs his functions

neutrally and independently. The IEM (s) will submit report to the Chairman, PPT.

(4) The Bidder(s) / Contractors (s) accepts that the IEM has the right to access without

restriction, to all tender/ contract documentation of the Principal including that provided by

the Bidder/ Contractor. The Bidder/ Contractor will also grant the IEM upon his request and

demonstration of a valid interest, unrestricted and unconditional access to his tender/ contract

documentation. The same is applicable to subcontractor also. The IEM is under contractual

obligation to treat the information and documents of the Bidder(s)/

Contractor(s)/subcontractor(s) with confidentiality.

(5) The Principal will provide to the IEM sufficient information about all meetings among the

parties related to the tender/contract for the cases referred to IEM, provided such meetings

could have an impact on the contractual relations between the Principal and the contractor.

The parties offer to the IEM the option to participate in such meetings.

(6) As soon as the IEM notices, or believes to notice, a violation of this pact, he will so inform

the Principal and request the Principal to discontinue or take corrective action or to take other

relevant action. The IEM can in this regard submit non binding recommendations. Beyond

this, the IEM has no right to demand from the parties that they act in a specific manner,

refrain from action or tolerate action.

(7) The IEM will submit a written report to the Chairman, PPT within four (04) to six (06)

weeks from the date of reference or intimation to him by the Principal and, should the

occasion arise, submit proposals for corrective actions for the violations or the breaches of

the provisions of the agreement noticed by the IEM.

(8) IEM may also submit a report directly to the CVO of PPT and the Central Vigilance

Commission, in case of suspicion of serious irregularities attracting provisions of the IPC /

PC Act.

(9) Expenses of IEM shall be borne by PPT as per terms of appointment of IEMs.

(10) The word “Monitor” means Independent External Monitor and would include both singular

and plural.


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Section 9 – Duration of the Integrity Pact:

(1) This Pact comes into force upon signing by both the Principal and the Bidder/Contractor. It

expires for the contractor twelve (12) months after the payment under the contract, and for all

unsuccessful Bidders, six(06) months after the contract has been awarded and accordingly

for the Principal after the expiry of respective periods stated above.

(2) If any claim is made/lodged during the valid period of the IP, the same shall be binding and

continue to be valid even after the lapse of this pact as specified above, unless it is

discharged/ determined by the Chairman, PPT.

Section 10 – Other provisions:-

(1) This agreement is subject to India Law. Place of performance and jurisdiction is the

Registered Office of the Principal, i.e Chairman, Paradip Port Trust , State of Orissa, India.

(2) Changes and supplements as well as termination notices need to be made in writing. Side

agreements to this pact have not been made.

(3) If the contractor is a partnership firm/ consortium, this agreement must be signed by all

partners / consortium members or their Authorized Representative (s) by duly furnishing

Authorization to sign Integrity Pact.

(4) Should one or several provisions of this agreement turnout to be invalid, the remaining part

of this agreement remains valid. In this case, the parties will strive to come to an agreement

to their original intensions.

(5) Wherever he or his is indicated in the above sections, the same may be read as he/she or

his/her, as the case may be.

(For & on behalf of the Principal) (For & On behalf of Bidder /

Contractor)

(Office Seal)

Place…………………………

Date…………………………

Witness 1 :

(Name & Address )

____________________________

____________________________

____________________________

Witness 2 :

(Name & Address )

____________________________

____________________________

____________________________


Page 53 of 286

GUIDELINES FOR INDIAN AGENTS OF FOREIGN

“SUPPLIERS / CONTRACT AGENCIES”

1.0 There shall be compulsory registration of Indian agents of foreign suppliers/ contract

Agencies with PPT in respect of all global (Open) Tenders and Limited Tenders. An Agent

who is not registered with PPT shall apply for registration in the prescribed Application form

(Annexure – I).

1.1 Registered agent needs to submit before the placement of order by PPT, an Original

certificate issued by his foreign supplier / contract Agency (or an authenticated Photostat

copy of the above certificate duly attested by a Notary Public) confirming the agency

agreement and giving the status being enjoyed by the agent along with the details of the

Commission / remuneration / salary/ retainer being paid by them to the agent (s).

1.2 Wherever the Indian representative has communicated on behalf of their foreign supplier/

contract agency and/or the foreign supplier/contract agency have stated that they are not

paying any commission to their Indian agent(s) but paying salary or retainer, a written

declaration to this effect given by the foreign supplier/contract agency should be submitted

before finalizing the contract.

2.0 DISCLOSURE OF PARTICULARS OF AGENT(S)/ REPRESENTATIVE(S) IN

INDIA , IF ANY

2.1 Bidders of foreign nationality shall furnish the following details in their quotation/bid.

2.1.1 The name and address of their agent(s)/ representative (s) in India, if any, and the extent of

authorization and authority given to them to commit them. In case the agent (s) /

representative (s) is a foreign company, it shall be confirmed whether it is a really substantial

Company and details of the Company shall be furnished.

2.1.2 The amount of commission/remuneration included in the quoted price(s) for such agent(s)

representative (s) in India.

2.1.3 Confirmation of the Bidder that the commission/ remuneration if any, payable to his agent(s)/

representative (s) in India shall be the responsibility of the bidder for which the bidder may

keep such provision included in the price bid and make the payment to the

agent/representative directly in Indian currency only. The Port Trust shall in no case shoulder

the responsibility for payment of such commission/ remuneration to the agent/representative,

if any, in India.

3.0 DISCLOSURE BY INDIAN AGENT(S) OF PARTICULARS OF THEIR FOREIGN

SUPPLIERS/CONTRACT AGENCY AND FURNISHING OF REQUISITE

INFORMATION :

3.1 Bidders of Indian Nationality shall furnish the following details/ certificates in/along

with their offers.

3.1.1 The name and address of foreign supplier/contract agency indicating their nationality as well

as their status, i.e , manufacturer or agent or manufacturer holding the Letter of Authority.


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3.1.2 Specific authorization letter by the foreign supplier/contract agency authorizing the agent to

make an offer in India in response to tender either directly or through their

agent(s)/representative(s) .

3.1.3 The amount of commission/ remuneration included for bidder in the price(s) quoted.

3.1.4 Confirmation of the foreign supplier/contract agency that the commission/remuneration, if

any, reserved for the bidder may be paid to the bidder himself in India in equivalent Indian

currency. The Port Trust shall in no case shoulder the responsibility for payment of such

commission/ remuneration, if any.

4.0 In either case, in the event of materialization of contract, the terms of payment will provide

for payment of the commission/ remuneration payable, if any, to the agent(s)/

representative(s) in India in Indian Rupees, as per terms of the contract.

4.1 Failure to furnish correct information in detail, as called for in para 2.0 and/or 3.0 above will

render the bid concerned liable for rejection or in the event of materialization of contract; the

same is liable for termination by PPT. Besides this, other actions like banning business

dealings with PPT, payment of a named sum etc., may also follow.

*****


Page 55 of 286

Annexure-I

PARADIP PORT TRUST

APPLICATION FORM FOR REGISTRATION OF INDIAN AGENTS

IMPORTANT INSTRUCTIONS:

1. Indian Agents representing a Foreign Supplier in tenders of Paradip Port Trust (PPT) shall

submit application in the format for registration. It shall be valid for the contract, If

(awarded) finalized on the Foreign Supplier, which the agent represents.

2. No Indian Agent shall be permitted to represent more than one Foreign Supplier in a Tender

3. Full and unambiguous reply to each query must be given or else application may not be

processed at all.

4. Wherever necessary extra sheet can be attached and mention of this may be made against the

appropriate column of the application.

REF. NO. : ___________________

(Not to be filled by Applicant)


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PARADIP PORT TRUST

PART – I

1. Name of the firm :

2. Date of incorporation :

(DD MM YY)

3. Address of the Registered Office :

Pin Code

Tel No.

Fax No.

4. Address of the Head Office :

Pin Code

Tel No.

Fax No.

5. Address of the Branches :

Pin Code

Tel No.

Fax No.

6. If you are registered with DGS&D, give registration No.

PART – II

Status of Firm & Company :

(Put a tick mark to whichever is applicable)

1. Proprietorship concern

2. Partnership concern

3. Private Limited

4. Public Limited

5. Central Govt. Undertaking

6. State Govt. Undertaking

(Detailed structure of your firm or company may be furnished at Appendix “A”)


Page 57 of 286

PARADIP PORT TRUST

PART – III

a. Name of the Principal :

(Whose agent is seeking registration)

b. Address

Pin Code :

Tel No. :

Fax No. :

c. i Details of the agreement / contract with principal.

ii Are you sole selling agent for the principal : Yes / No

(If yes, furnish copy of valid agreement duly attested)

a. Date of appointment as sole selling agent

b. Date up to which appointment is valid

c. Percentage of commission

d. Whether the agent has the authority to : Yes / No

commit and sign on behalf of the Principal

iii. Whether you are prepared to quote and receive : Yes / No

payment in Indian Rupees

iv. Do you have facility to offer after sales service? : Yes / No

If yes, give details of facilities at Appendix 'B'

v. Have your firm/partners/proprietors/

directors have business in the past with : a. PPT : YES / NO

b. DGS&D : YES / NO

c. Any other : YES / NO

Govt. Dept.

(If yes, give details at Appendix 'C')

Place : Signature of the Applicant

Date : Proprietor / Partner / Director


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APPENDIX - A

PARADIP PORT TRUST

STATUS OF THE FIRM :

1. Is your firm incorporated under the Companies Act or any other law. If so specify.

2. Is your firm registered under the Indian Partnership Act 1932

3. If Company registered under the Indian Companies Act, I of 1956, State :

a) Name in which it is registered (Furnish Articles of Association and

Memorandum)

b) The place at which registered along with registration

c) Registration Certificate No. & Date of Registration (True copy authenticated by a Notary

Public to be furnished).

d) Whether Private of Public Limited

e) Authorized Capital of the Company

f) Issued / Subscribed Capital

g) Paid-up Capital

h) Place from which business is carried on

i) Income-Tax Circle/Ward/District in which the company assessed for Income-Tax and

GIR.PAN NO.

j) Managing Director / Whole time Director / Manager-Name & Address

k) Board of Directors (Name & Address)

l) If a subsidiary of an Indian or Foreign / Holding Company.

m) Full details of any other companies in India of the parent / holding Company

n) Details of other companies in which the Directors have financial interest or are represented

on the Boards.

PARTNERSHIP FIRMS :

a) Whether the firm is registered under the India Partners hip Act, 1932 or any other Act,

requiring the registration of the firm/partnership .

b) Name and / or style in which it is registered.

c) Name and address of the Registrar with whom registered

d) Date of such registration and number and date of Registration Certificate

e) Name and addressed of all partners with the extent of share held by each partner

f) Place from which the business of partnership is carried on.


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g) i. Whether in accordance with the partnership deed, any one partner has been

authorized to sign and represent the firm in all contractual matters including power to refer

the cases to arbitration ?

If so, furnish one copy of partnership deed duly authenticated by a Notary Public.

ii. If the answer is negative, whether a separate power of attorney exists in favour of any

particular partner to perform such functions. In such a case, a copy duly attested by a

Notary Public should be submitted.

h) Whether Income-Tax has been paid by each partner during all the previous years.

i . Income-Tax Circle/Ward/District in which the partnership assessed

ii . Income-Tax Circle/Ward/District in which the partners are separately assessed with

PAN/GIR No.

iii . Whether partners have any connection with other Undertaking / Firm. If so, full

details to be given indicating names, address of the undertaking, the extent of shares

etc.

PROPRIETORSHIP FIRM AND OTHERS :

a) Name and / or Style of the firm.

b) Proprietor's name and address.

c) Full details of other undertakings owned/controlled by the proprietor.

d) Name and Style in which business is carried out.

e) Place from where business is carried out.

f) Names and addresses of all members/co-partners, with nature and extent of their interest. (In

the case of a joint family, information on all persons to be given).

g) Income-Tax Circle/Ward/District in which the concern and it's proprietor member/co-

partners are assessed for Income-tax with PAN/GIR No. of each person.

h)

i. Whether the applicant firm, Directors/Partners were at any time prosecuted for any

offence by any court for Civil/Criminal/Economic offences.

ii. If yes, give details of offence and penalty.

APPENDIX B

DETAILS OF AFTER SALES SERVICE :

a. Name and address of branches in India where such facilities are available.

b. Manpower details indicating :

i. Total :

ii. Qualification of each :

iii. Work Experience of each :

iv. Arrangement to supply the equipment and spare parts :

v. Extent of stock and value maintained.


Page 60 of 286

APPENDIX C

PARADIP PORT TRUST

DETAILS OF BUSINESS DONE WITH PARADIP PORT TRUST OR ANY

OTHER GOVT. DEPT. IN THE PAST

1. Are you already registered with any of the PSUs / Govt. Depts.? If yes, please furnish details

of Registration.

2. Are you doing business with Paradip Port Trust under any other name ? If so, give details.

3. Have the Partners / Proprietors / Directors of your firm done business with Paradip Port Trust

in the past? If so, indicate name and addresses, and the contract / relevant reference number

& dates.

4. Have you executed any order placed on you by Paradip Port Trust or any other department of

the Govt. of India in the last three years? If so, details to be furnished.

1) I ______________________________________________________Son of

_______________________ certify that the agency agreement is current and that the

applicant firm has no other agreement with any of its Principals for payment of commission

other than what is stated herein either abroad, or in India in foreign currency.

2) I also certify that I am duly authorized to submit this application on behalf of the firm

proprietor / authorized partner / authorized constituted attorney.

3) I confirm that in the event of any change in agency agreement, termination of the agreement

and / or change in the management of the applicant firm, the same will be duly intimated to

Paradip Port Trust within 15 days of such change.

(Signature of the applicant)

Proprietor / Authorized Partner / Director

Witness by (1)

(2)

Date:


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PARADIP PORT TRUST

DOCUMENTS TO BE ENCLOSED WITH THE APPLICATION FORM

(Check List)

1. Copy of the valid agreement with the foreign principal duly attested by a Notary

Public. Agreement should invariably include the following:

a. Date of appointment of the Indian Agent.

b. Date up to which appointment is valid.

c. Percentage of commission.

d. If the Indian Agent has the authority to commit, sign on behalf of the principal.

e. Indian Agent / Agency commission in rupees only.

f. Area/Place for which agreement is valid.

g. Stores / Item included in the agreement.

2. Documentary proof of the status of the firm:

a. For the Limited Companies :

i. Copy of the Memorandum and Articles of the Association duly notarized.

ii. Copy of the Certificate of incorporation, authenticated by Notary Public.

iii. General Power of Attorney in respect of officer, if any.

b. Partnership Firms:

i. Copy of Partnership deed fully authenticated by Notary Public.

ii. Power of Attorney in respect of Partner, if any, duly notarized.

iii. Certified copy of Entry in for 'a'.

Copy of Income-Tax Clearance Certificate.

Copy of Balance Sheet.

Affidavit of banning on non-judicial stamp paper of Rs.5/- duly notarized (sample

enclosed).

Performance against orders placed by DGS&D / Central Govt. Dept./ State Govt. Depts./Public

Sector Undertaking, if any. (To be executed on Non Judicial Stamp Paper and attested by a Notary

Public or 1sr. Class Magistrate).


Page 62 of 286

PARADIP PORT TRUST

AFFIDAVIT

I/We_______________________________________________________son of

_________________________________________am / are Proprietor/ Partner / Directors of

M/s.___________________________________________________

with their registered office at ________________________________________.

I/ We solemnly affirm that there has been no change in the address of our firm/ or factory / bankers /

in the constitution of the firm / in the plant and machinery installed in the factory / and in the line of

products being manufactured by the firm or reduction / changes in technical personnel, quality

control arrangements since the date of grant of last registration by Paradip Port Trust.

The information given above are true to the best of my / our knowledge and belief.

Signature of Deponent(s)

Firm's Company Seal

Place:

Date:

Sworn / Affirmed before a Notary public or 1st Class Magistrate on the

____________________________ day of ___________________________20

Note : Please strike out the entries which are not applicable. The changes, if any, should be indicated

in your forwarding letter.

PARADIP PORT TRUST

Agents / Agency Particulars Register Firms Represented by M/s. Code :

Vendor Code

(1)

Supplier’s Name

(2)

Remarks

(3)

List consolidated as above shall be communicated periodically to ENFORCEMENT

DIRECTORATE / MHRD.


Page 63 of 286

APPENDIX – 12

BANK GUARANTEE FORMAT FOR STAGE PAYMENT ( To be used only where payment against BG provision is there. )


Paradip Port – 754 142.

ORISSA, INDIA.


Work Order No. : ___________________________ Date: _______________________ .

Gentlemen:

In accordance with the provisions of the Contract for “ Payment” (Clause No. _______) ,

_______________________________ (Name and address of Contractor) (hereinafter called “the

Contractor”) shall deposit with The Paradip Port Trust a bank guarantee to guarantee his proper and faithful

performance under the said Clause of the Contract in an amount of ________________________________

(Amount of Guarantee in Words and Figures).

We, the ______________________________ (Bank), as instructed by the Contractor, agree unconditionally

and irrevocably to guarantee as primary obligator and not as Surety merely, the payment to The Paradip Port

Trust on his first demand without whatsoever right of objection on our part and without his first claim to the

Contractor, in the amount not exceeding ________________________ (Amount of Guarantee in Words and

Figures).

We further agree that no change or addition to or any modification of the terms of the Contract to be

performed thereunder or of any of the Contract documents which may be made between The Paradip Port

Trust and the Contractor, shall in any way release us from any liability under this guarantee, and we hereby

waive notice of any such change, addition or modification.






This guarantee shall remain valid and in full effect from the date of the payment and up to

__________ (the period is to be mentioned as per the relevant terms and conditions of the Contract).

The work order no. must be used for all correspondences on this Bank Guarantee.

Yours truly,

Signature and Seal _____________________

Name of Bank/

Date: _____________________________

(Finance Vetting: UOI 1829/FA dtd.16.09.2010 & Approval by Chairman dtd.16.09.2010, File No.

EM/PD/08/09)


Page 64 of 286

APPENDIX - 13

STANDARD FORMAT FOR JOINT VENTURE/CONSORTIUM AGREEMENT

(TO BE EXECUTED ON Rs.100/- NON-JUDICIAL STAMP PAPER)

(Legal Vetting: UOR 352/DCLO dtd.05.04.13, Finance Vetting: UOI.2082/FA dtd.04.06.13, Admn Approval:UOR.1714/CD dtd.04.06.13)

This Joint Venture / Consortium Agreement (herein after called the “Agreement”) made and

entered into on this ………………………day in the month of ……and year… by and among :-

Name and address of the leading member herein after called …………………………….,

which expression shall include its successor, legal representatives and permitted assignees, for the

purpose of this agreement shall hereinafter be called “leading member “.

And Name and address of the other member herein after called …………………………,

which expression shall include its successor, legal representatives and permitted assignees, for the

purpose of this agreement shall hereinafter be called “Principal foreign/ local member “.

Whereas Paradip Port Trust (herein after referred to as “Purchaser” invites sealed offers for

the work “………………………………………………………………………………….” and

whereas the members, in consideration of their complementary technical and commercial resources

and capabilities, intend to co-operate and join efforts to prepare and submit a bid for the project.

In consideration of the aforesaid, the members wish to establish and record the preliminary

principles of their co-operation in this Agreement.

M/s …………………………………would be the leader of the Joint Venture/Consortium

and M/s ……………………………would be a member of the Consortium. All the correspondences

shall be made with the lead member and the Work Order will be issued in favour of the lead member

on behalf of the joint venture/consortium. Payment for the work shall be made in favour of the lead

member of the joint venture.

Now therefore, the members hereto in consideration of their mutual covenants hereinafter set

forth and intending to be legally bound hereby, agree as follows:-

1. DEFINITION :

1.1. “Contract” shall mean the contract signed between the Purchaser and the Joint Venture /

Consortium for the execution of the project.

1.2 “Bid” shall mean the bid to be submitted by the Lead Member on behalf of the Joint

Venture/Consortium to the Purchaser in accordance with this agreement.

2. CO-OPERATION :

2.1 Subject to the terms and conditions of this Joint Venture/Consortium agreement, the

members agree to co-operate with each other on an exclusive basis in the preparation and

submission of bid for the project, and if the contract is awarded, for satisfactory

implementation of the project. The mode of co-operation shall be in accordance with clauses

laid herein.


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2.2 The members agree to co-operate fully with each other to ensure a smooth and timely

progress towards satisfactory completion of bid submission, to do all the things necessary to

assist each other and to provide mutual disclosure of relevant knowledge so as to procure the

award of the contract from the Purchaser. The members also undertake not to participate in

the subject tender either in individual capacity or with any other joint venture/consortium. In

case of any violation, Paradip Port Trust reserves the right to reject their bids and forfeit their

EMD.

3. SCOPE OF WORK AND PREPARATION OF BID:

3.1 The general and tentative Scope of Work of the members is outlined as under:-

Scope of Work of the project to be performed by the members.

Sl.

No.

Item of works To be executed by

the Lead Member

M/s………………….

To be executed by

the Member

M/s………………….

To be executed by

the Member

M/s………………….

3.2 The Members acknowledge that competitive pricing is a critical element in achieving a

successful outcome of this co-operation and shall use their best efforts to ensure that the

prices submitted will be competitive.

4. MODE OF CO-OPERATION :

4.1 M/s …………………………… shall be the Leader of the Consortium and shall submit the

bid to the Purchaser. The bid document shall be binding on all the members of Joint

Venture/Consortium. Based on the requirement of the enquiry issued by the Purchaser, the

other members shall submit its price and technical and commercial documents to the Leader

for its part of Scope of Work before submission of final price bid. However, the Leader shall

be entitled to modify the scope and / or price after consulting with the other members. The

other members shall revise their prices and technical and commercial documents

accordingly, if necessary. The revised price submitted by the other members shall be subject

to the Leader’s final confirmation, which shall constitute the final price for performance of

its scope of work.

4.2 Once the Purchaser decides to enter into a contract with the Joint Venture/Consortium, prior

to signing the contract, a detailed internal agreement, in line with the principle of this

agreement, shall be signed which shall include without limitation, the scope and price, the

obligation , responsibilities and liabilities of each member.

4.3 The Scope of Work for the Project will be divided between the members as per Clause 3.1.

The Members shall be responsible for the performance of their respective parts of the Scope

of work in accordance with the internal agreement. However, all the Members shall be

jointly and severally liable to the Purchaser for successful completion of the Scope of Work

as per terms and conditions under the Contract.


Page 66 of 286

4.4 After award of the Contract, the Leader shall appoint a representative as Project Manager.

Other members (……………………………..) shall submit a general authorisation

document, giving the Project Manager all authority necessary to act on the Consortium’s

behalf under the Contract. The Project Manager shall consult with the Members for those

parts under Scope of Work of the Members. The lead partner shall be solely responsible for

project management of work.

4.5 The Members shall be individually responsible for the guarantee and performance of their

respective parts of the Scope of Work. When required, performance guarantee and other

guarantees shall be supplied by each Member in proportion to their actual contract amount

under the Contract.

4.6 The Agreement shall not be assignable to 3rd

party without the prior permission of Paradip

Port Trust.

4.7 After award of the Contract, the Members shall perform their respective parts of the Scope of

work in accordance with the internal agreement and the Contract. Neither member shall

withdraw from the Consortium without the prior approval of the other Members of the Joint

Venture/Consortium agreement in writing. In the event of default by any member, the

defaulting member shall be responsible to compensate the other members of the Joint

Venture/Consortium agreement for any loss incurred thereof.

4.8 The agreement shall not, in any way, constitute an association of partnership agreement and

the association of persons.

4.9 The Members shall abide by the requirements and stipulations of the Bidding document and

the Contract.

5. COST

Each Member shall bear its own expenses incurred in connection with the performance of its

obligations under this agreement including submission of the bid.

6. DISPUTE RESOLUTION

The Members shall endeavor to resolve any dispute arising out of or in connection with this

agreement among themselves through amicable negotiations. Any such dispute including any

question regarding the existence, validity or termination of the agreement which the

Members are unable to resolve between themselves, shall be referred to and finally be settled

by arbitration in accordance with the Indian Arbitration and Conciliation Act, 1996 with an

arbitral tribunal comprising of three members and proceeding thereof shall be in English

Language. Award of arbitrators shall be final and binding to all the Members and shall not be

further challenged in the Court of law. The venue of arbitration shall be Cuttack /

Bhubaneswar, Odisha.

7. TERMINATION

This agreement shall come into force on the date of signing of the same and valid till Time of

Completion of the Project period. This agreement shall expire upon the date of occurrence of

any one of the following events, which ever shall occur first :


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a) Project is officially called off by the Purchaser.

b) The Purchaser has awarded the Contract for the Project to any other Bidder;

c) The completion of the Scope of Work and its obligations and liabilities of the

members under this agreement and the Contract ;

d) Become insolvent or bankrupt, or enter into a temporary receivership with any

creditors or enter into compulsory or voluntary liquidation (except for purposes of

recovery)

8. CONFIDENTIALITY

The Members hereto agree and undertake that all information and details, whether written or

oral, including but not limited to drawings, designs, information and data, in connection with

the Project shall not be disclosed to any other third party without prior written consent of the

other members of the agreement except for this agreement.

9. HEADINGS

The heading of this agreement is solely for reference and has no legal effect whatsoever and

shall not in any way affect the interpretation or constitution of this agreement.

10. FORCE MAJEURE

No Party shall be liable for any failure to perform its obligations under this agreement if the

failure results from events under Force Majeure. For the purpose of this agreement, such

events shall include, without limitation, strikes, lockouts, riots, civil disturbances, action or

inaction of governmental authorities, epidemics, wars, embargoes, acts of God or other

catastrophes.

11. MISCELLANEOUS

This agreement will conform to all relevant Indian laws and regulations. Any difference that

may exist will be negotiated in good faith and will not impact the effectiveness of the other

clauses.

IN WITNESS WHEREOF, the Members hereto have caused their respective duly authorized

representatives to execute this agreement the day and year first above written.

SIGNED BY

For and On Behalf of For and On Behalf of

M/s …………………………. M/s ………………………….

(Authorised Signatory) (Authorised Signatory)

Name: Name:

Common Seal of the Company Common Seal of the Company


APPENDIX - 14

PARADIP PORT TRUST

MANDATE FORM FOR ELECTRONIC FUND TRANSFER/RTGS TRANSFER

Sub : Authorization for release of payment / dues from Paradip Port Trust through

Electronic Fund Transfer/RTGS Transfer.

1. Name of the Party/Firm/Company/Institute:

2. Address of the Party: _____________________________________

3. City __________________________ Pin Code ______________

4. E-Mail ID ___________________________ Mob No: __________

5. Permanent Account Number ______________________________

6. Particulars of Bank

Branch Name Branch Name

Branch Place Branch City

PIN Code Branch Code

MICR No

(9 Digit number appearing on the MICR Bank of the Cheque supplied by the Bank, Please

attach a Xerox copy of a cheque of your bank for ensuring accuracy of the bank name,

branch name and code number)

IFS Code: (11 digit alpha numeric code)

Account Type Savings Current Cash Credit

Account Number:

Supplier’s name as per Account

DECLARATION

I hereby declare that the particulars given above are correct and complete. If any transaction

delayed and not effected for reasons of incomplete or incorrect information I shall not hold Paradip

Port Trust responsible. I also undertake to advise any change in the particulars of my account to

facilitate updating of records for purpose of credit of amount through NEFT/RTGS Transfer.

Place: _______________

Date: ________________

Signature & Seal of the Authorized Signatory of the Party

Certified that particulars furnished above are correct as per our records

Bankers Stamp:

Date: ______________

Signature of the Authorized Official from the Bank

__________________________________________________________________________ Page 68 of 286


APPENDIX -15

FORMAT FOR REFUND OF EMD FOR THE E-TENDERING IN E&M DEPT.PPT

SL

No

EMD Particulars

01 Name of the Bidder with address

02 Name of the Work

03 Tender No. / TCN No.& Date

04 Dept./Divn. of PPT

05 Amount of EMD in Rs. Rupees(………..)Only

06 Details of Bank Account from which the payment towards EMD was made

i) A/C No

ii) Bank/Branch

iii) IFSC Code

07 Reason for Refund

(Signature of Bidder / Contractor with date & seal)

Passed for Rs…………………………(Rupees.................................…………………………

…………………………………….……………………………………………………) only

Signature of the Controlling Authority

Concerned Division/Section/cell

Paradip Port Trust

Received Rs…………………………(Rupees……………………………………………. …

…………………………………………………………………………………) only

Signature of the Bidder /Contractor

With full postal address

__________________________________________________________________________ Page 69 of 286


PARADIP PORT TRUST


E-TENDER CALL NOTICE NO: EM/MCHP-19/ 17

E-TENDER CALL NOTICE (TCN),

SPECIAL CONDITIONS OF CONTRACT (SCC),

TECHNICAL DETAILS OF MCHP, SCOPE OF WORK,

VOLUME-2

NAME OF WORK: OPERATION & MAINTENANCE

OF

MECHNISED COAL HANDLING PLANT


Page 71 of 286

E-TENDER CALL NOTICE


Page 72 of 286

PARADIP PORT TRUST


MECHANISED COAL HANDLING PLANT

********

NO.: EM/MCHP/Tender-1/17/278 Date : 01.04.2017

e-TENDER CALL NOTICE (TCN) No. EM/MCHP-19/17

1. Paradip Port Trust invites online tenders from eligible bidders for the following work.

Sl.

No

Name of work Estimated Cost

of Work(in Rs)

E.M.D.

(in Rs.)

Tender fee/

Cost of

Tender

Document

(in Rs.)

Period of

Contract

1 2 3 4 5 6

01

.

Operation & Maintenance

of Mechanised Coal

Handling Plant

189,26,50,422/- 1,99,26,505/- *

20,000/- * 03 (three) years

*To be deposited through NEFT/RTGS as per Clause No.13, 15 &17 of ITB.

2. Bidders with the following eligibility criteria only may participate:

a) Similar Work Experience :

The bidders who have successfully executed similar work(s) as under within 7 years

ending on Dt.31.03.2017 (any one of the following) only may participate in the

tender.

i) One similar work of value not less than `151,41,20,338/- OR

ii) Two similar works of value not less than `94,63,25,211/- each OR

iii) Three similar works of value not less than `75,70,60,169/- each.

Similar work(s) shall mean:

(i) “Design, supply, erection and commissioning / Supply, erection and commissioning

of bulk material handling equipment such as stacker / reclaimer / stacker-cum-

reclaimer / ship-loader / ship un-loader / wagon tippler / wagon loader of capacity not

less than 1000 TPH. The equipment must have operated satisfactorily for at least 3

years after commissioning in a Sea Port or in a Power Plant or in a Steel Plant or in

mines exclusively where large bulk material such as iron ore, sinter, coal, lime stone

and dolomite are used.”

OR

(ii) Installation & commissioning of bulk material handling plant which includes

conveyor system and at least two bulk material handling equipments such as stacker/

reclaimer / stacker-cum-reclaimer / ship-loader / ship un-loader / wagon tippler /

wagon loader of capacity not less than 1000 TPH. The plant must have operated

satisfactorily for a period of at least 3 years after commissioning in a Sea Port or in a

Power Plant or in a Steel Plant or in mines exclusively where large bulk material such

as iron ore, sinter, coal, lime stone and dolomite are used.

OR


Page 73 of 286

(iii) “Maintenance” or “Operation & Maintenance” of a bulk material handling plant of

capacity not less than 1000 TPH comprising of conveyor system and at least two bulk

material handling equipment such as stacker/ reclaimer / stacker-cum-reclaimer / ship-

loader / ship un-loader / wagon tippler / wagon loader satisfactorily for a period of at

least 3 years in a Sea Port or in a Power Plant or in a Steel Plant or in mines

exclusively where large bulk material such as iron ore, sinter, coal, lime stone and

dolomite are used.

OR

(iv) The bidder must have proven technology and must have designed, manufactured,

supplied, erected and commissioned two nos. of Raw Material Handling Systems with

capacity of 1000 TPH and above. One no. of these Raw Material Handling Systems

must have operated satisfactorily for a minimum period of 3 years in a Sea Port or in

a Power Plant or in a Steel Plant or in mines exclusively where large bulk material

such as iron ore, sinter, coal, lime stone and dolomite are used.

b) Financial Turnover:

The bidder must have an average annual turnover of Rs.56,77,95,127/-(Rupees Fifty

Six Crore Seventy Seven Lakh Ninety Five Thousand One Hundred Twenty Seven)

only or more during last 03(Three) financial years ending on 31st March 2016.

c) Bidders should have (i) EPF Registration Certificates (ii) ESI/ Mediclaim Policy/

Employment injury & Compensation. If the firm is having any type of Mediclaim

Policy/ Employment injury & Compensation, etc. other than ESI, then the firm has to

submit an undertaking that if the work awarded in their favour, then the firm would

get registered under the ESI Scheme, (iii)Permanent Account Number [PAN],

(iv) Income Tax Return of preceding three years (FY: 2013-14, 2014-15 & 2015-16) ,

(v) Service Tax Registration Certificate and (vi) VAT/Sales Tax Registration on

works contract etc.

3. Bidders who have been debarred / terminated by any principal employer because of

breach of contract during the last 7 years shall not be allowed to participate in this

tender.

4. In case of continuation of the work such as operation & maintenance work, the work

experience for the completed period shall be considered only and if there is no

discontinuity in the period of such work, then the work shall be treated as one work.

5. Copies of supporting documents(work orders, completion certificates, etc.) of the

details of works / projects executed to meet similar work experience as per the

eligibility criteria indicated in the Tender Call Notice must be furnished by the bidders

in the Technical Bid. In case of work experience issued by private organizations, the

bidder has to submit the TDS certification in addition to the work experience

certificate, failing which it shall not be considered.

6. The prescribed Tender Document will be available in the website:

https://eprocure.gov.in/eprocure/app and www.paradipport.gov.in 1700 Hrs.

Dt.03.04.17 to 17:00 Hrs of Dt.22.05.2017 for online bidding.

https://eprocure.gov.in/eprocure/app%20and%20www.paradipport.gov.in%2017


Page 74 of 286

7. The bidder must possess compatible Digital Signature Certificate (DSC) of Class-II or

Class-III. Those Contractors not registered in the above mentioned website are

required to get themselves registered before hand with valid DSC.

8. Bids shall be received only “Online” on or before Dt.22.05.2017 upto 17:00 Hrs.

9. Bids received online shall be opened at 1100 Hrs on Dt.24.05.17. Bidders who

participated in the bid can witness the opening of bids after logging on to the site

through their DSC. In the event of the specified date of bid opening being declared a

holiday for Paradip Port Trust, the bids shall be opened at the appointed time on the

next working day.

10. Other details can be seen in the bidding documents.

11. The authority will not be held responsible for any technical snag or network failure

during on-line bidding.

12. The authority reserves the right to cancel any or all bids without assigning any reason.

Executive Engineer

MCHP Division

Paradip Port Trust

Copy forwarded to:

2. The PRO, PPT with a request to publish the TCN in the Port gazette Dt.15.04.2017

and publish the same in Newspapers as per norms and enclosed format in an early

date. The copy of Port gazette and news paper cuttings may please be sent to this

office for further action.

3. All HOD/Commandant, CISF/C.V.O,PPT / Heads of Offices/OOGF / Notice Board.

4. The Hindi Officer, PPT with a request to translate the TCN in Hindi and circulate.


Page 75 of 286

(Format for Publication of e-TCN in the News Paper)

PARADIP PORT TRUST

e-TENDER NOTICE

Name of the work “Operation & Maintenance of Mechanised Coal Handling Plant”

Estimated cost: Rs. 189,26,50,422/-. Last date & time of submission of bid: Dt. 22.05.2017

upto 1700 Hrs. Refer our Website for details https://eprocure.gov.in/eprocure/app and

www.paradiport.gov.in.

Executive Engineer

MCHP, PPT


http://www.paradiport.gov.in/


Page 76 of 286

CONTRACT DATA

(A) GENERAL INFORMATIONS

SL.NO. ITEMS DESCRIPTIONS

1. Name of Work Operation & Maintenance of Mechanised Coal

Handling Plant

2. Department/Organization ELECTRICAL & MECHANICAL DEPARTMENT /

PARADIP PORT TRUST

3. Executing Division MCHP Division.

4. Officer Inviting the Bid Executive Engineer (MCHP)

5. Immediate Next Authority Superintending Engineer (MCHP)

6. Sanctioning Authority Trust Board

7. Executing Authority Executive Engineer

(B) BID INFORMATION

Sl. No Item Date Time

1 Tender e-publication date 03.04.2017 1700 hrs.

2.a) Document download start date 03.04.2017 1700 hrs.

b) Document download end date 22.05.2017 1700 hrs.

3.a) Start date for seeking Clarification on-line 03.04.2017 1715 hrs.

b) Last date for seeking Clarification on-line 24.04.2017 1700 hrs.

4. Date of Pre-bid Meeting 28.04.2017 1200 hrs.

5. Date of uploading response to Clarifications sought 08.05.2017 1700 hrs.

6.a) Bid Submission start date 03.04.2017 1715 hrs.

b) Bid Submission end date 22.05.2017 1700 hrs.

7. Cost of Tender document/Tender fee of

Rs.20,000/- only to be deposited through

NEFT/RTGS and on following A/c details

as per Clause No.17.0 of ITB

Account No. : 34390705999


Type of Account: Saving

Branch : State Bank of India,

Bank Street, Paradip.

IFSC : SBIN0003945

On or before

22.05.2017

1700 hrs.

8. EMD of Rs.1,99,26,505/- only to be deposited

through NEFT/RTGS and on following

A/c details as per Clause No.17.0 of ITB

Account No. : 34390705999


Type of Account: Saving

Branch : State Bank of India,

Bank Street, Paradip.

IFSC : SBIN0003945

On or before

22.05.2017

1700 hrs.

9. Bid opening date 24.05.2017 1100 hrs.

10. Bid Validity period 180 days

11. Currency of Contract Indian Rupee

12. Language of Contract English


Page 77 of 286

SPECIAL CONDITIONS OF CONTRACT

Clause No. Description

1.0 SITE VISIT, PRE-BID MEETING AND CLARIFICATION TO BIDDERS

2.0 BID PRICE

3.0 BID VALIDITY

4.0 SECURITY DEPOSITS

5.0 DOCUMENTS ESTABLISHING BIDDER’S ELIGIBILITY &

QUALIFICATION

6.0 CONTRACT PERIOD

7.0 DATE OF COMMENCEMENT OF WORK

8.0 DATE OF COMPLETION OF WORK

9.0 PRICE VARIATION

10.0 PAYMENT TERMS

11.0 FACILITIES TO BE PROVIDED BY THE PURCHASER / PURCHASER’S

OBLIGATION

12.0 DRAWINGS & MANUALS OF THE PLANT

13.0 DEDUCTION ON DEFAULT

14.0 EVALUATION OF YEARLY PERFORMANCE

15.0 TERMINATION OF THE CONTRACT

16.0 WARRANTY

17.0 REQUIREMENT OF PAY-LOADERS, HYDRA CRANES, MAINTENANCE

VEHICLES

18.0 REQUIREMENT OF OPERATION OF 2nd

RECEIVING STREAM

19.0 REQUIREMENT OF INITIAL WORKS

20.0 RESPONSIBILITY TO RECTIFY LOSS OR DAMAGE

21.0 INCENTIVE SCHEME

22.0 SUBCONTRACTORS

23.0 THE CLAUSES OF THE TENDER DOCUMENT –

VOLUME-1 STANDS DELETED FOR THE SUBJECT TENDER

24.0 CONTENTS OF BID DOCUMENTS


Page 78 of 286

SPECIAL CONDITION OF CONTRACT (SCC)

1.0 SITE VISIT, PRE-BID MEETING AND CLARIFICATION TO BIDDERS:

1.1 The prospective bidders are strongly advised to depute their technical experts at their

cost with authorization letter to visit the site to assess and examine the site conditions,

requirement, the nature and quantum of work so as to prepare a realistic and

competitive bid for the execution of the work. It is the responsibility of bidders to

collect all information to their satisfaction in order to fulfill the obligations under the

contract.

1.2 A prospective bidder requiring any clarification on the Bid documents may request /

forward their queries to the Chief Mechanical Engineer, Paradip Port Trust in writing

on or before Dt.24.04.2017 in accordance with clause no. 7.0 of ITB. Queries raised

after Dt.24.04.2017 shall not be accepted. A pre-bid discussion based on the queries

received from the bidder will be held at 1200 hrs. on Dt.28.04.2017 in the chamber of

Dy.Chairman, PPT. In the pre-bid discussion, maximum 02 members from each firm

are allowed to participate. Consolidated list of queries by the bidders and response of

PPT will be issued by PPT as addendum in the website on or before Dt.08.05.2017

pursuant to Clause No.8 of ITB only if the clarifications requested for, are considered

appropriate by PPT.

2.0 BID PRICE:

2.1 The contract shall be for the whole works as described, based on the price submitted

by the bidder. The Bidder shall indicate in the prescribed Bill of Quantity tender

document, the prices towards fulfilling all obligations under the contract. The amount

indicated at Sl.No.1 of the BOQ i.e. “O&M of MCHP” is applicable for the first

contract year only. Similarly, the amount indicated at Sl.No.2 of the BOQ i.e. “One

time mandatory initial works” is a one-time payment and will be paid only after

satisfactory completion of the work listed at clause no. 19.0(ii) of SCC. The amount

quoted by the bidder must include all the costs including labour, materials for

operation & maintenance of equipment and systems including “One time mandatory

initial works”, transport charges, custom duties, octroi / entry tax, excise duty, sales

tax, works contract tax, turnover tax, all types of Cess, any other duties, taxes or

incidentals, insurance, compliance with statutes & regulations, retrenchment benefit

etc excluding service tax whatsoever payable for satisfactory performance of the

contractor’s obligations under this contract. PPT MAY REJECT ANY BID, WHICH

IS PRICED IN VIOLATION OF THE ABOVE REQUIREMENTS. The evaluation

and comparison of bids by PPT shall be made accordingly. The contract price for

item at Sl. no.1 of BOQ i.e. “O&M of MCHP” from second year onwards will be

governed by the price variation clause 9.0 of SCC.

2.2 Items not specially listed in the Bill of Quantity but required to be executed for

satisfactory compliance with the bid requirements as specified, shall not be separately

paid by PPT when executed and shall be deemed to be covered under price contained

in bidder’s Price bid. In order to prepare a realistic and competitive bid, the bidders

are advised to assess the site conditions, nature and quantum of the work to be done,

material and manpower requirements etc. correctly before submission of the bid.

Special Conditions of Contract


Page 79 of 286

2.3 For financial evaluation, the amount quoted for “Operation & Maintenance of

Mechanised Coal Handling Plant” for 12 months (per year) at Sl.No.1 of BOQ will be

multiplied with 03 (three) to find out the O&M cost for 03 years, which will be added

with the amount quoted for “One time mandatory initial works” at Sl.No.2 of BOQ to

find out the total price for evaluation purpose.

2.4 Mechanized Coal Handling Plant has been designed to handle sized coal of -100 mm

size. But oversize coal / big size coal are being handled in a continuous manner.

Hence bidders are advised to quote their prices considering the O & M cost arising

out of handling normal/oversized/big size coal.

2.5 The price to be quoted for “Operation & Maintenance of Mechanised Coal Handling

Plant” at Sl.No.1 of BOQ (Rate per month x 12 months) is applicable for Operation &

Maintenance cost of the Plant for the first contract year. The price quoted for “One

time mandatory initial works” at Sl.No.2 of BOQ is a one-time payment which will be

paid only after satisfactory completion of the work listed at clause no. 19.0(ii) of

SCC. The prices and rates quoted by the Bidder shall hold good and shall be binding

on the bidder, not withstanding any increase in the prices of materials & labour,

Taxes, Duties or any other charges whatsoever and the bidder shall not be entitled to

claim any increase over the rates quoted by him during the period of the contract.

However, price variation clause as brought out under clause no 9.0 of SCC will be

applied once in a year from second year onwards to revise the rate / price after

completion of each contract year for the price quoted for “Operation & Maintenance

of Mechanised Coal Handling Plant” at Sl.No.1 of BOQ. No price variation is

applicable for the price quoted for “one time mandatory initial works” at Sl.No.2 of

BOQ.

2.6 The break-up price of Bill of Quantity shall be submitted separately in the formats

given at Annexure-I, II, III, IV & V in cover C-“Financial Bid” in order to facilitate

necessary deductions for non-utilization / non-execution of respective systems/ sub

systems/ equipment. Further, the above break-up price shall be also applicable in

order to facilitate necessary deduction for non-performance of the respective systems/

sub systems as brought out under clause no. 13.0 of SCC. The sum of the breakup

prices and the price quoted in the BOQ format should match. In case of discrepancies

the lower price shall be accepted. Similarly, if different prices have been quoted by

any bidder for the same item, the lower price shall be accepted. If sum of break-up

prices is at higher side, then the differential amount shall be deducted in equal

distribution from break-up components so as to match the lower price.

2.7 Paradip Port Trust does not have ‘C’ or ‘D’ form facility. The contractor may arrange

way bill at his cost for inter-state transportation of all the materials required for

successful execution of the work. The bidder must quote its price accordingly.

3.0 BID VALIDITY:

The bids shall be valid for a period of 180 days from the date of submission of bids.



Page 80 of 286

4.0 SECURITY DEPOSITS:

4.1 INITIAL SECURITY DEPOSIT (ISD):

The contract will be awarded initially for a period of 3(three) years. Therefore, the

Contractor shall furnish an ISD equivalent to 10% each of 3 times of the contract

price for “O & M of MCHP” for the 1st contract year and “one time mandatory initial

works” i.e. 10% x [3 x (contract price for item at Sl.No.1 of BOQ i.e. O&M of MCHP

for 1st contract year) +(Contract price for item at Sl.No.2 of BOQ i.e. One Time

Mandatory Initial Works)] in accordance with the provisions laid down at Clause

No.14.0 (Security Deposit) of Instruction to Bidder [ITB] of Volume-1 of the Tender

Document. In case of extension of contract for further period of 2 years, the

Contractor has to furnish another ISD within 15 days of issue of such letter of

extension in the shape of a Bank Guarantee equivalent to 2 times of 10% of the

contract price for “O&M of MCHP” for the 3rd

year (contract price for the item at

Sl.No.1 of BOQ i.e. O&M of MCHP for 3rd

contract year) valid up to 45 days after

completion of the extended contract period of 2 years. The Security towards ISD for

the initial 3 years shall be returned back on submission of ISD for extended period of

2 years within 45 days of successful completion of contract period of initial 3 years.

4.2 PERFORMANCE SECURITY DEPOSIT (PSD):

The PSD is not applicable for the work at Sl.No.1 of BOQ i.e. Operation &

Maintenance of MCHP. However, the same shall be applicable for the work at

Sl.No.2 of BOQ i.e. “One time mandatory initial works” as specified at Clause

No.10.1.2 of SCC.

5.0 DOCUMENTS ESTABLISHING BIDDER’S ELIGIBITY & QUALIFICATION:

In addition to the procedure and documents outlined at Clause No.15.0 (Documents

comprising the bid) at Instruction to Bidder (ITB) of the Volume-1 of the Tender

Document, “Schedule of Supplementary Information” to be submitted as per the

format given in Appendix-16 attached to the Volume-II of the Tender Document in

the Cover-B “Technical Bid”.

6.0 CONTRACT PERIOD:

Initially, the Contract period is for 3 years extendable by further 2 years subject to

satisfactory performance. The initial contract period of 3 years shall comprise of

3(Three) contract years from the date of commencement. Each Contract year means

twelve calendar months commencing from the date of commencement.

7.0 DATE OF COMMENCEMENT OF WORK:

The date of commencement of work will be treated as 01.11.2017.

8.0 DATE OF COMPLETION OF WORK:

This work is meant initially for a contract period of 3 years extendable by further

2 years subject to satisfactory performance. Hence initially the date of completion will

be treated as 3 (three) years from the date of commencement.



Page 81 of 286

9.0 PRICE VARIATION:

9.1 Since this contract is intended for 3 (three) years, the price variation shall be allowed

once in a year from the 2nd

year onwards i.e. if the contract commenced on say

01.11.2017, then the price variation shall be allowed on 01.11.2018 which will

continue for the 2nd

year and the next price variation shall be allowed on 01.11.2019

for the 3rd

year.

The contract price shall be adjusted in accordance with the following escalation

formula:-

Pr= Po/100 (15+30 Mn/Mo+55 Ln/Lo).

Where;

Pr = Adjusted price.

Po = Price accepted.

Mn = Index number of wholesale price in India (average) for Machinery and

Machine Tools, as applicable on the 1st day of the contract year, published in

RBI Bulletin.

Mo = Index number of wholesale price in India (average) for Machinery & Machine

Tools as applicable on the base date i.e. due date of submission of bid,

published in RBI Bulletin.

Ln = Consumer Price Index Number for Industrial Workers (All India Average) as

published in RBI Bulletin , applicable on the 1st day of the contract year.

Lo = Consumer Price Index Number for Industrial Workers (All India Average) as

published by RBI Bulletin, as applicable on the base date i.e. due date of

submission of bid.

Mo and Lo shall remain unchanged during the contract period.

Po = Price accepted shall mean that the contract price for the 1st year of the contract

period as indicated in the LOI/Work Order i.e. for the item at Sl.No.1 of BOQ

“Cost of Operation & Maintenance of Mechanised Coal Handling Plant valid

for the 1st year of the contract period”.

.

Price escalation as per the above formula shall only be applicable for the 2nd

year

onwards.

9.2 In price escalation formulae, value for Mn/Mo and Ln/Lo shall be taken considering

2(two) digits after decimal and price adjustment shall be calculated accordingly.

9.3 In case of extension of the contract for further 2 years, the contract price for 4th

year

and 5th

year shall be adjusted as per price escalation formula mentioned above and it

shall be allowed on 01.11.2020 which will continue for the 4th

year and the next price

variation shall be allowed on 01.11.2021 for the 5th

year.

9.4 In case of delay in publication of RBI index, the previous year’s escalation will

continue provisionally subject to adjustment after publication of the RBI Index.

9.5 No price escalation is applicable for the item at Sl.No.2 of BOQ i.e. “One time

mandatory initial works”.



Page 82 of 286

10.0 PAYMENT TERMS:

10.1.1 The monthly payment for the item at Sl.No.1 of BOQ i.e. Operation & Maintenance

of Mechanised Coal Handling Plant shall be made as under.

The Contractor shall submit his bill in triplicate at the end of every month in specified

bill entry format. The pre-receipted bill in triplicate along with necessary satisfactory

performance certificate, supporting documents as required under this contract and

prescribed check list shall be submitted duly certified by the Engineer-In-charge for

the release of payment. The payment shall be made as below.

100% payment shall be made on monthly basis on every succeeding month within

15 days from the date of submission of bill provided bill submitted should be in order

in all respect. Recovery/ deduction, if any, shall be made from the monthly bill. Bills

submitted for less than a month shall be calculated on pro-rata basis considering a

month as 30 days.

10.1.2. The payment for the item at Sl.No.2 of BOQ i.e. One time mandatory initial works

shall be made as under :-

On satisfactory completion of all the one time mandatory initial works listed at Clause

No.19.0 (ii) of Special Conditions of Contract (SCC), 95% payment shall be released.

Balance 5% shall be retained towards Performance Security Deposit (PSD) for

warranty period. The warranty period is one year from the date of acceptance of the

works. The PSD shall be released within 60 days of successful completion of the

warranty period.

10.2 PAYMENT DURING CONTRACT PERIOD

For 1st year :-- Payment will be made pursuant to clause no 10.1.1 of SCC for the item

at Sl.No.1 of BOQ i.e. Operation & Maintenance of Mechanised Coal Handling Plant

based on 1st contract year price as indicated in the LOI/Work Order.

For 2nd

year and 3rd

year :-- Payment will be made pursuant to clause no 10.1.1 of

SCC for 2nd

year and 3rd

year contract price which will be derived as per clause

No.9.0 of SCC basing on price escalation formula and price indexes published by

RBI. The contractor shall submit the relevant documents in support of price indexes

published by RBI promptly so that contract price for 2nd

year and 3rd

year can be

calculated and communicated to the contractor with approval of PPT.

In case of extension of the contract for further 2 years, the payment for 4th

year and 5th

year will be made as per the above guideline.

For payment towards one time mandatory initial works : -- One time payment will be

made pursuant to Clause No.10.1.2 of SCC. No escalation is applicable for this work.

10.3.1 At present, tendering for installation of Dry Fog Dust Suppression System (DFDS) at

RRS, Transfer Towers and installation of plain water sprinkling system at Stackyards

is under process. The work is expected to be executed and put into operation during

the tenure of this O&M contract. Once, the installation of new system is commenced,

the operation & maintenance of the existing DCS in the following locations will be

discontinued.




Page 83 of 286

(a) Maintenance of 02 nos. of pumps and its installations at Process Water Pump

House.

(b) O&M of existing DCS at RRS including high pressure pump house.

(c) O&M of existing DCS at both the stackyard sprinklers.

(d) O&M of sprinkling system at Transfer Towers

Hence, the amount quoted for the above items in the break-up price at

Annexure-V(K) 1(b)[ proportionate cost of 02 nos of pumps], 2, 3, 4 shall not be paid

to the contractor from the date of discontinuation of O&M of above systems.

10.3.2 In case, it is decided to dismantle the conveyor S-11 & S-12 and the Switch Bin, the

amount quoted in the break-up price at Annexure-II - A (b)(ii) 29 “Up-keeping of

S-11 & S-12 and Switch Bin” shall not be paid to the contractor from the date of

intimation.

10.3.3 At present, Enterprise Resource Planning (ERP) is under tendering process. It is

expected that the ERP will be implemented during the tenure of this O&M contract.

Once the same is implemented, all the data related to the Plant are to be fed into the

system by the O&M contractor as per requirement. The amount quoted at break-up

price at Annexure-I (M) shall be paid from the actual date of implementation of ERP

at MCHP.

11.0 FACILITIES TO BE PROVIDED BY THE PURCHASER/PURCHASER’S

OBLIGATION :

Clause No.40.0 of ITB is amended as under:-

a) Electricity, water for execution of the work shall be provided free of cost to

the Contractor. It is the responsibility of the contractor to utilize the electric

and water sources provided in Transfer Towers, Drive Towers, Conveyors,

Machines, Substations, etc safely with up-to date maintenance of all the

sources.

b) Land inside harbour area and outside area for execution of the work may be

provided on payment of applicable tariff notified by Paradip Port Trust from

time to time. The Contractor shall have to indicate their requirement with

definite purpose in the technical bid for consideration by PPT in Appendix-16.

c) The space utilized for store inside PMR, some rooms in PMR, some rooms

inside amenity building and change room will be provided to the contractor on

free of cost for establishing site office, store and refreshment of Contractor’s

personnel. All office equipment including PCs, Telephone, Internet etc.

required for the Contractor’s establishment shall be arranged by the contractor

at his own cost.

d) The workshop building will be provided to the contractor free of cost for the

purpose of maintenance activities like fabrication / repairs / overhauling /

disassembly / assembly etc, storing of spares & stores & POL items, etc.

e) Upon request of the Contractor, PPT may provide Port Trust Quarters, during

the period of work, subject to availability and on payment of applicable Tariff.

The contractor shall specify the requirement in the technical bid in

Appendix-16.



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f) Medical facility will not be provided by the PPT to the Contractor. However

the contractor’s personnel can be provided with medical facilities at PPT

Hospital in emergency cases only on payment basis.

g) Issuance of Gate passes by PPT to Contractor’s personnel for entering into the

prohibited area shall be governed by the policies of PPT which is notified by

PPT from time to time from security angle.

h) Administrative support only, for obtaining clearance from any statutory

authority, shall be provided by Paradip Port Trust.

12.0 DRAWINGS AND MANUALS OF THE PLANT:

Drawings, specification and manuals of the plant, equipment, buildings, substations,

etc. whatever available with Paradip Port Trust in the plant information library shall

be handed over to the contractor. In addition to this, the programme for PLCs

available with Paradip Port Trust shall be handed over to the contractor. It is the

responsibility of the contractor to keep the above in the safe custody with

satisfactorily indexed. Photos of important activities may also be kept. The contractor

is also responsible for preparing drawings afresh for missing drawings or non

available drawings and updating the Plant drawings on a regular basis to ensure that

they are always maintained in a current state. Further, the contractor is also

responsible for preparing the drawings, manuals of the Plant, equipment, buildings,

substations etc. (Both existing and new) in the form of soft copy. However, the

drawings, manuals, etc are the property of Paradip Port Trust the secrecy of which

shall be maintained by the Contractor except for the scopes under contractual

obligations and same shall be returned to PPT on completion of the contract.

13.0 DEDUCTION ON DEFAULT:

Availability factor of machines, equipment and systems as per norms on demand,

maintaining the rated plant capacity, up keeping of proper cleanliness/housekeeping,

carrying out proper maintenance, attending breakdown in time (rectification of faults),

inventory management and following the safety aspects, statutory norms and

regulations are the essence of this contract. Therefore the Contractor shall meet the

performance parameters / norms / obligations pursuant to the contract. Failure on the

part of the Contractor to comply with the requirements shall attract a deduction on

account of underperformance. All the deductions on account of underperformance is

effective from the date of commencement of the work except for one time mandatory

initial works listed under clause No.13.7 of SCC.While calculating any deduction on

default only two digits after decimal will be considered for evaluation of ratios.

13.1 AVAILABILITY FACTOR OF MAIN SYSTEM:

The contractor shall ensure that the machine, equipment / system are available on

demand all the time. The Contractor shall guarantee an Availability factor of 95% in a

given month for the Main System i.e. shipping streams and receiving streams on

demand.

The percentage of availability shall be calculated as under.

A = Total demand time.

B = Stoppages on account of the Contractor

during the demand time.

% of Availability = (A-B) /A X 100.



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Availability of Shipping Streams for a given month shall be taken as the average of

individual availability of the Shipping streams. Similarly availability of Receiving

Streams for a given month shall be taken as the average of individual availability of

the receiving streams.

DEDUCTION ON ACCOUNT OF NON ACHIEVEMENT OF AVAILABILITY FACTOR:

Failure on the part of the contractor to meet the availability factor shall attract a

deduction due to underperformance on monthly basis and to be deducted from the

monthly bill.

i) Receiving Stream:

There are 4(four) possible combinations for receiving operation (i.e. Unloading of

coal from wagons, transportation through Conveyors, stacking of coal in the stackyard

by stacker(s). These routes are (a) Rail Receival 1 to stacker1, (b) Rail Receival 1 to

stacker2, (c) Rail Receival 2 to stacker1, and (d) Rail Receival 2 to stacker2.

However at any time maximum two routes can be put into operation as per demand.

The Deduction for underperformance shall be as follows:

Route Availability Deduction

95.0% and above NIL

>=90% and < 95% 2%

>=85.0% and < 90% 6%

>=80% and <85% 10%

The deduction shall be made from the quoted amount per month against operation &

maintenance of receiving streams in the break-up price Annexure-I A(a).

In case availability of receiving stream in a month is found to be below 80% then,

20% of the monthly quoted amount in Annexure-I, A (a) shall be deducted from the

monthly bill.

ii) Shipping streams:

There are 8(Eight) possible combinations for shipping operation (i.e. Reclaiming of

coal from stack-yard by Reclaimers, transportation through Conveyors, loading in the

ship(s) by Shiploader(s) OR loading of coal by ship-loaders through conveyors

directly from RRS). These are (a) Reclaimer1 to Shiploader1, (b) Reclaimer1 to

shiploader2, (c) Reclaimer2 to Shiploader1, (d) Reclaimer2 to Shiploader2, (e) Rail

Receival 1 to Shiploader1, (f) Rail Receival 1 to Shiploader2, (g) Rail Receival 2 to

Shiploader1, and (h) Rail Receival 2 to Shiploader2. Similarly there are 4(four)

possible combination for recycling operation (i.e. reclaiming the coal from one stack-

yard, transporting it through conveyors, and stacking in the same or another stack-

yard by Stacker(s)) which will be treated as the shipping stream. These are a)

Reclaimer1 to Stacker1, b) Reclaimer 1 to Stacker 2, c) Reclaimer 2 to Stacker1, and

d) Reclaimer 2 to Stacker2. At any time either one or two routes can be put into

operation.



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In case of requirement, vessel can be loaded by using two shiploaders

simultaneously (dual loading operation). Further, blending of coal i.e. high grade with

low grade shall be done (blending operation). In blending operation, coal unloaded at

RRS will be blended at Transfer Tower-1 with the coal conveyed in the recycling

operation.


Route Availability Deduction

95.0% and above NIL

>=90% and < 95% 2%

>=85.0% and < 90% 6%

>=80% and <85% 10%

The deduction shall be made from the quoted amount per month against operation &

maintenance of receiving streams in the break-up price Annexure-I, A (b).

In case availability of shipping stream in a month is below 80%, then 20% of the

monthly quoted amount in Annexure-I, A (b) shall be deducted from the monthly bill.

N.B

a) Demand time for shipping stream= Time of berthing of vessel to the time of

completion of vessel.

b) Demand time of Receiving Stream = Time of rake placement in Rail Receival

Station (RRS) to time of completion of unloading of rake.

c) In case of no ship/no rake in the berth/in RRS deck, demand time will be

treated as nil.

d) Two receiving streams will be operated at a time as per demand. However the

O&M Contractor shall operate the receiving streams alternatively taking into

account the back loading operation and depending on cargo particulars.

e) Availability of shipping streams & receiving streams will be calculated for a

month basing on daily availability of shipping and receiving streams

respectively.

f) In case of direct loading, the availability shall be calculated for the shipping

stream.

g) In case of dual loading, availability of individual route used for loading

operation shall be calculated separately.

h) In case of blending operation, availability of the recycling route used for the

purpose shall be calculated.

Stoppages of streams/routes due to following shall not be considered while

calculating Availability factor.

a) Stoppages due to power failure i.e. non availability of incoming Power supply

at SS#6, Ship’s account, No cargo, Stockpile changing, Hatch Change, Bench

Change, Draft Survey, Deballasting problem.

b) Stoppages due to Force majeure conditions like cyclone, flood, heavy rain etc.

c) Non working day declared by PPT.



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d) Stoppages due to removal of foreign materials, stone, concrete sleeper,

jamming of big size coal /stone/concrete sleeper, etc in-between the wagon

doors, engine dragging problem, non response of engine driver, ship account

in case of direct loading, railway track jamming and other Railway related

problems.

e) Stoppages due to machine placement depending on plot orientation.

f) Chute jamming by big size coal/ stone/ sticky cargo.

g) Delay in commencement of unloading of rakes after placement beyond control

of the Contractor.

h) Any other cause of stoppages which is beyond the reasonable control of the

Contractor for which the Contractor has promptly notified Paradip Port Trust

with sufficient justification and acceptable to the Engineer-In-Charge will not

be considered on account of contractor. In case of disagreement in

determining whether the cause is beyond the reasonable control of the

Contractor or not, the decision of Chief Mechanical Engineer, PPT shall be

final & binding.

Stoppages of streams/routes due to following shall be considered while calculating

Availability factor.

a) Apart from the stoppages mentioned above, all the stoppages shall be

considered on the account of the Contractor.

b) In case of route change over due to fault occurred in pre selected

shipping/receiving stream, then time taken for rectification of fault of the that

pre-selected route shall not be taken as non available time on account of the

Contractor though change over route is put into operation to meet the demand.

c) Unusual delay in stockpile changing, hatch change, clearing chute jamming &

spillage cleaning, clearing of RRS hopper grid as decided by the representative

of PPT shall be on account of the Contractor.

All the stoppages shall be communicated to the Engineer-In-Charge

designated by PPT or his representative at the time of occurrence and

subsequently in writing in suitable format.

13.2 DESIRED OPERATIONAL RATING OF MAIN SYSTEM.

Unless specified by the vessel, the contractor shall guarantee to maintain the loading

rate @3500 TPH (excluding the stoppages beyond contractor’s control) as desired

operational rating of shipping stream. However, the loading rate below the desired

rating as asked by the vessels shall be maintained by the Contractor. Dual loading of

vessel are covered under the operational requirement of the Plant. During dual

loading, calculation will be made as per the loading rate (for both the shiploaders)

specified by the vessel maximum upto 7000 TPH [@3500 x 2]. No separate

calculation will be made w.r.t. individual shipping stream. Similarly, the norm for

unloading of a rake (consisting of 58/59 wagons) is 1 hr. 45 mins. (Excluding the

stoppages beyond contractor’s control) which includes 15 mins. buffer for placement

of rake from top point to RRS table. The timing will be calculated from arrival of the

rake at top point/ departure of the previous rake from RRS in that route clearing the

down point (whichever is later) to completion of the rake.



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DEDUCTION ON ACCOUNT OF NON-COMPLIANCE TO DESIRED OPERATIONAL

RATING.

Shipping Stream

Failure on the part of the contractor to maintain the operational rating of the plant

shall attract a deduction due to under performance and to be deducted from the

monthly bill.

Calculation of operational rating of shipping stream:

M = Total quantity loaded as per the ship’s figure in Metric Tonnes.

T1 = Actual time period taken for completion of the vessel i.e. from time of

clearance for commencement of loading to the time of loading

completion excluding stoppages beyond control of the Contractor.

T2 = Scheduled time for completion of the vessel based on the loading rate

asked by vessel subject to the maximum rating of 3500 TPH.

T3 = (T1 – T2) = Excess time taken by the Contractor to complete the

Vessel.

Based on the above formula, excess loading hrs. (if any) for each

vessel handled during the given month shall be calculated and total

excess time over & above the scheduled loading hrs. shall be derived

for deduction as defined under;

‘A’ = Amount quoted per month against operation & maintenance of

Shipping stream as in Annexure-I, A (b).

∑T3 = Summation of T3 calculated for each Vessel in a month. (-ve figure of

T3 shall not be considered for calculation of ∑T3)

∑T2 = Summation Scheduled time for completion of the vessel based on the

loading rate asked by vessel subject to the maximum rating of 3500 TPH.

Deduction to be made from the monthly bill = A x ∑T3 / ∑T2

Receiving Stream

The contractor shall endeavor to promptly release BOBR rakes from the Rail Receival

Station (RRS) as per norm as fixed. Failure on the part of the contractor to release the

rakes within the schedule unloading time shall attract a deduction due to under

performance and to be deducted from the monthly bill.

Calculation of operational rating of receiving stream:

T1 = Actual time taken for unloading of a rake in hh:mm i.e. from arrival

of the rake at top point/ departure of the previous rake from RRS in

that route clearing the down point (whichever is later) to completion

of the rake to completion of the rake excluding stoppages beyond

control of the Contractor.

T2 = Scheduled time for completion of the rake i.e. 01 hr. 45 mins.

T3 = (T1 – T2) = Excess time taken by contractor in hr. for unloading of the

rake.



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Based on the above formula, excess unloading hrs. (if any) for each rake handled

during the given month shall be calculated and total excess hrs. over & above the

scheduled unloading hrs. shall be derived for deduction as defined under;

‘A’ = Amount quoted per month against operation & maintenance of

Receiving stream as in Annexure-I, A(a)

∑T3 = Summation of T3 in hr. calculated for each rake in a given month (-ve

figure of T3 shall not be considered for calculation of ∑T3).

N = No. of Rakes handled in a given month.

Deduction to be made from the monthly bill = A x ∑T3 / (1hr 45 min. x N).

Stoppages of streams due to following shall not be considered while calculating

desired operational ratings.

a) Stoppages due to power failure i.e. non availability of incoming Power supply

at SS#6, on Ship’s account, No cargo, Stockpile changing.

b) Stoppages due to Force majeure conditions like cyclone, flood, heavy rain etc.

c) Non working day declared by PPT.

d) Stoppages due to removal of foreign materials, stone, concrete sleeper,

jamming of big size coal /stone/concrete sleeper in-between the wagon doors,

Engine dragging problem, non response of engine driver, ship account in case

of direct loading ,Railway track jamming, other Railway problems.

e) Stoppages due to machine placement depending on plot orientation.

f) Chute jamming by big size coal/ stone/ sticky cargo.

g) Delay in commencement of rakes after placement beyond control of

contractor.

h) Slow operation due to non availability of required loadable cargo in the

stackyard / any other relevant reason to achieve the desired feed rate (Timing

of slow operation and quantity handled during that period shall be deducted

from the total operation time & total quantity handled respectively to evaluate

the rating factor).

i) Any other cause of stoppages which is beyond the reasonable control of the

Contractor for which the Contractor has promptly notified Paradip Port Trust

with sufficient justification and acceptable to the Engineer-In-Charge will not

be considered on account of contractor. In case of disagreement in determining

whether the cause is beyond the reasonable control of the Contractor or not,

the decision of Chief Mechanical Engineer, PPT shall be final & binding.

j) Delay in placement from top point due to grid cleaning for oversize coal,

foreign material, stone of the previous rake and handled in the same stream.

Stoppages of streams/routes due to following shall be considered while calculating

desired operational ratings.

a) Apart from the stoppages mentioned above, all the stoppages shall be

considered on the account of the Contractor.

b) Unusual delay in stockpile changing, hatch change, clearing chute jamming &

spillage cleaning, clearing of RRS hopper grid as decided by the representative

of PPT shall be on account of the Contractor.



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13.3 AVAILABILITY FACTOR OF ILLUMINATION SYSTEM

The contractor shall ensure that the illumination system is available at all the time.

The contractor shall guarantee the available factor of 99% as a whole keeping the

intensity of light as per industrial safety norms i.e. 10 lux in non-working area and

25 lux in working area as acceptable to the Engineer-in-Charge designated by PPT.

DEDUCTION ON ACCOUNT OF NON-AVAILABILITY OF ILLUMINATION:

The inspection of illumination system will be made by PPT once in a month without

any prior notice. Failure on the part of the contractor to meet the availability factor

during surprise inspection shall attract a deduction due to under performance and to

be deducted from the monthly bill. Availability of illumination system will be

calculated as given below.

The percentage of availability shall be calculated as under.

A : Installed quantity of light fittings as mentioned

in Data sheet.

B : Light fittings not in proper condition

including non-glowing.

% of availability : (A-B) / A x 100


Availability Deduction

99.0% and above NIL

>=98% and < 97% 2%

>=97.0% and < 96% 4%

>=96.0% and < 94% 6%

>=94.0% and < 92% 8%

>=92.0% and < 90% 10%

Below 90% 20%

The deduction shall be made w.r.t. quoted amount per month against Operation

& Maintenance of Illumination System as indicted in the break-up price

Annexure-I (D).

In case of availability below 90%, the contractor shall be given a time period of

7 days to rectify the system. If he fails to revive the system then 100% of the quoted

amount per month against Operation & Maintenance of Illumination System shall be

deducted from the monthly bill.

13.4 DEDUCTION DUE TO POOR OPERATION &MAINTENANCE OF MAIN SYSTEM

- RECEIVING STREAM & SHIPPING STREAM, AUXILIARY SYSTEM, HEAVY

EQUIPMENTS

Poor Operation & Maintenance shall mean

i) Operation of machines / equipments / systems / subsystems in abnormal

condition (s).

ii) Compromising in safety of machines and conveyor system by repeated &

prolonged by-passing of safety devices, field devices, and

monitoring/controlling devices during operation.



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iii) Tampering of Operational limits of the plant.

iv) Consecutive failure of machine / system / equipment or any component / sub-

system.

v) Maintenance not following the sound engineering practice.

vi) Non availability of any component in position.

vii) Nonworking of any system without information to PPT.

viii) Non availability of spares either new one or in overhauled/repaired condition.

ix) Non execution of deficiencies communicated by PPT in a mutually agreed

period.

x) Non attendance and non completion of breakdown in time agreed between

PPT and the Contractor.

xi) In case of failure of any component/ system of a machine / conveyor system/

substation, the Contractor may continue the operation of the stream by any

stopgap local mode in place of permanent arrangement / normal auto mode.

But, fault so occurred will be treated as poor maintenance.

Operation & Maintenance of different machines, substations, conveyor

systems, etc included in main system (receiving stream & shipping stream), auxiliary

system and heavy equipments shall be treated under poor operation and maintenance

if there is occurrence of any one situation or combination of situations as mentioned

above as per the EIC. This will attract a deduction from the monthly bill. The

deduction to be made is as under.

10% of the quoted amount for the individual machines, conveyor system,

substations, etc with reference to Annexure II, III, IV and V shall be deducted from

the monthly bill.

In case of disagreement, the decision of CME, PPT is final & binding for both.

13.5 DEDUCTION DUE TO POOR MAINTENANCE OF EOT CRANES, ELECTRICAL

& MANUAL HOISTS, CATHODIC PROTECTION SYSTEM, COMMUNICATION

FACILITY; i.e. INTERCOM, VHF COMMUNICATION etc.

Poor Maintenance shall mean

i) Non –operation of equipments at the time of requirement.

ii) Consecutive failure of any equipment / system or any component.

iii) Maintenance not satisfactory.

iv) Non availability of spares either in overhauled/repaired condition or new one.

v) Non execution of deficiencies communicated by PPT in a mutually agreed

period.

vi) Non-execution of OEM inspection w.r.t. schedule as per Clause No.5.3.6 of

Scope of Work.

Maintenance of different equipments shall be treated under poor maintenance if there

is occurrence of any one situation or combination of situations as mentioned above as

per the EIC. This will attract a deduction of 10% of the quoted amount for the items

with reference to Annexure I from the monthly bill.




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13.6 DEDUCTION DUE TO POOR MAINTENANCE & REPAIR OF SUBSTATION

BUILDINGS, PUMP HOUSES, CHANGE ROOM, PLANT MONITOR ROOM,

AMENITY BUILDING, COMPRESSOR ROOM, BELT WEIGHING ROOM,

WORKSHOP, YARD TOILETS, and CABLE PITS ETC.

Poor Maintenance shall mean non maintenance (Civil, mechanical & electrical

maintenance) of above buildings, pump houses, other rooms, etc including painting as

per scope of work.

In case of poor maintenance to be judged on annual basis as per the EIC, 10% of the

yearly quoted amount of the item with reference to Annexure-I (H) shall be deducted

from the 1st monthly bill of succeeding year.


13.7 DEDUCTION DUE TO POOR OPERATION & MAINTENANCE OF EXISTING

DUST CONTROL SYSTEM.

Poor operation & maintenance shall mean

i) Operation of Pumps / equipments / systems / subsystems in abnormal

condition (s).

ii) Consecutive failure of Pumps / equipments / systems or any component / sub-

system.

iii) Maintenance not following the sound engineering practice.

iv) Non-availability of any component in position.

v) Non-working of any system without information to PPT.

vi) Non-availability of spares either new one or in overhauled/repaired condition

at the time of requirement.

vii) Non-execution of deficiencies communicated by PPT in a mutually agreed

period.

viii) Non-attendance and non completion of breakdown in time agreed between

PPT and the Contractor.

Operation & Maintenance of different equipments shall be treated under poor

maintenance if there is occurrence of any one situation or combination of situations

as mentioned above as per the EIC. This will attract a deduction of 10% of the quoted

amount as indicated in the break-up price Annexure-V for that item from the monthly

bill for that month. Since the revamping of existing DCS has been covered under

“One time mandatory initial works”, a period of one year from the date of

commencement of the work shall be given to revamp the existing system and during

this period, no deduction shall be applicable. However, deduction due to poor

operation & maintenance of existing DCS will be effective after one year from the

date of commencement of the contract.


13.8 DEDUCTION DUE TO POOR HOUSE KEEPING /CLEANINESS

It is the responsibility of the Contractor to maintain the cleanliness on daily basis. In

case, the level of cleaning / housekeeping is not upto the satisfaction of EIC during

inspection, the contractor shall initiate immediate steps to undertake

cleaning/housekeeping work including internal drain & grass and bush cutting in a

time bound manner failing which the Contractor shall be liable for penalty of

`50,000/-for the 1st violation and `1,00,000/- for the 2

nd violation. For the 3

rd

violation, 10% of the quoted amount for the item i.e. “Housekeeping /Cleanliness”

with reference to Annexure-I (I) or `2,00,000/- whichever is more shall be deducted

from the monthly bill.




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13.9 DEDUCTION DUE TO VIOLATION OF SAFETY NORMS

The Contractor shall comply with all the requirements of safety regulations as

applicable and comply in all respect with all applicable laws of any duly constituted

Authority in India. Paradip Port Trust is certified with ISO 9001:2008 and ISPS. The

Contractor shall ensure that the maintenance work and documentation are maintained

to comply with the above said ISO requirements.

Without any prejudice, for any violation of safety requirements, the Contractor shall

be liable for a deduction of ` 10, 000/- for the 1st violation and ` 20, 000/- for the 2

nd

violation. For the 3rd

violation, the Contractor may be liable to be debarred from

execution of the contract and PPT shall have the right to get the contracted work done

by a 3rd

party at the risk and cost of the Contractor. The cost thereof shall be deducted

from the Contractor’s bill or any other dues payable to the Contractor along with an

overhead charge of 20% of the cost.

14.0 EVALUATION OF YEARLY PERFORMANCE:

The performance of the contract shall be judged depending upon the fulfillment of

obligations of the contract such as (a) availability factor of receiving & shipping

streams on demand, (b) maintaining the desired operational rating of plant, (c) up

keeping of proper cleanliness/housekeeping, and (d) carrying out proper operation and

maintenance, attending breakdown in time (rectification of faults), inventory

management, etc. Failure on the part of the Contractor to comply with the

requirements shall attract a deduction on account of default as outlined in clause

no.13.0 of SCC.

The overall performance of the contractor shall be treated as satisfactory if the total

deduction amount on default in a contract year does not exceed 10% of the contract

price in the concerned contract year.

15.0 TERMINATION OF THE CONTRACT:

15.1 In pursuant to clause no.12 of GCC, the contract may also be liable for termination if;

i) The availability of shipping & receiving stream on an average is found below

80% consecutively for 3 months.

ii) Total deduction on default in a contract year exceeds 10% of contract price for

the year.

15.2 The Board will pay the Contractor on pro-rata basis for the services rendered by the

contractor during the month within 30 days after the Contractor’s receipt of notice of

termination.

15.3 The Clause No.12.5 of GCC is amended as “The contract may be closed on mutual

closure basis by giving written notice of at least 120 days in advance and neither

party shall have any right of any claim on the other on account of such closure of

contract”.

16.0 WARRANTY:

The materials purchased by the Contractor except the self life items during execution

of the contract and handed over to PPT after completion of the contract shall be

warranted for a period of 12 months from the date of receipt of materials by PPT for

which the contractor shall furnish a BG amounting to 10% of the handed over

materials valid up-to 60 days beyond the expiry of the warranty period.

Cost of materials handed over to PPT by the Contractor shall be released only after

submission of BG towards warranty of the materials.



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17.0 REQUIREMENT OF PAY-LOADERS, HYDRA CRANES, MAINTENANCE

VEHICLES:

The Contractor shall maintain the above mentioned available equipments. In case of

requirement, PPT shall requisition the equipments giving 4 hrs. notice and the

Contractor shall provide the equipments with operator to PPT. For the period of

operation which shall commence from the time of Departure of the equipment from

the parking space and terminate on arrival of the equipment at the parking space, the

cost of the diesel only shall be reimbursed by PPT on monthly basis as follows w.r.t

Hour-meter:

a) Pay loader BL-200 ----- 8 Ltr. /hr

b) Pay loader –BL-40 ----- 25 Ltr./hr

c) Hydra Crane, 11 Ton – I/II ----- 3 Ltr./hr

d) Maintenance Vehicle- I / II ----- 1 Ltr. /3 KM.

e) DG Welding M/c ----- 1.5 Ltr./ hr.

18.0 REQUIREMENT FOR OPERATION OF 2ND

RECEIVING STREAM:

Highest 24 nos. of BOBRN rakes are handled in a day at RRS of MCHP.

Accordingly, the contractor should make all arrangements at RRS to handle

maximum no. of rakes available. The present scope of work for Operation &

Maintenance of MCHP includes operation of both the receiving stream. However, in

case of requirement, PPT may discontinue the operation of 2nd

receiving stream by

giving 30 days notice in advance and in such case, the rates furnished by the

Contractor in the break up price at Annexure-I,A(a)(ii) i.e. “Operation of 2nd

Receiving Stream” shall not be paid to the contractor.

19.0 REQUIREMENT OF INITIAL WORKS :

(i) The successful bidder is advised to make thorough survey/inspection of the plant

before taking over the plant and plan the initial works if any in his opinion required to

ensure the availability factor and desired operational rating of the plant in a consistent

manner during tenure of the contract period. The contractor shall give priority to the

works which are affecting the operational activity, safety aspects and also to avoid

further deterioration of the components which may affect in achieving the desired end

objective of the contract. All the materials, manpower required to carry out the works

is covered under the scope of the contractor and no extra payment will be made by

PPT on such account. Accordingly, the cost of such repairs shall be integrated in the

quoted price.

Time period to take up the initial works, if any, as opined by the Contractor shall be

taken up in a mutually agreed time schedule during operational gap.



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(ii) Mandatory Initial Works :-

Following initial works are mandatory in nature and are to be carried out by the

contractor and complete the same within one year from the date of commencement of

the contract.

(a) Revamping of existing Dust Control System :-

(b) Replacement of civil structurals of counter weight sheeve pulley of R-7 & R8.

(c) Shifting of belt weigher (Conveyor S-13 & S-14) from existing location

The details of above works to be executed have been described in the Scope of Work.

In case the contractor failed to carry out the above mandatory initial works within the

above time period, the work will be taken up by PPT at the cost & risk of the

contractor.

20.0 RESPONSIBILITY TO RECTIFY LOSS OR DAMAGE:

If any loss or damage happens to the works/property, or any part thereof due to

negligence of the Contractor for which the Contractor is supposed to take care thereof

during the period of the contract, the Contractor shall, at his own cost, rectify such

loss or damage to the works/property to the satisfaction of the PPT. The Contractor

shall also be liable for any loss or damage like damage to vessels / Railway wagons in

the course of any operations carried out by him and rectify the same in a time bound

manner for the purpose of complying with his obligations under the contract.

In the event of an emergency where, in the judgment of PPT, delay would cause

serious loss or damage, repairs or adjustments may be made by PPT or a third party

chosen by PPT without advance notice to the contractor and the cost of the work shall

be paid by the contractor.

21.0 INCENTIVE SCHEME :

Annual capacity of the Plant has been enhanced from 20 Million Ton to 28 Million

Ton. For handling beyond 28 Million Ton (shiploading quantity) per annum i.e. in a

financial year, additional amount shall be paid on pro-rata basis. That is the total

contract price for that financial year [for item at Sl.No.1 of BOQ i.e. Operation &

Maintenance of MCHP” ] divided by 28 million will be the rate per ton to be paid for

quantity above 28 Million Ton in that financial year.

In case shifting cargo is handled i.e. the cargo not unloaded at RRS of MCHP, but

shifted to the Stackyard of MCHP manually for shiploading purpose will be

considered for calculation of total quantity handled (shiploading quantity) in the

Plant. For calculation of above incentive scheme, the per ton rate for shifting cargo

will be calculated separately deducting the amount paid to the contractor towards

operation & maintenance of receiving stream as indicated in the break-up price as the

receiving operation is not carried out for handling of shifting cargo.



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22.0 SUBCONTRACTORS :-

Pursuant to Clause No.4.0 (Subcontractors) of General Conditions of Contract of

Volume-1 of the Tender Document, “Important activities of O&M contract cannot be

subcontracted. However, ancillary support services of the Plants such as

housekeeping, painting, providing services for heavy earth moving equipment can

only be subcontracted with prior approval of PPT.”

23.0 THE FOLLOWING CLAUSES OF THE TENDER DOCUMENT- VOLUME-1

STANDS DELETED FOR THE SUBJECT TENDER:

1. Clause No. 33.0 (Design Criteria), Clause No.34.0 (Drawings), Clause No.35.0

(Manuals), Clause No.37.0 (Quality Assurance Plan, Inspection& Testing),

Clause No.38.0 (Third Party Inspection), Clause. 42.0 (Vender list) of the

Instruction to Bidder (ITB)

2. Clause No.6.0 (Liquidated Damage), Clause No. 10.2 (Stage Payment),

Clause No. 10.3 (Advance Payment) of the General Conditions of Contract

(GCC).

3. Appendix-06 ((Bank Guarantee Format for Advance Payment), Appendix-07

(Corporate Performance Guarantee), Appendix-12 (Bank Guarantee Format for

Stage Payment).

24.0 CONTENTS OF BID DOCUMENTS :-

In addition to the contents of the Tender Document indicated at Clause No.6.1 of ITB,

following shall also form a part of Volume-2 of the Tender Document :–

Appendix-16 Schedule of Supplementary Information

Appendix-17 List of Long lead spares

Appendix-18 List of OEMs for Spare procurement

Appendix-19 Record keeping & Report generation for

Management Information System.



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TECHNICAL DETAILS

OF

MECHANISED COAL HANDLING PLANT


Page 98 of 286

TECHNICAL DETAILS OF MECHANISED COAL HANDLING PLANT

The Port of Paradip is one of the 12 Major Ports in India. It is a self financing body under

the administrative control of the Ministry of Shipping, GOI. The port is governed by the Major Port

Trust Act–1963 and the Indian Ports Act-1908. The port is headed by Chairman who is assisted by

the Deputy Chairman and functional Departmental Heads.

Paradip Port is situated on the east coast of India, in the state of Odisha, at a latitude of 200 -

15’- 58”.63 North and longitude 860-

40’-27”.34 East and is the only Major Port in the State of

Odisha. Paradip Port is situated 210 nautical miles south of Kolkata and 260 nautical miles north of

Visakhapatnam. The foundation stone for the Port was laid by late Prime Minister, Pandit

Jawaharlal Nehru on 3rd

January, 1962. The Port was opened to traffic with a single berth for

handling Iron Ore on 12th

March 1966. Paradip Port was declared as the Eighth Major Port of India

on 18th

April, 1966.

Paradip Port has excellent facility for handling variety of cargoes with modern cargo

handling plant & equipments, bagging and stitching plants, adequate back up space and storage

facilities. Paradip is a customer friendly ISO-9001-2008 certified and ISPS compliant port

rendering satisfactory service to the importers and exporters. The port functions round the clock,

365 days.

Meteorological Data:

Maximum temperature : 41o C

Minimum temperature : 8.9o C

Annual rain fall (average) : 1500 mm.

Average wave height : 2.76 mtr. to 3.07 mtr.

Maximum wave height : 6.14 mtr.

Minimum tide : 0.40 mtr.

Maximum tide : 3.46 mtr.

Wave direction (Apr-Sept.) : S-N

Wave direction (Oct.-Dec.) : N-E

Average wind speed (summer) : 35-42 km/hour

Average wind speed (winter) : 18-24 km/hour

Maximum wind speed : 180 km/hour as recorded on 29.10.1999

Port may experience strong winds and gales when any depression, storm or cyclone develop

in the Bay of Bengal and come close to the Paradip coast. Other technical details in this context

may be obtained by the bidder from the Meteorological Department.

Technical Details of MCHP


Page 99 of 286

ABOUT MECHANISED COAL HANDLING PLANT

Paradip Port Trust has installed a fully Mechanised Coal handling Plant with a handling

capacity of 28 million tones. The Coal handling Plant has been commissioned on 11.09.2001. The

plant is under commercial operation and working on 3-shift basis.

The Mechanised coal Handling System consists of a Rail Receiving Station (RRS) with two

parallel train unloading pits, a two row stock pile with two stacking conveyors with one stacker in

each line, two reclaiming lines in between the stock piles with two reclaimers over the same berm

& track & two ship loaders on the wharf. The system can unload two trains & load two vessels at

the same time. The stacking, reclaiming & vessel loading capacities are 4000TPH in each stream

with a designed annual Plant capacity of 20 million Ton which has been enhanced to 28 Million

Tons.

Apart from these, the plant have facilities for pollution control, communication, fire fighting

and fire detection system, ventilation and air-conditioning, water supply, drainage, approach roads

and auto plant control including measuring and monitoring instruments.

Paradip Port Trust now intends to outsource the Operation & Maintenance of the

Mechanized Coal Handling Plant with mandatory initial works in a consolidated manner to an

outside agency with sufficient experience in this field for which Paradip Port Trust (PPT) invites

bids online on the website eprocure.gov.in /eprocure/app from interested eligible bidders for the

work “Operation and Maintenance of Mechanised Coal Handling Plant”.

The following information in the Bid Document has been provided to assist the bidder in

preparing the tender. The Purchaser does not guarantee the accuracy or the completeness of the

information. Before using any of the information, the Bidder shall satisfy himself as to its

suitability, accuracy and completeness.



Page 100 of 286

1.0 SALIENT FEATURES OF MCHP:

PLANT COMMISSIONED ON - 11TH SEPTEMBER 2001

PROJECT COST - Rs. 831 CRORES

ANNUAL DESIGNED THROUGHPUT - 20 Million mT

PRESENT ANNUAL THROUGHPUT 28 Million mT

RATED PLANT CAPACITY - 2 X 4000 TPH

NUMBER OF STREAMS - 2

SIZE OF VESSEL - PANAMAX / SUPRAMAX / HANDYMAX

BASIN DEPTH - 14.5 Mtrs

BERTH DIMENSION - 520m X 20.45m

DRAUGHT - 14.5Mtrs

AIR DRAUGHT - 19Mtrs

TYPE OF BERTH - DECK ON PILES

TRAIN SIZE - 59 X 62mT BOBR WAGONS

HOPPER DIMENSION - 44 X 4mtr

CAPACITY - 700mT

Merigo Round Bulb Distance - RR2-1805Mtrs, RR1-1765Mtrs

RADIOUS - 330~350Mtrs

DISTANCE FROM PDP. RLY.STn TO RRS - 8Kms

MODE OF UN-LOADING - INDEXING

STACKYARD CAPACITY - 9 LAKHS Mt (Coal)

HEIGHT OF STACKING - 10 Mtrs (NORMAL), 15 Mtrs (MAXIMUM)

NO. OF STOCK PILES - 2

RIVER SIDE (STOCKPILE-1) - 60,600 M²

PORT SIDE (STOCKPILE-2) - 61,600 M²

TOTAL - 1,22,200 M²

STACKERS (Track Centre: 12m) - 2 NOS., BOOM – 57 MTRS, 4000 TPH EACH

RECLAIMERS (Track Centre: 14m) - 2 NOS., BOOM – 60 MTRS, 4000 TPH EACH

SHIPLOADERS(Track Centre: 12m) -

-

2 NOS., BOOM – (EXTENDED - 38 Mtrs.)

(RETRACTED - 26 Mtrs.)

NO OF SURGE BINS - 2 (600 mT EACH )

CONVEYORS -

-

-

LENGTH–9KMS,WIDTH–1800 / 2200/ 2400mm

& SPEED – 4.0 Mtrs /Sec

2.0 CARGO HANDLED IN MECHANISED COAL HANDLING PLANT:

Sl. No. YEAR No. of rakes No. of Ships Qty. Loaded in mT

1 2001-02 596 47 1,855,812

2 2002-03 1,937 155 6,850,150

3 2003-04 2,311 181 8,001,368

4 2004-05 2,291 154 7,946,236

5 2005-06 2,511 214 8,286,208

6 2006-07 2,758 232 10,079,252



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7 2007-08 3,023 224 10,478,804

8 2008-09 3,126 247 10,821,401

9 2009-10 2814 223 98, 18,024

10 2010-11 2533 204 88,29,781

11 2011-12 2700 213 10,057,265

12 2012-13 3424 270 13,612,763

13 2013-14 4398 352 18,818,682

14 2014-15 5227 388 21,151,580

15 2015-16 5653 416 23,683,568

16 2016-17

(Upto Feb-17) 4817 301 17,855,792

3. 0 SYSTEM DESCRIPTION:

3.1 GENERAL

The Mechanized Coal Handling Plant consists of the following major equipment / system /

Building:

Machine / Equipment / system

Sl.No. Equipment Quantity

1 Belt feeder 4

2 Arc gate 4

3 Belt conveyor 18

4 Shuttle head 4

5 Tramp metal magnet 4

6 Stacker 2

7 Reclaimer 2

8 Flow Diverter 2

9 Rack & pinion gate 4

10 Vibro- feeder 4

11 EOT crane 4

12 Manual Hoist with electrical operated trolley 4

13 Manual Hoist 36

14 Ship loader 2

15 Belt scale 4

16 Ventilation and Air Conditioning System

17 Dust suppression system

18 Sewage & effluent system and portable water system.

19 Electrics, control, Illumination and communication system



Page 102 of 286

Buildings / Galleries / Sub-stations

Sl.No. Description

1 Rail Receival Station and Tunnel

2 Transfer Tower TT-1



5 Drive House DT-4

6 Drive House DT-5




10 Drive House DT-9

11 Conveyor galleries

12 9nos Sub-stations

13 Plant Monitoring Room

14 Stores & Workshop

15 Amenity building, Change room, Compressor room, Pump houses, Building at up

& down railway point, Watch tower building, Belt weigher room near TT#8, etc.

3.2 RAIL RECEIVAL SECTION:

3.2.1 Railway:

A total of approximately 20Km of 60 Kg Railway track is laid with two separate lines in the

RRS area of the loop for independent & simultaneous unloading from two trains. The

holding yard at the station end has five tracks & is connected to the unloading loop through

a double track link. On arrival at Paradip station, trains move either to the Rail Receival

Station (RRS) via the rail loop or if the RRS is occupied or out of service, to the holding

yard.

3.2.2 Rail Receival Operation:

There are two parallel independent rail-unloading pits, one on each of the parallel

tracks of the loop. Presently coal is delivered in unit train of approximate 3658 tonnes

payload comprising of 59 nos. of 62 tonnes bottom dump wagons. The train called as rake

passes through the receival station at a low speed and the rake unloading is being done in

indexing method.

Beneath the rail receival station there are four un-loading hoppers 1, 2, 3 and 4

each with a capacity of 350 tones. There are four feeder conveyors. 2400mm wide Feeder

conveyors R1A and R1B are installed below rail unloading hoppers 1 and 2 respectively.

2400mm wide Feeder conveyors R2A and R2B are installed below rail unloading hoppers 3

and 4 respectively. Feeder conveyors R1A and R1B discharge the coal on to conveyor R3.

Similarly feeder conveyors R2A and R2B discharge the coal on to conveyor R4. Both

conveyors R3 and R4 start from bottom floor of Rail Receiving Station and terminate at

transfer tower TT-1. Arc gate ARG1, ARG2, ARG3 and ARG4 are provided with feeder

conveyor R1A, R1B, R2A and R2B respectively. Arc gates are provided to control the

discharge of coal from respective feeder conveyor. At present, the Arc gates are not in use.

The speed of feeder conveyor is automatically controlled by VVVF drives.



Page 103 of 286

The coal dumped to hoppers by the train gets transferred to the main conveyor

R3/R4 by the 2400mm wide feeder conveyors & pass through Tramp magnet on its way to

either to the vessel or to the coal stockyard.

3. 3 STOCK PILING:

3.3.1 Technical Data of Conveyor System:

There are total 18 conveyors apart from 4 feeder conveyors in two streams. There are

16 routes of operation for stacking & ship loading which is selected by the operator from

one of the end machines or the Plant Monitoring Room. Four conveyor shuttles are located

at transfer tower TT1 at the head ends of conveyors R3,R4(from RRS) & S3, S4 (from

reclaimers) to enable each to discharge at four different transfer points. Flow diverters are

provided at transfer tower TT-7 & to feed from S7 & S8 either to the transfer vessel loading

conveyors S9 & S10 or to the Switch bin conveyors S11 & S12 as per requirement. Flow

diverters, conveyors S11 & S12, Switch bin in the above arrangement at present are

not in use. All the conveyors except the yard conveyors are covered.

3.3.2 Stacker:

Two rails mounted travelling; slewing & luffing stackers operate along the berm on

the northern & southern side of stock piles. An on-board PLC system allows automatic

operation of the stackers.

3.3.3 Stock Piling Operation:

Conveyor R3 and R4 feed coal to 4 Nos. each of transfer chutes through motorised

travelling type shuttle heads SH3 and SH4 respectively. After positioning of respective

heads over transfer chutes, coal can be transferred from conveyors R3 and R4 to any one of

conveyor S5, S6, R5 and R6 in transfer tower TT-1. Conveyors S5 and S6 direct the coal to

the ship loaders while conveyor R5 and R6 direct the coal to the stockpile.

Stockpile transfer conveyor R5 receives coal from transfer tower TT-1 and

discharges it to stock out conveyor R7 in transfer tower TT-3. Similarly stockpile transfer

conveyor R6 receives coal from transfer tower TT-1 and discharges it to stack out conveyor

R8 in transfer tower TT-2.

Stack out conveyors R7 and R8 discharge coal to the stockpile 1 and 2 via their

stacker ST-1 and ST-2. Conveyor R7 and R8 are long horizontal conveyors with drives

located at drive tower DT-5 and DT-4 respectively.

3.4 SHIPLOADING:

3.4.1 Reclaimer- :

Two bucket wheel Reclaimers operate on a central berm between the stock pile pads.

Both reclaimers travel on the same track of long travel rails but each reclaimers feed on to a

separate parallel reclaiming conveyors. The reclaimers are capable of controlled reclaiming

in range from 2500TPH to 4000TPH to enable the loading of ships with limited ballast

pumping capacity. The surge-bin with feeder conveyor has been incorporated on each

reclaimer to absorb the surges of bucket-wheel delivery & to feed a steady flow of coal to

the conveyor system & limit any surges to 4400 TPH peak design capacity. On board PLC

allows automatic control of the machine.



Page 104 of 286

3.4.2 Re-Circulation:

Recycling of coal from any location of the coal yard to another location in the same

pile row or the other at a rate of 4000TPH is done to prevent spontaneous combustion of

coal owing to prolonged storage by following means. Other purpose of recycling is to

accumulate scattered coal at one point to ease the reclamation during vessel loading.

Blending of coal i.e. high grade with low grade shall be done (blending operation). In

blending operation, coal unloaded at RRS will be blended at Transfer Tower-1 with the coal

conveyed in the recycling operation.

Coal reclaimed from the stockpile by reclaimers RC-1 and RC-2 is conveyed to

transfer tower TT-1 by means of conveyors S3 and S4 respectively. Reclaim conveyors S3

and S4 are equipped with shuttle head SH-1 and SH-2 respectively and discharge at various

points. For recycling of stacked coal, the shuttle heads SH1 and SH2 direct the coal to

conveyor R5 and R6 in transfer tower TT-1. For vessel loading of stacked coal shuttle head

SH-1 and SH-2 direct the coal to conveyors S5 and S6.

3.4.3 Switch-bins :

Two off line switch-bins each of 600T capacity are provided in the circuit between the

reclaiming & ship loading operations. During reclaiming operations, the switch-bins are by-

passed & the coal is conveyed directly to the ship-loader. When the ship-loader is required

to change the hatches, the coal is directed into the switch-bins where it is temporarily stored.

Thus the reclaimers & the conveyors can operate at a sustained output without stoppages.

The switch-bins are provided with 2 Vibrating feeders on each to feed to the wharf

conveyors. But the above system at present is not in use.

3.4.4 Shiploader:

Two Rail mounted, slewing, luffing & shuttling ship-loaders operate on the wharf to load

vessels between 30,000DWT to 90,000DWT. Each ship-loader is supplied by a separate

ship-loading conveying system. The ship-loaders have been provided with swiveling

loading spout equipped with a rotating & tilting spoon to direct the trajectory of the coal

stream as required for loading & trimming.

3.4.5 Ship loading Operation:

Ship loading conveyors S5 and S6 receive feed in Transfer tower TT-1 either from rail

receival station or from stockpile and direct it to conveyors S7 and S8 respectively in

transfer tower TT-6. From conveyor S7, coal feed to conveyor S9. Similarly from conveyor

S8, coal feed to conveyor S10. Conveyors S9 and S10 feed directly to wharf conveyors S13

and S14 respectively in transfer tower TT-8. Conveyor S-13 and S-14 supply coal to ship

loaders SL-1 and SL-2 respectively. The drives of conveyors S-13 and S-14 are located in

drive tower DT-9.

3.5 ELECTRICAL SYSTEM:

The existing 132 / 33 kV sub-station with two 40MVA 132KV/33KV transformers caters to

the power requirement of the entire Paradip Port which includes Mechanised Coal Handling

Plant also. Power supply at 132 kV is received from Paradip Garh sub-station in double

circuit at the 132 kV Receiving Gantry Towers of the sub-station. The power at 132 kV is

fed to 40 MVA transformers through the 132 kV indoor sub-station. The 33 kV switch-

board receives power from the 40 MVA transformers.



Page 105 of 286

For the Mechanised Coal Handling Plant there are six (6) major sub-stations namely sub-

station - 1,2,3,4,5 & 6. Sub-station-6 (33 / 6.6KV, 2 nos. 20 MVA transformers) is called in

the plant as Main sub-station as this Sub-station-6 receives main power of 33 kV from 132 /

33 kV sub-station and steps down to 6.6 kV and feeds other sub-stations, main machines

like stacker, reclaimer, shiploader etc. In this connection it may be mentioned here that the

operating voltage of the main drives of the plant are 6.6KV.

The 132 KV substations is equipped with PLC system, which is linked to the plant PLC

system at SS#6 through radio modem for auto operation of the capacitor bank.

The details of the power distribution is given in the “Block diagram of Power distribution

system” enclosed with this Document. A key single line diagram is also enclosed which

gives over all distribution scheme. The scope of the Bidder starts from 33 kV bus incomer

breakers in sub-station-6 downstream up to the ship loaders and other installations including

other 8 substations in the plant.

In addition to the above there are 3 smaller 6.6 kV / 415 V sub-stations in the plant to

feed various drives / machines / systems pertaining to the Mechanised Coal Handling Plant.

HT / LT switch gear, power distribution boards, PLC panels, Motor Control Centers,

ACDB, DCDB, LPDB etc. as per requirement are located in sub-stations.

3.5.1 Demand & Loading factor of MCHP:

1) Total connected load of the Coal Handling Plant is 18.5 MVA approx.

2) Total operational load of two receiving Streams & two Shipping streams is 12 MVA

approx. at peak load.

Main machines like stackers, reclaimers, ship-loaders etc. have their own electrical

Transformers, MCC Panels, PLC Panels, VVVF controllers, LPDB, HT Isolator etc.

installed on the machines itself.

In addition to the main machines / equipment / systems, the plant also has many auxiliary

systems with associated electrical drives and control like air conditioning system,

ventilation systems, dust suppression system, fire detection & alarm system, inter plant

communication system, plant illumination etc.

In case the Bidder wants to know more details of the plant elelctrics, he shall visit site,

interact with Purchaser and obtain the required information / data / drawings etc.

3.6 CENTRALISED MONITORING AND AUTO-REMOTE AND AUTO-SEQUENCE

CONTROL:

Summary;

The Control system is based on a centralised monitoring arrangement from the Plant Control

Room (PMR). The operation can be controlled from the machine operators at the destination

point or the operators at PMR. There are 08 possible combinations of routes for routing the

coal unloaded from the wagons either to the stack-yard or to the Ships. There are 04

possible combinations of routes for reclaiming of coal for shipping operation. There are 04

possible combinations of routes for re-circulation of coal to prevent spontaneous

combustion of coal owing to prolonged storage. The operator has to select the intended

route he wants to take the coal before starting the system. The status of all the routes is

available to him by the Human Machine Interface (HMIs) in the cabin or in the PMR. The

electronic data processing system is linked to the belt weighers and the operator of the

equipment programme the ship-loading plan using the control system. Data can be keyed in



Page 106 of 286

at all the points so that printouts for reports etc. can be generated at the PMR. Interface with

the main electronic data processing unit is not planned now. It is possible to link up if

necessary in future. The auxiliary operations like dust suppression etc. can be controlled

from either from the PMR or in a localised manner.

The control system architecture is designed for efficient operation of the plant and alteration

in the field parameters can be done using programming units.

3.6.1 Control System Overview:

The Coal Handling Plant is provided with a fully networked Programmable Logic

Controller (PLC) based Control System. Siemens PLCs S7 - 400 & Win CC operator based

Control System is employed. There are 21 nos. of PLCs net worked together which includes

2 Nos. of Gateway PLCs at PMR for interfacing the even and odd networks available in the

system.

All fixed plant PLCs within the Coal Handling Plant are linked via plant communication

network that will allow peer to peer data transfer between the respective PLCs.

The mobile machine PLC's shall communicate directly with their respective yard conveyor

PLC's, that in turn provide this information to the network. This will be a serial

communication link via copper flexible reeling cables and slip rings onto the machines.

The 132 kV substation PLC communications using a serial communication link via a radio

modem connection to the 33kV coal handling plant substation PLC for auto operation of

capacitor bank installed at SS#6.

There are 5 types of communication adopted in MCHP.

1) Ethernet communication

It is connected with gateway PLC (20, 21) in PMR to SCADA software (WinCC

Siemens).

2) Profibus communication

In PMR, both gateway PLCs are connected with two types of Bus 1) Odd, 2) Even.

Even / Odd PLC’s are connected with all substations.

3) Point to Point

Substation PLC to machines PLC is connected with serial modem.

4) Radio frequency

It is used at shiploader for remote operation of both Tx & Rx. These are connected

with related PLC.

5) Wireless communication

132 KV substation is connected to SS#6 (main Receiving substation of MCHP) by

using wireless modem. This line of sight around 2.5 KM & data transferring is done

in both ways (both way communication).

3.6.2 Control Philosophy:

The coal transfer system has been designed to operate as two independent parallel streams

but routes can be set up using elements from both streams.

All drives onboard the machines are controlled by machine operators. All applicable routes

can be selected or deselected by the operators at either end of the route or from Plant

monitoring room. The selection of a route will not start any drives. Since all sequences

depend upon the downstream drives operating, the downstream machine operator (Stackers

or Shiploaders) is required to initiate the route sequence start from on-board machine. The

boom conveyor on the downstream machine will then start up followed by the subsequent

plant drives along the selected route. With all down-stream plant and drives running, the up-

stream operator (Reclaimer or Rail Receival) may then start the source of coal. A sequence

stop of the route can be initiated from operators at either end of the route.



Page 107 of 286



Page 108 of 286



Page 109 of 286

3.7 PLANT OPERATION MODES:

3.7.1 Auto/Local Mode (for fixed plant):

Control of the individual drives will depend upon the mode of operation selected. Each

individual drive in the fixed plant (i.e. conveyor, feeder, shuttle, pump etc.) shall have an

associated auto/local mode.

These modes of control are defined as follows:

Local: In local mode each drive shall be started and stopped from a local start/stop station

adjacent to the drive motor. Only hardwired interlocks for each drive such as overload,

emergency stop, travel limits and statutory safety devices will remain part of the motor

control circuit. This mode is to be used during maintenance, testing and for local control.

Auto: In Auto Mode, each drive shall be started & stopped as part of an automatic sequence

of the selected route.

For process stream drives (conveyors, feeders, shuttles, etc.), auto/local selection will occur

upon selection/de-selection of routes respectively i.e. all drives comprising a selected route

will be set to auto mode. A route cannot be selected, if any of the required plant drives are

running in local or is faulted.

For non-process stream drives (sewage and water pumps, dust suppression sprays, etc.),

auto/local selection will be via field selector switches.

3.7.2 Manual/Local Mode (for mobile machines):

Each stacker, reclaimer & shiploader will be controlled by an operator from the non-board

control cabin and will be equipped with its own PLC and operator interface screens. The

machines shall be capable of being operated in manual/local mode. The manual/local mode

is synonymous with the auto/local mode for fixed plant i.e. in manual mode, each drive will

be started and stopped as part of the automatic PLC controlled sequence, in response to

commands from the operator. The local mode is same as for fixed plant machines and is

meant for maintenance purpose.

3.7.3 Plant Control Points:

The Control system Philosophy is designed for efficient operation of the plant & alteration

in the field parameters. The plant controls are performed from the plant monitoring room,

rail receival station, stackers, reclaimers and / or ship loaders depending on the route in

operation.

Plant control includes the following operations.

(a) Selecting plant routes

(b) Starting / stopping machines & plant routes

(c) Machine movement (Travel, slew, luff , shuttle ) & modes ( manual / Local )

(d) Acknowledging alarms

(e) Setting plant variables (i.e. feed rates etc.)

3.7.4 Rail Receival Station:

Rail Receival Station can unload coal either to stockpiles via the stackers, or directly to the

ships via the ship loaders.

The rail receival station is equipped with two operator interface stations from which the

operation of drives associated with both streams can be controlled.

The rail unloading signaling system is controlled independently from the Plant Control

System and is performed by the rail receival station operator.



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All drives and equipment used to transfer coal from the rail receival area to the stackers or

direct to the ship loaders are monitored from the rail receival station operator interface

stations. All associated route selections may be selected from either of these operator

interfaces. However, the stacker or ship loader operator will initiate the sequence starting of

these routes.

Indication of the current status of drives in each part is displayed in order to enable the

operator to select a flow path for the coal when commencing rail unloading operation.

Co-ordination with Loco drivers during unloading of coal wagons is carried out over hand

held radio sets.

3.7.5 Stackers, Reclaimers and Ship-loaders:

Control of the operation functions of each of these machines is performed by the respective

on board operator.

Each machine is equipped with an operator interface OP-37 of Siemens make. The operator

interface provides a means of monitoring machine positional status, drive status and alarm

indication.

The current status (ready/running/faulted) of all major drives within the plant relevant to

machine routes will be monitored and displayed by each operator interface.

3.7.6 Plant Monitoring Room:

Coal handling plant system monitoring and co-ordination is performed at the Plant

Monitoring Room. Limited operator control of the coal handling plant is possible from the

plant monitoring room operator interface screens. This is restricted to non-process stream

equipment such as stockpile dust suppression sprays.

The function of the Plant Monitoring Room is to provide a centralised point for plant co-

ordination, system performance monitoring, reporting and alarm logging.

3.7.7 Local Stop/Start Stations:

Adjacent to each drive is a local start/stop control station with start and lockout stop push

buttons. The start push-button shall only be effective when the drive is in Local Mode.

When operating from the local start/stop stations adjacent to the drives all hardwired

interlocks and protection devices such as emergency stop, pull wire and isolation switches

will be operable but no drive to drive interlocking or blocked chute interlocking is provided.

3.8 PLANT SEQUENCING:

3.8.1 General

On receipt of a route sequence start command from the downstream machine operator, all

selected conveyor equipment will start in sequence from the downstream through to the

most upstream. Immediately preceding the start of each drive the respective warning siren

shall be sounded. All equipment shall be interlocked in Auto mode such that it cannot run

without its immediate downstream drive running.

A route sequence stop command will drain the system of coal and subsequently shutdown

the plant in a controlled sequence.

The Plant control system incorporates trip sequences which will shutdown necessary plant if

any stoppage occur in any part of the plant. A stoppage may be caused by deselecting a



Page 111 of 286

route, by switching a machine to local, by pressing the emergency stop or by any one of the

protective trips. All upstream equipment will immediately stop. The downstream equipment

from such a fault will continue to operate for a predetermined time period or until the fault

is rectified and reset. The upstream drives can then be restarted by initiating another route

sequence start command from the downstream machine. For this purpose, the status of the

relevant routes must be clearly displayed to the machine operators.

3.8.2 Route Selection:

Each Rail Receival, Stacker, Reclaimer and Shiploader Operator shall be able to select one

of the four possible routes for their respective equipment via their operator interface screens.

Routes may be selected by Operators at either end the coal flow path.

Upon receipt of a route selection request, the Control System (after validating availability of

the requested route) shall place all inclusive drives in Auto mode. Shuttles and flow diverter

gates shall then automatically move to the required positions. Any condition preventing

setting of the selected route (e.g. required drives unavailable, shuttle failed to move etc.)

shall be clearly displayed to the relevant operators. Only when the route has been

successfully set, then only a route sequence start is possible. These conditions are clearly

displayed to the downstream operator via the operator interface screen.

Any drive with provision for controlled feed rates such as rail receival belt feeders,

reclaimer belt feeders and shiploading switch bin vibrating feeders shall ramp up at a

controlled rate from the minimum value to the desired set point as set by the respective

operator.

3.8.3 Route Sequence Start:

Sequence is started beginning with the most downstream drive in the selected route.

Successive upstream drives are started after the preceding drive is running and required

minimum speed has achieved. Route sequence starts or restarts can only be initiated from

the operator for the downstream machine (stacker and shiploader). For the start sequence to

commence, the route must be successfully set, no required drives faulted and the

downstream must be ready.

3.8.4 Route Sequence Stop:

A route sequence stop shall have set time delays between each conveyor stopping to allow

the plant equipment to completely empty coal from the conveyors. Route sequence stops

may be initiated from Operators at either end of the route. Selection of a sequence stop shall

be clearly displayed to both operators on the route via their operator interface screens.

3.8.5 Sequence Trips:

In the event of a fault occurring on a selected drive the faulted drive plus the upstream

drives shall stop immediately. Downstream drives shall continue to operate for a pre-set

time delay before shutting down. Restarting part of or the entire route shall be by the

downstream Operator’s route sequence start command.



Page 112 of 286

3.8.6 Fault Detection:

As most of the likely faults and their cause are programmed in the software, the system

helps in identification of almost all faults.

Whenever a fault occurs in the plant, it will be automatically displayed on the monitor

screen of all the operators indicating the unit that has developed a fault. A red light will be

blinking in the mimic page indicating that area. A message will also come at the top of the

screen showing the type and region of fault that has occurred. The operator of the Control

Room In-charge can further see the list of faults occurred and cleared by operating the

keyboard. This helps to attend the fault without loss of time.

3.9 ANTI-COLLISION SYSTEM:

As two reclaimers and two shiploaders travel on the same track located in the reclaimer

berm & on the wharf respectively, to prevent collision between the two machines anti-

collision sensors are provided.

3.10 WEGHING SYSTEM:

In order to maintain accurate accounts of loading and stock pile inventory a weighing

system has been incorporated in to the coal handling system located in the wharf conveyers

S13 & S14 and in the booms of stackers. The weighing system works on the principle of

Load Cells.

Auxiliary Equipment

Tramp metal magnet MA-1, 2, 3 and 4 have been provided on conveyors R3, R4, S3 and S4

respectively.

3.11 VENTILATION SYSTEM

Ventilation systems of 6000 cum. per hour capacity for supply of fresh and filtered air by

fan, ducting and supply air grills have been provided in sub-stations SS1, SS2, SS3, SS4,

SS6, Rail Receival Station and tunnel of conveyors R3 & R4.

3.12 AIR-CONDITIONING SYSTEM

15 TR capacity air conditioning system has been provided for air conditioning of

switchboard room and control room.

3.13 GENERAL & ANCILLARY ELEMENT SYSTEM:

3.13.1 Dust Control System (D.C.S)

The system is installed in MCHP for suppression of dust generated from different sources in

the year 2010. This comprises of the followings;

(a) PWPH

(b) Process Water Underground & Overhead pipe network

(c) High Pressure Pump House at RRS

(d) All Transfer Towers

(e) Stack-yard (Sprinklers and Fire monitors)

At present, tendering for installation of Dry Fog Dust Suppression System (DFDS) at

RRS, Transfer Towers and installation of plain water sprinkling system at Stackyards is

under process. The work is expected to be executed and put into operation during the tenure

of this O&M contract. The operation & maintenance of new DFDS system at RRS, Transfer

Tower and plan water sprinkling system at Stackyards is not included in the scope of this

contract.



Page 113 of 286

3.13.2 Service Water System

Wash down points are provided at different points in the coal handling plant for washing

purpose. These points are provided in each reinforced concrete floor of transfer towers, rail

receival Station and conveyor galleries.

3.13.3 Fire Detection and Alarm System

An automatic fire detection and alarm system is installed to cover all strategic points of the

plant. The detection and alarm system comprises of a number of individually addressable

fire detectors, manual break glass type call points, microprocessor based main fire alarm

panel and some repeater panels. The repeater panels repeat the annunciation processed in

the main panel and activate the local sounders to alert the nearby operating personnel. They

give indication of the area affected by fire and the exact location of actuated detector. For

coal conveyers, transfer points and tunnels infrared detectors have been provided which will

immediately stop the conveyer drive motor if a fire is detected. An “OPEN” type medium

velocity spray system is provided in the conveyor tunnel that will be activated by infrared

detector and solenoid actuated deluge valves. In the substations Electronic rate of rise of

temperature cum fixed temperature type of heat detectors have been provided.

For extinguishing small local fires, portable fire extinguishers are provided at transfer

towers and rail receival station.

There are plant hydrant system for conveyors, transfer towers and rail receival station.

These hydrants are fed from a common header for process water, dust suppression and fire

fighting. From these hydrant valves the water is directed to the fire through hose & nozzle.

3.13.4 Environmental Protection Measures:

To prevent pollution to Marine Environment & leakage to ground water, precautions have

been taken. Stockyards have been constructed with longitudinal & transverse gradients to

enable easy drainage of water to two settling ponds. The water from the settling ponds over-

flows to the process water pond situated in between the settling ponds for ready discharge.

An impermeable foundation material like LDPE (Low density Polyethylene) liner has been

laid under the stockyards, stackers, & reclaimers berms & slopes & bed of the settling &

process water ponds to prevent contamination of ground water. Dust control is achieved by

water spray system at both sides of the stockyard & water sprinkling at all the transfer

towers including rail receival stations & by provision of enclosed structures at all transfer

towers & covered conveyors wherever possible.

A green belt has been developed by the Port for the coal handling plant. The area around the

stockyard, near the buildings & adjacent to security wall are getting landscaped with trees &

other plants of natural Indian species. These shall provide a windbreak thereby reducing

wind impact on the coal stockpiles & minimizing air borne dust problems.



Page 114 of 286

4.0 TECHNICAL DETAILS OF EQUIPMENT, MACHINES, AND SYSTEMS

ETC.

4.1 MAIN SYSTEM (SHIPPING & RECEIVING STREAM)

4.1.1 Stacker-1 & Stacker-2

4.1.2 Reclaimer-1 & Reclaimer-2

4.1.3 Shiploader-1 & Shiploader-2

4.1.4 Data sheet of pulleys for machines (Stackers, Reclaimers & Shiploaders)

4.1.5 Conveyor -1 A / 1 B & 2 A / 2 B

4.1.6 Conveyor R3 / R4



4.1.9 Conveyor S3 / S4





4.1.14 Status of Conveyor Belt

4.1.15 Status of Gear Box

4.1.16 Brief Description of Dust Control System

4.1.17 Substations – 1 to 9

4.1.18 Automation System

4.1.19 Rail Receival Station, Arc gate ,Compressor and Ventilation system

4.1.20 Chutes

4.1.21 Track line of Machines

4.1.22 Belt weighing system

4.1.23 Tramp Magnet

4.2 AUXILIARY SYSTEM

4.2.1 Raw water, Sewage water & Effluent water Pump house

4.2.2 Potable water system

4.2.3 DG set

4.2.4 Air conditioning system in MCHP

4.3 HEAVY EQUIPMENT

4.4 ILLUMINATION

4.5 EOT CRANES, ELECTRICAL & MANUAL HOISTS:

4.5.1 Electric Operated Trolley Crane

4.5.2 Manual Hoist

4.6 CATHODIC PROTECTION

4.7 COMMUNICATION FACILITY, I.E. INTERCOM, VHF COMMUNICATION ETC.

4.8 CLEANLINESS / HOUSEKEEPING

4.8.1 Drain Layout & Details

4.8.2 Grass Cutting & Details

4.9 PAINTING AREA OF THE PLANT



Page 115 of 286

4.1 MAIN SYSTEM (SHIPPING & RECEIVING STREAMS)

4.1.1 STACKER-1 & 2:

Name of Manufacture : LARSEN & TOUBRO with JV

STRACHAN& HENSHAW LTD.; U.K.

No. of Equipment : 02 Nos.

The stacker runs on four rails (double track on each side) with the base frame being

supported on three legs with fully compensated bogies. The base frame carries a

combination ball and roller bearing slew ring with external gear ring. The upper half of the

slew ring carries the boom and slew structure. The machine is of rocker type. The

counterweight is located on the tail boom which ensures that the machine remains back

heavy under all conditions of operation ensuring stability. The boom and luff superstructure

are raised and lowered by means of twin double acting hydraulic cylinders. The combined

center of gravity is at all times within the slew ring diameter. The boom carries the stacking

belt conveyor. The operator’s cabin is located on the slew-deck to provide optimum

visibility to the operator. Power is fed to the slewing structure by means of a looped cable

system. Access to all components requiring maintenance and inspection is provided.

Stacker consists of the following main assembly units:-

1. Bogie assembly and Long travel drive units

2. Main Structure

3. Slew deck and Slew drive unit.

4. Boom Assembly

5. Conveyors

6. Boom support and Luff Super Structure

7. Hydraulic system for Luff Operation

8. Tripper Assembly

9. Electric Gantry

10. Chutes & Skirt boards

11. Other Accessories

a) Power and Control cable reeling drum.

b) Manual & Auto Control lubrication system.

c) Belt cleaning system

d) Air Conditioning System

A) MAIN PARAMETERS:

Stacking Capacity (Avg.) : 4000 TPH

Stacking Capacity (Designed) : 4400 TPH

Total M/c weight : 675 MT

Stock Pile Shape : Trapezoidal

Maximum Height : 15 meters.

Length of Stockpile : River side:-1134 meters.

Port side:- 1155 meters.

Track gauge : 12 meters.

Rail Size : 60 kg/m.

Length of the Travel : 1074meters/1086meters

Counter weight : 121MT

No of points of support of main frame: 3

Rope size in Boom Side : 55x38982mm – 02 Nos

Rope size in Tail Side : 95x24161mm – 02 Nos



Page 116 of 286

B) LONG TRAVEL:

Total no of wheel : 72 nos

Two wheel Bogie unit : 34 nos

One wheel bogie unit : 04 nos

No of drive : 30 nos

Wheel model : Double flanged type

Material of the wheel : Cast steel BS: 3100 Gr.BT – 3

Shaft size : 132 mm

Material : Cast steel (BS: 3100 Gr-BT-3)

Travel speed : 3-30 m/min.

Travel wheel bearing type : Taper roller bearing

Bearing no : AJ 6431135

Long travel provided with rail cleaners and storm lock. Motor:-

Make : SEW EURO DRIVE ( GERMANY)

Power : 5.5 KW

Rpm : 1430

Gear box:-

Make : SEW EURO DRIVE

Type : KH97TDVI32S4BMG/HR

Speed ratio : 70.54:1

Gear type : Helical gear

Oil Qty & grade : 18 litres & SERVO MESH SP 220

Oil seal no & Qty : 95x170x13/10mm & 02nos

Shaft size : 132 mm

Brake:-

Type : Inbuilt Electro Magnetic disc brake

C) PCRD:-

Nos. : 01

Make : Electro Zavod

Type : Barrel (Motorized cable reeling)

Size : 2000 x 3000 x 4 mm

Gear box:-

Make : I C BAUER

Type : G52-10-SN


Oil Qty & grade : 3.5 liters & SERVOMESH SP 220 Oil seal No

Input : 50 x 68 x 8

Output : 55 x 80 x 8

Bearing No : 6208 Z:-02, 6311:-01 & NJ306E:-02

D) CCRD:-

Nos. : 01



Size : 1200 x 2300 x 4 mm



Page 117 of 286

Gear box:-

Make : I C BAUER

Type : G22-10-SN


Oil Qty & grade : 0.9 Liters & SERVOMESH SP 220

Oil seal No

Input : 35x62x7, 38x55x7

Output : 42x62x8

Bearing No : 6206 – 02 Nos

: 6306 – 01 No

E) SLEWING:-

Slewing speed : n= 3-30 mtrs./min.

Slewing angle : +/-115

Slew bearing:-

Make : SKF-RKS SA

Type : Antifriction with external gear

Dia. Of Slew bearing ID : 4370

OD : 7500

Slew drive:-

No of drive unit : 03 nos (VVVF Type speed control)

Drive : Electro Mechanical drive

Motor:-

Make : NGEF

Frame : 180L

Power : 11 KW

Rpm : 1485

Coupling:-

Make : Flender – Bocholt AG

Type : Slip clutch type

Model : KPPLG–N-EUPEX

D200–ALMAR62RR Gr. 5

Type of control : Slipping clutch type (3 Nos)

Brake:-

Brake lever

Make : Bubenzer (Germany)

Model : Disc Brake

Type : SB 14.11.400.23/5

Brake torque : 50 – 300 Max

Thrust Brake motor:-

Type : BB 25/5 S

Force : 250N

IP : 65

Voltage : 415V



Page 118 of 286

Gear box:- Type : Vertical Planetary gears

No. of Drive units : 03

Make : Flender-Bocholt AG

Model : P 3KL 16

Ratio : 1092.871:1

Type of lubrication : Immersed

Oil qty & grade : 65 Liters & SERVO MESH SP 320

Oil seal No

Input : 40 x 52 x 7

Output : 340 x 380 x 20

Bearing Number:-

Rolling contact Bearing : 22308 E/C3 - 01 No.

Rolling contact Bearing : WAELZL 33209 - 01 No.

Rolling contact Bearing : WAELZL 33210 - 02 Nos

Rolling contact Bearing : WAELZL 33210 B - 01 No.

Rolling contact Bearing : WAELZL 32309 B - 02 Nos

Rolling contact Bearing : WAELZL 183018 SL C3 - 01 No.

Rolling contact Bearing : WAELZL 181848 SL - 01 No.


Rolling contact Bearing : WAELZL 22312 E/C3 - 01 No.

F) LUFFING :-

Hydraulic luff cylinder:-

No. of cylinder : 02 No.

Luffing angle : +10.25 up & -2.75 down

Make : VICKERS system international ltd.

Oil Qty & grade : 200 litres & SERVO SYSTEM 68

Size of the cylinder : 160 x 280 X 1105mm

Piston Dia. : 280 mm

Piston rod Dia. : 160 mm

Stroke length : 1105 mm

Power pack unit:-

Motor:-

Make : CROMPTON GREAVES

Motor power : 22KW

Rpm : 1475

Frame size : 180 M

Pump:-

Make : VICKERS system international ltd.

Model : PVH57Q1C-RSF-IS-10-C-25V-31

Type : Axial Piston

Working pressure : 34 lpm (210 bar)



Page 119 of 286

G) BOOM CONVEYOR ARRANGEMENTS:

Motor:-

Name : CROMPTON GREAVES

Type : 3 Squirrel cage induction motor

Power : 150 KW

RPM : 1485 rpm

Volt : 415V

Frame : 315 L

Fluid coupling:-

Make : VOITH

Model : 487-TVVV-YR

Type : DELAYED FILL

Installed Qty : 02 Nos.

Oil Qty & Grade : 18 LITERS & HLPB 32

Fluid coupling bearing : 6214 – 02 Nos.

Gear box:-

Make : FLENDER

Type : KEN 280


Oil Qty & Grade : 46 liters & Servo System 460

Installed Qty : 02Nos

Type of Gear : Bevel/Helical

Bearing Number of the gear box:

Input shaft : 31315(13A) – 02 Nos.

Input shaft : 23NU16EC – 01 No.

Intermediate : 32217A – 02 Nos.

Output Shaft : RSL/SL18 3028 A – 02 Nos.

Gear box seal No:-

Input oil seal : 85X110X12/10

Output oil seal : 140X170X12

Spigot rigid coupling:-

Drive side coupling : 130 x 470 x 205

Driven side coupling : 195 x 470 x 250

No. of Bolts : 16Nos.

Hexagonal head plug : ¼” BSP

Heating Temp for drive side coupling : 230˚C – 250 ˚C

Heating Temp for driven side coupling : 200˚C – 220 ˚C



Page 120 of 286

Pulleys:-

Pulley Name Drum

(in

mm)

Bearing

Dia

(in mm)

Shaft

length

(in mm)

Brg.

C-C

(in mm)

Bearing

Housing

Brg.

No.

Sleeve Locking

Assy.

Torque

In Nm

Drive

800 200 3550 2576 SDD

3144

23144/

CCK/

W33

OH3144H RFN 7012

240 X 305

295

Tail 800 240 2500 THDD

3152

23152

CCK/

W33

OH3152H RFN 7012

320 X 405

295

Lagging

16mm Thickness with diamond groove lagging for Drive pulley

12mm Thickness with plain lagging for Non Drive pulley

Belt :-

Boom Length : 58.15 mtrs.

Belt speed : 4.9 mtr/sec

Counter Weight : 121 MT

Take up type & travel length : Sliding with hydraulic jack & 500mm

Width : 1800 mm

Type & strength : Steel cord -ST 800/900 Grade M

Belt cleaners:-

Primary Cleaner : 1set, Thejo /Martin Make

Secondary Cleaner : 1set, Thejo /Martin Make

Return Belt Cleaner : 1 set, Fabricated “V” Scrapper.

Idlers:-

No of troughing idlers : 128 nos.

Size of the idlers : 35 X 152.4 X 670mm

Bearing no : 6307

No of transition idlers : 07 nos


Bearing no : 6307

No of impact idlers : 33 nos

Size of the idlers : 35 X 190 X 670mm

Bearing no : 6307

No of Return idlers : 24 nos


Bearing no : 6306

No of Flat idlers : 02 nos


Bearing no : 6306



Page 121 of 286

Idler’s frame:-

No of troughing idler frame : 34 nos

No of transition idler frames : 07 nos

No of impact idler frames : 11 nos

No of troughing self alignment frames: 04 nos

No of return idler frames : 10 nos

No of return self alignment frames : 02 nos

H) TRIPPER CAR:

Pulleys:-

Pulley

Name

Drum

(in

mm)

Bearing

Dia (in

mm)

Shaft

length

(in mm)

Brg.

C-C

(in mm)

Bearing

Housing

Brg.

No.

Sleeve Locking

Assy.

Torque

In Nm

Drive

800 200 3550 2576 SDD

3144

23144 /

CCK /

W33

OH3144H RFN 7012

240X 305

295

Tail 800 240 2500 THDD

3152

23152

CCK/

W33

OH3152H RFN 7012

320X 405

295

Idlers:-

No of troughing idlers : 125 nos


Bearing no : 6307



Bearing no : 6307



Bearing no : 6306

No of Flat idlers : 01 no


Bearing no : 6306

Idler’s frame :-

No of troughing idler frames : 34 nos





Belt cleaners:-

Primary Cleaner : 1set, Thejo/ Martin Make

Secondary Cleaner : 1set, Thejo/ Martin Make



Page 122 of 286

I) ELECTRICAL SYSTEM:

The machine is fed from a land mounted 6.6KV Junction Box located at midpoint of

travel through 6.6 KV flexible trailing cable and onboard barrel type CRD for reeling and

unreeling of the trailing cable while the machine is traveling. The CRD feeds 6.6 KV

Power to on machine 6.6KV load break switch located inside the onboard E house and in

turn to the Oil immersed type (ONAN) transformer with Class F insulation. The transformer

is located outside the E house but provided with suitable enclosure with proper ventilations.

The transformer steps down the 6.6 K.V. power to 433V +/- 5% and the L.T. power is fed to

the MCC located inside the electric house. Total installed Power is 527 KW(Approx.)

1. All the motors required for running of the machine as well as allied auxiliary is fed from

MCC through a combination of Armored and flexible cables.

2. Voltage and power supply conditions:

Low voltage supply

Voltage (V) : 433V ± 5%

Frequency : 50 Hz ± 4%

Phases : 3

Neutral : Earthed through earth shoe on

both side rails.

Auxiliary voltages : 230 +/- 10%

Control (V) : 230 V, 48V DC

Lighting (V) : 230 V

Solenoid valves (V) : 48V DC

Electronic equipment (V) : 48V DC (PLC)

Control voltages : 48V DC

Digital I/O(V) : 48V DC

Signal lamp (V)/Field devices : 48V DC

3. Degree of protection:

All outdoor panels : IP 65

All indoor panels : IP 54

All field devices : IP 65

All Motors : IP 65

4. Operation of the machine is achieved by a PLC system having a Central processing Unit

located inside the electric house and a remote I/O panel located inside the operator’s

cabin connected by a RIO Link cable for communication.

5. The machine is controlled by an operator control desk having joysticks and push buttons

and HMI.

6. Hardware signal exchange between the stacker machine and the Central Control room of

the Plant is achieved through a control trailing cable and control CRD to the land

mounted control Junction Box.

7. Operational and safety limits of the drives and their motions are cut off by a no. of limit

switches, proximity switches located strategically all over the machine.

8. Long travel and slew drives of the machine are controlled through variable voltage

variable frequency (VVVF) converters located inside the Electric house for wide range

of speed control.

9. Travel position, slew position, luffing position of machine is detected through HMI and

Plant monitoring room.

10. Communication within the machine and with Central control station is achieved via

wireless system.



Page 123 of 286

11. HT Isolator details:

Installed Qty. : 1 No.

Make : A. Bond Strands (P) Ltd.

Year of Manufacture : 1999

Type : TKL3

Un : 12 KV

Ith : 31.5 KA

In : 630 A

12. MCC Panel (Non drawn out type) of Stacker-1 & 2

Sl.

No.

Description Type of switch

gear

Type of

Starter

Type of overload

protection

1 Incomer ACB - With shunt trip,O/L and

E/F module

2 Conveyor SFU DOL With Microprocessor

based Motor protection

relay

3 Boom Luffing SFU DOL Bi-metallic thermal type

overload relay with single

phasing preventor.

4 Long Travel MCCB VVVF

Control

Bi-metallic thermal type


phasing preventor.

5 Slewing MCCB VVVF

Control

Bi-metallic thermal type


phasing preventor.

6 Other drives like,

Centralized

lubrication system etc.

SFU DOL Bi-metallic thermal type


phasing preventor

7 Lighting transformer SFU

8 Welding sockets SFU

9 Control transformer MCCB

(Incoming &

outgoing)

J) Manual Lubrication system has been provided for bogie assemblies.

Auto lubrication system has been provided for slewing system.

4.1.2 RECLAIMER-1 & 2:

Make : LARSEN & TOUBRO with JV

STRACHAN & HENSHAW Ltd.; U.K.

No. of equipment : 02 Nos.

The Reclaimer runs on four rails (double track on each side) with the base frame

being supported at three points through equalizing beam and fully compensated bogies. The

base frame carries a live roller slew bearing with internal gear ring. The upper half of the

slew ring carries the boom and slew structure. The counterweight is connected to the tail

boom, so that the stability of machine is maintained under all conditions of operation. The

boom and luff superstructure are raised and lowered by means of twin double acting



Page 124 of 286

hydraulic cylinders. The combined center of gravity is at all times within the slew ring

diameter. The boom carries a bucket wheel assembly along drive, chutes, etc at the extreme

end of the boom. The reclaimed material from the bucket wheel is fed to a boom conveyor

which in turn feeds to yard conveyor via feeder conveyor. The operator’s cabin located on

the boom provides the optimum visibility for the operator. Power to the slewing structure is

fed through a cable drag chain arrangement. Access to all components requiring

maintenance and inspection is provided.

Reclaimers consists of the following main assembly units

1. Bogie assemblies and Long travel drive units

2. Main Structure

3. Slew deck and Slew drive unit.

4. Boom Assembly

5. Conveyors

6. Boom support and Luff Super Structure

7. Hydraulic system for Luff Operation

8. Surge hopper and belt feeder

9. Chutes & Skirt boards

10. Electric Gantry

11. Cable drag chain with housing

12. Other Accessories

a) Power and Control cable reeling drum

b) Manual & Auto Control lubrication system.

c) Belt cleaning system

d) Operator cabin hydraulic system

e) Air Conditioning System

f) Hanging frame, etc

A) MAIN PARAMETERS:

Reclaiming Capacity (Avg. ) : 4000 TPH

Reclaiming Capacity (Designed) : 5000 TPH

Total M/c weight : 935 MT

Stock Pile Shape : Trapezoidal

Maximum Height : 15 meters.

Length of Stockpile(meters) : 1134-SP#1/1155-SP#2.

Track Gauge : 14meters.

Rail Size : 60 kg/m.

Reclaimer bund length : 1152meters.

Counter weight : 200MT

No of points of support of main frame: 3

Rope size in Boom Side : Ø80x49750mm – 04 Nos

Rope size in Tail Side : Ø90x32552mm – 04 Nos

B) LONG TRAVEL:

Total no of wheel : 98 nos

Two wheel Bogie unit : 48 nos

One wheel bogie unit : 02 nos

No of drive : 48 nos

No of driven : 50 nos

Wheel model : Double flanged type

Material of the wheel : Cast steel BS: 3100 Gr.BT - 3

Travel speed : 3-30 m/min

Travel wheel bearing type : Taper roller bearing

Bearing no : AJ 6431135



Page 125 of 286

Motor:-

Make : SEW EURO DRIVE, GERMANY

Power : 5.5 KW

Rpm : 1430

Gear box:-

Make : SEW EURO DRIVE

Type : KH97TDVI32S4BMG/HR


Gear type : Helical gear

Oil Qty & grade : 18 litres & SERVO MESH SP 220

Oil seal no & Qty : 95 x 170 x 13/10mm & 02 Nos

Shaft size : 132 mm

Brake:-

Type : Inbuilt Electro Magnetic disc brake

C) PCRD:

Nos. : 01



Size : 2000 x 3000 x 4 mm

Gear box:-

Make : I C BAUER

Type : G52-10-SN


Oil grade : SERVOMESH SP 220

Qty. : 3.5 Liters

Oil seal No

Input : 50x68x8-01no

Output : 68x90x8-01no

Bearing No : 6208 Z-02nos

: 6311-01no

: NJ306E-02nos

D) CCRD :

Nos. : 01



Size : 1200 x 2300 x 4 mm

Gear box:-

Make : I C BAUER

Type : G22-10-SN


Oil Qty & grade : 0.9 Liters & SERVOMESH SP 220

Oil seal No

Input : 35x62x7, 38x55x7

Output : 42x62x8

Bearing No : 6206 – 02 Nos

: 6306 – 01 No



Page 126 of 286

E) SLEWING:-

Slewing speed : 3-30 m/min

Slew angle : +165 to -161

Dia of slew bearing : 8750 PCD of slew ring/7500 of slew

gear live roller type

Type of bearing : Roller bearing

No of rack segment : 15

Size of rack segment bolt & Qty : M33X150, 30nos

Size of rack segment bolt & Qty : M30X150, 90nos

No of reaction rails : 15

Size of rails fixing bolt & Qty : M24x120, 120nos

No of reaction roller : 04 Nos

Drag chain:- Length of PCRD Drag chain : 5 Meters

No. of bottom & side rollers : 30 & 30 respectively

Length of CCRD Drag chain : 5 Meters

No. of bottom & side rollers : 30 & 30 respectively

Slew Drive:-

No of drive unit : 03 nos (VVVF Type speed control)

Drive : Electro Mechanical drive

Motor:-

Make : NGEF

Frame : 180L

Power : 22KW

Rpm : 1485

Coupling:-

Make : Flender – Bocholt AG

Type : Slip clutch type

Model : KPPLG – N- EUPEX D 200 –

ALMAR 62 RR Gr.5

Type of control : Slipping clutch type No.3

Brake:-

Brake lever:

Make : Bubenzer (Germany)

Model : Disc Brake

Type : SB 14.11.400.23/5

Brake torque : 50 – 300 Max


Type : BB 25/5 S

Force : 250N

IP : 65

Voltage : 415V

Gear box:-

Make : Flender D – 46393 Bocholt AG

Type : Vertical planetary gear

Model : P 3KL 17




Page 127 of 286

Gear type : Bevel/Helical

Input KW Rating : 22

Oil Qty & grade : 80 liters &Servo mesh SP 320

Input oil seal : 40x52x7

Output Oil seal no : 340x380x20

Bearing Number:-

Rolling contact Bearing : 22308E/C3 - 01 No.





Rolling contact Bearing : WAELZL 183020 SL C3 - 01 No.



Rolling contact Bearing : WAELZL 22312 E/C3 - 01 No.

Gear Material : 42 Cr Mo 4V

Pinion Material : 17 Cr Ni Mo 6 (Case Hardened)

F) LUFFING:

Hydraulic luff Cylinder:-

No of cylinder : 02 nos

Make : Vickers system International Ltd

Size of the cylinder : 180 x 360 X 2265mm

Piston Dia. : 360 mm

Piston rod Dia. : 180 mm

Stroke length : 2265 mm

Oil Qty & grade : 800 liters & Servo system 68

Maximum pressure : 285 Kg/cm2

Power pack unit:-

Motor:

Make : Siemens

Motor power : 45 KW

Rpm : 1500

Frame size : 225 M

Pump:

Make : VICKERS System International Ltd.

Pump type : Axial piston

Model No : PVH98QIC-RSF –1S –10–C25V-31

Capacity : 115 LPM

Pressure : 175 bar

1. Working pressure: 190kg/cm2

2. Test pressure: 285kg/cm2 (by isolated pump with ext)

3. Use seamless pipe conforming to DIN 2391/C up to ǿ38mmOD



Page 128 of 286

G) BELT FEEDER:

Motor:-

Name : NGEF

Type : 3 Ǿ Squirrel cage induction motor

Power : 90 KW

RPM : 1485 rpm

Volt : 415V

Bush coupling:-

Model : Bush coupling

Bolt size : M16x75 with bush

No of Bolts : 09 Bolts

Gear box:-

Type &Make : KCN 400, ELECON

Speed ratio : 80:1

Oil Qty : 180 liters

Oil Grade : Servo Mesh SP320

Installed Qty : 01 No


Bearing Number of the gear box:-

Input shaft : 31315 – 02 Nos(Taper roller),

22315 – 01Nos(Spherical roller)

Intermediate : 32319 – 02Nos(Spherical roller),

22326–02Nos (Spherical roller)

Output Shaft : 32038 – 02 Nos(Taper roller)

Gear box seal no:-

Input oil seal : 90 X 110 X 12/10 mm

Output oil seal : 210 X 240 X 15 mm

Rigid coupling:-



No. of Bolts : 16nos

Hex Head plug : 1/4”BSP

Heating Temp for drive side coupling : 230˚C – 250 ˚C

Heating Temp for driven side coupling : 200˚C – 220 ˚C

Pulleys:-

Pulley

Name

Drum

(in

mm)

Bearing

Dia

(in mm)

Shaft

length

(in mm)

Brg.

C-C

(in mm)

Bearing

Housing

Brg.

No.

Sleeve Locking

Assy. RFN

7012

Torque

In Nm

Drive

800 220 3397 2800 SDD

3148 23148

CCK/

W33

OH 3148

H

300 X 275 190

Tail 500 180 2990 2800 THDD

3140

23140

CCK/

W33

OH 3140

H

220 X 285 190

Lagging:-





Page 129 of 286

Belt:-

Width : 2200mm

Strength : Fabric EP 800/5 Grade M

Speed : variable speed (0.2 to 0.7 m/sec)

Idlers:-

Frame Type : Retractable

Idler frames : 11 Nos.

Size of Impact idler : 40x 190 x 300 mm

Installed qty of impact idlers : 22Nos

Impact idler : 40 x 190 x 1800 mm


Flat idler : Ø 30 X Ø152.4 X 2400

Installed qty of impact idler : 01Nos

Hanging frame : 08 Nos

Size of Impact idler : 35 x 190 x 670 mm


Belt cleaners:-



H) BOOM CONVEYOR ARRANGEMENTS:

Motor:-

Name : Siemens


Power : 200 KW

RPM : 1485 rpm

Volt : 415V

Frame : 315 L

Fluid coupling:-

Make : VOITH

Model : 1487-TVV-YR

Type : DELAYED FILL

Installed Qty : 02 Nos

Oil Qty : 18 LITERS

Oil Grade : HLPB 32

Bearing number : 6214 (FAG/SKF)

Gear box:-

Make : FLENDER

Type : KEN 280


Oil Qty : 46 liters

Oil Grade : Servo System 460





Page 130 of 286

Bearing Number of the gear box:-

Input shaft : 31315(13 A) – 02 Nos

Input shaft : 23 NU 16 EC – 01 No

Intermediate : 32217A – 02 Nos

Output Shaft : RSL/SL18 3028 A – 02 Nos

Gear box seal no:-

Input oil seal : 85X110X12/10

Output oil seal : 140X170X12

Rigid coupling:-



Hex Head bolt : M 36 X 285 long

No of Bolts : 16 Nos

Hex Head plug : 1/4”BSP

Heating Temp for drive side coupling: 230˚C – 250 ˚C

Heating Temp for driven side coupling: 200˚C – 220 ˚C

Pulleys:-

Pulley

Name

Drum

(in

mm)

Bearing

Dia

(in mm)

Shaft

length

(in mm)

Brg.

C-C

(in

mm)

Bearing

Housing

Brg.

No.

Sleeve Locking

Assy.

Torque

In Nm

Drive

800 200 3550 2600 THDD

3144

23144/

CCK/W3

3

OH

3144H

RFN

7012

240 X

305

295

Tail 900 180 2780 2580 SDD314

0

23140

CCK/W3

3

OH

3140

H

RFN

7012

240 X

305

295

Lagging:



Belt :-

Width : 1800 mm

Strength : ST 800/900 Grade M Steel cord

Speed : 4.9m/sec

Boom length : 60meter

Belt thickness : 16mm

Take up type : Sliding with hydraulic jack

Take up travel : 500mm

Idlers:-

Transition Idler : Ø 35 X Ø152.4 X900

Troughing idler : Ø 35 X Ø152.4 X670

Impact idler : Ø 35 X Ø190 X 670

Return idlers : Ø 30 X Ø152.4 X1000

Flat idler : Ø 30 X Ø152.4 X2000



Page 131 of 286

Installed qty of idlers:-

Troughing idler : 133nos.

Transition Idler : 05 nos.

Impact idler : 24nos

Return idlers : 26nos.

Flat idler : 07nos. Idler’s frame details:-






No of impact frames : 08 nos

Belt cleaners:-




I) BUCKET WHEEL DRIVE:

Motor:

Name : Siemens


Power : 200 KW

RPM : 1492 rpm

Volt : 415V

Fluid coupling:-

Type : Delayed fill

Make : VOITH

Model : 1562 TV-R

Oil type : SERVO PRIME 46

Quantity : 17.5 Liters

Bearing number : 6219 FAG/SKF

Thruster brake:

Make : Bubenzar Bremsen

Model : EBN 400-80/6

Type : Electro Hydraulic Thruster operated

Rated Torque : 118 kg

Brake type : Drum

Size of the drum : 400X150mm

Gear box:-

Make : FLENDER

Model : P2 KA-25

Type : Bevel helical planetary gear.

Input Seal No. : 125 x 100 x 12

Output seal No : 540 x 500 x 20

Ratio : 292.983:1

Type of Lubrication : Forced

Oil type : SERVOMESH SP 320

Quantity : 220 Liters Total weight without oil:-

Torque arm : 952 Kg(Approx)

Swing : 650 Kg (Approx)

Gear box : 6150 Kg (Approx)

Total weight : 7752 Kg (Approx)



Page 132 of 286

Bucket:-

Diameter Of Wheel : 9.2 meters

RPM : 4.84

Plummer block : CSDD 3176

Bearing number : 23176

Make : MS Body with Alloy steel Lip

Numbers : 10 Nos

Capacity : 2150 Liters

Dimension (Each) : 1571 x 1466 x 1640mm

Weight (Each) : 650 kg

J) ELECTRICAL SYSTEM:

The machine is fed from a land mounted 6.6KV Junction Box located at midpoint of

travel through 6.6 KV flexible trailing cable and onboard barrel type CRD for reeling and






the MCC located inside the electric house. Total Installed Power is 996KW (Approx.).




Low voltage supply

Voltage (V) : 433V

Voltage fluctuations % : ± 5%

Frequency : 50 Hz

Frequency fluctuations : ± 4%

Phases : 3

Neutral : Earthed through earth shoe on

both side rails.





Electronic equipment (V) : 48V DC(PLC)








All Motors : IP 65

4. Operation of the machine is achieved by a PLC system having a Central

processing Unit located inside the electric house and a remote I/O panel located inside

the operator’s cabin connected by a RIO Link cable for communication.


and HMI.



Page 133 of 286

6. Hardware signal exchange between the reclaimer machine and the Central Control room

of the Plant is achieved through a control trailing cable and control CRD to the land

mounted control Junction Box.




variable frequency ( VVVF) converters located inside the Electric house for wide range

of speed control.

9. Travel position, slew position, luffing position of machine are detected through HMI

and Plant monitoring room.


wireless system.

11. HT isolator details:


Type : TKL3

Un : 12 KV

Ith : 31.5 KA

In : 630 A


Year of Manufacture : 1999

12. MCC Panel (Non drawn out type) of Reclaimer-1 & 2

Sl.

No.

Description Type of

switch gear

Type of

Starter

Type of overload protection

1 Incomer ACB - With shunt trip,O/L and E/F module

2 Conveyor MCCB DOL With Microprocessor based Motor

protection relay

3 Boom Luffing SFU DOL Bi-metallic thermal type overload

relay with single phasing preventor.

4 Bucket Wheel MCCB DOL With Microprocessor based Motor

protection relay


Control

Bi-metallic thermal type overload


6 Slewing MCCB VVVF

Control



7 Belt feeder MCCB VVVF

Control




Centralized

lubrication system

etc.

SFU DOL Bi-metallic thermal type overload

relay with single phasing preventor

9 Lighting

transformer

SFU


11 Control transformer MCCB

(Incoming

and outgoing)



Page 134 of 286

K) Manual Lubrication system has been provided for bogie assemblies.

Auto lubrication system has been provided for slewing system and bucket wheel system.

4.1.3 SHIP LOADER-1 & 2:

Name of the Manufacture : KRUPP FORDERTECHNIK

No. of Equipment : 02 Nos.

Ship-loader consists of the following main assembly units

1. Travel gear

2. Portal

3. Slewing gear

4. Hoisting gear

5. Boom

6. Shuttle head

7. Belt conveyor on the boom and in the shuttle head

8. Loading chute

9. Tripper car

10. Accessories

a) Power and Control cable reeling drum

b) Automatic central lubrication system.

c) Electrical Hoist units

d) Wash down and fire fighting system

e) Belt cleaning system

f) Operator cabin hydraulic system

g) Air Conditioning System

A) MAIN PARAMETERS:

Capacity : 4000 TPH

Type of vessels Handled : 30,000 MT to 90,000 MT

Total Machine Weight : 735 MT

Total Installed Power : 605 KW

B) LONG TRAVEL:

Track gauge : 12 meters

Travel Speed : 4.5 to 30Mtr/minute

No of Wheels in Sea Side : 17nos

No of Wheels in land Side : 23

Total No. of Wheels : 40

No of Drive Wheel : 22

No of Driven Wheel : 18

Size of the Wheel : 630mm

No. of Rail Clamp : 01(EACH SIDE)

No. of Motor : 22

No. of Gear Box : 22

No. of Thrust Brake Motor : 22

No. of Track Cleaner : 22

Rail cleaners : 8



Page 135 of 286

LT motor:-

Type & MAKE : 200L & CROMPTON GREAVES

Power : 11KW

Rpm : 975

Voltage : 415V

Efficiency : 88%

Brake:-

Brake type : Drum

Lever make : Sigerland bremsen

Type : SB 200/220 with Eldro Ed 23/5

Thrust Brake Motor:-

Make : Emg-eltma D39387 Oschersleben

EB : 220-50/3 SII

Power : 0.16KW

IP : 66

Bj : 99

Voltage : 415V

Hub : 50mm

Stellkraft : 220N

S1 and S3 bis : 2000 C/h

Weight of the motor : 9.6kg

Gear box:

Make : Getribebau Nord

Type : Bevel wheel gearbox

SK 9062AZSH-DWIII

Ratio : 55.42

Rail clamps:-

Runner wheel for rail clamp : 02(each side)

No of hydraulic rail clamp : 02

Holding power : 300KN

Holding power pack:-

Motor:

Power : 1.5KW

Pump : 6 LPM

Pressure : 100BAR

Type : 80/45-270

Piston diameter : 80mm

Piston rod : 45mm

Stroke : 270mm

Power Cable Reeling Drum (PCRD):-

Type : BNA 47. IC55 M1448 VS/3T H12

Diameter : 1800/4800mm

Control Cable Reeling Drum (CCRD):-

Type : BNA 47.IC33 M1642/19TCO10+15AG




Page 136 of 286

Hose Reeling Drum (HRD):-

Type : BNA 47. 2C55 M1131 VST 2.5”


C) TRIPPER CAR:

Length of tripper car : 69 meters

No of frame in carrying : 58nos

No of troughing idlers : 174nos

No of impact idler : 01no

No of return idlers using in tripper car: 04nos

Size of troughing idler : 30x165X670mm

Size of impact idler : 35X190X670mm

Size of return idler : 30X152.4X2000mm

Bearing number for 30mm shaft : 6306

Bearing number for 35mm shaft : 6307

Details of belt cleaners:-

Primary Cleaner : 1set, Thejo/ Martin make

Secondary Cleaner : 1set, Thejo/ Martin make

Tripper Car Pulleys:

Discharge pulley : 01 no

Discharge pulley dimension : 1000X2000mm

Bearing housing for discharge pulley : SD3144

Bearing no : 23144 CCK/W33

Bend pulley : 02 nos

Bend pulley dimension : 1000X2000mm

Bearing housing for bend pulley : SD3144

Hold down pulley : 01 no

Dimension of hold pulley : 400X1800mm

D) LUFF HYDRAULIC:-

No of cylinder : 01 no

Type : CYTUMP5/0360/0200/03351D10/D1KLDKWAN

Piston dia : 360mm

Piston Rod : 200mm

Stroke : 3351mm

Maximum Pressure : 250bar

Mass without fluid : 2908 Kg

Oil grade : Servo system 68

Quantity : 250 liters

Inner seal : 360mm

Outer seal : 200mm

Boom angle (Maneuvering position) : +13

Upper working position : 0

Lower working position : -17



Page 137 of 286

E) BOOM CONVEYOR OF SHIP LOADER:

Boom and shuttle conveyor:-

Boom Conveyor speed : 4.4m/Sec

Belt Width : 1800mm

Type of belt : ST 800/900 Grade M Steel Cord

Boom length at the stage of extended : 38 meters

Boom length at the stage of retracted : 26 meters

Axial Distance extended : 45250mm

Axial Distance retracted : 28870mm

No of frames using in carrying : 44 nos


Troughing idler dimension : 30X165X670mm


Impact idler dimension : 35X190X670mm

No of rubber return idlers : 22 nos

Rubber idler dimension : 30X190X2000mm

No of heavy duty idler in return : 01 no

Heavy duty idler dimension : 50X175X2000mm

Flat idler : 01 No.

Flat idler dimension : 30X190X2000mm

Details of belt cleaners:-

Primary Cleaner : 1set, Thejo/ Martin make

Secondary Cleaner : 1set, Thejo/ Martin make

Return Belt Cleaner : 1set, Fabricated “V” Scrapper.

Pulley:-

Drive pulley : 01no

Dimension of drive pulley : 800X2000mm

Bearing housing : SD3138

Bearing No : 23138 CCK/W33

Non Drive pulleys : 01no

Dimension of discharge pulley : 630X2000mm


Bearing No : 23136

Return pulleys : 01nos

Dimension of return pulley : 630X2000mm


Bearing No : 23136

Take up pulley : 01no

Dimension of take up pulley : 630X2000mm

Bearing housing : SPA2236

Bearing No : 22236

Snub pulleys : 03nos

Dimension of drive pulley : 400X2000mm

Bearing housing : SNH528


Deflector pulleys : 01no



Page 138 of 286

Dimension of deflector pulley : 400X2000mm

Bearing housing : SNH528


Screw Take up:-

No of hydraulic cylinder : 02 nos


Piston rod diameter : 70mm

Stroke : 600mm

Motor:-

Make : Crompton greaves

Type : ND 315L

Power : 200KW

Speed : 1490RPM

Fluid coupling:-

Type : TVN 487 with MTS

Oil Grade & Qty : SHELLTEGULA 32&11.3 Liters

Flexible coupling:-

Type : GBT 194 GG-315-118

Brake:-

Type : SBH 315 with eldro ED50/6

Braking moment : set to 700Nm

Gear box:-

Make : Krupp Fordertechnik

Type : Kszg280pu

Combination of gear : Shaft mounted bevel spur wheel gear

Power : 200KW

Input Speed : 1500Rpm

Oil : Servo mesh sp 220

Quantity : 160 liters

Shuttle head:-

Shuttle track Gauge : 3000mm

Travelling speed : 0 to 7.2 m/min

Travel length : 16meter

Runner wheel diameter : 315/630mm

No of 315mm dia wheels : 02

No of 630mm dia wheels : 08

Chain wheels:-

No of chain : 02 nos

Type : Ro4B

Breaking Load : 700KN

Length : 396 links

Drive chain wheel : 02 nos

Pitch circle dia : 497.6mm

No of teeth : 15

Pitch : 103.45mm

Non Drive chain wheel : 02nos



Page 139 of 286


No of teeth : 15

Pitch : 103.45mm

Deflection chain wheel : 04 nos


No of teeth : 11

Pitch : 103.45mm

Chain supporting roller : 48nos

Length : 160mm

Diameter : 108mm

Motor:-


Type : ND 250M

Power : 37.5KW

Speed : 1475Rpm

Flexible coupling:-

Type : GBT 148 GG-250-95

(Additional brake disc dia 250x95)

Brake:-

Design : Drum

No of drums : 02

Brake lever:-

Make : Sigerland Bremsen D-35708 Haiger

Type : TE 250/220

M.Br : 40-325

Reibwert : 0.4

Thrust brake motor:-

Make : EMG ELTMA D 39387 Oschersleben

P : 0.16KW

IP : 66

Bj : 99

Voltage : 415V

Stellkraft : 220N

Hub : 50mm



Gear box:-

Make : Krupp Fordertechnik

Type : K3szg450

Combination of gear : Shaft mounted bevel spur wheel gear

Power : 55KW

I : 315

n1 : 1450Rpm

Oil Qty & grade : 160 litres & Servo mesh sp 220



Page 140 of 286

Loading chute:-

Length of the chute : 8200mm

Diameter of the pipe : 1050mm

Thickness o f the pipe : 13mm

Wear lining : Manganese

F) SLEWING DRIVE UNIT:

Motor : Geared motor

Make : Bauer D73734 Esslingen

Type : BG 60-37/D09LA4-S/Z008 A8

Power : 1.5KW

Speed : 21 to 1400 min-1

Voltage : 415V

Brake : Double disc spring loaded

Type : Z008 A8

Braking moment : set to 12 Nm

Slewing connection : Large diameter antifriction

bearing with external Toothing

Type : 061.25.1145.000.27.1503

Dimension : 1288/1050X68mm

Z : 126

M : 10

Drive pinion for slew connection:-

Z : 14

M : 10

Kicking angle : 20

Hydraulic power pack:-

Motor power : 3 KW

Pump : 12 LPM

Pressure : 175 bar

Hydraulic cylinder detail:-


Piston rod diameter : 110mm

Stroke : 1146 mm

Trimmer spoon:-

Thickness : 50mm

Adjusting angle : -17 to +21

Hydraulic power pack:-

Motor power : 1.5 KW

Pump : 6 LPM

Pressure : 120 bar

Hydraulic cylinder detail:-

Piston dia : 63mm

Piston rod dia : 45mm

Stroke : 750 mm



Page 141 of 286

Central lubrication system:-

Travel gear portal : Automatic lubrication system

SL1 : Land side 36 Points / Water side 24 points

SL2 : Land side 24 Points / Water side 36 points

Type : F2A/B with IMB 14 C90-63 X 0,

0.018 KW, 400V, 50HzX1500min-1

Lubrication Interval : approx 1:20

SLEW GEAR:-

Slewing speed : 0.06 U/min

Max .slew speed : 15m/min (Referred to the boom tip)

Boom slewing angle during operation: -45to 143 (Referred to the tripper car)

Max. Slewing angle (SL1) : +194(In out of operation position referred to

the tripper car)

Max. Slewing angle (SL2) : +180(In out of operation position referred to

the tripper car)

No of drive units : 03 nos

Electric motor:-


Type : ND 160L

Power : 5.5KW

Speed : 970rpm

Flexible coupling

Make : KTR

Type : 48 BSA-200-75X32 with

slewing torque Limitation + over

load hub SI-DK X FT-7542

BRAKE:-

Brake lever:

Make : Sigerland Bremsen D-35708 Haiger

Type : TE 200/220

M.Br : 50-300

Reibwert : 0.4

Kom. Nr : 115572


Make : EMG ELTMA D 39387 Oschersleben

EB : 220-50/2 II

Voltage : 415V

Hub : 50mm

Stellkraft : 220N



Bj : 99

Gear box:-

Type : HK 210 (Angular gear box)

I : 4



Page 142 of 286

Slew Bearing:-

Large diameter antifriction bearing with external toothing

Type : 121.32.4000/100.41.1502

Dimension : 4256 X 3808 x 161mm

Z : 210

M : 20

No of drive pinion for slewing connection: 03

Z : 16

M : 20

G) AUTOMATIC LUBRICATION SYSTEM:

Travel gear : Tripper Car SL1 & SL2 each

side has 14 lubrication points in

water side and land side

Type : F2A/B with IMB 14 C90-63X0,

.018 KW ,400V, 50Hz X 1500min-1

Lubrication Interval : approx 1:20

Lubrication at portal:-

Slewing gear and slew connection SL1 & SL2 lubrication points both at race way (51) and

toothing (3X2).

Fixed leg : 36 lub points

Pendulum leg : 24 lub points

Pump type : F2A/B with IMB 14 C90-63X0,

0.018 KW ,400V, 50HzX1500min-1

H) ELECTRICAL ARRANGEMENTS OF MACHINES

The machine is fed from a land mounted 6.6KV Junction Box located at midpoint

of travel through 6.6 KV flexible trailing cable and onboard barrel type CRD for reeling and






the MCC located inside the electric house.




Low voltage supply

Voltage (V) : 433V

Voltage fluctuations % : ± 5%

Frequency : 50 Hz

Frequency fluctuations : ± 4%

Phases : 3

Neutral : Earthed through earth shoe on both side rails.





Electronic equipment (V) : 48V DC(PLC)






Page 143 of 286





All Motors : IP 65

4. Operation of the machine is achieved by a PLC system having a Central

processing Unit located inside the electric house and a remote I/O panel located inside

the operator’s cabin connected by a RIO Link cable for communication.


and HMI.

6. Hardware signal exchange between the Shiploader machine and the Central Control

room of the Plant is achieved through a control trailing cable and control CRD to the

land mounted control Junction Box.




variable frequency ( VVVF) converters located inside the Electric house for wide range

of speed control.

9. Travel position, slew position, luffing position of machine are detected through HMI

and Plant monitoring room.


wireless system.

11. HT Iisolator details:


Type : TKL3

Un : 6.6 KV

Ith : 31.5 KA

In : 830 A


Year of Manufacture : 1999 12.MCC Panel (Non drawn out type) of Shiploader-1 & 2

Sl.

No.

Description Type of

switch gear

Type of

Starter

Type of overload protection

1 Incomer ACB - With shunt trip,O/L and E/F module

2 Conveyor SFU DOL With Microprocessor based Motor

protection relay

3 Boom Luffing SFU DOL Bi-metallic thermal type overload



Control



6 Slewing MCCB VVVF

Control



7 Shuttle drive MCCB VVVF

Control





Page 144 of 286


Centralized

lubrication system

etc.


relay with single phasing preventer

9 Lighting

transformer

SFU


11 Control transformer SFU

(Incoming &

Outgoing )

12 Chute slew,

trimmer flap, Kick

off


relay with single phasing preventer

4.1.5 CONVEYOR-1A, 1B, 2A & 2B

BELT MOVING DIRECTION

1. DRIVE PULLEY 2.TAIL PULLEY

1. Motor:-

Name : Crompton greaves

Type : 3 Ǿ Squirrel Cage induction motor

Power : 400 KW

RPM : 987 rpm

Volt : 415V

Motor wt : 3600 Kg

Frame : TPC400

2. Gear coupling:-

Make : Elecon

Model : BZWG2240

Type : crowned toothed

3. Gear box:-

Make : Elecon

Type : KCN560


Oil : Servo mesh SP320

Oil Capacity : 370 Liters

Bearing Number:-

Input shaft : 31322 – 02 No’s ( Tapper roller Bearing )

Input shaft : 22322 – 01 No’s ( Spherical roller bearing )

Intermediate : 22326 – 02 No’s ( Spherical roller bearing )

Intermediate output : 22338 – 02 No’s ( Spherical roller bearing )

Output Shaft : 23056 – 02 No’s ( Tapper roller Bearing )

2 1



Page 145 of 286

4. Rigid coupling:-

Drive side coupling

Outer Dia : 825mm

Inner Dia : 250mm

Length : 415mm

Driven side coupling

Outer Dia : 825mm

Inner Dia : 375mm

Length : 515mm

Bolt M 36 X 285mm : 24 Nos

5. Pulleys:-

6. Belt :-

Width : 2400mm

Strength : ST 2000 Grade A Steel cord

Speed : 0.2m/sec to 0.7 m/sec

7. Idlers:-

Frame Type : Retractable

Impact Idler frames : 57 Nos.

Size of Impact idler : 35 x 190 x 380 mm


Frame Type : Transition

Installed qty of transition frame : 01No

Size of transition idler : 30 x 152.4 x 380 mm

Installed qty of transition idlers : 07Nos

Flat idler : Ø 30 X Ø152.4 X2600

Installed qty of Flat idler : 07Nos

8.Belt cleaners:-

Primary Cleaner : 1set, Thejo Martin Make

Secondary Cleaner : 1set, Thejo Martin Make

Return Belt Cleaner : 1set,Fabricated “V” Scrapper

TAKE UP:-

Type : Screw

Pulley

Name

Drum

(in

mm)

Brg.

Dia

(in

mm)

Total

shaft

lg.(in

mm)

Brg.

C-C

(in

mm)

Bearing

Housing

Bearing

number

Sleeve Locking

Assy

RFN

7012

Torque

In Nm

Weight

in Kg

Drive

(D1)

1000 380 4545 3480 SDJD

3180

23180

CAK/C3/

W33

OH

3180 H

520 X

630

1000 11591

Tail

(N1)

1000 260 3664 3200 TDD

3256

23256CA

K/C3/W3

3

OH235

6H

360 X

455

780 6600



Page 146 of 286

2

1

3

4

5 6

4.1.6 R3 & R4 CONVEYOR

BELT MOVING DIRECTION

10 8

12 11

9 7

1. SHUTTLE HEAD PULLEY 2. SHUTTLE RETURN PULLEY 3. SHUTTLE BEND PULLEY 4. HT SNUB PULLEY 5. DRIVE A 6. DRIVE B 7. TAKE UP BEND PULLEY (TOWARDS HEAD END) 8. TAKE UP PULLEY 9. TAKE UP BEND PULLEY (TOWARDS TAIL END) 10. LT BEND AT CENTER 11. DEFLECTOR PULLEY 12. TAIL PULLEY

1. Motor:-



Power : 300 KW

RPM : 1500 rpm

Volt : 6.6 KV

2. Fluid coupling:-

Make : M/s PEMBRIL

Model : SDFC -580

Type : DELAYED FILL

Installed qty : 02 nos

Oil Qty : 38 LITERS in each F/C

Oil Grade : SERVO PRIME 46

Fluid coupling oil seal : 110x140x13mm

Fluid coupling bearing : 6220, 6022 each 01 No

Safety devices : FUSIBLE TRIP 1450 + 5

0

FUSIBLE PLUG 1650 + 5

0

3. Gear box:-

Make : Elecon

Type : KCN400

Inst. Qty of gear box : 02 Nos


Oil Qty & grade : 180 Liters &Servo mesh - SP320




Page 147 of 286

Bearing Number:-

Input shaft : 31315–02 Nos(Tapper roller Bearing )

Input shaft : 22317–01 No.(Spherical roller bearing )

1stIntermediate : 32319 – 02 No.’s (Spherical roller bearing )

2ndIntermediate output : 22326 – 02 Nos (Spherical roller bearing )

Output Shaft : 32038 – 02 Nos (Tapper roller bearing

Gear box seal no:-

Input oil seal : 90x110x12mm– 02 Nos. (5RG/10RG)

Output oil seal : 210x240x15mm– 02 Nos. (5RG/10RG)

4. Rigid coupling:-

Drive side coupling

Outer Dia : 470mm

Inner Dia : 170mm

Length : 235mm

Driven side coupling:

Outer Dia : 470mm

Inner Dia : 195mm

Length : 300mm

Bolt M30X120mm : 16 Nos

5.Pulleys:--

Pulley Name Dru

m (in

mm)

Brg.

Dia

(in

mm)

Total

shaft

lg.(in

mm)

Brg.

C-C

(in

mm)

Bearing

Housing

Brg.

No.

Sleeve Lockin

g Assy

RFN

7012

Torque

In Nm

Wt.

in Kg

SH. HEAD,

SH. RETURN,

SH. BEND&

HT BEND

(N5)

1000 220 3064 2576 SDD

3148

2314

8

OH

3148H

320 X

405

580 4140

Drive A & B

(D2)

1000 200 3235 2576 SDD31

44

2314

4/C3

OH

3144H

280 X

355

405 3700

Take up Bend

(H.E.D) &

(T.E.D), Take

up, Tail (N2)

630 140 2850 2500 SSNHD

532

2223

2/C3

H 3132 220 X

285

295 1660

Deflector 323.

9

75 2400 2300 SN 517 2217

K

H 317 417.3

Lagging:-



6. Belt:-

Width : 1800mm


Speed : 4 m/sec



Page 148 of 286

7. Idler:-


Size of the idlers : 30X152.4X670mm

Bearing no : 6307



Bearing no : 6306


Size of the idlers : 35X190X670mm

Bearing no : 6307

No of Non magnetic idlers : 06 nos


Bearing no : 6307

No of garland idlers : 21 nos


Bearing no : 6306



Bearing no : 6307



Bearing no : 6306

8.Idler’s frames:-


No of transition idler frames : 0 5nos

No of impact idler frames : 13nos

No of troughing self alignment frames: 16nos

No of return idler frames : 57nos

No of return self alignment frames : 06nos

No of garland idler links : 07 nos

9.Belt cleaners:-


Secondary Cleaner : 1set, Thejo / Martin Make


10.Shuttle Head

Quantity : 4 Nos.

Make : L & T

Type : Reversible

Travel length : 12 m

Travel speed : 0.2 m/sec

Drive : Rack & pinion

Pinion detail : 30 teeth, 12 module 20o involute

Rack detail : 12 Module, 20o involute teeth

Motor quantity : 2 Nos. Crompton Greaves make

Motor power : 11 KW



Page 149 of 286

Gear box quantity : 2 Nos. Elecon make

Type : Bevel/ helical, KCN-225/ S

Gear ratio : 90 : 1

Fluid coupling quantity : 2 Nos. Pembril make

Type of fluid coupling : Traction type, 14.5 FCU

No. of brakes : 2 Nos. Kateel make

Type of brake : Disc., KCHF – 700

Wheel dia. : 160 mm

Material of rail : CR- 60

4.1.7 R5 / R6 CONVEYOR

6. DRIVE PULLEY 3. TAKE UP BEND PULLEY (H) 2. TAKE UP PULLEY

4. TAKE UP BEND PULLEY (T) 1. DEFLECTOR PULLEY 5. TAILPULLEY

1. Motor:-



Power : 300 KW

RPM : 1500 rpm

Volt : 6.6 KV

2. Fluid coupling:-

Make : M/s PEMBRIL

Model : SDFC -580

Type : DELAYED FILL


Oil Qty : 38 LITERS

Oil Grade : SERVO PRIME SP 46


Fluid coupling bearing : 6220,6022 each 01 No

Safety devices : FUSIBLE TRIP 145o + 5

0C


0C

1



Page 150 of 286

3. Gear box:-

Make : Elecon

Type : KCN400



Oil Grade : Servo mesh SP320


Capacity : 550Kw


Bearing Number:-

Input shaft : 31315 – 02 No’s (Tapper roller bearing)

Input shaft : 22317 – 01 No. (Spherical roller bearing)

Intermediate : 32319 – 02 No’s. (Spherical roller bearing)

Intermediate output : 22326 – 02 No’s (Spherical roller bearing)

Output Shaft : 32038 –02 No’s (Tapper roller bearing )

Gear Box Seal No.:-

Input oil seal : 90x110x12mm

Output oil seal : 210x240x15mm

4. Rigid coupling:-

Drive side coupling

Outer Dia : 470mm

Inner Dia : 170mm

Length : 235mm


Outer Dia : 470mm

Inner Dia : 195mm

Length : 300mm


5. Pulleys:-

Pulley

Name

Drum

(in

mm)

Brg.

Dia

(in

mm)

Total

shaft

lg.(in

mm)

Brg. C-

C (in

mm)

Bearin

g

Housin

g

Brg.

No.

Sleeve Lockin

g Assy

RFN

7012

Torque

In Nm

Wt. in

Kg

Drive

(D2)

1000 200 3235 2576 SDD31

44

23144/

C3

OH314

4H

280 X

355

405 3700

Take up

Bend

(H.E.D) &

(T.E.D),

Take up,

Tail (N2)

630 140 2850 2500 SSNH

D 532

22232/

C3

H 3132 220 X

285

295 1660

Deflector 323.9 75 2400 2300 SN 517 2217 K H 317 417.3

Lagging:-





Page 151 of 286

6. Belt:-

Width : 1800mm


Speed : 4.0 m/sec

7. Idler:-



Bearing no : 6306

No of transition idlers : 05nos


Bearing no : 6306



Bearing no : 6307



Bearing no : 6306



Bearing no : 6306



No of transition idler frames : 05nos

No of impact idler frames : 44 nos




9.Belt cleaners:-




TAKE UP:-

Type : Vertical

Weight : 8.7MT

4.1.8 R7 / R8 CONVEYOR

6

9

1



Page 152 of 286

10. DRIVE B 11. DRIVE A 4.TAKE UP BOTTOM BEND

2. TAKEUP 3.TAKE UP TOP BEND 6. DEFLECTOR

5. TAIL PULLEY. 9.TRIPPER DISCHARGE 1. TRIPPER BEND

1. Motor:-



Power : 450 KW

RPM : 1500 rpm

Volt : 6.6 KV

2. Fluid coupling:-

Make : M/s PEMBRIL

Model : SDFC -660

Type : DELAYED FILL







0C


0C

3. Gear box:-

Make : Elecon

Type : KCN450


Oil Qty : 220 liters in each G/B



Bearing Number:-

Input shaft : 31322 – 02 No’s ( Tapper roller bearing )

Input shaft : 22322 – 01 No. ( Spherical roller bearing )

1st


2nd


Output Shaft : 23056 – 02 No’s ( Tapper roller bearing )

Gear box seal no:-

Input oil seal : 90x110x12mm(5RG / 10RG)

Output oil seal : 210x240x15mm(5RG / 10RG)

4. Rigid coupling:-

Drive side coupling

Outer Dia : 580mm

Inner Dia : 190mm

Length : 255mm



Page 153 of 286

Driven side coupling:

Outer Dia : 580mm

Inner Dia : 255mm

Length : 340mm

Bolt M30 X 160mm : 22Nos

5. Pulleys:- Pulley

Name

Drum

(in mm)

Brg.

Dia

(in

mm)

Total

shaft

lg.(in

mm)

Brg.

C-C

(in

mm)

Bearin

g

Housin

g

Brg.

No.

Sleeve Lockin

g Assy

RFN

7012

Torque

In Nm

Wt. in

Kg

Drive (D4) 1000 260 3280 2568 SDD

3156

23156

CCK/C

3/W33

OH

3156H

320 X

405

580 4610

Take up

bend ( Top

&Bottom)

N3

630 150 2950 2572 SDD

3134

23134

CCK/C

3/W33

H3134 240 X

305

295 1840

Take up

(N4)

630 160 2866 2470 SDD

3136

23136

CCK/C

3/W33

OH

3180H

240 X

305

295 1855

Deflector 323.9 75 2400 2300 SN 517 2217 K H 317 417.3

Tail(N4) 630 160 2470 2500 SSNH

D 532

22232/

C3

H 3132 220 X

285

295 1660

6. Belts:-

Width : 1800mm

Strength : ST 900 Grade M Steel cord

Speed : 4.0 m/sec

7. Idlers:-



Bearing no : 6306



Bearing no : 6306

No of impact idlers : 33nos


Bearing no : 6307

No of Return idlers : 900nos


Bearing no : 6306

No of Flat idlers : 01nos


Bearing no : 6306


No of troughing idler frames : 795nos

No of transition idler frames : 05nos

No of impact idler frames : 11nos






Page 154 of 286

9.Belt cleaners:-



Return Belt Cleaner : 1set, Fabricated “V” Scrapper

TAKE UP:-

Type : Horizontal

Weight : 17.8MT

No. Of sheave pulley : 10 No’s

4.1.9 S3 & S4 CONVEYOR:

7. SHUTTLE HEAD PULLEY 8. SHUTTLE RETURN PULLEY

9. SHUTTLE BEND PULLEY 12. HT SNUB PULLEY

10. DRIVE A 11. DRIVE B

4. TAKE UP BOTTOM BEND PULLEY 2. TAKE UP PULLEY

3. TAKE UP TOP BEND PULLEY 1. LT BEND AT CENTER

6. DEFLECTOR PULLEY 5. TAIL PULLEY

1. Motor:-



Power : 350 KW

RPM : 1500 rpm

Volt : 6.6 KV

2. Fluid coupling:-

Make : M/s PEMBRIL

Model : SDFC -580

Type : DELAYED FILL


Oil Qty : 38 LITERS





0C


0C

3. Gear box:-

Make : Elecon

Type : KCN400 (EXTENDED SHAFT)

Inst. Qty of gear box : 02 Nos


6



Page 155 of 286

Oil : Servo Mesh SP320

Oil Qty : 180 Liters in each G/B


Bearing Number:-





Output Shaft : 32038 – 02 No’s (Tapper roller bearing)

Gear box seal no:-

Input oil seal : 90 x 110 x 12mm(5RG / 10RG)

Output oil seal : 210 x 240 x 15mm(5RG / 10RG)

4. Rigid coupling:-

Drive side coupling

Outer Dia : 530mm

Inner Dia : 170mm

Length : 237mm


Outer Dia : 530mm

Inner Dia : 235mm

Length : 325mm

Bolt M30x140mm : 20 Nos

5.Pulleys :

Pulley Name Drum

(in mm)

Brg.

Dia

(in

mm)

Total

shaft

lg.(in

mm)

Brg. C-

C (in

mm)

Bearing

Housing

Brg.

No.

Sleeve Locking

Assy

(RFN

7012)

Torque

In Nm

Wt. in

Kg

Sh.Head,

Return,Bend,

HT Bend (N5)

1000 220 3064 2576 SDD

3148

23148 OH

3148H

320X

405

580 4140

Drive (D3) 1000 240 3280 2574 SDD

3152

23152

CCK/C3

OH

3152H

320 X

405

580 4400

Take up Bend

(N3) (Top &

Bottom)

630 150 2950 2572 SSD

3134

23134CC

K/C3/W33

H 3134 240 X

305

295 1840

LT bend at

center ,

Take up (N2)

630 140 2850 2500 SSNHD

532

22232/C3 H 3132 220 X

285

295 1660

Deflector 323.9 75 2400 2300 SN 517 2217 K H 317 417.3

Tail (N4)

630 160 2470 3458 SDD

3136

23136CC

K/C3/W33

H 3132 240 X

305

295 1855

Lagging:-



6. Belt :-

Width : 1800mm


Speed : 4.0 m/sec



Page 156 of 286

7. Idlers:-



Bearing no : 6306



Bearing no : 6306

No of Non magnetic idlers : 06 nos


Bearing no : 6306

No of garland idlers : 21 nos


Bearing no : 6306



Bearing no : 6306



Bearing no : 6306

8.Idler’s frame:-






No of garland idler links : 7 nos

9.Belt cleaners:-


Secondary Cleaner : 1set, Thejo / Martin Make


10.Take up:-

Type : Horizontal

Weight : 15 MT

No. Of sheave pulley : 14 Nos

11.Shuttle Head

Quantity : 4 Nos.

Make : L & T

Type : Reversible

Travel length : 12 m

Travel speed : 0.2 m/sec

Drive : Rack & pinion

Pinion detail : 30 teeth, 12 module 20o involute

Rack detail : 12 Module, 20o involute teeth

Motor quantity : 2 Nos. , Make-Crompton Greaves

Motor power : 11 KW



Page 157 of 286

Gear box quantity : 2 Nos. , Make-Elecon

Type : Bevel/ helical, KCN-225/ S

Gear ratio : 90: 1

Type of Lubrication : Immersed lubrication.

Oil type : Servo Mesh SP-320

Quantity : 40 Litres

Fluid coupling quantity : 2 Nos. , Make-Pembril

Type of fluid coupling : Traction type, 14.5 FCU

Rotation : Unidirectional

Oil type : Servo system 46

Oil Qty : 11 Litres

Oil Degree : 650

Safety devices : Fusible trip 1450±50

Fusible plug 1650 ±50

No. of brakes : 2 Nos. , Make-Kateel

Type of brake : Disc., KCHF – 700

Wheel diameter : 160 mm

Material of rail : CR- 60

4.1.10 S5 / S6 CONVEYOR:

6. DRIVE PULLEY 3. TAKE UP BEND PULLEY (H)

2. TAKE UP PULLEY 4. TAKE UP BEND PULLEY (T)

1. DEFLECTOR PULLEY 5. TAILPULLEY

1. Motor:-


Type : 3 Ǿ Squirrel Cage induction motor

Power : 300 KW

RPM : 1500 rpm

Volt : 6.6 KV

Weight : 3300 Kg

2. Fluid coupling:-

Make : M/s PEMBRIL

Model : SDFC -580

Type : DELAYED FILL

Installed qty : 01 no

Oil Qty : 38 Litres





0C


0C

Oil filling degree : 650

1



Page 158 of 286

3. Gear box:-

Make : Elecon

Type : KCN400



Oil Grade : Servo Mesh SP320


Capacity : 550KW


Bearing Number:-

Input shaft : 31315 – 02 Nos. (Taper roller bearing)

Input shaft : 22317 - 01 No. (Spherical roller bearing)

Intermediate : 32319 – 02 Nos. (Spherical roller bearing)

Intermediate output : 22326 – 02 Nos. (Spherical roller bearing)

Output Shaft : 32038 – 02 Nos. (Taper roller bearing) Gear box seal no:-

Input oil seal : 90x110x12mm (5RG / 10RG)

Output oil seal : 210x240x15mm (5RG / 10RG)

4. Rigid coupling:-

Drive side coupling

Outer Dia : 470mm

Inner Dia : 170mm

Length : 235mm Driven side coupling

Outer Dia : 470mm

Inner Dia : 195mm

Length : 300mm


5. Pulley:- Pulley Name Drum

(in

mm)

Brg.

Dia

(in

mm)

Total

shaft

lg.(in

mm)

Brg.

C-C

(in

mm)

Bearing

Housing

Brg.

No.

Sleeve Locking

Assy

RFN

7012

Tor

que

In

Nm

Wt. in

Kg

Drive (D2)

1000 200 3235 2576 SDD

3144

23144C

CK/C3/

W33

OH

3144H

280X

355

405 3700

Take up

Bend(H.E.D

& T.E.D),

Take up,

Tail (N2)

630 140 2850 2500 SSNHD

532

22232/

C3

H 3132 220 X

285

295 1660

Deflector 323.9 75 2400 2300 SN 517 2217 K H 317 417.3

Lagging:-



6. Belts:-

Width : 1800mm


Speed : 4.0 m/sec



Page 159 of 286

7. Idler :-



Bearing no : 6306



Bearing no : 6306

No of Impact idlers : 132 nos


Bearing no : 6307



Bearing no : 6306



Bearing no : 6306

8. Idler’s frames:-






9.Belt cleaners:-




10.Counter weight:-

TYPE : VERTICAL

WEIGHT : 10 MT

4.1.11 S7 / S8 CONVEYOR:




1. Motor:-



Power : 350 KW

1



Page 160 of 286

RPM : 1500 rpm

Volt : 6.6 KV

Weight : 3400 Kg

2. Fluid coupling:-

Make : M/s PEMBRIL

Model : SDFC -580

Type : DELAYED FILL


Oil Qty : 38 LITERS





0C


0C


3. Gear box:-

Make : Elecon

Type : KCN400 (EXTENDED SHAFT)





Capacity : 550 KW


Bearing Number:-






Gear box seal no:-

Input oil seal : 90x110x12mm (5RG / 10RG)

Output oil seal : 210x240x15mm (5RG / 10RG)

4. Rigid coupling:-

Drive side coupling

Outer Dia : 530mm

Inner Dia : 170mm

Length : 237mm


Outer Dia : 530mm

Inner Dia : 235mm

Length : 325mm

Bolt M30x140mm : 20 Nos



Page 161 of 286

5. Pulley status:-

Pulley

Name

Drum

(in

mm)

Brg.

Dia

(in

mm)

Total

shaft

lg.(in

mm)

Brg.

C-C

(in

mm)

Bearing

Housing

Brg.

No.

Sleeve Lockin

g Assy

RFN

7012

Torque

In Nm

Wt. in

Kg

Drive (D3) 1000 240 3280 2574 SDD

3152

23152

CK/C3

OH

3152H

320 X

405 580 4400

Take up

Bend

(H.E.D) &

(T.E.D),

Take up,

Tail (N2)

630 140 2850 2500 SSNHD

532

22232/

C3

H 3132 220 X

285

295 1660

Deflector 323.9 75 2400 2300 SN 517 2217K H 317 417.3

Lagging:-



6. Belts:-

Width : 1800mm


Speed : 4.0 m/sec

7. Idlers:-



Bearing no : 6306



Bearing no : 6306



Bearing no : 6307



Bearing no : 6306



Bearing no : 6306

8.Idler’s frame details:-



Impact idler frames : 11 nos






Page 162 of 286

9. Belt cleaners:-




10.Counter weight:-

TYPE : VERTICAL

WEIGHT : 10 MT

4.1.12 S9 / S10 CONVEYOR




1. Motor:-


Type : 3 Ǿ Squirrel Cage Induction Motor

Power : 300 KW

RPM : 1500 rpm

Volt : 6.6 KV

Motor wt : 3300 Kg

2. Fluid coupling:-

Make : M/s PEMBRIL

Model : SDFC -580

Type : DELAYED FILL

Installed qty : 01 no

Oil Qty : 38 LITERS





0C


0C


3. Gear box:-

Make : Elecon

Type : KCN400






1



Page 163 of 286

Bearing Number :-






Gear box seal no:-

Input oil seal : 90x110x12mm – 02 Nos. (5RG / 10RG)

Output oil seal : 210x240x15mm – 02 Nos. (5RG / 10RG)

4. Rigid coupling :-

Drive side coupling

Outer Dia : 470mm

Inner Dia : 170mm

Length : 235mm


Outer Dia : 470mm

Inner Dia : 195mm

Length : 300mm


5. Pulleys:-

Pulley Name Drum

(in

mm)

Brg.

Dia

(in

mm)

Total

shaft

lg.(in

mm)

Brg.

C-C

(in

mm)

Bearing

Housing

Brg.

No.

Sleeve Locking

Assy

RFN

7012

Torque

In Nm

Wt.

in Kg

Drive (D2) 1000 200 3235 2576 SDD

3144

23144

CCK/C

3/W33

OH

3144H

280 X

355

405 3700

Take up Bend

(H.E.D &

(T.E.D), Take

up, Tail (N2)

630 140 2850 2500 SSNHD

532

22232/

C3

H 3132 220 X

285

295 1660

Deflector 323.9 75 2400 2300 SN 517 2217 K H 317 417.3

Lagging:-



6. Belt :-

Width : 1800mm


Speed : 4.0 m/sec

7. Idler:-



Bearing no : 6306



Bearing no : 6306



Page 164 of 286



Bearing no : 6307



Bearing no : 6306



Bearing no : 6306

8.Idler’s frame:-







9.Belt cleaners:-




10.COUNTER WEIGHT:-

Type : Vertical

Weight : 10 mt

4.1.13 S13 / S14 CONVEYOR

10. DRIVE A 11. DRIVE B 1. LT SNUB

4. LT BEND AT CENTER 3. TAKE UP BEND 2.TAKE UP

5.TAIL PULLEY 6.TRIPPER DISCHARGE 7.TRIPPER TOP BEND

8.TRIPPER BOTTOM

1. Motor:-


Type : 3 Ǿ Squirrel Cage Induction Motor

Power : 350 KW

RPM : 1500 rpm

Volt : 6.6 KV

Motor wt : 3400 Kg

2. Fluid coupling:-

Make : M/s PEMBRIL

Model : SDFC -660

Type : DELAYED FILL


8

6

7



Page 165 of 286






0C


0C


3. Gear box:-

Make : Elecon

Type : KCN450


Oil Qty : 180 liters in each G/B



Bearing Number of Gear Box:-

Input shaft : 31322 – 02 No’s ( Tapper roller bearing )

Input shaft : 22322 – 01 No. ( Spherical roller bearing )

1stIntermediate : 22326 – 02 No’s ( Spherical roller bearing )

2ndIntermediate output : 22338 – 02 No’s ( Spherical roller bearing )

Output Shaft : 23056 – 02 No’s ( Tapper roller bearing )

Gear box seal no:-

Input oil seal : 100x130x12mm – 02 Nos. (5RG / 10RG)

Output oil seal : 220x250x15mm – 02 Nos. (5RG / 10RG)

4. Rigid coupling:- Drive side coupling

Outer Dia : 530mm

Inner Dia : 190mm

Length : 252mm


Outer Dia : 530mm

Inner Dia : 235mm

Length : 325mm

Bolt M30X140mm : 20Nos

5. Pulleys:-

Pulley Name

Dru

m

(in

mm)

Brg.

Dia

(in

mm)

Total

shaft

lg.(in

mm)

Brg. C-

C (in

mm)

Bearing

Housing

Brg.

No. Sleeve

Lockin

g Assy

RFN

7012

Torqu

e

In Nm

Wt.

in

Kg

Drive(D3) 1000 240 3280 2574 SDD

3152

23152

CK/C3

OH

3152H

320X4

05 580 4400

LT snub (N3) 630 150 2950 2572 SDD

3134

23134

CCK/C

3/W33

H 3134 240X3

05 295 1840

LT bend at

center,Take up

bend,Take up

& Tail (N4)

630 160 2866 2470 SDD

3136 23136

OH

3180H

240X3

05 295 1855



Page 166 of 286

Lagging:-



6. Belt :-

Width : 1800mm


Speed : 4.0 m/sec

7. Idlers:-



Bearing no : 6306



Bearing no : 6306



Bearing no : 6307



Bearing no : 6306



Bearing no : 6306








9.Belt cleaners:-




10.Take up:-

Type : Horizontal

Weight : 22MT

No. Of sheave pulley : 10 Nos

4.1.14 STATUS OF CONVEYOR BELT

Sl.

No. Conveyor

Name ST-800

Gr. M ST-900 Gr.

M ST-2000 Gr.

A EP-800/5 Gr.

M Total Installed Qty.

(in Mtrs.)

1 RR1-(A+B) 50+50 100

2 RR2-(A+B) 50+50 100

5 R3 485 485

6 R4 470 470

7 R5 196 196

8 R6 219 219

9 R7 2767 2767



Page 167 of 286

10 R8 2760 2760

11 S3 2000 622 2622

12 S4 1288.5 1335 2623.5

13 S5 313 313

14 S6 345 345

15 S7 462 462

16 S8 433 433

17 S9 420 420

18 S10 418 418

19 S13 514.5 926 1440.5

20 S14 688 762 1450

21 ST-1 120 120

22 ST-2 120 120

23 RC-1 B/C 127 127

24 RC-2 B/C 127 127

25 RC-(1+2) B/F 12+12 24

27 SL-1 105 105

28 SL-2 105 105

Total: 7874 10254 200 24 18352

Specific Parameters

Sl. No. Conv. No. C to C length, m Lift, m Type of take

up unit No. of Pulleys

1. R3 242.5 25.4 VG 11

2. R4 235.0 25.4 VG 11

3. R5 98.0 7.3 VG 5

4. R6 109.5 7.3 VG 5

5. R7 1383.5 2.65 HG 6

6. R8 1380.0 2.65 HG 6

7. S3 1311.0 4.75 HG 11

8. S4 1311.8 4.75 HG 11

9. S5 156.5 6.0 VG 5

10. S6 172.5 6.0 VG 5

11. S7 231.0 10.0 VG 5

12. S8 216.5 10.0 VG 5

13. S9 210.0 8.0 VG 5

14. S10 209.0 8.0 VG 5

15. S13 720.25 23.0 HG 7

16. S14 725.0 23.0 HG 7



Page 168 of 286

Year Wise Consumption of Conveyor Belt-

Year ST-800 ST-900 ST-2000 ST-630 ST-500 EP-800 TOTAL

2001 – 02

2002 – 03 20 377 397

2003 – 04 252 107 359

2004 – 05 70 54 105 229

2005 – 06 178 348 148 731 12 1417

2006 – 07 588 256 844

2007 – 08 65 27 995 785 12 1884

2008 – 09 50 106 156

2009 – 10 30 49 127 10.5 216.5

2010 – 11 56 250 314.5 620.5

2011 – 12 395 45 51 12.5 503.5

2012 – 13 1080 252 90 81 13 1516

2013 – 14 733 792 50 1575

2014 – 15 2407 3717 50 66 6240

2015 – 16 2747 4978.9 50 36 7811.9

2016 - 17 787.9 830 50 1667.9

TOTAL 9070.9 11129.9 350 2495 2229.5 162 25437.3

Present status of conveyor belts as on dt:01.03.17

Sl. No.

BELT NUMBER GRADE BELT LENGTH DISTANCE REPLACED DATE

1 RR1A

15307 ST-2000 Gr. A 50 05.09.14

TOTAL 50

2 RR1B

102900 ST-2000 Gr. A 50 18.08.11

TOTAL 50

3 RR2A

15328 ST-2000 Gr. A 50 29.08.16

TOTAL 50

4 RR2B

15328 ST-2000 Gr. A 50 07.03.16

TOTAL 50 5 R3

19483 ST-900 Gr. M

250 0 - 250 21.05.16

18290 235 0 - 235 07.05.15

TOTAL 485 6 R4

19484 ST-900 Gr. M

235 15 - 250 24.07.16

18292 235 5 - 240 02.04.15

TOTAL 470 7 R5

19113 ST-800 Gr. M 196 54 - 250 06.05.15

TOTAL 196 R6

16720 ST-800 Gr. M 219 30 - 249 12.04.12

TOTAL 219



Page 169 of 286

8 R7

19488

ST-900 Gr. M

250 0 - 250 03.05.16

19096 95 115 - 250 03.05.16

19101 250 0 - 250 16.07.15

19100 250 0 - 250 16.07.15

18279 250 0 - 250 07.08.14

18287 250 0 - 250 07.08.14

18293 300 0 - 300 06.09.14

18281 250 0 - 250 06.09.14

18282 250 0 - 250 06.09.14

18285 250 0 - 250 09.09.15

19099 250 0 - 250 09.09.15

18286 122 0 - 122 09.09.15

TOTAL 2767 9 R8

4 05 2665

ST-900 Gr. M

250 0 - 250 19.10.05

8456 205 0 - 205 03.05.14

8455 250 0 - 250 03.05.14

8454 85 0 - 85 06.11.10

18277 250 0 - 250 08.06.14

19098 145 105 - 250 13.12.15

19487 250 0 - 250 13.12.15

19486 250 0 - 250 13.12.15

19097 250 0 - 250 13.12.15

15123 75 0 - 75 13.12.15

19485 250 0 - 250 13.12.15

8459 250 0 - 250 30.05.13

8460 250 0 - 250 30.05.13

TOTAL 2760

10 S3

18291

ST-800 / 900 Gr. M

250 0 - 250 20.04.15

19115 250 0 - 250 20.04.15

18274 250 0 - 250 05.10.14

18273 250 0 - 250 05.10.14

18272 250 0 - 250 09.06.14

17897 250 0 - 250 09.06.14

18269 250 0 - 250 09.06.14

18276 250 0 - 250 09.06.14

19094 250 0 - 250 20.04.15

19095 250 0 - 250 20.04.15

18289 122 0 - 122 20.04.15

TOTAL 2622

11 S4

19090 ST-800 / 900 Gr. M

250 0 - 250 03.07.15

19102 250 0 - 250 03.07.15



Page 170 of 286

19103 250 0 - 250 03.07.15

19118 250 0 - 250 04.08.15

19117 250 0 - 250 04.08.15

19116 250 0 - 250 04.08.15

16719 190 0 - 190 13.10.12

19113 53.5 0 - 53.5 24.04.16

8458 85 15 - 100 04.02.12

2558 45 0 - 45 15.09.13

17892 250 0 - 250 15.09.13

19093 250 0 - 250 05.06.15

19114 250 0 - 250 05.06.15

TOTAL 2623.5

12 S5

8453 ST-800 Gr. M

165 0 - 165 08.05.11

8452 148 102-250 08.05.11

TOTAL 313

13 S6

16723 ST-800 Gr. M

295 5 - 300 23.10.12

16719 50 195 - 245 23.10.12

TOTAL 345

14 S7

19111 ST-800 Gr. M

250 0 - 250 03.06.15

19112 212 0 - 122 03.06.15

TOTAL 462

15 S8

17895 ST-800 Gr. M

250 0 - 250 26.07.14

17894 183 67 - 250 26.07.14

TOTAL 433

16 S9

2554

ST-800 Gr. M

100 0 - 100 17.12.14

19112 38 212 - 250 08.04.16

8453 35 175 - 210 21.06.11

16722 247 0 - 247 14.09.13

TOTAL 420

17 S10

19496 ST-800 Gr. M

250 0 - 250 02.04.16

19495 168 0 - 168 02.04.16

TOTAL 418

18 S13

18283

ST-800 / 900 Gr. M

250 0 - 250 18.12.14

18284 250 0 - 250 18.12.14

8449 22.5 227.5 - 250 14.04.16

18270 230 20 - 250 01.05.14

17896 143 0 - 143 01.05.14

17893 50 195 - 245 31.10.13



Page 171 of 286

8461 176 59 - 235 25.06.14

2555 24 0 - 24 03.01.17

8457 250 0 - 250 25.06.14

1959 30 220 - 250 24.07.04

104399 15 180 - 195

TOTAL 1440.5

19 S14

2553

ST-800 / 900 Gr. M

248 0 - 248 02.10.06

18288 230 0 - 230 29.07.14

18280 250 0 - 250 29.07.14

2557 130 120 - 250 19.09.05

8461 32 0 - 32 12.12.14

18278 250 0 - 250 12.12.14

2555 200 50 - 250 17.05.06

2556 110 135 - 245 02.10.06

TOTAL 1450

20 ST#1

19497 ST-800 Gr. M 120 0 - 120 20.08.16

TOTAL 120

21 ST#2

8449 ST-800 Gr. M 120 105 - 225 14.12.10

TOTAL 120

22 RC#1 (B/C)

18286 ST-900 Gr. M 127 123 - 250 16.04.15

TOTAL 127

23 RC#2 (B/C)

19497 ST-800 Gr. M 127 123 - 250 17.03.16

TOTAL 127

24 RC#1 (B/F)

18518 EP-800/5 12 36 - 48 02.07.15

TOTAL 12

25 RC#2 (B/F)

18518 EP-800/5 12 48 - 60 12.09.15

TOTAL 12

26 SL#1

19498 ST-800 Gr. M 105 145 - 250 14.07.16

TOTAL 105

27 SL#2

19092 ST-800 Gr. M 105 0 - 105 13.11.15

TOTAL 105



Page 172 of 286

TECHNICAL SPECIFICATION OF CONVEYOR BELT.

A. ST-800 Gr. M

PARAMETERS SPECIFICATION

1. Belt Dimensions

Belt Width 1800 mm

Belt Thickness 16.4 mm

Top Cover Thickness 8.0 mm

Bottom Cover Thickness 5.0 mm

2. Steel Cords

Number Cords 128 no.

Diameter of Cords 3.4 mm

Cord Pitch 13.8 mm

Cord Construction 7 x 7

3. Cover Plate Rubber

Tensile Strength 25.0 N/mm2

Elongation at Break 500 %

Tensile Strength / at 70°C for 7 days 25 N/mm2

Elongation at Break / at 70°C for 7 days 500 %

Abrasion 125 mm3

4. Adhesion

Top Cover / Bonding rubber 12.0 N/mm

Bottom Cover / Bonding rubber 12.0 N/mm

Cord Pull Out Strength of cord 70 N/mm

After Thermal Treatment 150°C – 150 min. 65 N/mm

5. Troughability (35°) 0.14 Min.

Cord Construction (7 x 7)

STANDARD

Unit mm kN % mm g/m g/m2 g/m2 N / mm %

Minimum 3.30 12.30 - 24.25 43.60 24.60 22.80 90.00 60.00

Maximum 3.50 0.350 25.75 46.40 41.00 38.00

B. ST-900, Gr. M


1. Belt Dimensions

Belt Width 1800 mm




2. Steel Cords



Cord Pitch 15.3 mm








Page 173 of 286


Abrasion 125 mm3

4. Adhesion







STANDARD


Minimum 3.64 14.90 - 26.40 53.20 27.60 23.40 95.00 60.00

Maximum 3.96 0.350 29.60 56.80 46.00 39.00

C. ST-2000, Gr. A


1. Belt Dimensions

Belt Width 2400 mm




2. Steel Cords



Cord Pitch 17.3 mm







Tear Resistance 15.0 M / mm

Hardness 63 Shore A

Abrasion 70 mm3

4. Adhesion





5. Dynamic pull out strength 10000 Cycles



STANDARD


Minimum 6.20 37.90 - 46.00 147.00 28.20 22.80 135.00 60.00

Maximum 6.60 0.350 50.00 157.00 47.00 38.00



Page 174 of 286

D. EP-5, 800, 5.0/5.0, Gr. – M


1. Belt Dimensions

Belt Width 2200 mm



2. Belt Characteristics

Breaking force warp direction 800.0 N/mm

Elongation at break warp direction 10.0 %

Reference elongation (10%FBmin) 4.0 %

3. Adhesion Strength

Top cover to fabric ply 4.50 N/mm

Between fabric ply 5.25 N/mm

Bottom cover to fabric ply 4.50 N/mm

4. Cover Rubber

Tensile strength 24.0 N/mm2

Elongation at break 450.0 %

Tensile strength / at 70°C for 72 hours +10/ -20

Elongation at break / at 70°C for 72 hours +10/ -25

Abrasion 150.0 mm3


4.1.15 STATUS OF GEAR BOX

Machine Gear Box Sl. No. & Last Replacement Date

SL. No. CONVEYOR GEAR

BOX NAME TYPE OF GEAR

BOX SERIAL NO.

LAST REPLACEMENT DATE

1 RR1A KCN- 560 WHG 19553 LH

2 RR1B KCN- 560 WHG 19551 RH

3 RR2A KCN- 560 WHG 19550 LH

4 RR2B KCN- 560 WHG 19552 RH

5 R7A KCN-450 WHG 18411 LH 26.04.12

6 R7B KCN-450 WHG 500068 LH 21.12.07

7 R8A KCN-450 WHG 500069 RH 04.11.16

8 R8B KCN-450 WHG 503853 RH 07.06.14

9 S13A KCN-450 WHG 18386 RH 27.10.09

10 S13B KCN-450 WHG 18374 LH



Page 175 of 286

11 S14A KCN-450 WHG 503834 LH 09.12.16

12 S14 B KCN-450 WHG 18416 RH 21.08.13

13 R3 A KCN 400 WHG18341 RH 29.11.10

14 R3B KCN-400 WHG 26427 RH

15 R4A KCN-400 WHG 19545 LH 24.12.10

16 R4B KCN-400 WHG 18258 LH

( S11 ) 03.07.08

17 R5 KCN-400 WHG 18257 LH 11.01.17

18 R6 KCN-400 WHG 18315 RH 26.08.09

19 S3A KCN-400 WHG 18302 LH EX

20 S3B KCN-400 WHG 18336 RH EX 11.05.12

21 S4A KCN-400 WHG 18274 LH EX 24.01.11

22 S4B KCN-400 WHG 26426 RH 19.01.10

23 S5 KCN-400 WHG 18256 LH 21.12.11

24 S6 KCN-400 WHG 18316 RH 22.02.13

25 S7 KCN 400 WHG19544 RH EX 26.11.10

26 S8 KCN-400 WHG 18276 RH 12.11.15

27 S9 KCN-400 WHG 19546 LH 08.01.16

28 S10 KCN-400 WHG 19543 RH 22.02.13

Machine Gear Box Sl. No. & Last Replacement Date

SL. NO

MACHINE LOCATION TYPE OF

GEAR BOX SERIAL NO.

LAST REPLACEMENT

DATE

1

ST#1

BOOM CONV. ( Drive -1 )

KEN 280 9834.5001.001.5 13.02.17

2 BOOM CONV.

( Drive -2) KEN 280 9834.5001.001.2 07.01.15

3

ST#2


KEN 280 9834.5001.001.5 13.10.16

4 BOOM CONV.

( Drive -2) KEN 280 9834.5001.001.1 27.04.11



Page 176 of 286

5

RC#1


KEN 280 9834.5001.002.4

6 BOOM CONV.

( Drive -2) KEN 280 NFO 1001703 03.01.16

7

RC#2


KEN 280 3003480564 /

101 05.06.16

8 BOOM CONV.

( Drive -2) KEN 280 9834.5001.002.3

9

ST#1

SLEW DRIVE 1 P3KL 16 445.808.005.006.5 14.04.11

10 SLEW DRIVE 2 P3KL 16 445.808.005.006.1

11 SLEW DRIVE 3 P3KL 16 445.808.005.006.3

12

ST#2

SLEW DRIVE 1 P3KL 16 445.808.005.006.7

13 SLEW DRIVE 2 P3KL 16 445.808.005.006.2

14 SLEW DRIVE 3 P3KL 16 445.808.005.006.6

15

RC#1

SLEW DRIVE 1 P3KL 17 445.808.005.010.4

16 SLEW DRIVE 2 P3KL 17 445.808.005.010.2

17 SLEW DRIVE 3 P3KL 17 445.808.005.010.1 05.03.15

18

RC#2

SLEW DRIVE 1 P3KL 17 445.808.005.010.7 10.11.11

19 SLEW DRIVE 2 P3KL 17 445.808.005.010.3 13.09.16

20 SLEW DRIVE 3 P3KL 17 445.808.005.010.6 03.10.12

21 RC#1 BELT FEEDER KCN-400 WHG 19549 LH 24.06.10

22 RC#2 BELT FEEDER KCN-400 WHG 19548 LH

23 RC#1 BUCKET GEAR BOX P2KA25 445.808.005.001.1 14.10.16

24 RC#2 BUCKET GEAR BOX P2KA25 445.808.005.001.3 27.03.16

25

SL#1 & SL#2

SHUTTLE DRIVE (SL#1)

K3SZG450 G25013

26 SHUTTLE DRIVE

(SL#2) K3SZG450 G25013

27 BOOM DRIVE (SL#1) KSZG280PU G24946 14.06.16

28 BOOM DRIVE (SL#2) KSZG280PU G24946 10.09.16

29

SL#1

SLEW DRIVE 1 K3P160 9/991914200.001

30 SLEW DRIVE 2 K3P160


32

SL#2

SLEW DRIVE 1 K3P160 9/991914200.001





Page 177 of 286

4.1.16 BRIEF DESCRIPTION OF DUST CONTROL SYSTEM IN MCHP:

The original Dust Control System in MCHP commissioned by M/s.SPML was revamped and the

new system was commissioned during January, 2011by M/s.KUPPL. The system includes dust control as

well as fire-fighting in MCHP. The dust control and fire-fighting system operates using raw water drawn

from Balijhara Water Reservoir. The Dust Control System has got two Pump Houses i.e. Raw Water Pump

House and Process Water Pump House. Raw Water Pump House is utilized to draw water from the Balijhara

Water Reservoir and is stored in the Process Water Pond having a capacity of 90,000 m3 at MCHP.

From the Process Pond, water is being distributed to three different locations i.e. Rail Receival Station,

Stackyard and for the Shipping Stream through the Process Water Pump House.

The Raw Water Pump House has got two nos. of Pumps each of capacity 37 KW having a discharge

capacity of 275 m3 per hour. The Process Water Pump House has got four nos. of Pumps each of capacity

125 KW having a discharge capacity of 300 m3 per hour. Further,

(i) To control dust at Rail Receival Station, the system has 320 nos. of high pressure nozzles and 120

nos. of multi-tip nozzles at the hopper RR-1 & RR-2.

(ii) To control dust at the Shipping & Receiving Stream, the system is equipped with 478 single-tip

nozzles & 02 nos. multi-tip nozzles at different Transfer Towers as well as in machines.

(iii) To control dust at the Shipping & Receiving Stream, additional sprinkling provision by through

holes in pipes at R-7 & R-8 tail end, S-3 & S-4 after magnet and S-7 & S-8 conveyor are incorporated.

(iv) To control dust at both the Stackyards, the system has 108 nos. of auto-swivel sprinklers and for

fire-fighting, the system has 52 nos. of fire monitors & 04 nos. fire hydrants. Also for fire fighting, the

system has 72 nos. of fire hydrants.

(v) The total average water consumption of the system is 4000 m3 per day.

4.1.16.1 Existing Dust Control System (D.C.S) of MCHP:-

The system is installed in MCHP for control of dust generated from different sources in the year 2011.

This comprises of the followings;

(a) PWPH

(b) Process Water Underground & Overhead pipe network

(c) RRS

(d) All Transfer Towers

(e) Stack-yard

(f) RRS including High Pressure Pump House

Most of the existing DCS are in a defunct condition. PPT is in the tendering process for installation of

Dry Fog Dust Suppression System (DFDS) at RRS, Transfer points and separate pipelines at the

existing stackyards for installation of new sprinklers. The work is expected to be completed during the

tenure of this O&M contract. Once the installation of new system is commenced, the existing DCS

system will be left with only fire fighting system at RRS, Transfer Points and Fire hydrants and Fire

monitors in both the stackyards. The installations of existing DCS which will be retained shall be

revamped under this contract in mandatory initial works.

4.1.16.2 Pump Details:-

Sl.

No. Location Specification Qty. Date of Installation

1

PWPH

Motor-125KW/167HP, 1485rpm, Crompton Greaves Make

Model No.: DSM 150/46 A, Head: 105 Mtrs.

Capacity: 300m3/Hour, Make: Kirloskar Brothers Ltd.

4 Nos.

2007

2

Model: KV 30, Size: 32x32, 2840 RPM, Max. Vacuum

developed: 65mm of Hg, Max. Intake rate: 55.0 m3/Hr.,

Working fluid pressure: 0.15 Kg/cm2, KW/HP: 5.5/7.5, 4.7

Amp., 415 Volt, Make: Kirloskar Brothers Ltd.

2 Nos.

3

HPPH

Motor-30KW/40HP, 1470rpm, ABB Make

Head: 11 Mtrs. Discharge-103 lpm,Make: Kaveri. 6 Nos. 2011



Page 178 of 286

4.1.16.3. Process Water Pipeline details:

Size of Pipe (in mtr.)

UPVC MS / GI SS

200

NB

150

NB

100

NB

80

NB

300

NB

250

NB

200

NB

150

NB

100

NB

80

NB

65

NB

50

NB

25

NB

25

NB

6580 278 192 373 25 100 235 600 3500 2700 250 1300 250 500

4.1.16.4. Layout of Process Water Pipe Line and Plant :-



Page 179 of 286

4.1.16.5. SPECIFICATIONS-

ITEM CI AIR RELEASE VALVE BODY CI IS 210 Gr. 200

BODY COVER CI IS 210 Gr. 200

PROTECT COVER CI IS 210 Gr. 200

BALL NEOPRENE COATED TIMBER

SEAT NEOPRENE / NITRILE

COVER BOLTS & NUTS CARBON STEEL

BODY TEST PRESSURE 15 Kg/cm2

TYPE GATE VALVE WITH NON RISING SPINDLE &

BOLTED BONNET BODY CAST IRON AS PER IS : 210 - 1993, GR-200

BONNET BOLTED(CAST IRON AS PER IS : 210 - 1993, GR-200)

SPINDLE SS AS PER AISI - 410

DISC CAST IRON AS PER IS : 210 - 1993, GR-200

BODY SEAT RING &

DISC SEAT RING SS AS PER AISI - 410 (13 % Cr.)

END CONNECTION FLANGE END TO IS IS : 6392 T 17 RF

PRESSURE RATING PN - 1.6

HAND WHEEL CAST IRON AS PER IS : 210 - 1993, GR-200

APPLICATION WATER

BODY TEST PR. 24 KG/CM2

SEAT TEST PR. 16 KG/CM2

BOLTS & NUTS CARBON STEEL, IS: 1363-1992, CI - 4

GASKET CAF, IS : 2712, Gr - C

PACKING GRAPHITED ASBESTOS

PAINTING GREEN (AS PER IS:14846)

TYPE GLOBE VALVE WITH NON RISING SPINDLE

BODY CAST IRON AS PER IS : 210 - 1993, GR-200

BONNET WITH

YOKE, GLAND CAST IRON AS PER IS : 210 - 1993, GR-200

HAND WHEEL CAST IRON AS PER IS : 210 - 1993, GR-200

BODY SEAT RING &

DISC SEAT RING SS AS PER AISI - 304

YOKE BUSH,

BACK SEAT BUSH LEADED TIN BRONZE IS : 318 -1981, LTB - 2

SEAM STAINLESS STEEL, AISI : 410 (13% Cr.)

SLEEVE LEADED TIN BRONZE IS : 318 -1981, LTB - 2

END CONNECTION FLANGED END (IS - 6392, T-17)

APPLICATION WATER

HYDROSTATIC TESTING PN 1.6



BOLTS, STUDS & NUTS CARBON STEEL, IS: 1363-1992



PAINTING GREEN (AS PER IS:9338)

ITEM C.I Pr. RELIEF VALVE SIZE OF VALVE 100 NB


COVER, BRIDGE, DISC CAST IRON AS PER IS : 210 - 1993, GR-200

SPINDLE SS AS PER AISI - 410(13% Cr.)

STAY ROD MILD STEEL IS : 2062



Page 180 of 286

BODY SEAT RING &

DISC SEAT RING STAINLESS STEEL AISI 304

SLEEVE STAINLESS STEEL AISI 304

END CONNECTION FLANGE END TO IS : 6392 T 17 RF

ADJUSTABLE

PRESSURE RANGE 0 - 15 KG/CM2



GASKET CAF, IS: 2712, Gr. C

SPRING CARBON STEEL, IS: 1363-1992

BOLTS & NUTS CARBON STEEL, IS: 1363-1992

ITEM CONTROL CABLE APPLICATION DUST SUPPRESSION SYSTEM

TYPE CONTROL CABLE-1.1KV GRADE FRLS OUTER SHEETHED,

PVC INNER SHEETHED,ARMOURED, COPPER CONDUCTOR

MANUFACTURING STD AS PER IS :1554(PART-2)

HEAT RESISTING MAXIMUM OPERATING CONDUCTOR TEMPERATURE 85

DGREE FOR 1.1KV

CONDUCTORS IS:8130-1984

BENDING RADII 12D FOR MULTI CORE FOR 1.1 KV CABLE

IR VALUE >100 Ohms.BETWEEN ALL PHASE & ARMOURED

D.E STRENGTH 2.5 KV FOR 1 MIN.

ITEM CONTROL PANEL ENCLOSURE 2MM THICK CRCA SHEET FABRICATED

INCOMING SUPPLY 230V/AC, 50 Hz.

MOUNTING WALL

DEGREE OF

PROTECTION IP-55

PROVISION OF EARTH

TERMINAL STUD

PAINTING RAL-7032

SIZE OF INCOMING

CABLE AS PER REQUIREMENT

MAKE OF SW. GEAR &

MEASURING

INSTRUMENT

REPUTED MAKE

IR VALUE >100 Ohms.AT PHASE TO NEUTRAL & PHASE TO EARTH.

ITEM CI FLOAT VALVE SIZE OF VALVE(NB) 40

DESIGN

STANDARD GK FIG-H-48

TYPE CAST IRON BALL FLOAT VALVE

BODY,

COVER,PISTON,DISC

GLAND NUT

CAST IRON AS PER IS : 210 - 1993, GR-200

FLOAT COVER

SEAT RING GM IS: 318 LTB

VALVE FACE NEOPRENE RUBBER

SPINDLE 13% Cr. STEEL

FULCRUM, LEVER,

HINGE, GLAND MS IS : 2062(GALVANISED)

PILOT VALVE & SEAT SS AISI 304


APPLICATION WATER



Page 181 of 286



BOLTS, STUDS & NUTS CARBON STEEL, IS: 1367-1992


ITEM HIGH PRESSURE NOZZLE TYPE HIGH PRESSURE FOG TYPE

FLUID WATER

BODY BRASS WITH ZINC COATING

CAPACITY 0.5 LPM

TIPS SS-304

CONNECTION SCREWED 3/16" (BSW)

WORKING PRESSURE 60 TO 100Kg/CM2

ITEM HIGH PRESSURE PUMP TYPE RECIPROCATING PLUNGER TYPE

MODEL KAV DC-100/150(DIAMOND)

NO OF PLUNGER 3 NOS

RPM 850

CAPACITY 100 LPM

MAX. RATED PRESSURE 100 Kg/CM2

MAIN BODY CAST IRON

PLUNGER SS-316 WITH CERAMIC COATING

MANIFOLD SS-316

CRANK SHAFT NITRITE CHROMEMOLYBDENUM STEEL

PLUNGER SEAL POLYTETRAFLUORO ETHYLENE

DRIVE MOTOR

COUPLING PULLY WITH V BELT

INLET SIZE 40 NB

OUTLET SIZE 25 NB

ITEM HIGH PR. BALL VALVE MANUFACTURING

STANDARD BS 5159 / BS 5351 (R.B.)

BODY ASTM A 105

CONNECTOR ASTM A 105

BALL AISI 304 / ASTM A351 Gr. CF8

STEM AISI 304

GLAND AISI 304

BALL SEALS PTFE

BODY SEALS PTFE

STEM PACKING PTFE

GLAND PACKING PTFE

BODY BOLTS & NUTS ASTM A193 Gr. B7 & ASTM A194 Gr. 2H

GLAND NUTS & STEM

NUTS AISI 304

HANDLE CARBON STEEL

SLEEVE PVC

END CONNECTION SCREWED END BSP (M)

BODY TEST PRESSURE 5400 PSIG (380 KG/cm2)

SEAT TEST PRESSURE 4000 PSIG (281 KG/cm2)



Page 182 of 286

ITEM HYDRANT / LANDING VALVE SIZE OF VALVE(NB) 65

MANUFACTURING

STANDARD IS : 5290/93

BODY GUN METAL IS:318

BONNET GUN METAL IS:318

SPINDLE BRASS IS:319

STOP VALVE GUN METAL IS:318

VALVE SEAT RUBBER IS:937

GLAND GUN METAL IS:318

GLAND NUT GUN METAL IS:318

HAND WHEEL CAST IRON IS :210

MALE BLANK CAP ABS PLASTIC

FEMALE ADAPTOR GUN METAL IS:318

RUBBER GASKET RUBBER IS:937

SPRING PHOSPOR WIRE IS:7608

CHECK NUT GUN METAL IS:318

ITEM JUNCTION BOX WAY 4/10/20/40/80 WAY

ENCLOSURE 2 MM THICK CRCA SHEET FABRICATED

MOUNTING WALL

DEGREE OF

PROTECTION IP-55

PROVISION OF EARTH

TRMINAL STUD

PAINTING RAL-7032

ITEM LOCAL PUSH BUTTON STATION ENCLOSURE 2 MM THICK CRCA SHEET FABRICATED

SIZE AS PER APPROVED DRG.

INCOMING SUPPLY 230V/AC, 50Hz

MOUNTING WALL

DEGREE OF PROTECTION IP-55

PROVISION OF

EARTH TERMINAL STUD

PAINTING RAL-7032(80 TO 100 MICRON)

MAKE OF SW. GEAR &

MEASURING

INSTRUMENT

REPUTED MAKE

IR VALUE >100 Ohms.AT PHASE TO PHASE & PHASE TO EARTH

ITEM MCC-CUM-CP ENCLOSURE 2 MM THICK CRCA SHEET FABRICATED

INCOMING SUPPLY 415V,AC, 50HZ, 3 PHASE & N

CONTROL SUPPLY 230V,AC,50Hz

MOUNTING FLOOR MOUNTING/ WALL MOUNTING

CONTROL WIRING 1.5MM2 COPPER FLEXIBLE WIRE

BUSBAR SIZE 25X6 MM FOR PH. AND 20X6 MM FOR NUTRAL(aluminium)


PROVISION OF EARTH

TERMINAL STUD

PAINTING RAL 7032(80 TO 100 MICRON)

SIZE OF INCOMING

CABLE AS PER REQUIREMENT



Page 183 of 286

MAKE OF SW.GRAR &

MEASURING

INSTRUMENT

REPUTED MAKE

D.E STRENGTH 2.5 KV FOR 1 MIN

IR VALUE >100 Ohms.AT PHASE TO PHASE & PHASE TO EARTH.

ITEM LT MOTOR KW/HP 30/40

FREQUENCY 50(Hz)

VOLTAGE 415V

CURRENT 54.50(Amps)

INSULATION CLASS F

SPEED 1470(RPM)

AMBIENT 50(Degree C)

DUTY S1


PROVISION OF EARTH

TERMINAL STUD

TERMINAL

ORIENTATION TOP

ITEM MS TANK CAPACITY 3000 LITRE

TYPE VERTICAL

MOUNTING FLOOR

THICKNESS OF PLATE 3 MM

WORKING PRESSURE 10Kg/cm2

DESIGN PRESSURE 15Kg/cm2

ITEM FINEMIST NOZZLE SIZE OF NOZZLE 3 LPM 2 LPM

STRAINER MESH 80 80

NOZZLE TIPS SS 304 SS 304

STRAINER BRASS IS - 318 NA

WORKING PRESSURE 4.5 KG/ CM2 4.5 KG/ CM2

ADAPTER OF NOZZLE BRASS IS - 318 BRASS IS - 318

BODY

CAST IRON AS PER IS : 210 -

1993, GR-200

CAST IRON AS PER IS : 210

- 1993, GR-200

GASKET "O" RING RUBBER "O" RING RUBBER

END CONNECTION SCREWED - BSP (FEMAL) SCREWED - BSP (FEMAL)

CAP

CAST IRON AS PER IS : 210 -

1993, GR-200

CAST IRON AS PER IS : 210

- 1993, GR-200

ITEM FINEMIST NOZZLE SIZE OF NOZZLE 15 LPM

STRAINER MESH 100

NOZZLE TIPS SS 304

STRAINER BRASS IS - 318

WORKING PRESSURE 4.5 KG/ CM2


GASKET & "O" RING RUBBER

END CONNECTION SCREWED - 1"BSP (FEMAL)

CAP CAST IRON AS PER IS : 210 - 1993, GR-200



Page 184 of 286

ITEM MS-GI STEEL PIPE SIZE OF PIPE 20 NB, 25 NB, 50 NB, 65 NB, 80 NB, 100 NBNB

TYPE GI ERW

STANDARD

20 NB TO 150 NB IS : 1239 PART – 1&IS:3589(Hot deep

Galvanized)

CLASS OF PIPE HEAVY DUTY

MOC MILD STEEL

ITEM POWER CABLE

TYPE POWER CABLE-1.1KV GRADE PVC OUTER SHEATH, PVC

INNER SHEATH,ARMOURED, ALUMINIUM CONDUCTOR

MANUFACTURING STD AS PER IS :1554(PART-2)

HEAT RESISTING MAXIMUM OPERATING CONDUCTOR TEMPERATURE 85

DGREE FOR 1.1KV

CONDUCTORS IS:8130-1984

BENDING RADII 12D FOR MULTI CORE FOR 1.1 KV CABLE

IR VALUE >100 Ohms.BETWEEN ALL PHASE & ARMOURED

D.E STRENGTH 2.5 KV FOR 1 MIN.

ITEM SIMPLEX STRAINER SIZE 200 NB

BODY MS IS - 2062

STRAINER ELEMENT SS 304

END CONNECTION FLANGED END TO IS : 6392 T 17 RF

TOP COVER FLANGE BS - 10, TABLE -E

STRAINER MESH 80

WORKING PRESSURE 13 Kg/ cm2

TEST PRESSURE 16 Kg/cm2

BOLTS & NUTS CARBON STEEL, IS: 1363-1992, CI - 4

PRESSURE DROP 0.12 BAR

ITEM SPRINKLER TYPE OF SPRINKLER PART CIRCLE

THROW RADIOUS 30 - 35 MTR

DISCHARGE 550 LPM

END CONNECTION 80 NB FLANGED (DRILLED AS PER ANSI B 16.5)

WORKING PRESSURE 6 KG/CM2

BODY DIE CAST ALLUMINIUM - IS - 617

DEFLECTOR ARM C.I. (IS : 210, FG-220)

NOZZLE SS - 304

INCLINATION 40 DEG

SPRING SS - 304

PAINTING ORANGE (SYNTHATIC ENNAMEL)

ITEM UPVC PIPE SIZE OF PIPE 80 NB, 150 NB, 200 NB

TYPE U - PVC

STANDARD ASTM D - 1785

CLASS OF PIPE SCH 80 / HEAVY DUTY

MOC PVC 1120 / 2120

SPECFIC GRAVITY 1.41 - 1.46

WORKING PRESSURE 10KG/CM2

DESIGN PRESSURE 16KG/CM2

IMPACT STRENGTH AT 20

DEG C 3 KGF/CM2

VICAT SOFTENING POINT 80 DEG C



Page 185 of 286

ITEM ELECTRONIC SPEED SWITCH MODEL RM E214 - BL

TYPE OF SENSOR SP12 - ES100

SUPPLY VOLTAGE 110/240V AC

SPEED RANGE 100 - 1000 RPM

NO. OF FLAGS 2 imp/rev

O/P CONTACTS 2 NO + 2 NC

CONTACTS RANGE 5 A resistive AT 240V AC

ITD 1 - 20 S

NTD 2 - 20 S

EFFECTIVE SN BUILT IN

GLAND SIZE 3/4 INCH

ENCLOSURE MATERIAL MU CAST ALUMINIUM / IP 65

ENCLOSURE MATERIAL SP CAST ALUMINIUM / IP( 67) 65

PAINT SHADE LIGHT GRAY

DIMENSIONS MU 210(L)X135(W)X95(D)

DIMENSIONS SP O / LENGTH 353 MOUNTING C/C 100 mm

BASE PLATE DIMENSIONS 245X280X3 mm

ITEM FIRE WATER MONITER SIZE 63mm

MANUFACTURING

STANDARD AS PER IS : 8442 - 1977

TYPE SWIVELLING AROUND BOTH AXIS

MINIMUM VERTICAL

JET DISTANCE 22 M

MINIMUM HORIZANTAL

JET DISTANCE 50 TO 80 MTR.

HORIZONTAL SWIVEL 360 DEG

WATER PRESSURE

AT INLET 8 KG/cm2g

TYPE OF JOINT BALL BEARING

BASE FLANGE IS : 6392

DRAIN VALVE BRASS

REDUCER M.S. I.S. : 1239 PART - II

SWIVEL JOINT BRONZE IS : 318 LTB - II

GREASE NIPPLE BRASS

LOCK NUT BRASS IS : 291 LTB - I

HANDLE M.S. I.S. : 1732 - 1971

WATER BARREL SEAMLESS PIPE IS : 1239 PART - I

NOZZLE BRONZE IS : 318 LTB - II OR ALUMINIUM IS : 617

ITEM Y- STRAINER SIZE OF STRAINER (NB) 40


STRAINER ELEMENT SS

STRAINER SS 304

GASKET CAF

BOLTS & NUTS MS

STRAINER MESH SIZE 80





Page 186 of 286

ITEM Y- STRAINER SIZE OF STRAINER (NB) 25 20 15


STRAINER ELEMENT BRASS

STRAINER SS 304

STRAINER MESH SIZE 80


END CONNECTION SCREWED - BSP (FEMALE)

ITEM CI NON RETURN VALVE SIZE OF VALVE 40 NB

MANUFACTURING

STANDARD IS: 5312

TYPE SWING CHECK


COVER CAST IRON AS PER IS : 210 - 1993, GR-200

HINGE (BRACKET) CAST IRON AS PER IS : 210 - 1993, GR-200

FLAP CAST IRON AS PER IS : 210 - 1993, GR-200

BODY SEAT RING &

FLAP SEAT RING SS AS PER AISI - 410

HINGE PIN SS AS PER AISI - 304

END CONNECTION FLANGE END TO IS IS : 6392 T 17 RF

PRESSURE RATING PN - 1.6

APPLICATION WATER



BOLTS & NUTS CARBON STEEL, IS: 1367, CL-4.6 & 4.0


GI FLANGE FLANGE ENDS TO BS 10 TABLE - D/ISS/1538

AIR RELEASE VALVE BODY, BODY COVER, PROTECT COVER : CI IS 210 Gr.200,

BALL:NEOPRENE COATED TIMBER, SEAT : NEOPRENE/

NITRILE, COVER BOLTS & NUTS : CARBON STEEL, BODY TEST

PRESSURE : 15 Kg/Cm2, , END CONNECTION : FLANGE ENDS TO

BS 10 TABLE - D/ISS/1538

GI BEND SIZE OF PIPE : 50 NB TO 200 NB

STANDARD : 50 NB TO 200 NB IS : 1239 PART - 1/ IS :3589 (Hot

Deep Galvanised)

CLASS OF PIPE : HEAVY DUTY

DEGREE : 90

MOC : MILD STEEL

200 NB UPVC SOCKET /

TAIL PIECE

TYPE : U - PVC, STANDARD : ASTM D - 1785, CLASS OF PIPE,

SCH 80 / HEAVY DUTY, SCH 80 / HEAVY DUTY, MOC : PVC 1120

/ 2120, SPECFIC GRAVITY : 1.41 - 1.46, WORKING PRESSURE :

10KG/CM2, DESIGN PRESSURE : 16KG/CM2, IMPACT STRENGTH

AT 20 DEG C :3 KGF/CM2, VICAT SOFTENING POINT :80 DEG C

SOLVENT CEMENT FOR UPVC Pipe Joint – 500 POWER



Page 187 of 286

4.1.17 SUBSTATION #1, #2, #3, #4, #5, #6, #7, #8, #9

a) Transformer details of MCHP: S

L N

O

LOCATION

RATING OF

TRANSFORMER

(KVA)

O E M SL NO OF

TRANSFORMER

INST.

QTY

YE

AR

OF

MA

NU

FA

CT

UR

E /

INS

TA

LL

AT

ION

1 SS#1 500

(6.6KV/433V) GEC ALSTHOM D 1693

2 1998/2000

2 SS#1 500


3 SS#2 2500 (6.6KV/433V) GEC ALSTHOM 14149

2 1998/2000

4 SS#2 2500 (6.6KV/433V) GEC ALSTHOM 14150

5 SS#3 250


2 1998/2000

6 SS#3 250


7 SS#4 500


2 1998/2000

8 SS#4 500


9 SS#5 250

(6.6KV/433V) GEC ALSTHOM D 1688 2 1998/2000

10 SS#5 250


11 SS#6 16/20 MVA

(33KV/ 6.6KV) GEC ALSTHOM B-29414

5 1998/2000

12 SS#6 16/20 MVA

(33KV/ 6.6KV) GEC ALSTHOM B-29414

13 SS#6 250


14 SS#6 250


15 SS#6 500

(433V/6.6KV) GEC ALSTHOM D 1704

16 SS#7 1000 (6.6KV/433V) GEC ALSTHOM D 2233 1 1998/2000

17 SS#8 500

(6.6KV/433V) GEC ALSTHOM D 2234 1 1998/2000

18 SS#9 1000 (6.6KV/433V) GEC ALSTHOM 581 1 1998/2000

19 ST#1 630

(6.6KV/433V) EMCO 775 1 1998/2000

20 ST#2 630

(6.6KV/433V) OTPL 9305 1 2006/2007

21 RC#1 1250 (6.6KV/433V) EMCO 775 1 1998/2000



Page 188 of 286

22 RC#2 1250 (6.6KV/433V) EMCO 776 1 1998/2000

23 SL#1 800

(6.6KV/433V) KIRLOSKAR 99P/KC001/1 1 1998/2000

24 SL#2 800

(6.6KV/433V) OTPL 9304 1 2006/2007

25 SPARE

(ST)

630

(6.6KV/433V) EMCO 776 1 1998/2000

26 SPARE

(RC) 1250 (6.6KV/433V) OTPL 9303 1 2006/2007

27 SPARE

(SL)

800

(6.6KV/433V) KIRLOSKAR 99P/KC001/2 1 1998/2000

b) Technical details of Capacitor bank:

Installed Qty. : 6 Nos.

(It is installed at substation # 6

for voltage regulation of the plant)

Power Capacitor:

Type : Discharge Resistor fitted

Range : 151.25 KVAR, 35.85A Conn.1Ø

Voltage : 422 KV, 50 Hz, 1L 22/60

Dielectric : PP

Impregnate : NPCB

Weight : 32 Kg

Make : Meher Capacitor (P) Ltd. (Now Schenider)

Qty. : 12 Nos.

Expulsion Fuse:

Type : ASSMPLY / CARRIER

Range : 80 A

Make : THERMS INDIA

Qty. : 12 Nos.

Reactor:

Type : Dry Type Series Reactor

Rated KVAR : 3.63 KVAR

Rated Voltage : 7200 V, 3 PH, 50 Hz

Over current factor : 16.6

Impedance / Phase : 0.644Ω

Type of Cooling : ANAN

Ins. Class : F

Total Weight : 145 Kg

Qty. : 1 No.

Guaranteed Max. temperature rise at 130% of rated current of winding by resistance 105oC.



Page 189 of 286

Residual Voltage Transformer (RVT):

Type : GWI-0/7.2

(Three phase voltage transformer)

Ratio : 7.2 KV / 110 – 190 V

Rating : V.F:1.2, Cont. and 1.9 for sec. 50 Hz, 1L

22 / 60 KV

Connection : Star / Star – Open Delta

Sec Winding 1 : 50 VA, Class.1, Terminal Marking

- a b c n

Sec Winding 2 : 50 VA, Class.3P, Terminal Marking

- da dn

Make : Gyro Laboratories (P) Ltd.,

Bombay – 400002

Qty. : 1 No.

c) HT Breaker Details:

RATING TYPE SUBSTATIONS

INS

T.

QT

Y

OE

M

YE

AR

OF

MA

NU

FA

CT

UR

E/

INS

TA

LL

AT

ION

SP

AR

E

TO

TA

L

1 2 3 4 5 6 7 8 9

400A,

6.6KV

VACCUM

(HWC) 12 4 8 4 28

AL

ST

OM

(AR

EV

A/

Sch

enid

er)

1999

/

2000

2 30

630A,

6.6KV

VACCUM

(VMX) 6 6

AL

ST

OM

(AR

EV

A/

Sch

enid

er)

1999

/

2000

1 7

800A,

6.6KV

VACCUM

(HWX) 7 5 7 7 19 45

AL

ST

OM

(AR

EV

A/

Sch

enid

er)

1999

/

2000

2 47

2000A,

6.6KV

VACCUM

(HWX) 3 3

AL

ST

OM

(AR

EV

A/

Sch

enid

er)

19

99

/

20

00

1 4

800A, 33KV SF6

(GMH) 5 5

VO

LT

AS

(Sch

enid

er)

19

99 /

20

00

0 5

LINE PT

6.6KV HWX 2 2 2 2 2 10

AL

ST

OM

(AR

EV

A/

Sch

enid

er)

1999 /

2000

0 10



Page 190 of 286

CAPACITOR

BANK 1812

KVAR

VMX 6 6

AL

ST

OM

(AR

EV

A/

Sch

enid

er)

19

99

/

20

00

0 6

BUS PT

6.6KV HWX 2 2

AL

ST

OM

(AR

EV

A/

Sch

enid

er)

19

99 /

20

00

0 2

LINE PT

33KV

HEXA

PACK 2 2

VO

LT

AS

(Sch

enid

er)

19

99 /

20

00

0 2

TEST

CABINET

6.6KV

1 1 1 1 1

AL

ST

OM

(AR

EV

A/

Sch

enid

er)

19

99

/

20

00

5 5

TEST

CABINET

33KV

1

VO

LT

AS

(Sch

enid

er)

19

99 /

20

00

1 1

EARTH

TRUCK

6.6KV

1 1 1 1 1

AL

ST

OM

(AR

EV

A/

Sch

enid

er)

1999

/

2000

5 5

EARTH

TRUCK

33KV

1 V

OL

TA

S

(Sch

enid

er)

1999

/ 2

000

1 1

RING

MAIN

FEEDER

1 1 1 3

SO

UD

I

LA

US

I

1999

/

2000

0 3



Page 191 of 286

d) L.T Breaker Details: R

AT

ING

TY

PE

SUBSTATIONS MACHINES

INS

T. Q

TY

OE

M

YE

AR

OF

MA

NU

FA

CT

UR

E/

INS

TA

LL

AT

ION

SP

AR

E T

OT

AL

1 2 3 4 5 6 7 8 9

ST

#1

ST

#2

RC

#1

RC

#2

SL

#1

SL

#2

80

0A

AC

B

3 3 3 3 1 1 1 15

L&

T

19

99

/

20

00

15

10

00

A

AC

B

4 1 1 6

L&

T /

Sie

men

s

19

99

/

20

00

1 7

2000A

AC

B

1 1 2

Sie

men

s

1999/

2000

1 3

1250A

AC

B

1 1 2

Sie

men

s

1999/

2000

2 4

4000A

AC

B

3 3

L&

T

1999/

2000

3



Page 192 of 286

e) Relay Details of MCHP:

SL

. N

O

RE

LA

Y T

YP

E

OE

M

DESCRIPTION

SS

#1

SS

#2

SS

#3

SS

#4

SS

#5

SS

#6

ST

#

1 &

2

RC

#

1

& 2

SL

#

1 &

2

TO

TA

L R

EL

AY

1 CDG31

Alstom

( AREVA /

Schenider)

OVER

CURRENT

RELAY:(INVE

RSE)

8 6 6 8 8 29 -- -- -- 65

2 CDG11

Alstom

( AREVA /

Schenider)

EARTH

FAULT

RELAY:(51N)

6 4 6 8 6 30 -- -- -- 60

3 CAG14

Alstom

( AREVA /

Schenider)

INSTANTANIO

US EARTH

FAULT

RELAY (64R)

-- -

- -- -- -- 4 -- -- -- 4

4 CDG61

Alstom

( AREVA /

Schenider)

OVER

CURRENT

RELAY(INVER

SE)

-- -

- -- -- -- 2 -- -- -- 2

5 VAA23

Alstom

( AREVA /

Schenider)

AUX

RELAY(30A&

B):

8 -

- 4 4 4 4 -- -- -- 24

6 VAA33

Alstom

( AREVA /

Schenider)

AUXILARY

RELY

(63.1,2&3)

-- -

- -- -- -- 6 -- -- -- 6

7 VAX31

Alstom

( AREVA /

Schenider)

TRIP CIRCUIT

SUPERVISION

RELAY(74)

10 7 8 10 10 33 -- -- -- 78

8 VAJH13

Alstom

( AREVA /

Schenider)

MASTER

RELAY 20 6 10 16 12 27 -- -- -- 91

9 VAJH23

Alstom

( AREVA /

Schenider)

MASTER

RELAY(33K.V) --

-

- _ _ _ 4 -- -- -- 4

10 VAA11

Alstom

( AREVA /

Schenider)

ANTIPUMPIN

G RELAY(94) 7

-

- 5 7 7 41 -- -- -- 67

11 VAA21

Alstom

( AREVA /

Schenider)

DC FAIL

RELAY (80F) 8

-

- 6 8 8 29 -- -- -- 59

12 VAJC11

Alstom

( AREVA /

Schenider)

CONTROL

RELAY(52X) 7

-

- 5 7 7 26 -- -- -- 52

13 VTT

Alstom

( AREVA /

Schenider)

DEFENITE

TIME RELAY --

-

- -- -- -- 10 -- -- -- 10



Page 193 of 286

14 VDG11

Alstom

( AREVA /

Schenider)

OVER

VOLTAGE

RELAY

-- -

- -- -- -- 6 -- -- -- 6

15 VDG13

Alstom

( AREVA /

Schenider)

UNDER

VOLTAGE

RELAY

-- -

- -- -- -- 6 -- -- -- 6

16 VAGM22

Alstom

( AREVA /

Schenider)

INSTANTANIO

US UNDER

VOLTAGE

-- -

- -- -- -- 6 -- -- -- 6

17 VAPM31

Alstom

( AREVA /

Schenider)

FUSE

FAILURE

RELAY(98)

-- -

- -- -- -- 2 -- -- -- 2

18 VDG14

Alstom

( AREVA /

Schenider)

NEUTRAL

DISPLACEME

NT

RELAY(27N)

-- -

- -- -- -- 6 -- -- -- 6

19

MiCom

P220/P22

5

Alstom

( AREVA /

Schenider)

MOTPRO +

RELAY 12

-

- 4 4 4 _ -- -- -- 24

20 APR31P Ashida 3 ELEMENT

O/C RELAY --

-

- -- -- -- -- 2 2 2 6

21 ACAG14 Ashida

INSTANTANE

OUS E/F

RELAY:

-- -

- -- -- -- -- 2 2 2 6

22 ATSR31

A Ashida

TRIP CKT

SUPER

VERSION

RELAY

-- -

- -- -- -- -- 2 2 2 6

23 APR11E Ashida IDMTL E/F

RELAY --

-

- -- -- -- -- 2 2 2 6

24 AVA33 Ashida EMERGENCY

TRIP RELAY --

-

- -- -- -- -- 2 2 -- 4

25 AVAG11 Ashida

EMERGENCY

TRIP RELAY

PROTECTION

RELAY

-- -

- -- -- -- -- -- -- 6 6

26 AVAJH-

13 Ashida

LOCKOUT

TRIPING

RELAY

-- -

- -- -- -- -- 2 2 2 6

27 RQE0001

092

AREVA

(Schenider)

EARTH

LEAKAGE

RELAY

-- -

- -- -- -- -- 10 16 12 38

28

7SJ6001-

6EA00-

0DA0

/BB

Siemens MOT PRO -- -

- -- -- -- -- 4 6 -- 10

TOTAL 660



Page 194 of 286

f) Details of Field Devices at MCHP:

SL

ITE

MS

/

LO

CA

TIO

N CONVEYORS MACHINES

TO

TA

L

R1

A

R1

B

R2

A

R2

B

R3

R4

R5

R6

R7

R8

S3

S4

S5

S6

S7

S8

S9

S1

0

S1

3

S1

4

ST

#1

ST

#2

RC

#1

RC

#2

SL

#1

SL

#2

1

PC

S

2

2

2

2

4

4

2

2

14

14

14

14

2

2

2

2

2

2

8

8

8

8

6

6

9

9

15

0

2

BS

S

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

4

6

6

6

6

11

2

3

RB

D

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

2

1

1

1

1

1

1

46

4

HO

OT

ER

1

1

1

1

3

3

1

1

3

3

4

4

1

1

1

1

1

1

2

2

2

2

2

2

3

3

50

5

Under

Spee

d

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

22

6

Tak

e up

trav

el

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1 1

6

7

Flu

id

ther

mal

lim

it

2

2

1

1

2

2

2

2

1

1

1

1

1

1

2

2

2

2

3

3

1

1

36

8

Blo

ck c

hu

te

4

4

1

1 4

4

1

1

1

1

1

1 1

1

1

1

2

2

32

9

Lo

ng

tra

vel

lim

it s

wit

ches

1

1

2



Page 195 of 286

SL

ITE

MS

/

LO

CA

TIO


TO

TA

L

R1

A

R1

B

R2

A

R2

B

R3

R4

R5

R6

R7

R8

S3

S4

S5

S6

S7

S8

S9

S1

0

S1

3

S1

4

ST

#1

ST

#2

RC

#1

RC

#2

SL

#1

SL

#2

10

Lo

ng

tra

vel

end

lim

it

sen

sor

1

1

2

11

Lo

ng

tra

vel

bra

ke

sen

sors

22

22

44

12

Sle

w T

rav

el -

Ov

er t

ravel

Lim

it

2

2

4

13

Sle

w t

hru

ster

bra

ke

senso

r

3

3

6

14

Tra

vel

bogie

- T

ripw

ire

3

3

6

15

Boom

Convey

or

Tri

pw

ire

4

4

8

16

Luff

Boom

lim

it s

wit

ch

2

2

4

17

Bo

om

Co

nvey

or

thru

ster

bra

ke

sen

sor

1

1

2



Page 196 of 286

SL

ITE

MS

/

LO

CA

TIO


TO

TA

L

R1

A

R1

B

R2

A

R2

B

R3

R4

R5

R6

R7

R8

S3

S4

S5

S6

S7

S8

S9

S1

0

S1

3

S1

4

ST

#1

ST

#2

RC

#1

RC

#2

SL

#1

SL

#2

18

Bo

om

Co

nvey

or

Rip

ped

Bel

t sw

itch

1

1

2

19

Bo

om

Co

nvey

or

Bel

t M

is-

Ali

gh

nm

ent

swit

ch

4

4

8

20

Boom

Convey

or

Under

spee

d

swit

ch

1

1

2

21

Tip

per

car

pull

wir

e

2

2

4

22

Tri

pper

convey

or

Bel

t m

is-

Ali

ghnm

ent

swit

ch

2

2

4

23

PC

RD

cen

ter

po

int

by

pas

s

1

1

2

24

PC

RD

tig

ht

cable

forw

ard

RH

S

1

1

2



Page 197 of 286

SL

ITE

MS

/

LO

CA

TIO


TO

TA

L

R1

A

R1

B

R2

A

R2

B

R3

R4

R5

R6

R7

R8

S3

S4

S5

S6

S7

S8

S9

S1

0

S1

3

S1

4

ST

#1

ST

#2

RC

#1

RC

#2

SL

#1

SL

#2

25

PC

RD

tig

ht

cable

forw

ard

LH

S

1

1

2

26

PC

RD

cab

le

slag

nes

s

1

1

2

27

CC

RD

cen

ter

poin

t b

yp

ass

1

1

2

28

CC

RD

tig

ht

cable

forw

ard R

HS

1

1

2

29

CC

RD

tig

ht

cable

forw

ard L

HS

1

1

2

30

CC

RD

cab

le

slag

nes

s

1

1

2

31

Rai

l cl

amp

en

gag

ed /

dis

eng

aged

sen

sors

2

2

4



Page 198 of 286

SL

ITE

MS

/

LO

CA

TIO


TO

TA

L

R1

A

R1

B

R2

A

R2

B

R3

R4

R5

R6

R7

R8

S3

S4

S5

S6

S7

S8

S9

S1

0

S1

3

S1

4

ST

#1

ST

#2

RC

#1

RC

#2

SL

#1

SL

#2

32

Sh

utt

le t

hru

ster

bra

ke

senso

r

2

2

4

33

Sh

utt

le c

hai

n

bal

anci

ng

sen

sor

2

2

4

34

Shutt

le o

ver

spee

d s

enso

r

1

1

2

35

Shutt

le f

orw

ard &

bac

kw

ard s

enso

r

2

2

4

36

Shutt

le e

nd

lim

it s

wit

ch

2

2

4

37

chu

te s

lew

clo

ckw

ise

and

anti

clo

ckw

ise

senso

r 2

2

4

38

Shutt

le s

torm

an

cho

rin

g

bolt

sen

sor

1

1

2



Page 199 of 286

SL

ITE

MS

/

LO

CA

TIO


TO

TA

L

R1

A

R1

B

R2

A

R2

B

R3

R4

R5

R6

R7

R8

S3

S4

S5

S6

S7

S8

S9

S1

0

S1

3

S1

4

ST

#1

ST

#2

RC

#1

RC

#2

SL

#1

SL

#2

39

Tra

vel

gea

rs s

torm

anch

ori

ng s

pin

dols

sen

sor

4

4

8

40

Monit

ori

ng

sto

rm

anch

ori

ng b

olt

sen

sor

10

10

20

41

Kic

k o

ff

Pen

dulu

m

42

All

pow

er p

ack o

il

tem

per

ature

sen

sor

6

6

12

43

All

po

wer

pac

k o

il l

evel

sen

sor

(Ex

cept

Hois

t p

ow

er p

ack)

5

5

10

44

Tra

vel

cod

ed

posi

tion s

enso

r

5

5

10



Page 200 of 286

SL

ITE

MS

/

LO

CA

TIO


TO

TA

L

R1

A

R1

B

R2

A

R2

B

R3

R4

R5

R6

R7

R8

S3

S4

S5

S6

S7

S8

S9

S1

0

S1

3

S1

4

ST

#1

ST

#2

RC

#1

RC

#2

SL

#1

SL

#2

45

Tra

vel

lu

bri

cati

on

pu

mp

co

ntr

ol

card

6

6

12

46

Tra

vel

anti

coll

isio

n

1

1

2

47

PC

RD

, C

CR

D

Cam

sw

itch

2

2

2

2

8

48

Sle

w t

hru

ster

bra

ke

lim

it s

wit

ch

3

3

3

3

12

49

Sle

w O

ver

Tra

vel

CW

Lim

it s

wit

ch

3

3

2

2

10

50

Sle

w O

ver

Tra

vel

AC

W L

imit

sw

itch

3

3

2

2

10

51

Long T

rav

el l

imit

swit

ches

4

4

4

4

16



Page 201 of 286

SL

ITE

MS

/

LO

CA

TIO


TO

TA

L

R1

A

R1

B

R2

A

R2

B

R3

R4

R5

R6

R7

R8

S3

S4

S5

S6

S7

S8

S9

S1

0

S1

3

S1

4

ST

#1

ST

#2

RC

#1

RC

#2

SL

#1

SL

#2

52

Lo

ng

Tra

vel

-

Co

ded

Po

st s

enso

r

5

5

5

5

20

53

Lo

ng

Tra

vel

- T

ie

Do

wn

lim

it s

wit

ch

2

2

2

2

8

54

Em

ergen

cy

Sto

p

9

9

8

8 3

4

55

Sle

w E

nco

der

Chec

k

Lim

it se

nso

r

3

3

3

3

12

56

Til

t

Sw

itch

1

1 2

57

Op

erat

or

cabin

- W

ind

Sp

eed

sen

sor

1

1

1

1

4

58

Boom

Co

nvey

or

-

Anti

-Co

llis

ion

sen

sor

4(I

nfr

ared

sen

sor)

4(I

nfr

ared

sen

sor)

8



Page 202 of 286

59

Bo

om

Co

unte

r w

eigh

t -

Sen

sor

3

3

6

g) ACDB Details of MCHP:

RA

TIN

G

TY

PE

SUBSTATIONS

INS

T.

QT

Y

YE

AR

OF

MA

NU

FA

CT

UR

E

/ IN

ST

AL

LA

TIO

N

SP

AR

E

TO

TA

L

1 2 3 4 5 6 7 8 9

400A CSSF -- 2 -- -- -- 2 -- -- 4 1998/1999 4

250A CSSF250 -- 1 2 -- 2 1 -- -- 6 1998/1999 6

125A CSSF 125 3 2 4 3 -- 3 -- -- 15 1998/1999 1 16

125A FN 125 -- -- -- -- -- 1 -- -- 1 1998/1999 1

63A CSSF 63 2 7 2 4 1 4 -- -- 20 1998/1999 20

32A CSSF32 12 16 9 9 10 27 -- -- 83 1998/1999 2 85

SL

ITE

MS

/

LO

CA

TIO


TO

TA

L

R1

A

R1

B

R2

A

R2

B

R3

R4

R5

R6

R7

R8

S3

S4

S5

S6

S7

S8

S9

S1

0

S1

3

S1

4

ST

#1

ST

#2

RC

#1

RC

#2

SL

#1

SL

#2



Page 203 of 286

h) DCDB with battery bank details of MCHP:

RA

TIN

G

TY

PE

SUBSTATIONS

INS

T.

QT

Y

YE

AR

OF

MA

NU

FA

CT

UR

E/

INS

TA

LL

AT

ION

SP

AR

E

TO

TA

L

1 2 3 4 5 6 7 8 9

FL

OA

T:

50

-53

V D

C

(12

A)

BO

OS

T:

41-6

6V

DC

(1

0A

)

FU

LL

W

AV

E

FU

LL

Y

CO

NT

RO

LL

ED

M 0

48

012

1

1 1 1 1 1 1 -- -- -- 6 1998/1999 -- 6

BA

TT

ER

Y B

AN

K (

2V

X

24 N

OS

.)

150 A

H A

T 1

0 H

R.

LE

AD

AC

ID,

TM

150 P

1 1 1 1 1 1 -- -- -- 6 1998 / 1999 -- 6

i) UAF Details of MCHP:

RA

TIN

G

TY

PE

SUBSTATIONS

INS

T.

QT

Y

YE

AR

OF

MA

NU

FA

CT

UR

E/

INS

TA

LL

AT

ION

SP

AR

E

TO

TA

L

1 2 3 4 5 6 7 8 9

63A FFO 1 1 1 1 -- 1 -- -- -- 5 1998/1999 5

32A FFO 1 1 1 1 -- 1 -- -- -- 5 1998/1999 5

j) LPDB Details of MCHP:

RA

TIN

G

TYPE

SUBSTATIONS INST.

QTY

YEAR OF

MANUFACTURE

/ INSTALLATION SP

AR

E

TO

TA

L

1 2 3 4 5 6 7 8 9

125A CSSD

125D1 -- -- -- -- -- 1 -- -- 1 1998/1999 1

125A CSSD

125D3 -- -- 1 -- -- -- -- -- 1 1998/1999 1

125A CSSD

125D3 -- -- _ _ 1 -- -- -- 1 1998/1999 1

63A OETL

63K3 1 -- -- 1 -- -- -- -- 2 1998/1999 2

125A FN 125 -- 1 -- -- -- -- -- -- 1 1998/1999 1



Page 204 of 286

k) LT MCC Details of MCHP:

RATING TYPE

SUBSTATIONS

INS

T.

QT

Y YEAR OF

MANUFA

CTURE/

INSTALL

ATION

SP

AR

E

TO

TA

L

1 2 3 4 5 6 7 8 9

630A FN630 _ 2 _ _ _ _ _ _ 2 1998/1999 0 2

400A DM-400 _ _ _ _ _ _ _ _ 4 4 2010 0 4

250A FN250 2 _ 2 2 2 _ _ _ 8 1998/1999 0 8

250A DN2-250N _ _ _ _ _ _ _ _ 2 2 2010 0 2

100A FSB100 _ _ _ _ _ _ 4 _ 4 1998/1999 0 4

100A 3KL5130-

1YA00 _ _ _ _ _ _ _ 4 4 1998/1999 0 4

125A FN125 4 8 2 6 2 _ _ _ 22 1998/1999 0 22

125A 3KL5230-

1YA00 _ _ _ _ _ _ _ 1 1 1998/1999 0 1

63A FN63 3

3

2

1 9

1

8

1

5 _ _ _ 96 1998/1999 0 96

63A FSB63 _ _ _ _ _ _ 1

9 _ 19 1998/1999 0 19

63A 3KL5030-

1YA00 _ _ _ _ _ _ _

1

6 16 1998/1999 0 16

32A FSB32 _ _ _ _ _ _ 5 _ 5 1998/1999 0 5

32A 3KL4730-

1YA00 _ _ _ _ _ _ _ 4 4 1998/1999 0 4

48-50v

DC

TRIPPING

RELAY

VAJH13YF

59B

2 1 2 2 2 _ _ _ 9 1998/1999 0 9



Page 205 of 286

RATING TYPE

SUBSTATIONS

INS

T.

QT

Y YEAR OF

MANUFA

CTURE/

INSTALL

ATION

SP

AR

E

TO

TA

L

1 2 3 4 5 6 7 8 9

48-50v

DC

TRIPPING

RELAY

VAJH13YF

59A

_ 5 _ _ _ _ _ _ 5 1998/1999 0 5

48-50v

DC

EARTH

FAULT

RELAY

CDG11AF0

16SA(M)

4 4 4 4 3 _ _ _ 19 1998/1999 0 19

48-50v

DC

EARTH

FAULT

RELAY

CDG3FF01

4SB(M)

_ 4 _ _ _ _ _ _ 4 1998/1999 0 4

48-50v

DC

OVER

CURRENT

RELAY

CDG31FF0

12SA(M)

6 6 6 6 6 _ _ _ 30 1998/1999 0 30

48-50v

DC

OVER

CURRENT

RELAY

CDG31FF0

14SB(M)

_ 8 _ _ _ _ _ _ 8 1998/1999 0 8

48-50v

DC

TRIP

CIRCUIT

SUPERVIT

ION

RELAY

VAX31ZG8

073B(M)

3 7 3 3 3 _ _ _ 19 1998/1999 0 19

l) Motor Details of MCHP:

SL.

NO. LOCATION

RATING

OF

MOTOR

( KW)

INSTA

LLED

QTY

SPARE

AVAIL

ABLE

YEAR OF

MANUFACTURE /

INSTALLATION

TOTAL

QTY

1 CONV

S3,S4,S7,S8,S13,S14 350 10 1 1999/2001 11

2 CONV R7,R8 450 4 1 1999/2001 5

3

CONV

R3,R4,R5,R6,S5,S6,S9,S1

0, S11, S12

300 14 1 1999/2001 15



Page 206 of 286

SL.

NO. LOCATION

RATING

OF

MOTOR

( KW)

INSTA

LLED

QTY

SPARE

AVAIL

ABLE

YEAR OF

MANUFACTURE /

INSTALLATION

TOTAL

QTY

4 RC#1 (B/W) 200 1 0 1999/2001 1

5 RC#2 (B/W) 200 1 1 1999/2001 2

6 RC(B/C) 200 4 1 2004/2005 5

7 RC BELT FEEDER 90 2 1 1999/2001 3

8 RC(LT) 5.5

96 8 1999/2001 164

9 ST(LT) 60

10 RC(SLEW) 22 6 1 1999/2001 7

11 RC(HPP) 45 2 1 1999/2001 3

12 RC(PCRD) 8.5 2 1 1999/2001 3

13 RC(CCRD) 2.3 2 1 1999/2001 3

14 ST(B/C) 150 4 1 1999/2001 5

15 ST(HPP) 22 2 1 1999/2001 3

16 ST(SLEW) 11 6 1 1999/2001 7

17 ST(PCRD) 8.5 2 1 1999/2001 3

18 ST(CCRD) 2.3 2 1 1999/2001 3

19 SL(B/C) 200 2 1 1999/2001 3

20 SL(SHUTTLE) 37.5 2 1 1999/2001 3

21 SL(SLEW) 5.5 6 1 1999/2001 7

22 SL(HPP#1) 18.5 2 1 1999/2001 3

23 SL(HPP#2) 1.5 2 1 1999/2001 3

24 SL(HPP#3) 2.2 2 1 1999/2001 3

25 SL(HPP#4) 1.5 2 1 1999/2001 3

26 SL(LT) 11 44 1 1999/2001 45

27 SL (CCRD,PCRD) 1.5 4 1 1999/2001 5

28 SL(RAIL CLAMP) 1.5 4 1 1999/2001 5

29 SL(WATER HOSE) 1.5 2 0 1999/2001 2

30 SHUTTLE(TT#1) 11 8 1 1999/2001 9

31 RR1A,1B,2A,2B 400 4 1 1999/2001 5

32 RR1A,1B,2A,2B

(COOLING FAN) 3 4 1 1999/2001 5

33 VIBRO FEEDER 15 4 0 1999/2001 4

34 FLOW DIVERTER 7.5 2 0 1999/2001 2



Page 207 of 286

4.1.18 TECHNICAL DETAILS OF PLC SYSTEM:

a) Automation drive details (VVVF):

Sl

No.

DRIVE TYPE /

DETAILS LOCATION OEM RATING

INSTALLED

YEAR

INSTALLED

QTY.

1 CMIR 616 G5

A 4011 Stacker -Slew

L&T

Automation 11 KW 1999/2000 6

2

CIMR

AD4A0058AMA

1000

Stacker - Long

Travel

L&T

Automation 160KW 2013/2014 2

3

CMIR 616 G5

A 40180C

Reclaimer- Slew L&T

Automation

18.5KW 1999/2000 4

CIMR

AD4A0058AMA

1000

22KW 2013/2014

2015/2016 2

5 CMIR 616 G5

A 41100C

Reclaimer-Belt

Feeder

L&T


6

CMIR 616 G5

A 43000C Reclaimer Long

Travel

L&T

Automation 300KW

1999/2000 1

CIMR

AD4A0058AMA

1000)

2016/2017 1

7

CIMR G5

A 40180C

Shiploader- Slew L&T

Automation

18.5KW 1999/2000 1

CIMR

AD4A0058AMA

1000)

22 KW 2016/2017 1

8 CIMR G5

A 40550C Shiploader- Shuttle

L&T


9 CIMR G5

A 43000C

Shiploader- Long

travel

L&T


10 CMIR G5

A 46000C RRS-Belt Feeder

L&T


NOTE : The Plant is in the process of replacing some of G5 model of VVVF drive into A1000

model VVVF drive.

b) Automation PLC details (Comprising of 21 Nos. PLC network):

Sl.

No PLC TYPE / NO.

INSTALLED

LOCATION OEM

INSTALLED

YEAR TOTAL I/O

1 S7-400 PLC-1 132kv substation Siemens 1999/2000 128

2 * S7-400 PLC-2 SS-6 Siemens 1999/2000 184

3 * S7-400 PLC-3 SS-1 Siemens 1999/2000 384

4 S7-400 PLC-4 SS-1 Siemens 1999/2000 408

5 S7-400 PLC-5 SS-2 Siemens 1999/2000 232

6 S7-400 PLC-6 SS-2 Siemens 1999/2000 232



Page 208 of 286

7 S7-400 PLC-7 SS-3 Siemens 1999/2000 120

8 S7-400 PLC-8 SS-3 Siemens 1999/2000 120

9 * S7-400 PLC-9 SS-4 Siemens 1999/2000 248

10 S7-400 PLC-10 SS-4 Siemens 1999/2000 248

11 S7-400 PLC-11 SS-5 Siemens 1999/2000 120

12 S7-400 PLC-12 SS-5 Siemens 1999/2000 120

13 S7-400 PLC-14 ST-1 Siemens 1999/2000 528

14 S7-400 PLC-15 ST-2 Siemens 1999/2000 528

15 * S7-400 PLC-16 RC-1 Siemens 1999/2000 624

16 * S7-400 PLC-17 RC-2 Siemens 1999/2000 624

17 * S7-400 PLC-18 SL-1 Siemens 1999/2000 672

18 * S7-400 PLC-19 SL-2 Siemens 1999/2000 672

19 * S7-400 PLC-20 PMR Siemens 1999/2000 0

20 * S7-400 PLC-21 PMR Siemens 1999/2000 0

NOTE : The CPUs of above PLCs marked with * have been upgraded from 413-1 to 412-1/412-2.

c) Details of Monitoring 8 Control stations:

Location Equipment installed Purpose

Plant Monitoring Room WinCC panel – 3 Nos.

V-7.0 / OS- WinXP

For monitoring & control of

plant operation

RRS Control station

WinCC panel – 2 Nos.

V-4.0 / OS- Win95/WinNT /

Win2000

For monitoring & control of

receiving stream

Reclaimer-1 MP-370 For monitoring & control of

Reclaimer-1

Reclaimer-2 MP-377 For monitoring & control of

Reclaimer-2

Stacker-1 MP-370 For monitoring & control of

Stacker-1

Stacker-2 MP-370 For monitoring & control of

Stacker-2

Shiploader-1 OP-37 For monitoring & control of

Shiploader-1

Shiploader-2 MP-370 For monitoring & control of

Shiploader-2



Page 209 of 286

4.1.19 RAIL RECEIVAL STATION, ARC GATE,COMPRESSOR AND VENTILATION

SYSTEM:

1.Rail Receival Station:

Number of Tracks : 2 Nos.

Name of Manufacturer : L&T

Design Operation:

Unloading Capacity : 4000 TPH

Length of Track : 50 m each

Gauge : 1750 mm

Hoppers : 2 Nos. / Track

Capacity of Hoppers : 350 Ton

2.Arc Gate:

Make : Hindustan Machine Tools Corporation

Type : Hydraulic operated

Location : For conv. R-1A, R-1B, R-2A, R-2B

Quantity : 4 Nos.

Hydraulic cylinders : Stroke – 675 mm

Working stroke – 670 mm

Power pack : 2 Nos.

Power pack oil specification : SERVO SYSTEM 68

Qty of oil : 550 lts

Oil changing duration : 12 months

3.Compressor:

Sl. No.

Compressor Tpe

Model Make Qty. Free Air Deliver

Working Pressure

Oil type Oil

Qty. Motor Power

Motor Rated Speed

1 Screw

Compressor E30-13 ELGI

02 Nos.

4.53 m3/min

9.5 kgf/cm2

Air Lube Plus

20 Ltr. 30 KW 1467 RPM

2 Reciprocating base mounted

HV 40 100

ELGI 02

Nos. 3.40

m3/min 10

kgf/cm2 Servo SP 150

3 ltr. 40 HP 1470 RPM

3 Reciprocating Tank mounted

TS 15 120

ELGI 01 No.

1.06 m3/min

12 kgf/cm2

Servo SP 150

1.1 ltr. 15 HP 1500 RPM



Page 210 of 286

4. Ventilation System:

Location : Substation SS1, SS2, SS3, SS4, SS6. RRS and

tunnel of R-3, R-4.

Make : M/s C Doctor & Co. Pvt. Ltd.

System No. V-1A V-2A V-3A V-6A V-8A

Location SS1 SS2 SS6 SS3 SS4 RRS Tunnel

Fan size 182

SWS1

200

SWS1

200

SWS1

150

SWS1

165

SWS1

402

SWS1

402SWS

1

Fan speed 1652 1485 1671 1924 1800 857 960

System

cap.m3/hr

6000 6000 6000 6000 6000 6000 6000

Motor make ---------------------------------- CROMPTON & GREAVES---------------------

--------------

Motor

rating 2.2 3.7 3.7 1.5 2.2 11.0 15.0

Nos. of

grills 10 6 7 7 10 20 20

Grill size 275 x

150

300 x

300

600 x

150

230 x

150

225 x

150

400 x

200

400 x

200

Pump, make ---------------------------------- KIRLOSKAR -------------------------------------

------------

Cap., m3/h

Pump

model KDS355 KDS225 KDS355 KDS355 KDS355 KDS225 KDS225

Total head

in meter 25 30 30 30 30 25 25

Pump motor

cap.

kW/pole

2.2/’2 1.5/2 2.2/2 2.2/2 2.2/2 1.2/2 1.5/2



Page 211 of 286

4.1.20 CHUTE DETAILS:

Location Head Chute

(in Nos.)

Intermediate

Chute

(in Nos.)

Lower Chute

(in Nos.)

Skirt Board

(in Nos.)

Spill over

chutes

(in Nos.)

TT-1 4 16 16 16 0

TT-2 1 1 1 1 0

DT-4 0 0 0 0 1

DT-5 0 0 0 0 1

TT-6(A) 1 1 1 1 0

TT-6(B) 1 1 1 1 0

TT-7 2 2 2 2 0

TT-8 2 2 2 2 0

DT-9 0 0 0 0 2

4.1.21 TRACK LINE OF MACHINES.

a) Track line of Reclaimers:

Track centre : 14 m

No. of Tracks : 2 Nos.

Gauge Distance : 1074 ± 3 mm

Rail size : 60 kg/m

Reclaimer bund length : 1152 m

Pre-stressed Concrete Sleeper : 1700 / track

b) Track line of Shiploaders:

Gauge : 12 m

Rails : ISCR 100

c) Track line of Stackers:

No. of Tracks : 2 Nos.

Length : 1150 mtrs

Gauge Distance : 1074 ± 3 mm

Track Centre : 12000 ± 10 mm

Pre-stressed Concrete Sleeper : 1700 / track

4.1.22 BELT WEIGHING SYSTEM:

Belt Scale

Type : Electronic, digital totaliser with indicator

Flow indicator : Digital type

Make : Power Build Ltd.

Model : Micro – Mate (100 – 2001)

Location : On Conv. No. S-13, S-14,

Stacker (2 Nos.)

Belt speed, : 4 m/sec

Belt width, mm : 1800

Troughing angle, degree : 35

Accuracy : (minimum) 0.5 over the range of

1000 to 5000 t/h

Total installed Qty. : 04 Nos.



Page 212 of 286

4.1.23 TRAMP MAGNET:

Make : ERIEZ MAGNETS, SE-7938


Location : R3, R4 & S3, S4

Operating Height : 700 to 800 mm from the centre top of

belt

Cooling requirement : Oil cooled

Oil Specification : TEXACO – 55

Oil Qty. : 1750 Ltrs. for each

Operating Temp. : 70C

Electro magnet coil material : Aluminum

Size and weight of Tramp iron : Rail wagon brake shoes, reclaimer

to be lifted bucket teeth, round bars 25 dia x 1000m, plate

upto 300 x 300 x 12mm thick

4.2 AUXILIARY SYSTEM:

4.2.1 RAW WATER, SEWAGE WATER & EFFLUENT WATER PUMP HOUSE:

Sl.

No. Location Specification Qty.

Date of Purchase

/ Receipt from

other department

1

RWPH

Model No.: DSM 150/38 A

Head: 40 Mtrs.

Capacity: 270m3/Hour, 50 KW

Make: Kirloskar Brothers Ltd.

Serial: 174600-6156 to 6157

2 Nos 2007

2

Model: KV 30, Size: 32x32, 2840 RPM,

Max. Vaccum developed: 65mm of Hg,

Max. Intake rate: 55.0 m3/Hr., Working fluid

pressure: 0.15 Kg/cm2, KW/HP: 2.2/3, 4.7

Amp., 415 Volt, Serial: A7CAJL0290

1 No. 2007

3 SWPH

Head: 50 Mtrs.

Capacity: 50m3/Hour, 5.5 KW

Make: Kirloskar Brothers Ltd.

2 Nos 2001

4 EWPH

Head: 11 Mtrs.

Capacity: 25m3/Hour, 1.1 KW

Make: Mather & Plate

2 Nos 2001

Raw Water Pipeline details:

Sl.

No. Location

Size of Pipe (UPVC) Size of Pipe (MS)

250NB 200NB 150NB 100NB 80NB 250NB 80NB

1 RWPH to PWPH 3381.5 120 23.8

4.2.2 POTABLE WATER SYSTEM:

Size of UPVC pipe

25 NB 65 NB 80 NB 100 NB

250 m 2500 m 900 m 900 m



Page 213 of 286



Page 214 of 286

4.2.3 DG SET:

Engine Specifications

Make Caterpillar

Number of Cylinders 12 – V – 65 deg

Bore 137mm (5.4 in)

Stroke 152mm (6.00 in)

Aspiration T or TA or STA

Displacement 27L (1689 cu.in)

Firing Order 1-4-9-8-5-2-11-10-3-6-7-12

Rotation (viewed for flywheel) Counterclockwise

AC Generator Specifications

Make Kirloskar Electric Co. Ltd.

Frame 4AB 355/D2

KVA 500

RPM 1500

VOLT 415

AMP 695.6

EXTN 52.0 V

EXTN 1.5 A

PROTECTION XXXX

P.CODE FEROT CODE-2916

RATING S1TD IS-4722-1992, STF-/RT=/EX F, ALTD-

1000M

HZ 50

PH 3

CONN STAR

COOLANT TEMP 40OC

VIEWING AT DRIVEN END CW/ACW

BEARINGS DE-6319 / NDE-6316-22

M/C NO. 9731013-04

4.2.4 AIR CONDITIONING INSIDE MCHP CANTEEN & PMR

a) Central Air Conditioned Package of Plant Monitoring Room Technical Details:

Compressor:


Make : ACCEL

Model : SMC/8/65

Ton : 25

Gas : R22

Motor:


Make : ABB

Rating : 30 KW / 40 HP

Chiller pump , Condenser pump:


Rating : 5 HP

Make : Best crompton Engg. Ltd., Madras



Page 215 of 286

AHU:


Make : ABB

Rating : 3.7 KW / 5 HP

Cooling Tower:


Rating : 2.2 KW

b) Package Air Conditioned System of MCHP Canteen:

11 TR Unit:


Make : Blue Star

Model : D.P.A 132 1R1-I

NOM Capacity : 33000 KCal / Hr.

Power Supply : 415 V, 3 Phase, 50 Hz, 23 A

Gas : R-22

5.5 TR Unit:


Make : Blue Star

Model : DPA 66 1R1-I

NOM Capacity : 16500 KCal / Hr.

Power Supply : 415 V, 3 Phase, 50 Hz, 13 A

Gas : R-22

c) Air Conditioned System of All substations, machines, amenity building and workshop:

RA

TIN

G

TY

PE

SUBSTATIONS

AM

INIT

Y

BU

ILD

ING

WO

RK

SH

OP

MACHINES

1 2 3 4 5 6 7 8 9

S

T-

1

S

T-

2

R

C

-

1

R

C

-

2

SL

-1

SL-2

15T Package

AC 1 1 1

10T Package

AC 3 1 2

2.5T Split 2 2

1.5T Split 1 1 1 1 1 1 1

1T Window 1

3T Split 2 4 3

2T Split 2 2 2 2



Page 216 of 286

4.3 HEAVY EQUIPMENT:

Specification Make Capacity Quantity

Hydra Crane ACE 11 Ton 2 Nos.

Pay-loader- BL200 BEML 1.7m3 1 No.

Pay-loader-BL40 BEML 4.7m3 1 No.

Maintenance Vehicle (SA 1210),

Crane mounted (N80) with

Portable Welding Diesel Generator-II

TELCO 10 Ton 1 No.

National Crane

TIL Ltd. 2 Ton 1 No.

ESSAB 1 No.

Maintenance Vehicle ( SA 1210),

Crane mounted (N80) -I TELCO 10 Ton 1 No.

National Crane

TIL Ltd. 2 Ton 1 No.

4.4 ILLUMINATION:

Illumination Details of MCHP

DE

SC

RIP

TIO

N O

F L

IGH

T

SU

BS

TA

TIO

N

09 N

os.

TR

AN

SF

ER

TO

WE

R

09 N

os.

CO

NV

EY

OR

24 N

os.

HIG

H M

AS

T

TO

WE

R

23 N

os.

MA

CH

INE

(ST

/RC

/SL

)

06 N

os.

TO

TA

L

INS

TA

LL

ED

QT

Y

2 X 40 WATTS

TUBE 273 NIL NIL NIL 51 324

1 X 70 WATTS

HPSV 1 190 986 NIL 488 1665

1 X 150 WATTS

HPSV NIL 12 12 NIL NIL 24

1 X 250 WATTS

HPSV 55 11 54 NIL NIL 120

1 X 400 WATTS

HPSV 15 11 26 NIL 56 108

2 X 400 WATTS

HPSV NIL 5 3 276 NIL 284

4.5 EOT CRANES, ELECTRICAL & MANUAL HOISTS:

4.5.1 ELECTRIC OPERATED TROLLEY CRANE:

Location Make Capacity Span length Quantity

Workshop Reva 8 Ton 18 m 01 No.

Workshop Reva 16 Ton 18 m 01 No.



Page 217 of 286

Location Make Capacity Span length Quantity

TT-1 Reva 8 Ton 11.5 m 2 Nos.

RRS Top* Reva 16 Ton Mono rail /

ISMB-600 4 Nos.

RRS Bottom Reva 16 Ton Mono rail /

ISMB-600 2 Nos.

Ship loader Demac 2 Ton Mono rail /

ISMB-250 2 Nos.

Tramp Magnet Reva 15 Ton ISMB-500 4 Nos.

* Removed & kept at Workshop

4.5.2 MANUAL HOIST

Make Reva Industries Ltd

Loc. T8 T8 BIN T7 T7 T6 T6 T4/

T5

T2/

T3

T2/

T3

T1 RR

S

RR

S

RR

S

Cap. 7.5 5 10 6.5 8.5 7.5 6.0 10 5 7.5 5 12.

5 10 5

Nos. 1 1 2 1 1 2 2 6 2 2 6 4 5 1

Lengt

h

14.41

3

14.7

9

10.22

5

16.5

0

15.

0

13.0

0

13.0

0

9.6

5

13.7

5

13.7

5

6.5

0

6.0

0

6.0

0

5.0

0

4.6 CATHODIC PROTECTION:

Cathodic protection system is a process for mitigating corrosion on a metallic structure in

contact with a corrosive electrolyte by introducing an electrolytic action greater in strength

and opposite in direction to the electrolyte corrosion activity. Based on this principle a CP

system has been designed, installed and commissioned to protect all the steel piles of the

Mechanised Coal Handling Plant jetty.

The overall protection area is the Mechanised Coal Handling Plant jetty. The protections are

is split into four parts.

1) Main Wharf

2) Access bridge

3) Mooring dolphin

4) Maintenance roadway and conveyor support

The CP system installed is an impressed current cathodic protection (ICCP) utilizing mixed

metal oxide (MMO) anode with transformer rectifier to power the system and also other CP

components were also installed to complete the installation of the CP system. The system

comprises of 392 Nos. of Steel tubular piles.

The ICCP system for the protection of tubular piles comprises of 2 Nos. oil cooled

transformer rectifier units (DC output 15V/ 600A), 86 Nos. mixed metal oxide tubular

anodes (1.25” dia x 48” long), 13 Nos. anode junction boxes and associated cables. Two

separate monitoring terminals (M1 & M2) have been provided in each junction box to

monitor performance of cathodic protection system.



Page 218 of 286

Technical details;

Sl.

No. Description Qty.

1

Transformer rectifier oil cooled, 600A/15V output, step control,

415V, 3 phase 4 wire with necessary transducer for converting

current output to 4-20mA signal for alarm relay output.

2 Nos.

2

Impressed current anode (mixed metal oxide anode) 1.25” dia x

48” long, connected with 1x 16mm2 Halar / HMWPE cable

86 Nos.

3 Anode junction box with resistors / shunts and two monitoring

point each. 13 Nos.

4 Ag/Agcl reference electrode for potential measurement 2 Nos.

4.7 COMMUNICATION FACILITY;

VHF COMMUNICATION, INTERCOM ETC.

a) VHF Communication:

Basically the VHF systems are used for communication purpose at different locations of the

plant for smooth operation and maintenance of the plant.

There are two types of VHF sets in use (MOTOROLA Make)

i) Fixed Station (Base Station) – GM-338 - 21 Nos.

ii) Hand Set – GP-338 - 65 Nos.

iii) Repeater for signal enhancement - 04 Nos.

b) Intercom:

All machines / substations are equipped with intercom facility & centrally controlled from

PMR. .



Page 219 of 286

4.8 CLEANLINESS / HOUSEKEEPING:

4.8.1 DRAIN LAYOUT & DETAILS:



Page 220 of 286

Drain details:

D1/1 92.5 D1/12 87.5 D1/23 97.5 D1/2 370 D1/13 45 D1/24 74.5 D1/3 47.5 D1/14 75 D1/25 15 D1/4 107.5 D1/15 95 D1/26 326.5 D1/5 64 D1/16 50 D1/27 567.5 D1/6 50.1 D1/17 207 D1/28 574 D1/7 90 D1/18 125 D1/29 767 D1/8 67.5 D1/19 11.5 D1/30 17.5 D1/9 80 D1/20 11.5 D1/31 37.5 D1/10 7.5 D1/21 35 D1/32 65 D1/11 45 D1/22 26.5

D1 Total: 4332.6

D2/1 105 D2/3 135 D2/5 23.5 D2/2 D2/4 130

D2 Total: 393.5

D3/1 205 D3/2 180 D3 Total: 385

D4/1 47.5 D4/2 55 D4 Total: 102.5

D5/1 82.5 D5/3 927.5 D5/5 440 D5/2 57.5 D5/4 432.5

D5 Total: 1940

D7/1 127.5 D7/3 127.5 D7/2 122.5 D7/4 127.5 D7 Total: 505

D8/1 571.5 D8/2 150 D8 Total: 721.5

D9/1 57 D9/3 57 D9/2 57 D9/4 57 D9 Total: 228

D10/1 177.5 D10/2 240 D10 Total: 417.5

D11/R7 1200 D11/S3 1200 D11/R8 1200 D11/S4 1200 D11 Total: 4800

D1/Tunnel to Plot 87.5 D1/SS2

Surrounding 90

D1/Tunnel to RRS

front side 57.5 D1/RRS Back side 46.5 D1 Total: 281.5

D1/SS3

Surrounding 80

D1/SS6

Surrounding 185

D1/workshop

surrounding 200

D1/SS4

Surrounding 150 D1 Total: 615

Total Length: 14722.1



Page 221 of 286

Note:

Width (in mm)

D1 400

D2 500

D3 600

D4 750

D5 900

D7 3000

D8 3250

D9 4940 – 5260

D10 3.96 - 6.716 3.13 - 3.295

D11 2000



Page 222 of 286

4.8.2 GRASS & BUSH CUTTING & DETAILS:



Page 223 of 286

Grass & Bush Cutting area details:

Location (Approx.) Area in Sq. mtr.

PMR surrounding area 4000

Canteen surrounding area 1000

Change Room surrounding area 1000

SS-7 surrounding area 200


TT-8 surrounding area 1000

TT-6 to TT-7 surrounding area 3500

Workshop surrounding area 1000


Change Room to TT-6 service road area 1000


Sewage pump house surrounding area 1000

TT-1 to TT-2 Area 500

R6 Front room surrounding area 500

Slope TT-1 to S-3/4 track 1000

Slope TT-2 to R-8 track 1000

Slope TT-3 to R-7 track 1000

Slope DT-4 to R-8 track 1000

Slope DT-5 to R-7 track 1000

Slope Stack-yard-1 R7 side 15000

S3 side 15000

Slope Stackyard-2 R8 side 15000

S4 side 15000

Slope R-8 track to pond 15000

Slope R-7 track to Service road 15000

SS-1 to SS-3 Service road 6000

SS-3 to TT-6 Service road 6000

TT-1 to RRS 2000

SS-6 front to Tunnel surrounding 2000

Process pump house surrounding 1000

Process pond service road surrounding 1000

Effluent pump house 1000

Raw water pump house 1000

Yard Toilet surrounding 1000

Sewage pond surrounding 1000

R8 track main drain to R7 track main drain 2000

PMR to SS-1 service road 1000


Surrounding SS#1 Area 1000


Settling pond Surrounding area 1000

Watch Tower-1 Service road 2000

Watch tower-1 to Railway point area 1000

Gate No. 2 to Railway point area 2000

R7 Service Road 1500

R8 Service Road 1500

S3 / S4 Service Road 1500

Total: 150000



Page 224 of 286

4.9 PAINTING AREA OF THE PLANT:

Location Approximate Structural Surface Area

(in Sq. mtr) D

rive/

Tra

nsf

er T

ow

er: TT-01 17,500

TT-02 1084

TT-03 1416

DT-04 1338

DT-05 1338

TT-06 (A+B) 3035

TT-07 4581

TT-08 2186

DT-09 1770

Mac

hin

es:

STACKER-01 5041

STACKER-02 5276

RECLAIMER-01 6,902

RECLAIMER-02 6,902

SHIPLOADER-01 6,934

SHIPLOADER-02 6,800

Convey

ors

:

S-11 CONVEYOR 3904

S-12 CONVEYOR 4244

SURGE BIN & STRUCTURE 5456

S-14 CONVEYOR 8677

S-13 CONVEYOR 8790

CONVEYOR S#10 3149

CONVEYOR S#09 3149

CONVEYOR S#08 2630

CONVEYOR S#07 2695

CONVEYOR-S#06 1620

CONVEYOR S#05 1377

CONVEYOR S#04 5051

CONVEYOR S#03 5051

CONVEYOR R#8 3909

CONVEYOR R#7 3909

CONVEYOR R#6 1006

CONVEYOR R#5 1006

CONVEYOR R#4 1339

CONVEYOR R#3 1433

RRS 11472

WORK SHOP 12350

MISC. STRUCTURE 2000

STRUCTURE AT SS 1050

DCS PIPE & STRUCTURALS(EXISTING) 5630

Total: 1,73,000



Page 225 of 286



Page 226 of 286



Page 227 of 286

SCOPE OF WORK

Clause No. Description

1.0 BROAD SCOPE OF OPERATION AND MAINTENANCE OF MCHP

2.0 EXCLUSION FROM THE O&M OF CONTRACT

3.0 SERVICES DURING THE MOBILIZATION PERIOD

4.0 STANDARDS OF PERFORMANCE OF SERVICES

5.0 SERVICES DURING TERM OF CONTRACT

6.0 OTHER WORKS

7.0 MONTHLY REPORTS

8.0 FINAL INSPECTION, ACCEPTANCE AND PAYMENT


Page 228 of 286

SCOPE OF WORK

The Mechanized Coal Handling Plant (MCHP) in Paradip Port Trust was commissioned on

Dt.11.09.2001. The coal handling system consists of a Rail Receival Station (RRS) with two

parallel train unloading pits, a two row stockpile with two stacking conveyors having one Stacker in

each line, two reclaiming lines in between the stockpiles with two Reclaimers over the same track

and two Ship-loaders on the wharf. The system can unload two trains and load two vessels at the

same time. The stacking, reclaiming and ship-loading capacities are 4000TPH in each stream with

designed annual plant capacity of 20 Million Tons which is enhanced to 28 Million Tons.

Paradip Port Trust now intends to outsource the “Operation & Maintenance (O&M) of the

Mechanised Coal Handling Plant (MCHP)” in a consolidated manner to a resourceful outside

agency with sufficient expertise in the field. The main objective of the work “Operation and

Maintenance (O&M) of Mechanized Coal Handling Plant (MCHP)” is underlined below.

i) To ensure efficient, safe, and reliable operations of the Plant.

ii) To maintain the plant in a healthy and efficient condition.

iii) To ensure high availability of the plant in a consistent manner.

Therefore this contract will be an outcome based service agreement, vesting responsibility

on successful bidder to achieve the desired level of performance.

It may be noted that Mechanized Coal Handling Plant has been designed to handle sized

coal of -100 mm size. However, BOBR wagons received at RRS very often contain oversized coal,

big size coal, boulders, stones & concrete blocks etc.. There is provision of grids in the RRS hopper

having width maximum up to 250mm in order to prevent the big size coal / oversize coal / stones /

concrete blocks etc. from directly falling into the hopper. The coal having size more than 250mm

are getting accumulated over the grid and the same is being pushed to hopper after breaking the

same to the required size. Also impact idlers under the chutes have been provided. Due to handling

of big size coal / oversize coal / stones / concrete blocks etc., belt damages like pot hole & through

cut has been occurred .In the last 5 years, around 1800 mtrs of Conveyor belts have been replaced

due to through cut by foreign material. In addition to above temporary repairs in form of Hot

vulcanizing patch has been carried out in many occasions. The bidder while quoting the price shall

take into account the prevailing situation and will integrate the repairing/replacement cost in the

O&M price without any additional claim provision towards damage claim. Accordingly the

successful bidder is advised to plan and execute the operation and maintenance of MCHP at his

own cost without any price implication to Paradip Port Trust as per the scope outlined in this

section.

Also, in case of exigency, cargo other than coal i.e. iron ore pellet, iron ore fines and coke

are to be handled in the Plant for a temporary period without any additional financial implication.

Scope of Work


Page 229 of 286

1.0 BROAD SCOPE OF OPERATION AND MAINTENANCE OF MCHP:

The scope of the contractor shall cover the following broad functional activities:

1.1 Operation and Maintenance

1.1.1 Operation and Maintenance of main system of plant;

Main system consists of

i) Rail Receival Station (RRS) including pneumatic system, ARC gate, and ventilation

System of RRS.

ii) All machines i.e. Stackers (2 Nos.), Reclaimers (2 Nos.), Ship-loaders (2 Nos.)

iii) 33/6.6 KV substation (1 no.) & 6.6KV/415V substations (8nos.)

iv) PLC Network comprising of 21 PLCs.

v) VVVF drives.

vi) Conveyor system comprising 10 nos. receiving conveyors and 10nos. shipping

conveyors.

vii) Transfer towers, drive towers, etc.

viii) Belt Weighing system and Tramp magnet.

ix) Air conditioning System of substations, machines, amenity building near RRS,

workshop and belt-weighing room.

x) Ventilation System in all Substations.

xi) Track-line of Ship-loaders, Reclaimers, Stackers and RRS.

xii) All Plant structures, technological structures, Chutes, hoppers, walkway, handrails,

conveyor galleries, etc.

xiii) All safety devices, field devices and monitoring devices.

xiv) Cable Networking (HT, LT, Control &Communication) of plant.

1.1.2 Operation and Maintenance of Auxiliary System;

Auxiliary System consists of

i) Raw water pump house and raw water pipe line.

ii) Sewage and Effluent system,

iii) Potable Water System

iv) 500KVA D.G set

v) Sump Pump and slurry disposal system in tunnel

vi) Air Conditioner System inside MCHP Canteen and PMR.

1.1.3 Operation and Maintenance of Heavy equipments.

Heavy equipments consist of

i) Hydra Crane-I (11 T)

ii) Hydra Crane-II (11 T)

iii) Pay loader-BL200

iv) Pay loader-BL 40

v) Maintenance Vehicle-I

vi) Maintenance vehicle-II with DG set.

Scope of Work


Page 230 of 286

1.1.4 Operation and Maintenance of Illumination System of plant including High mast lighting

systems installed /fitted in different equipment /areas viz:

i) Conveyors and conveyor galleries

ii) Transfer / Drive towers, tunnel.

iii) Rail Receival Station

iv) Substations lighting (Indoor and Outdoor)

v) Amenity building, compressor room, change room, pump houses, plant monitor

room, building at top & down railway point, watch tower buildings, workshop, yard

toilets and other buildings in MCHP premises.

vi) Stackers, Reclaimers & Ship-loaders.

vii) Security gate No.1

viii) Other working and non working areas.

1.1.5 Maintenance of Cathodic Protection System and hand-railings of Coal Berth i.e. CB-1 &

CB-2.

1.1.6 Maintenance of EOT cranes, hoists, electrical hoists of plant and belt splicing machine.

1.1.7 Maintenance of communication facility such as intercom, VHF communication, etc.

1.1.8 Maintenance including maintenance of civil installations.

Buildings consist of 9 nos. of substations, amenity building, change room, compressor

room, pump houses, plant monitor room, building at up & down railway point, tunnel, RRS

& feeder, transfer tower/drive tower pits, pedestals of columns & stringer post, watch tower

building, workshop, belt weigher room near TT#8, cable pits and yard toilets, etc.

1.1.9 Housekeeping and cleanliness of plant.

It includes conveyors, machines, substations, drive towers, transfer towers, RRS, Tunnel &

pits, all the buildings and near all watch tower, etc and shifting of debris to the earmarked

locations. It also includes cleaning of all internal drains, grass/bush cutting inside plant and

disposal.

1.2 Proper stores management and inventory control of spares with supply of all types of spares

including imported spares, store items, conveyor belts, steel materials, consumables, T&P,

special T&P and instruments, etc. Stores management like record keeping, spares part

planning, consumables planning and procurement is under the scope of the Contractor.

1.3 Administration, Engineering support, Safety, Training, Record keeping and report

generation, Management Information system.

1.4 All other works, facilities and services required for successfully achieving the objectives of

O&M of the plant and other obligation of the contract are included in the scope of work.

1.5 The liasioning activities with agencies related to RRS and backloading operation such as

Railways and Traffic Department of PPT.

1.6 Operation & Maintenance of existing Dust Control System and Process water pump house.

1.7 Cleaning of debris beneath the conveyor galleries, service roads and coal berths.

1.8 Operation of ERP.

1.9 Minor repairing of defective wagons at RRS.

N.B Operation of main stream means operation of two shipping streams and two receiving

streams including RRS operation but excluding back-loading operation.

Scope of Work


Page 231 of 286

2.0 EXCLUSION FROM THE O & M CONTRACT.

i) The liasioning activities with Shipping agents, cargo agents, handling contractor for

loading operation.

ii) Operation of Arc Gate, Shipping Conveyor S11 & S12, Switch Bin, Flow Diverter,

Rack & Pinion Gate, Vibro Feeders.

iii) Maintenance of Flow Diverter, Rack & Pinion Gate, Vibro Feeder.

iv) Civil maintenance of (i) internal and outside drains, (ii) Settling & Process ponds and

sewage ponds, (iii) Maintenance of Main roads and Service roads.

v) Stack-yard Management.

vi) MCHP Canteen operation and maintenance.

vii) Cleaning of outside drain.

viii) Plant horticulture.

ix) Disposal of spillage coal.

3.0 SERVICES DURING THE MOBILIZATION PERIOD:

The plant will be handed over by PPT and taken over by the successful bidder for

O&M of the plant on dtd.01.11.2017 in operating condition on “As is where is basis”.

However the successful bidder upon being selected for Operation and Maintenance (O&M)

of Mechanized Coal Handling Plant shall be provided maximum 30 days for mobilization

prior to 01.11.2017.

Services during mobilization period includes following activities

3.1 ESTABLISHMENT

3.1.1 The contractor shall set-up its establishment such as office & office facilities and initiate

related activities for taking over the plant and equipment for operation and maintenance

w.e.f. 01.11.2017.

3.1.2 Nomination of Authorized representative.

The Contractor shall nominate his representative as Over All In-Charge for the Contract to

ensure that all the obligations under the Contract are discharged smoothly. He shall be

authorized and empowered by the Contractor on all matters concerning this Contract. In all

such matters, the Contractor shall be bound by the communications, directions, requests and

decisions issued in writing by the Contractor’s Representative.

The Contractor’s representative will report to the PPT’s designated officer(s) in matters

relating to performance of the Services under the contract.

3.2 STAFF SELECTION & DEPLOYMENT

3.2.1 The Contractor shall ensure that all the required personnel / resources are available at the

time of the handover so as to be able to appropriately takeover and commence the intended

services in relation to each systems and equipments.

3.2.2 The Contractor’s personnel shall be recruited and/or deputed by the contractor whose trade,

grade, experience and qualification shall suit to the intended purpose.

3.2.3 The Contractor shall submit organization structure and job descriptions in reasonable details

for each category of the contractor’s personnel (O & M staff) and staffing plan before

commencement of work for a) administration, b) operation of two receiving stream and two

shipping streams including PMR operation & other auxiliary services and c) maintenance of

plant and equipments to support round the clock operation of plant including all the scope

described at Clause No.1.0 of Scope of Work.

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3.2.4 The Contractor shall submit a consolidated list of contractor’s personnel (O&M staffs)

indicating the name, date of birth, trade, grade, experience, qualification etc. for the

operation and maintenance of the plant and equipment.

3.3 PRELIMINARY WORKS FOR SMOOTH HANDING OVER AND TAKING OVER OF

THE PLANT

3.3.1 The handing over and taking over process includes joint inspection of the plant, equipment,

systems, buildings, substations, spares and store items, mobile equipment by the

representative of Purchaser and the Contractor. The joint inspection report shall contain the

condition and status of the plant, equipment, systems, buildings, substations, spares and

store items, mobile equipment with specific comments on the detected visual abnormalities.

These Report / documents are treated as base level document for effecting proper operation

& maintenance planning and monitoring. PPT will provide all drawings, manuals, past

maintenance record and major failures, test records, log books etc. if available, to the

Contractor.

3.3.2 The spares and stores items, consumables and lubricants available in good condition with

Paradip Port Trust applicable for the plant and equipment shall be handed over to the

Contractor for safe custody and use. During handing over of spares, stores and consumables,

a list shall be prepared indicating the details through joint inspection.

3.3.3 Development of formats, schedules and procedure acceptable to the EIC during the term of

the contract for reporting the feed-back, status of O&M activities and maintaining records &

log books, etc. shall be the responsibility of the Contractor.

4.0 STANDARDS OF PERFORMANCE OF SERVICES:

The Services shall be performed in accordance with the express and implied standards

including the following:

a) The provisions of this Contract.

b) The Operating logic of Plant.

c) Obtaining forecast of rakes, providing starting order for movement of empty rakes to

backloading zones / Station and load BOBRN rakes from backloading zones to

Station, operation of receiving stream including rake unloading operation in co-

ordination with Loco-driver of East coast Railway, and Shipping streams w.r.t hatch

plan of vessels & in coordination with authorized representative of vessels. Sharing

of operational informations as per requirement.

d) Operation and Maintenance as per the O&M Manuals taking into account the current

status of plants and equipment.

e) Prudent Utility Practices.

f) All Directives.

g) Compliance with Dock safety regulation and all relevant orders & directives of PPT

and regulating Authorities i.e. Dock Safety Inspector or any Govt. Authority

appointed under any law from time to time.

h) Compliance with statutes, regulations as per clause 16.0 of GCC.

i) Compliance with the provision of Major Port Trust’s Act, 1963 as amended from

time to time, by laws, rules & regulations made there under, any administrative or

other directions given under the said Act and all other statutory enactment in relation

to the “Operation and Maintenance of MCHP.”

j) Quality Control in accordance with the requirement of ISO.

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k) The contractor shall agree and undertake not to use the Plant and MCHP site for any

purpose other than for the work or any other designated purposes specified in the

contract without obtaining prior written consent from PPT.

l) Operate and Maintain the plant facilities & services in accordance with sound

industrial practice, financial & administrative practice and ensuring that the plant

facilities and services to be transferred to PPT on expiry of the contract period in

good working condition.

5.0 SERVICES DURING TERM OF CONTRACT:

5.1 GENERAL

5.1.1 Contractor’s personnel

a) “Contractor’s Personnel” mean the Managers, engineers, supervisors, technicians and

other personnel including labours to be provided and deployed by the Contractor for

smooth Operation and Maintenance of the Plant.

b) The Contractor must engage appropriately trained, qualified and experienced staff for

smooth, safe & trouble free operation and maintenance of the machine/

equipment/system, as applicable. The core personnel of the contractor including

engineers so deployed must have adequate qualification & experience in their

respective fields such as assembly and sub-assembly of the machine/system

/equipment, electrical circuit of electrical power/control system, PLC & VVVF

system (Automation System), maintenance of HT/LT equipment, lighting system,

earthing system, hydraulic system, structural, Dust Control System etc. preferably in

Bulk Material Handling Plant and are in a position to rectify any defects developed

during the operation of the Plant with minimum down time.

c) The Contractor shall deploy adequate workmen such as operator, electrician, fitter,

etc so as to discharge all the obligations under the contract during the contract period.

In emergency situations, the Contractor shall plan and make arrangements and bear

all the costs associated with such arrangements for ensuring the presence of staff on-

site for uninterrupted operation and maintenance of the Plant.

d) Where PPT reasonably determines that the Contractor has not employed the required

resources at the Plant for the Services, then PPT shall have the right to ask the

Contractor to arrange for such resources. In case the contractor does not respond

reasonably within eight hours period from the receipt of PPT’s request, PPT shall

have the right to arrange for such resources at the cost of the Contractor.

e) The normal deployment of Contractors’ personnel shall be preferably on 8 hrs. basis

per day. However, in exigencies, extended duty may be performed by the

Contractors’ personnel. The duty hour for each shift shall be 8 hours. Extended duty

beyond the shift hour can be adopted only on special requirements and certainly not

as a practice.

f) The Contractor must disengage immediately the workmen in case of indiscipline,

misconduct, negligence in duty, suppression of facts, deliberate mishandling of

machine & equipment, sabotage, professional incompetency etc and replace him with

due intimation to PPT.

g) Any damage caused by the workmen engaged by the Contractor to any machinery or

equipment or installation of PPT due to negligence, ignorance or malafide intention

shall be made good at the cost of the Contractor within a reasonable period of time

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acceptable to PPT, failing which the cost of the damages assessed by PPT shall be

deducted from the bill of the Contractor or any money due to the Contractor.

h) All individuals engaged in the performance of the Contractor’s obligations under this

contract shall be the employees of the Contractor and their working hours, rates of

compensation and all other matters relating to their employment shall be determined

solely by the Contractor in accordance with the applicable laws & regulations. The

Contractor shall be solely responsible for employment policies that specify the

requirements for staff working under him and such policies are to be consistent & in

conjunction with the applicable labour laws and any government directives

applicable on the PPT.

i) During the continuance of the Contract, if the Contractor intends to induct new

workmen or make alterations in their grade, the Contractor shall communicate the

same for appraisal of PPT.

The Contractor shall employ a shift-in-charge in each shift for overall co-ordination of operation

and maintenance of the plant apart from managers, engineers, supervisor for different

departments/systems /equipments and Overall-in-charge, who will oversee and be responsible for

all the functions of plant operation and maintenance. The shift-in-charge shall co-ordinate with

shift –in-charge of PPT posted in each shift or EIC for smooth execution of the contract. The

overall-in-charge shall review day-to-day activities, co-ordinate with the Engineer-in-Charge and

Executive Engineer(s) of PPT & shall handle all administrative matters including labour problems

etc. He has to ensure smooth & trouble free operation and maintenance of plant with execution of

the instructions & requirements duly intimated by PPT from time to time.

5.1.2 Tools and tackles, special tools and tackles, testing equipment, consumables, scaffolding

etc. required for operation and maintenance shall be arranged by the Contractor. However

tools and tackles, if any available with PPT shall be handed over to the Contractor for use.

At the time of contract closure, these tools and tackles shall be returned back to PPT by the

Contractor in proper usable condition.

5.1.3 During the O&M contract watch and ward of the systems & equipment under the scope of

the contractor shall be the responsibility of the Contractor.

5.1.4 The Contractor shall observe all applicable regulations regarding safety of man and

machine.

5.1.5 Authority for Access: No persons other than Contractor’s Personnel shall be allowed on the

plant premises except with the consent of PPT. The personnel of the Contractor must

possess proper identity card having their photographs. The Contractor shall grant access to

all plant related data, records, reports and software that is being generated or used as part of

its services for the plant for verification of PPT. All such data shall be the property of PPT

and shall not be used by the Contractor for any purposes other than contractual

requirements. Use of such information for any other purpose by the contractor is strictly

prohibited.

5.1.6 Routine interaction with PPT / his authorised representative regarding plant operation and

maintenance shall be held every day or as desired by PPT.

5.1.7 The O&M activities and also other activities(if any) shall be reviewed/discussed weekly in

the site meeting to plan the operational & maintenance requirements which will be presided

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by Superintending Engineer / Executive Engineer, MCHP. The Overall in-charge, Managers

of the Contractor and Shift-in-charges along with the Engineers from PPT shall attend this

meeting.

5.1.8 PPT shall conduct inspections/audit of the plant to check the health of the plant and

maintenance & operation standards followed by the Contractor. The Contractor shall

provide all necessary assistance / documents for such inspections/audit as desired by PPT.

Non- conformance observed during the inspection/audit shall have to be complied by the

Contractor within the mutually agreed time failing which PPT shall have the right to make

good the non-conformance at the Contractor’s risk and cost.

5.1.9 The contractor shall notify PPT promptly regarding the occurrence of any emergency

situation and take quick action to prevent any threatened damage, injury or loss to the plant

or persons or property inside the plant.

5.2 OPERATION

5.2.1 The plant will operate in 3 Shift basis (24 hrs a day) & 365 days a year. The normal shift

timings are as follows:

1st Shift - 0600 hrs to 1400 hrs

2nd

Shift - 1400 hrs to 2200 hrs

3rd

Shift - 2200 hrs to 0600 hrs

Arrival & Departure of staff should be well-planned to up-keep the operation and

maintenance requirement in tact round the clock.

5.2.2 Normally the plant operation i.e. main system operation can be divided into following 4

activities for transportation of cargo through conveyor system, connecting chutes and

machines.

- Rail Receival operation:

Receipt and unloading of cargo from railway (BOBR) wagons at Rail

Receival Station.

- Stockpiling operation (Receiving Operation):

Receipt of cargo at Rail Receival Station and stock piling in the stock yard.

- Ship-loading Operation (Shipping Operation) :

Reclamation of cargo from stock yard and loading into the vessel.

Receipt of cargo at Rail Receival Station and directly loading into the vessels

bypassing stockyard, if required.

Receipt of manually shifted cargo through Dumpers at Stockpile and loading

through Reclaimers into the vessel.

- Recycling Operation (Recirculation)

Recirculation and Blending operation as and when required, to avoid self-

ignition of cargo / fire-hazards / as required by PPT for operational

requirements and mixing of high grade with low grade coal respectively.

N.B: Back-loading operation is not under the scope of the Contractor. However the

isolation operation of OHE line for back-loading operation, maintenance of RRS and for

any other purpose shall be done by the Contractor. The nominated personnel of the

Contractor will be trained with the help of East Coast Railways for isolation operation

during the term of the contract.

The contractor shall manage the operation following the operating logic of the plant on all

time and shift basis as per the requirement. Stacking of cargo in stockyard, reclaiming of

stacking/ manual shifting cargo from stockyard, direct loading and recycling / blending shall

be made as per plot plan, requirement and in consultation with PPT. Allotment and

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adjustment of plots to different exporters is under the scope of PPT. Reclaiming of cargo

shall be based on “First Come First Basis” or as per the directions of PPT in order to avoid

long storage of cargo which may lead to self combustion. The contractor shall ensure that

there is no ridge formation while reclaiming.

5.2.3 Depending on the placement of rakes in RRS and stacking of cargo in its designated plot,

the route shall be selected as per scheduled requirement of the plant or as desired by PPT.

Similarly the shipping route shall be selected depending on berthing of vessels in berths and

designated plot from where reclaiming is to be done as per scheduled requirement of the

plant or as desired by PPT. Once the route is selected, then the route will be treated as a

running stream. The plant shall be operated in the sequence described in control philosophy.

5.2.4 Unless specified by the vessel, the loading facility shall be operated at its rated capacity i.e.

to maintain the loading rate @3500 TPH for loading of vessel with one loader and @7000

TPH for dual loading (i.e. loading of vessel using two loaders) (excluding stoppages beyond

control of the Contractor) as desired operational rating of shipping stream. However, the

loading rate below the desired rating as asked by the vessels shall be maintained by the

Contractor. Similarly, the norm for unloading of a rake (consisting of 58/59 wagons) is

1hr. 45 mins. (Excluding the stoppages beyond contractor’s control) which includes

15mins. buffer for placement of rake from top point to RRS table. The timing will be

calculated from arrival of the rake at top point/ departure of the previous rake from RRS in

that route clearing the down point (whichever is later) to completion of the rake.

5.2.5 During operation of plant all field devices, safety devices and monitoring devices shall be in

working condition and set as per the designed parameters. In any circumstances these

settings alongwith plant operational limits shall not be tampered/ or modified. Normally

bypassing of field devices and monitoring devices is not permissible. However, the same if

done for operational urgency should be made good promptly.

5.2.6 Before and during operation of plant, observance of basic rules of operation, systematic and

careful inspection of the individual parts of the system and equipment, checking the

functions of all sub-assemblies and components in time are essential and to be ensured. The

checks have to be made strictly in accordance with the check lists for the concerned

machine/equipment.

5.2.7 In order to have safe operation of the facilities, the operating personnel should be conversant

with the functional requirement and control philosophy of system(s) & equipment and

should be capable of recording the events / incidents during operation, noting the parameters

& maintain the log books at the following stations as per the scheduled requirement and

instructions issued by PPT from time-to-time.

Rail Receival Station

All Substations

All Six (6) machines (Stackers, Reclaimers, Ship-loaders)

Plant Monitoring Room

5.2.8 The engineers / supervisors attached to operation must be conversant with the technology of

various systems, equipment, machines and conveyor systems and has to co-ordinate with the

operating personnel for smooth operation. They have to be vigilant & should promptly

respond to any operational requirements.

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5.2.9 During operation, if any abnormality, defect / fault are noticed, the same shall be promptly

communicated and remedial steps must be taken under intimation to the Shift-in-charge of

PPT. The contractor shall place a suitable mechanism for rectification of problems so that

delay in operation can be avoided.

5.2.10 In no case, running of machine/ equipment should be without proper & required no. of

manpower. Similarly operation of machine /equipment /system /subsystem shall not be

carried out in abnormal condition (s) and by compromising with safety of machines and

conveyor system by repeated & prolonged by-passing of safety devices, field devices, and

monitoring/controlling devices. The plant shall be operated consistently with the operational

limits, safety and Prudent Utility Practices.

5.2.11 The shift in charge/Engineers/Supervisors of the Contractor associated with operation shall

plan & co-ordinate all the operational activities including pre-operational checks. Also,

necessary interaction with Shippers, Agents & Railways for operational requirements should

be done in close co-ordination with Shift-in Charge / Engineer-in-charge of PPT.

5.2.12 Stoppages during operation, any type of abnormalities including adverse operating condition

or characteristics, bypass of safety devices shall be recorded and same shall be intimated to

Shift-in Charge / Engineer-in charge with follow–up action.

5.2.13 The contractor shall be responsible for proper documentation of operational activities in

order to furnish management information system data to PPT on daily, weekly, monthly and

yearly basis and its analysis. At present, implementation of Enterprise Resource Planning

(ERP) is under tendering process. It is expected that the ERP will be implemented during

the tenure of this O&M contract. Once the same is implemented, all the data related to the

Plant are to be fed into the system by the O&M contractor as per requirement.

5.2.14 In addition to main system operation, the Contractor shall be responsible for other

operations such as

- Operation of auxiliary system

- Operation of heavy equipments

- Operation of Illumination system.

- Operation of existing Dust Control System

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5.3 MAINTENANCE

5.3.1 Maintenance of plant primarily aims at keeping the plant & equipment under the scope of

the Contractor (as indicated in clause no1.0 of Scope of work) in efficient and reliable

operating conditions, minimizing the downtime during operation so as to ensure their

maximum availability and productivity.

5.3.2 The contractor’s scope covers deployment of different maintenance teams comprising of

engineers, supervisors, technicians, skilled / semiskilled workmen for efficient and effective

preventive, predictive and corrective maintenance during the term of the contract.

5.3.3 The maintenance of machine / system / equipment shall be done by the Contractor in

accordance with recommendation of Original Equipment Manufacturer and taking into

account the current status of system / machinery / equipment by following sound

engineering practice and proper maintenance standards.

5.3.4 The contractor shall carry out the maintenance activities to prevent failures and also execute

improvement activities / repair activities for prolong equipment life, reduce maintenance

hours in order to ensure maximum availability of the system & equipment optimizing

productivity.

5.3.5 The contractor shall follow the maintenance practices/activities as under:

Generally there are two types of maintenance in use:

a) Preventive Maintenance :

- The care and servicing for the purpose of maintaining the systems and

equipment in satisfactory operating conditions by providing systematic

inspection, detection and correction of incipient failures either before they

occur or before they develop into major defects.

- Maintenance including tests, measurements, calibration and part/component

replacement performed specially to prevent occurrence of faults /failures.

b) Corrective Maintenance (Unscheduled Maintenance):

- Maintenance which is required when an item has failed or worn out to bring

it back to working order.

Preventive Maintenance:

Preventive maintenance can be divided into following subgroups

Planned maintenance or Scheduled maintenance.

Maintenance Activities to be done as per Schedule or Plan (Preventive Maintenace

Schedule) which may be related to Time like Daily / Weekly/ Monthly / Qtrly /Half

Yeary / Yearly basis and so on or equipment running hours or other paramenters as

per recommendation of OEM. Besides the PMS shall be reviewed and modified

taking into account the aging of systems / machinery / equipment, operational

conditions (environment) and operational requirement, etc.

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Conditioned based Maintenance.

Maintenance activities to be done when need arises. CBM is based on using real

time data to priortize and optimize maintenace resources. This is being achieved by

observing the state of the system known as condition monitoring by extensive

instrumentation of equipment and together with better tools for analysing condition

data. Such a system will determine the equipment’s health, and act only when

maintenance is actuall necessary. Ideally condition-based maintenance will allow the

maintenance personnel to do only the right things, minimising spares parts cost,

system downtime and time spent on maintenance. Condition Based Maintenance is

aimed at avoiding the unnecessary shutdowns and increase the availability time of

the equipment.

Another variant of preventive maintenance is Predictive Maintenance which tends to

do maintenance activities in time by regular observation of the operation of

systems/machines/equipment.

Condition based maintenance together with planned maintenance comprises the

preventive maintenance, in which maintenance event is preplanned, and all future

maintenance is pre-programmed. The effectiveness of a preventive maintenance

schedule depends on the Reliability Centered Maintenance (RCM) analysis. RCM

enables to monitor, assess, predict and understand the working of the assets i.e.

plant. RCM shall be implemented to create a cost effective maintenance strategy to

address dominant causes of equipment failure and it is a systematic approach in

defining a routine maintenance programme composed of cost-effective tasks that

preserve important functions in a defined operating context for systems / machinery /

equipment. RCM emphasizes the use of Predictive techniques in addition to

traditional preventive measures.

Corrective Maintenance or Un-scheduled Maintenance.

During operation abnormalities/ defects/faults are observed and some cases failures of

components are occurred resulting breakdown of plant or equipment. Corrective

Maintenance is a maintenace activity to identyfy, isolate and rectify a fault so that the failed

component,equipment,machine or system can be restored to an operational condition within

the tolerances or limits by repairing otherwise by replacement.

Corrective Maintenance can be divided into following subgroups

Immediate Corrective Maintenace (Breakdown maintenance) --- Work starts

immediately after failure. It signifies repair work, which is to be carried out after the

failure of the equipment in service, to restore it to its working condition and unlike

other maintenance, cannot be given careful advance planning.

Defereed corrective maintenace (post fault maintenace) --- Works which can be

delayed in conformation to a given set of maintenace rules depending on the nature

of abnormalities/defects/faults and its effect on operation.

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5.3.6 Basing on maintenance practices as mentioned above, following are the gist of the

maintenance to be adopted.

The contractor shall take up mechanical maintenance, electrical maintenance,

automation maintenance, automobile maintenance, structural maintenance and

hydraulic maintenance, etc of different systems, machines and equipment by using

predictive maintenance techniques in addition to traditional preventive measures so

as to maintain the plant in efficient and reliable manner with an objective to increase

in plant uptime and productivity.

The contractor shall prepare a routine maintenance plan and ensure timely

maintenance of the systems, machines and equipment as per the plan. While

deciding on the schedule maintenance plan (PMS), the manufacturer’s

recommendations should be followed. However, the schedule may be reviewed and

amended from time to time, if necessary and in consultation with the Engineer-in-

charge with a view to make it more appropriate to meet the site needs.

The Contractor shall submit to the EIC the PMS for equipment, machines and

system, etc under his scope during the mobilization period which are to be carried

out in this contract for approval. The same is to be approved by the EIC with

corrections, if any, and to be returned to the contractor within 30 days from the date

of receipt of format. The maintenance activity shall be carried out as per the

approved PMS from the 1st month of commencement of work.

The contractor shall prepare and implement long term maintenance, major

maintenance & overhaul schedules. The Contractor shall be responsible for any

additional resources as necessary for all major overhauls, shutdowns and other

repairs/replacements.

Planning of maintenance work as to what job are to be done, how they are to be

carried out (Determining the best method of carrying out the work), when they

should be taken up and the various resources required to execute the work shall be

done by the Contractor.

The maintenance planning shall be made on the basis of

Routine maintenance plan ( Preventive Maintenance Schedule)

Pending scheduled activities

Observation made during execution of PMS

Observation made during operation

Condition monitoring

Observation of PPT inspection

Observation of OEM experts

Any additional works /requirements

Shutdown :

For undertaking the major maintenance activities, planning shall have to be done by

the Contractor in advance and in consultation with the Engineer-in-charge so as to

make the best use of the idle period. The contractor shall properly plan for execution

of maintenance activities during non-operational time of systems/equipments.

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Routine inspection and Condition monitoring

Inspection of all equipment shall be carried out by the Contractor in accordance with

maintenance manual of individual equipment / manufacturer’s recommendation.

Before and after operation of plant, the Contractor shall carry-out careful and

detailed inspection of all equipment and its components. An effective maintenance

practice should include Condition Monitoring and assessment along with Visual

inspection. Effective monitoring of such information and intelligent analysis of the

same can provide valuable information on the condition of the equipment and can

avoid failure while in operation. Most of the tasks associated with Condition

Monitoring are generally caried out while the equipment is in service or when the

equipment is shut down for some other reason.

The Contractor shall prepare a check list in order to ensure correct and proper

inspection. Inspection and condition monitoring shall also include use of inspection

equipment and testing devices to determine the extent of defect at the cost of the

Contractor.

Action shall be taken on the observations during inspection and condition

monitoring.

Periodic Inspection through OEM :

The Contractor shall have to arrange for periodic inspection of specialized

equipment such as control and automation system (PLC & it’s networking and

VVVF Drives), Electricals ( Relays, Transformers, both LT & HT Breakers, Belt

Weigher, Fire Detection System, Centralized Air-conditioning System at PMR and

Package ACs ), hydraulic system, conveyor system (Conveyor Belt), Civil Structural

(RRS including Tunnel, Counter Weight, Columns), Steel Structurals (all machines,

Conveyors, Transfer / Drive Towers, Pumps at Raw Water Pump House and

Process Water Pump House) once in a year by the manufacturer’s experts to assess

the health of the systems and make suitable recommendations to maintain the

reliability of the system. Manufacturer’s experts shall mean that the representative

from the OEM, but not the authorized dealer / system house. However, the first

inspection should preferably be done during first six months from the date of

commencement of the work. The inspection report shall contain present condition,

recommendations covering the works to be carried out, spares to be replaced and

stock/ inventory to be maintained for smooth operation & maintenance. In case the

OEM did not respond for inspection, the contractor will request written permission

from Purchaser to carry out the inspection through a competent person i.e. through

authorized dealer / system house or any other expert in the field other than the

representative of OEM with all supporting documents as required. The cost of such

inspections to be conducted by the experts shall have to be borne by the Contractor

without any additional financial liability to Paradip Port Trust. A copy of the

inspection report and action plan thereof shall be forwarded by the Contractor to the

Engineer-in-charge for reference and monitoring of implementation of

recommendation. However PPT reserves the right to have independent audits of the

health of the systems and equipment by OEMs at the cost of the Contractor and the

contractor shall implement the findings of such audits in a mutually agreed schedule.

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Lubrication:

Lubrication is an important activity in the system of maintenance. The Contractor

shall prepare and implement the lubrication schedule as per the maintenance manual

for all equipment in MCHP. The Contractor shall supply all type of lubricants

recommended by the equipment manufacturer. A well-conceived lubrication

schedule should include its application by the right method, at proper frequency,

storage, handling and identification.

Contractor shall conduct i) periodic test of gauges, meters, wire rope, handling

tackles etc., ii) periodic load test of lifting appliances such as EOT cranes, test

weights, hoists, and chain pulleys, etc and iii) periodic calibration of relays,

voltmeter, ammeter, current transformer, potential transformer, other electrical

metering devices, electrical testing instruments, etc as per the ISO requirement and it

shall be his responsibility to make good any defects promptly.

The contractor shall maintain all field devices, safety devices and monitoring

devices in perfect working condition, functional all the time and set as per the

designed parameters. In any circumstances these settings along with plant

operational limits shall not be tampered/ or modified. In case of malfunctioning of

field devices, safety devices and monitoring devices during operation, the same may

be bypassed if feasible for continuous operation. However prompt action shall be

taken to rectify the faults for which the field devices, safety devices and monitoring

devices are bypassed and put into services.

Breakdown Maintenance:

During operation, fault /defect if any once appeared/observed shall be identified,

isolated, and rectified so that the failed equipment,machine, or system can be

restored to an operational condition in a shortest possible time. However defects

which can be deferred for the regular periodic maintenance (provided it will not

have any type of adverse effect on equipment,machine, or systems) shall be recorded

and reported in a suitable form for follow up action.

Faults once observed shall be promptly attended and rectified to avoid major

failures. In case it is not possible to rectify the faults/defects due to any constraints,

alternate feasible temporary arrangement shall be made to restore the system and

resume operation at the shortest possible time. The permanent measures shall be

taken up thereafter in the next immediate operational gap. Also, if the services of

any expert are required, the Contractor shall arrange the same in the most

expeditious manner at his own cost.

In the event of any break down maintenance, the Contractor shall put in it’s best

effort to promptly attend the break down and bring the machine to an operating

condition as early as possible. If necessary, the Contractor shall arrange and deploy

more manpower and other resources to reduce the break down period.

Overhauls/ Repairs of Plant and Equipment:

Overhauling, both major and minor repairing and replacement of components /

equipment and systems & subsystems are under the scope of the Contractor. The

Contractor shall supplement the Plant personnel with additional resources as

necessary for all major overhauls, shutdowns and other repairs.

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Overhauling Maintenance:

The equipment of machines or systems which are removed either due to

defective/breakdown condition or as per schedule planning shall be overhauled with

replacement of defective /worn out /aging components and kept as stand by spares

for future requirement. Besides the overhauled items shall be tested if required to

ascertain its performance so that it can be used whenever required. The overhauled

equipment shall be preserved as per proper engineering standard. The overhauled

components are to be kept properly with proper lubrication. The contractor shall

avoid overhauling of equipments in-situ.

Repair / Replacement Maintenance:

Both major and minor repairing and replacement of components/equipment and

systems & subsystems due to normal wear and tear or due to defects / failures are

under scope of the Contractor. The spares which were repaired shall be installed or

put into service immediately after repair for assessing its performance. Repairing

activities shall be made in such a manner that the equipment can run its balance life

without further deterioration in its performance otherwise replacement of equipment

shall be considered.

In case of repair of electrical equipments like motors & transformers for winding

damage, if the equipment is de-rated beyond 10%, then the equipment shall be

discarded and new procurement shall be processed. Similarly, in case of damage to

the rotor of motors, the rotors should be replaced without going for repair.

For circuit breakers, in case of failure of spring charging mechanism, the breakers

shall be discarded.

For Gear boxes, any damage to the gear components & the shaft shall not be

repaired and new replacement shall be done. Similarly, in case of damage to the

housing like enlargement of bore & development of cracks on the body, repair if

feasible can be done once beyond which the same shall be discarded.

If there is any damage / worn-out to the shaft, shell, failure of welding of end disc,

the pulley is to be discarded & suitably replaced.

For fluid couplings, crack on the body & continuous oil leakage after over hauling,

the fluid couplings shall be discarded.

In case of pitting on the surface of the shell & wear out of the shell, the rollers shall

be completely discarded. No repair to the shaft of the rollers is permissible.

In case of pitting on the surface of the piston rod, the same is to be replaced.

Hydraulic pumps & valves shall be discarded & suitably replaced if the pressure

development & the flow rate are not proper as per the ratings.

For other important components of plant and equipment, repairing shall be

considered if feasible as per standard engineering practice, otherwise the same shall

be discarded.

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Modification/Improvement Maintenance:

During the course of the contract, the contractor may take up improvement /

modification activities to avoid repeated nature of breakdown of a particular

component to facilitate easy maintenance, operational convenience and to bring

more reliability & efficiency of machines/ equipment / systems at his cost without

compromising with the basic design, operational logic, characteristics, and safety

aspect under intimation to Engineer-in charge.

Other Specific Maintenance

Structural of Drive/Transfer Tower, Conveyors & conveyor galleries & columns,

RRS, Workshop, and Machines, etc:

Due to normal wear & tear and saline climate, the structural of the plant are prone to

damage. The contractor has to carry out the routine inspection of various structural

of the plant with special attention to important load bearing members. Any

defect found in the structure shall be made good promptly by the Contractor. The

Contractor shall be responsible for carrying out repair/replacement of worn out,

corroded, pitted, and damaged structures of drive/transfer towers, conveyors &

conveyor galleries & columns, RRS, workshop, machines, etc in time as per

requirement so as to avoid premature failure of structures with application of epoxy

paint having thickness 350 micron DFT & proper surface preparation.

It shall be ensured by the contractor that replacement of structure shall not be done

in piecemeal basis. The section either from bolting to bolting or welding to welding

shall be replaced. In no case welding joints shall be increased. Similarly the

dimensions of structures shall not be altered in any case. The drawings, specification

if available or otherwise physical dimensions shall be referred / taken for fabrication

of the structures. The fabrication and erection shall be made as per applicable

standards. The thickness of structures if found reduced then it shall be completely

replaced.

Replacement of damaged colour coated corrugated sheets (either pitted in the

surface, formation of pot holes) shall also be done by the Contractor.

Up keeping of structures of S-11, S-12, switch bin and etc. are under the scope of the

contractor.

The sheet metal items including outdoor & indoor Junction boxes (control & power)

shall be maintained properly and in case of damage or depleted; the same shall be

replaced immediately which shall be either GI sheet or aluminum sheet. The

handrails, seal plates, chequered plates, gratings to be fitted during the term of the

contract shall be galvanized.

Conveyor Belt Maintenance:

Repair work on conveyor belt like longitudinal through-cut, groove cutting, edge

damages, pot holes, surface damages, perforation repair, and strip cut by suitable

methods are included in the scope of the Contractor. In case of damage to the belt

during operation, temporary repairs may be done in order to resume the operation

followed with permanent repair in the next non operation time. The belt shall be

replaced if repairing of belt is not possible. The belt replacement due to wear & tear,

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damage of belt beyond economic repair & repairs not sustainable to the remaining

life, etc are included in the scope of the Contractor with belt jointing including

supply of belt. In case of side/edge cut of the belt resulting in damage and exposure

to steel cord and affecting the rated carrying capacity of the belt, then replacement of

belt is to be done by the Contractor.

The initial conveyor belt repair/replacement if any in the opinion of the contractor

shall have to be done by the Contractor, the cost of which shall be included in the

quoted price. The belt repairs/ renewal work shall be done by the Contractor during

tenure of the contract period.

Different types of belts like; ST-500, ST-630, ST-800, ST-900, EP-800/5 & ST-2000

are being used in the plant presently. During the contract the old belt ST-500, ST-

630 will be replaced with ST-800/ST-900 after consumption of the available stock.

Maintenance including civil maintenance Work:

All type of civil maintenance and repairs including door locker, door lock, door,

window and shutters, etc of installations like all machines,9 nos of substations,

workshop, amenity building, change room, compressor room, all pump houses, plant

monitor room, building at up & down railway point, tunnel, RRS & feeder, pedestals

of columns & stringer post, Counter weight Sheeve pulley, transfer tower/drive

tower pits, cable pits, yard toilets, belt weigher room and watch tower buildings etc.

are to be done regularly by the Contractor. The maintenance of electrical system

including lighting, drinking water system & sanitation & maintenance of doors /

windows are included in the scope of the contractor.

Maintenance of Tie-down Towers:

Tie-down towers have been installed for six (6) machines i.e. Stacker-1 & 2,

RC-1 & 2, Shiploader-1 & 2 to tie-down the machines safely during cyclonic

weather and to carry out various maintenance activities. However, the area where the

tie-down structure of Reclaimer-2 is located is presently used as storage area

(stackyard), thereby the tie-down of RC-2 is not in place. Accordingly, the

Contractor will make an alternative arrangement in form of temporary structures to

be used to take up the maintenance work of Reclaimer-2 in place of Tie-down tower.

Maintenance of Earthing system:

Earthing system is provided for substations, machines, rail tracks, conveyor

structural and control system keeping the earth resistance value below 1.

Substations There are nine (09) nos. substations provided with solidly earthed

system except two nos. of 20MVA transformers which are resistance earthed. All

the solidly earthed points are interconnected with each other to form a grid. The said

earthing system is provided to ensure the proper earthing of substations.

Machines The neutral of transformers (LV side) is provided with earth cables,

connected with earth shoe fitted in travel bogie to ascertain continuous earth through

rail track.

Rail Track Rail track earthing is provided for R-7, R-8, S-3, S-4 & ship-loaders

track line. There are 06 nos. of earth pit in each of the track-lines R-7, R-8, S-3 & S-

4 and strips are provided with rigid welding with rail track from the earth electrodes

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and rails are also interconnected through earth strips. Ship-loaders’ track is earthed

through GI strips run from the piles.

Structural Structural earthing of each transfer tower is provided through two

separate earth pits with continuous running G.I. strips along the conveyor structures.

Control System Separate earthing system is provided for control system of the

Plant with separate earth pit and GI strips connecting the earth electrode with the

earth point of control panels.

Maintenance will be referred to as the monthly, quarterly, bi-annual or annual

inspection monitoring and repair / replacement of the earthing system. The

contractor should perform the timely inspection & monitoring of the system as per

the recommended and preferred frequency as per the O & M manual.

The contractor shall take the measurement of earth resistance and measurement data

shall be produced in quarterly basis for healthy monitoring of the system.

Cable Schedule and Maintenance:

There are different types of cables spread around the plant:

HT Cable (Power):

XLPE, 11KV grade HT cable network of length around 18 km is spread to different

locations of the plant of sizes 25, 50, 150, 185, 300 & 400 Sq.mm. The cables are

laid in trenches and also over-ground in aluminum cable trays dressed with

aluminum clamps.

No. of existing joints are defined in cable schedule. In case of failure of cable

beyond existing jointing locations, new joint has to be made and same shall be

incorporated in the cable schedule for future reference. However in case, increase in

no of joints affects the reliability of the cable, the cable is to be entirely replaced.

LT Cable (Control & Power):

PVC armored, 1.1KV & 650V grade LT cable (Control & Power) network of around

42km in different sizes & span is spread to different locations of the plant.

The Control & Power cables are mostly laid on aluminum cable trays dressed with

aluminum clamps.

Profibus Communication cable:

24V grade, screen communication cable (profibus) network of around 12 KM. is

spread in the plant. The no. of joints in the cable network is restricted to maximum

one joint per KM.

Trailing cable (Control & Power):

Copper flexible Trailing power cable (6.6KV grade) and trailing control cable

(1.1KV grade) are used in stacker, reclaimer and ship-loader. There are 6 spans of

trailing power cable and also 6 spans of trailing control cable.

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No joint is allowed in the trailing cable. In case of failure of cable, the complete span

of the cable is to be replaced by new one.

Corrosion Maintenance of Structures, Electrical panels & outdoor / indoor junction

box and Painting of Civil Installations:

Painting of all equipment, structures and civil buildings shall be done as per the

following specification by the Contractor. In all the cases, the Contractor shall have

to make thorough surface preparation before application of coating.

Paint of reputed make such as Shalimar, Berger, Asian Paint, J&N or equivalent

shall be used.

Complete painting of the Plant is to be carried out minimum once in 02(two) years

from the date of commencement of the work in the tenure of the 03(three) years

contract and the same is to be maintained for the balance period of the contract. In

case of extension, the contractor has to repaint the complete plant minimum once

during the extension period as per the initial painting. Special attention shall be

given to the areas like welding joints, and other critical areas, etc.

Protective coating colour schedule:

Item

Colour

AS 2700 Colour

OR

Equivalent Standard

Structural Steel work, equipment etc. Grey Blue B-43

Handrails Golden Yellow Y-14

Equipment excluding guards Primrose Yellow Y-21

Equipment guards Light Orange X-15

Electric Motors Bright Blue B23

Underside of floors, interior surfaces

of wall cladding

White

Electrical panels & Junction boxes Grey

Pipelines:

Fresh water

Process water (from pond)

Fire fighting systems

Compressed Air

Hydraulic Oil

Middle Blue

Emeraid Green

Signal Red

Arctic Blue

Brown

B15

G13

R13

B25

TBA

Coating may be applied using conventional, air atomizing or airless spray

equipment.

Previously coated structures:

All steel surfaces to be coated showing traces of oil, grease or other

contaminants shall be thoroughly cleaned with an approved solvent,

preferably with an approved emulsifying degreasing agent, and washed with

clean water before commencement of coating application.

Apply a quick drying surface tolerant self priming epoxy coating to achieve a

minimum dry film thickness 100 m with appropriate surface preparation as

per requirement.

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NOTE: Thickness of original coatings should be measured prior to commencement

of coating operation to allow gauging of upgraded coatings.

Apply two components of high build micacious iron oxide coating to achieve

a minimum dry film thickness 100 m (200 m total thickness).

Apply intermediate epoxy coating to achieve a minimum dry film thickness

100 m (300 m total thickness).

Apply modified polyurethane coating to achieve a minimum dry film

thickness 50 m (350 m total thickness).

All Steel works:

Abrasive blast cleaning shall be carried out by grit blasting using compressed

air nozzles. For all steelwork the blast cleaned surface shall have a profile of

not less than 25m or greater 50m as measured by a probe type surface

profile gauge.

Apply a quick drying surface tolerant self priming epoxy coating to achieve a

minimum dry film thickness 100 m.

Apply two components of high build micacious iron oxide coating to achieve

a minimum dry film thickness 100 m (200 m total thickness).

Apply intermediate epoxy coating to achieve a minimum dry film thickness

100 m (300 m total thickness).

Apply modified polyurethane coating to achieve a minimum dry film

thickness 50 m (350 m total thickness).

Equipment (including Electrical panels & Junction Boxes):

As per recommendation in O & M manual.

Civil building:

Outside of the building shall be painted with two coats of weather coat whereas

inside shall be painted with two coats of distemper of reputed brand such as

Shalimar, Asian Paint, Berger, and J & N. These painting shall be done once in every

contract year.

Maintenance of Communication Facility:

The contractor shall be responsible for maintenance of communication facility such

as intercom system and VHF communication system in healthy condition with

supply of all instruments, spares, networking components during the term of the

contract. This is very much essential for smooth operation, maintenance of the plant.

The contractor shall be responsible for providing and maintaining VHF

communication system at Area Controller, and Main yard, etc in connection with

unloading operation of rake at RRS. Minimum 20 VHF handsets with batteries and

spare 20 batteries alongwith chargers are to be handed over to Eco. Railway in

connection with unloading operation of rake at RRS.

At the time of hand over of plant, PPT shall handover the existing VHF sets

(handsets, base stations, etc) to the Contractor for his use. At the end of the contract

the Contractor shall return the VHF sets and other communication facility received

from PPT in reasonably good and working condition.

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Operation and maintenance of Cathodic protection system provided for marine

structure of coal berth:

The operation & maintenance procedure generally relate to specific inspection,

current & potential measurement, general checks and tests, repair & replace the

components / equipments of CP system. All testing and maintenance works shall be

performed as per applicable project specification and relevant documents. The

operation & maintenance shall also be in accordance with established and accepted

procedural practices. It should be properly maintained in order to operate the system

effectively. To accomplish this efficient, diligent monitoring & maintenance are

required.

Maintenance will be referred to as the monthly, quarterly, bi-annual or Annual

inspection monitoring and repair / replacement of the cathodic protection system.

The contractor should perform the timely inspection & monitoring of the system as

per the recommended and preferred frequency as per the equipment manufacturer’s

operation & maintenance instructions.

The contractor shall take the measurement of current drawn by each anode and the

voltage difference between a buried or submerged metallic (Steel piles) structure and

a reference electrode (Ag/Agcl) in contact with the electrolyte. The above

measurement data shall be produced in monthly basis for healthy monitoring of the

system.

Maintenance of Illumination System:

The contractor shall be responsible for maintenance of illumination system of plant

for desired illumination level in different areas of plant during day and night

operation of the plant as per requirement which is very much essential from

operation and safety point of view.

Maintenance of Fire detection and Fire fighting System :

The contractor shall be responsible for maintenance of fire detection system in

machines, substations and fire fighting system in RRS & Tunnel for safety point of

view.

Maintenance of Auxiliary system, heavy equipments and EOT cranes, Electrical &

Manual hoists, Belt Splicing Machine, etc:

The contractor shall be responsible to maintain the auxiliary system, heavy

equipment and EOT cranes, and Electrical & Manual hoists in healthy condition to

meet the requirement as and when required. The existing heavy machineries

available in MCHP are in good operating conditions. Withdrawal of any heavy

equipment due to non-availability of spares/ ageing during the contract can be

decided on case to case basis subject to submission of documentary evidence and the

contract price shall be adjusted accordingly i.e. the amount quoted for that heavy

equipment in the break-up price shall not be paid.

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Operation & Maintenance of existing Dust Control System :-

The contractor is to operate and maintain the dust control system and fire fighting

system installed at MCHP in an effective manner on round the clock basis to fulfill

the requirement of the Pollution Control Board norms from time to time. The work

involves O&M of Process Water Pump House, Fire Monitors at Stackyards, Pipeline

connecting Process Water Pump House to Fire Monitors at Stackyards and all the

Fire Hydrants located in the Plant.

The Contractor is responsible for carrying out proper maintenance, attending

breakdown in time (rectification of faults). During operation, if any abnormality,

defect / fault are noticed, the same shall be promptly communicated and remedial

steps must be taken under intimation to the Shift-in-charge of PPT.

The Contractor shall closely co-ordinate with the respective Engineer

in-charge and plans the work so as to avoid interruptions in operations of dust

control system and fire fighting system.

Additional work:

Additional work is any work which neither applies to scheduled service nor to

emergency service work. It may arise from the identification of failures and non-

compliance during inspections which the Contractor executes at regular intervals

without any price implication to PPT.

Minor repair to the defective wagons –

During unloading of BOBRN rakes at RRS, defective wagons are observed.

These wagons are either of damaged door, door not opening, cylinder pin

removed. In order to either unload the cargo from these wagons or to close

the wagon door after unloading, minor repairing of wagon like cutting,

welding of wagon door, cylinder pin welding / cutting are to be carried out.

These works are covered under the scope of the contractor without any price

implication to PPT. As and when such requirement comes, the Contractor

will take up the work in consultation with the representative of E.Co.

Railway available at RRS on round the clock of basis.

Mandatory Initial Works :-

Following mandatory initial works are to be carried out by the contractor and

complete the same within one year from the date of commencement of the

contract. The Contractor will submit the requirement of shutdown if any to

the EIC 30 days prior to commencement of work for acceptance. The

contractor will ensure that the plant operation is least affected during the

shutdown period.

- Revamping of existing Dust Control System:-.

- Replacement of civil structurals of counter weight sheeve pulley of

R-7 & R8.

- Shifting of belt weigher at S-13 & S-14 from existing location

i.e. near TT-8.

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(a) Revamping of existing Dust Control System:-.

At present, there is one existing Dust Control System available in the Plant covering

RRS hopper, Transfer Towers, Stackyard. In the Stackyard, both fire hydrant & fire

monitors and stackyard sprinklers are available. Most of the DCS are in a defunct

condition. PPT is in the tendering process for installation of Dry Fog Dust

Suppression System (DFDS) at RRS, Transfer points and separate pipelines at the

existing stackyards for installation of new sprinklers. The work is expected to be

completed during the tenure of this O&M contract. Once the installation of new

system is commenced, the existing DCS system will be left with only fire fighting

system at RRS, Transfer Points and Fire hydrants and Fire monitors in both the

stackyards.

In view of above, the revamping of existing DCS system will cover the following

work:-

(i) Stackyard : - The spool piece available for 108 sprinklers at both the stackyard

are to be replaced with 200 NB UPVC pipe with socket and tail piece. All the 52

nos. of fire monitors available with damaged spool pieces and globe valve

wherever required in the stackyards are to be replaced with a new one. The

leakages available in the 200 NB UPVC pipe line at the stackyard are to be either

arrested or replaced with a new one as per requirement. The supporting steel

structurals of the fire monitors are to be either repaired or replaced as per

requirement.

(ii) Fire Fighting System :

The fire fighting system available in the Plant are to be revamped. The damaged

pipelines, fire hydrants, different types of valves such as globe, gate and air

release valve with fittings shall be replaced with a new one. Where there is a

provision for fire hydrant, but the same is either not available or blocked will be

replaced with a new fire hydrant valve.

All the fire fighting and stackyard, DCS equipments are to be painted as per the

painting schedule provided in the scope of work. Materials used in the work shall

be as per the specification given in Technical Details of MCHP.

(b) Replacement of civil structurals of counter weight sheeve pulley of R-7 & R8.

The existing civil structurals for counter weight sheeve pulleys of conveyor R-7 & R-8

are to be replaced with new civil structural. The replacement work is to be carried out as

per the existing design. The work is to be taken up one after another for each conveyor.

30 days prior to commencement of the work, the contractor will submit the details of

work to be executed alongwith bar chart indicating the minimum shutdown requirement

for acceptance of EIC. As shutdown of this conveyor will stop one of the Stacking route,

the contractor will make his best effort so as to handle maximum no. of rakes available

in the other available stream without any dislocation in RRS operation.

(c) Shifting of belt weigher from existing location.

As per the plant design, the belt weigher room is installed near the Transfer Tower-8

(TT-8). Due to elevation of surrounding roads, now the belt weigher room is below the

road level resulting in deposition of rain water. The belt weigher of conveyor S-13 & S-

14 alongwith its installations are to be suitably installed in the nearby substation i.e.

Substation-4. The contractor will shift the belt weigher into the Substation-4 alongwith

its cables and other installations at suitable location. In case of requirement of any

additional spares for this work, the same are to be provided by the Contractor at his cost.

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5.3.7 Adequate precautions shall be taken to prevent danger from electrical equipment. When

workers are employed on electrical installations, which are already energised, insulating

mats, working apparels such as gloves, sleeves and boots as may be necessary shall be

provided by the Contractor.

5.3.8 Written Clearance: All the maintenance activities shall be executed after taking shutdown

and issuance of L.C. from substations or E-house of machines. The Contractor must obtain

written clearance, in a format (maintained in shutdown register) acceptable to PPT, clearly

indicating the nature of maintenance intended to be undertaken, the equipment name,

expected time of commencement and completion. The Contractor shall also mention the

time that he would require to bring the machine to operational condition in the event of any

emergency need.

5.3.9 The contractor shall prepare the Plant and systems for inspections and allow inspections of

the Plant by Competent Authorities;

5.3.10 The Contractor shall use the workshop building with EOT cranes for the purpose of

maintenance activities like fabrication / repairs / overhauling/ disassembly-assembly, etc

and also storing of spares & stores & POL items. In case the Contractor has intention to

install machine tools, then statutory clearance as applicable shall be obtained by the

contractor before installation of machine tools. PPT is having some workshop equipments

which will be handed over to the Contractor. On closure of the contract, the machinery shall

be handed over to PPT in efficient operating condition.

5.3.11 The contractor shall ensure that all the components of equipments, machines and systems as

per O& M manual shall be available in all time. In case of defect, the same shall be replaced

with the spare one.

5.4 HOUSE-KEEPING:

Good housekeeping is essential for efficient operation of plant and maintaining good health

of the plant & equipments.

5.4.1 The contractor shall be responsible for good housekeeping and cleanliness. The scope of the

Contractor shall cover, but not limited to, the following:

a) Cleaning of all equipment (like Stackers, Reclaimers & Shiploaders), conveyors&

Conveyor galleries, various floor of transfer towers/ drive towers and its surrounding

& pits, all substation, other buildings of plant from all muck, spillage, debris and

lubricants, etc.

b) Muck deposit, spillage on ground near take-up unit, drive end.

c) Muck deposit, spillage inside tunnel and various floors of Rail Receival Station.

d) Muck and spillage clearance in case of spillage due to any reason and make ready

the equipment, machine or system for operation.

e) Cleaning of muck accumulated on ground due to non working of scrappers.

f) Pit cleaning.

The muck and spillage shall be disposed at earmarked location acceptable to PPT.

g) All scrap material shall be sent to the scrap yard and kept in a segregated manner

like MS scrap, rubber items, belt, sheets and electrical & automation items, etc.

h) Removal of tramp iron from respective bin and transfer to the scrap yard.

i) Dumping of waste material at a place within plant boundary specified by the PPT.

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j) Shrub/ Bush cutting in the Plant area as per details specified in technical details of

MCHP.

k) Internal drain cleaning including pit cleaning near transfer towers inside the plant

area (approx. 9km length) as per details specified in technical details of MCHP.

(The main drain between the Road from Gate No.2 to Gate No.1 and MCHP is

excluded from the scope of the Supplier).

l) It shall be the responsibility of the Contractor to keep the sewage system and

effluent system and drainage system inside MCHP always in good working

condition. Special attention in this regard shall be given prior to monsoon to avoid

water logging.

m) Dewatering of cable pits.

n) Floor of the Coal Berths.

o) Area under all conveyor galleries at ground level.

p) Service Road cleaning.

5.4.2 Special attention shall be given for keeping the structures clean and free from trash, spill

over and debris. The Contractor shall employ sufficient personnel to thoroughly clean all the

work areas continuously and shall ensure that the plant and equipment are clean.

5.4.3 Material shall be stored in locations, which will not block access ways and permit easy

cleaning of the area. In areas where equipment might drip oil or cause damage to the floor

surface, a protective cover shall be provided between the equipment and the floor surface so

that no oil or grease drips to the floor surface.

5.4.4 All hoses, cables, and similar items shall be located, arranged, and grouped so that they will

not block any access way and will permit easy cleaning and maintenance.

5.4.5 All trash, debris, and waste materials shall be collected, stored, and deposited in waste

collection areas as designated by the Contractor acceptable to the Purchaser.

The Contractor shall ensure that scrappers shall work all the time so that muck deposit on

floor of the coal berths, area under all conveyor galleries shall be minimum .

5.5 SPARES AND STORE MANAGEMENT:

5.5.1. All the spares (mechanical, automation, electrical, and automobile etc) including insurance

spares, imported spares, steel materials, store items (hardwares, paints, etc), consumables,

POL, conveyor belt etc. required for satisfactory execution and performance of the work

“Operation and Maintenance of MCHP” during the Contract period shall be supplied,

controlled and maintained by the contractor at his cost. The contractor shall maintain

desirable inventory of spares &store items, consumables and POL, etc to meet the

requirement.

5.5.2 DURING TAKING OVER THE PLANT BY THE CONTRACTOR.

a) The spares and store items, consumables and POL available in good condition with

Paradip Port Trust applicable for the plant and equipment shall be handed over to the

Contractor for safe custody and use. During handing over of spares & store items,

consumables, and POL, etc, a list shall be prepared in the joint inspection indicating

the details. These items shall be consumed by the contractor on priority basis on

payment of the purchase cost with 3.5% overhead which will be recovered from the

bill of the contractor in the succeeding month.

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b) Some of the insurance spares called as long lead spares as given at

Appendix-17 available with PPT shall be handed over to the Contractor for safe

custody and use with proper up-keeping. The Contractor shall use the long lead

spares available with PPT on exchange basis only i.e. it shall be the Contractor’s

responsibility to replenish the stock of Paradip Port Trust by either overhauling the

spare one which is removed /replaced. In case the removed / replaced unit is

damaged / could not be overhauled, then the Contractor shall have to procure a new

unit of the same make or as approved by PPT to replenish the stock of PPT. The

overhauling cost and/or replacement cost shall have to be borne by the Contractor.

The contractor shall plan additional procurement of such spares if necessary to meet

the contractual obligations. Inventory of other long lead spares not covered in

Appendix-17 is included in the scope of the contractor.

5.5.3 PROCUREMENT, INSPECTION, STORAGE, MAINTENANCE AND USE OF

INVENTORY:

Following the taking over of plant, the Contractor shall plan and prepare a detailed report on

the inventory of spare & store items, consumables, POL, steel materials and conveyor belt,

etc and initiate procurement action so that the materials are timely available in site as per the

requirement.

a) The required spares & store items including imported spares, consumables, POL,

hardware, steel material, and conveyor belt, etc shall confirm to applicable standard,

specifications, drawings and suitable for intended purpose and shall be new and

genuine.

b) The Spares and components shall be procured from OEMs (Appendix-18) or from

their authorized representatives. The authorization certificate and renewal shall be

submitted to PPT from time to time. During procurement of spares & illumination

items, contractor shall ensure that the materials procured are of the latest version of

the OEM and energy efficient.

c) Maintaining the quality of materials is the essence of healthiness of plant which

results in increase in reliability of plant. Therefore material shall be procured

following predetermined QAP in order to maintain the quality of the material where

ever required.

d) The contractor shall forward copy of purchase order along with specification and

QAP if applicable to PPT for reference.

e) After receipt of material (Spares, steel materials, conveyor belts, hardware,

fasteners-above 8.8 grades) at site store, intimation shall be given to PPT for

inspection and acceptance of material in accordance with specification, drawing and

test & inspection certificates. Without test certificate materials shall not be accepted.

Acceptance of material by PPT shall not relieve the contractor from its obligations.

The test certificate is to be issued by OEM of the material. For important items such

as conveyor belts, rollers and idlers, scrappers, the Component Test Certificate of

OEM i.e. Steel Cord for Conveyor Belt, Pipes for Scrappers and Bearings for

Rollers, Idlers, Gear Box and Motors are to be submitted in addition to OEM Test

Certificate. Further, for lifting appliances and wire ropes, test certificate of statutory

authorities as required are to be submitted.

Scope of Work


Page 255 of 286

f) Paradip Port Trust reserves the right to subject any part / component / equipment for

re-test and on written instruction from Paradip Port Trust, the Contractor shall

arrange for the re-test and the cost shall be reimbursed by Paradip Port Trust as per

actual, only if the test results are satisfactory. In case of unsatisfactory test results,

the part / component / equipment shall be rejected and the Contractor shall be

responsible for replacement of the item at his own cost and also bear the cost of the

re-test.

g) Paradip Port Trust’s right to inspect, test and, where necessary, reject the Goods

after the Goods’ arrival in Paradip Port Trust’s premises shall in no way be limited

or waived by reason of the Goods having previously been inspected, tested and

passed by Paradip Port Trust or its representative prior to the Goods’ shipment from

the place of origin.

h) The entire inventory shall be stored in accordance with ISO. Maintenance of

inventory shall be made following the applicable standards and procedures. No

material on any of the sites of the MCHP shall be so stacked or placed as to cause

danger or inconvenience to any person.

i) The lubricants shall be stored in a clean and dry place under cover to prevent

deterioration and contamination due to exposure to varying environment. Drums of

lubricants shall be stored in the condition prescribed by the lubricant supplier.

Receptacles shall be kept clean/ open. Lubricants, which are contaminated with dirt

or other foreign materials, shall not be used. Storage & disposal of waste &

hazardous oil and used cotton waste and cotton rags are to be carried out following

the guidelines of State Pollution Control Board from time to time.

j) The rubber items shall be stored properly and consumed before its expiry date;

otherwise expired rubber items shall be disposed off following standard procedure.

k) Material brought into the site shall not be taken out without the gate pass issued by

PPT.

l) The steel materials must be of reputed make i.e. SAIL /TATA / Vizag Steel / Jindal

conforming to IS 2062. All materials shall be new, free from loose rust, pitting,

flaws, cracks & any other defects and shall have a smooth uniform finish. The test

certificate for the steel materials is to be produced by the contractor.

m) Materials once issued and used shall not be returned to the contractor’s store.

n) During the term of this contract, the Contractor shall maintain adequate record of

spare parts procurement, inventory and usage and shall submit a report as and when

required by PPT.

o) Maintenance of Long lead spares of PPT shall be done by the Contractor.

p) First In – First Out (FIFO) is generally the basis for consumption of items and

specifically for items having self life. Stock of handed over materials of PPT shall be

used first before using materials purchased by the Contractor.

5.5.4 INVENTORY CONTROL.

Inventory shall be planned depending on categorization of material i.e. Vital (Insurance) –

Essential - Desirable and basing on consumption pattern i.e. fast moving - slow moving. The

Contractor shall ensure that stock of items available at end of the contract is within 10% of

the installed capacity of MCHP for all spares except long lead / insurance items which will

be decided on mutually agreed terms. A proper balance is to be maintained between the

consumption and procurement of materials with proper analysis and timely action so as to

avoid the unwanted situations like non availability & overstock of materials.

Scope of Work


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At the end of the contract, the Contractor can handover to PPT the balance stock of

materials as per the following guidelines.

a) Spill-over PPT materials at the end of the contract shall be taken over by PPT in

complete shape.

b) Inventory of spill-over materials inclusive of PPT materials at the end of the contract

should not exceed 10% of the installed capacity of the respective items in MCHP.

c) The spill-over materials at the end of the contract procured by the contractor during

execution of the contract shall be taken over by PPT on re-imbursement basis subject to

the following conditions.

i. The payment to the contractor for the handed-over materials shall be as per the

actual procurement cost of materials for which the contractor has to produce

supporting purchase documents.

ii. Taking over of the materials by PPT shall be on priority for spill-over PPT

materials first & then short-fall quantity w.r.t. maximum 10% installed quantity

of respective items from the materials procured by the contractor except long

lead/ insurance items which shall be decided on mutual terms.

d) The surplus materials if any procured by the contractor during contract after above

mentioned handing over of materials to PPT at the end of the contract can be taken back

by the contractor with the certification & approval from PPT.

5.5.5 During the term of contract following situation may arise.

Case-1

Some of the components or equipments or systems will be getting obsolete and spares will

not be available but the components or equipments or systems are getting upgraded or new

versions developed with new features & compatible with plant requirement.

In this case the Contractor shall procure the higher version/upgraded components or

equipments compatible with plant requirement without affecting plant efficiency /

performance at his own cost.

Case-2

(i) Some of the components or equipments or systems will be getting obsolete and spares

will not be available and the OEM has closed his business.

(ii) Some of the components or equipments or systems are not available in spite of best

effort of the Contractor from OEM.

In both the cases following procedure shall be followed by the Contractor.

(a) Intimation with supporting documentation to PPT regarding closure of OEM / non

availability of material from OEM after exploring all options / materials getting

obsolete & OEM is no more existing.

(b) The Contractor may make written request to PPT for acceptance of the use of

alternative equipment or materials. Such request shall contain complete data to show

that such alternative item is quality wise same and has the required characteristics

for the intended use with proof of performance from users.

(c) The contractor shall make such request at least 30 calendar days before a final

decision to be taken by PPT.

Scope of Work


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(d) Within 30 calendar days following receipt of all requested information from the

Contractor, PPT will determine whether the proposed alternative and change meets

the requirements of the Contract and will inform the Contractor in writing of its

decision. However, the decision shall not relieve the Contractor of his obligations

under this contract.

(e) No cost shall be borne by PPT on this account.

Case-3

Some of the components or equipments or systems are not through OEM, but through some

other firm/Agency who have taken over the manufacturing / assembling / marketing of the

products from OEM.

a) Intimation with supporting documentation to PPT regarding non availability of

material from OEM due to either the OEM stopped assembly or marketing or taken

over by the other firm/agency.

b) The Contractor may make written request to procure components or equipments or

systems from the new vendor with all supporting documents.

c) Upon request, the Contractor shall furnish to PPT such additional information

relating to such cases as PPT may require.

d) The contractor shall make such request at least 30 calendar days before a final

decision to be taken by PPT.

e) Within 30 calendar days following receipt of all required information from the

Contractor, PPT will determine whether the proposed alternative and change meets

the requirements of the Contract and will inform the Contractor in writing of its

determination. However, the decision shall not relieve the Contractor of his

obligations under this contract.

f) No cost shall be borne by PPT on this account.

5.6 ADMINISTRATION, ENGINEERING SUPPORT, SAFETY, TRAINING:

The objectives of Engineering Support, Training and Administration & Safety have been

summarized in clause no.1.0 of Scope of Work. Accordingly the contractor shall establish

the procedures, plan & schedules and resources to accomplish the intended objectives which

are required for smooth operation and maintenance of the plant. Timely compliance to

statutory requirement is the foremost responsibility of the plant.

The contractor shall responsible to ensure the safety of the Plant and all of the Plant

personnel, and other personnel employed by the Contractor for the service and other

individuals and invitees who are at any time on the Plant. The contractor shall provide first

aid equipment for on-site emergency medical treatment and deploy a safety engineer to

enforce and refreshment of safety measures among all the Contractor’s personnel. The

contractor shall provide on-going and refresher training for all his personnel which will help

in increase productivity.

Scope of Work


Page 258 of 286

5.7 RECORD KEEPING & REPORT GENERATION FOR MANAGEMENT

INFORMATION SYSTEM:

During execution of the contract, the Contractor shall maintain adequate records and

generate reports for management information system. Record keeping & report generation

for the following activities of the plant should be done.

i) Operation

ii) Maintenance.

iii) House-keeping & cleanliness

iv) Stores & Spares.

v) Administration, Engineering support, Safety, ERP and Training, etc.

Building up of data / records and its analysis is one of the basic aspects of proper operation

and maintenance of the system. Various decisions involved in respect of fulfilling the

performance of this contract i.e. i) maintaining the operational rating of plant at its rated

capacity and improvement in availability of plant combined with safety of plant & personnel

are all dependent on an analysis of accurate data. The Contractor shall maintain the data to

determine the cause of failures and take decision on the corrective action for operation and

maintenance and improving the performance of the plant and equipment.

The Contractor shall develop a framework of systems or adopt the existing system

implemented in MCHP, procedures and guidelines towards record keeping and report

generation for proper O & M management. The log books and reports mentioned in

Appendix-19 for various functional activities are to be maintained by the Contractor. The

requirement of records and reports may vary from time to time depending upon the

requirement of either PPT or the Contractor. Formats, schedules and procedures for record

keeping and report generation are already developed for monitoring of operation,

maintenance, inventory and administration and the same may be followed by the Contractor.

If required the formats and procedure can be further customized/modified on mutually

agreed terms between EIC and Contractor. Also these may be reviewed, monitored and

modified, by mutual agreement, if required, during the term of contract. The Contractor may

develop computerized log books and reports instead of conventional method of record

keeping and report generation under Management Information System.

The Contractor shall keep PPT appraised of the plant health and operating performance

data. The Contractor shall furnish the management information system (MIS) data to PPT

on daily, weekly, monthly and yearly basis and its analysis regarding plant performance.

6.0 OTHER WORKS:

At present, a new Raw Water Pump House similar to the existing Raw Water Pump House

at Balijhara is under tendering process. It is expected that the new Raw Water Pump House

will be operational during the tenure of this O&M contract. Once the same is functional, the

operation and maintenance of new Raw Water Pump House shall be covered under the

scope of the contractor without any price implication to PPT.

Scope of Work


Page 259 of 286

7.0 MONTHLY REPORTS.

The Contractor shall submit the following monthly reports in a format acceptable to PPT

along with the Bills

a) Monthly availability factor of main system as per the format acceptable to PPT.

b) Operation rating of plant as per the format acceptable to PPT.

c) Extract of Preventative maintenance as per the format acceptable to PPT.

d) Extract of Corrective maintenance as per the format acceptable to PPT

e) Report on house -keeping & safety as per the format acceptable to PPT

f) Spares Consumption Report as per the format acceptable to PPT.

g) Satisfactory compliance to site order or site instruction of PPT.

h) An Undertaking that all statutory rules and regulation shall have been followed.

Without these reports Bills shall not be processed for payment.

8.0 FINAL INSPECTION, ACCEPTANCE AND PAYMENT.

8.1 The Contractor shall, three months prior to the expiry of the Contract Period, notify PPT in

writing to take-over the system. Paradip Port Trust shall make a final inspection within 45

days of receiving such Notice from the Contractor and take over the system on expiry of the

Contract in fully working and reasonable good condition.. In case of any defect or

abnormality, observed during inspection, the same shall be made good by the Contractor at

his own cost within a reasonable period failing which, the final payment shall be withheld.

8.2 The Contractor shall remove all of the Contractor’s tools, equipment and materials brought

by the Contractor.

8.3 The Contractor shall hand-over an updated inventory list taking into account all additions

and deletions during the term of the this Contract and deliver to the PPT all the then-

existing inventory and documents in accordance with clause no.5.5.4 of Scope of Work.

8.4 The Contractor shall remove its entire personnel except as otherwise instructed by PPT. The

Contractor shall be solely liable for resettlement, compensation or any other obligations in

respect of the Contractor’s personnel engaged during the term of the contract. The

Contractor shall keep PPT indemnified against claims, if any, pertaining to his personnel.

8.5 The Contractor shall settle all dues, recoveries, insurance claims, if any, with PPT.

8.6 The Contractor shall handover all the records / instruction manuals/ drawings / documents

received from PPT in properly bound and documented condition.

8.7 The Contractor shall prepare and handover all the records such as, but not limited to, plant

performance, logs and history data of the equipment which may or may not be part of day to

day report in hard and soft copy.

8.8 The Contractor shall remove & dispose from the site premises all scraps, petroleum, waste

materials, rubbish and other debris generated during the term of contract, as well as all tools,

his equipment, machinery and surplus material and shall leave the site premises area in a

neat, clean and usable condition. All cleanup and disposal activities of the Sub-contractor

shall be conducted in accordance with all applicable laws and applicable procedures.

8.9 Upon receipt of the certificate of final acceptance, the Contractor will make application to

PPT for final payment i.e (monthly payment for 3 months) within

30 days. PPT shall make payment to the Contractor within 30 days after receiving the final

payment application, complete in all respect.

Scope of Work


Page 260 of 286

APPENDIX-16

SCHEDULE OF SUPPLEMENTARY INFORMATION

The bidder shall submit following information relevant to the contract which are reasonably

justified for smooth execution of the contract.

1. Tentative Organization Structure for the subject work with duty and responsibilities

in reasonable details.

2. Tentative manning & deployment plans along with their qualification and

experience.

3. Any other details /information like

a) Requirement of open space inside harbor area and outside harbor area.

b) Requirement of PPT quarters A type, B type & C type.

c) Other relevant information if any.


Page 261 of 286

APPENDIX-17

LIST OF LONG LEAD SPARES

Sl. No. Description Unit Available Qty.

As on dt.01.03.17

MECHANICAL SPARES - CONVEYOR SYSTEM

1 Steel Cord Belt ST-800, Grade: M Mtr 405

2 Steel Cord Belt ST-900, Grade: M Mtr 1781.5

3 Steel Cord Belt ST-500, Grade: M Mtr 172

4 Steel Cord Belt ST-630, Grade: S Mtr 163

5 Belt EP 800/S Grade: M (Fabric Polyster)

Nylon No. of Plies-05, Width : 2200mm Mtr 42

6 Gear Box KCN 225 No 2




10 Pulley Type D1 No 1

11 Pulley Type D2/ D2B No 3



14 Pulley Type N1 No 1





19 Pulley type Deflector No 2

20 Pulley type N4 (Extended Shaft) No 1

21 Fluid Coupling Type SDFC 580 No 1

22 Fluid Coupling Type SDFC 660 No 1

23 Fluid Coupling Type FCU 14.5 No 1

MECHANICAL SPARES - SHIP LOADER

1 LT Drive Wheel Catridge Non Drive Bogie No 1

2 LT Drive Wheel Catridge Drive Bogie No 1

3 Long Drive Wheel & Shaft Assy. No 1

4 Long Travel Drive Gear Box No 1

5 Slew Drive Gear Box & Pinion With Bracke No 1

6 Slew Bearing Assy. No 1

7 Luffing Hydraulic Cylinder No 1

8 Luffing Hydraulic Pump No 1

9 Boom Conveyor Drive Pulley without

Pillow Block Assy. No 1

10 Boom Conveyor Head Pulley without


11 Boom Conveyor Snub Pulley without Pillow

Block Assy. No 1

12 Boom Conveyor Bend Pulley without



Page 262 of 286

Sl. No. Description Unit Available Qty.

13 Boom Conveyor Gear Box No 1

14 Boom Conveyor Fluid Coupling No 1

15 Trailing Tripper Discharge pulley No 1

16 Trailing Tripper Wheel & Shaft Assy. (Hold

down pulley) No 1

17 Boom Shuttle Drive Gear Box with Brake No 1

18 Boom Shuttle Wheel Assy. No 1

19 Loading Spout Tube Chute No 1

20 Trimmer Flap No 1

21 Loading Spout Hydraulic Kick up Cylinder No 1

22 Loading Spout Hydraulic Trimmer Cylinder No 1

23 Loading Chute Bearing Assy. No 1

MECHANICAL SPARES - STACKER

1 Drive Wheel & Shaft Assy. (Wheel & Shaft) No 1



4 Boom Conveyor Gear Box [KEN-280] No 1

5 Slew Gear Box No 1


7 Boom Conveyor Drive Pulley (without

Pillow Block Assy) No 1

8 Boom Conveyor Head Pulley (without


9 Trailing Discharge Pulley (without Pillow

Block Assy) No 1

10 Trailing Tripper Wheel & Shaft Assy. (Hold

down pulley) No 1

11 Trailing Tripper Bend Pulley (without Pillow

Block Assy) No 1

12 Slew Bearing No 1

MECHANICAL SPARES – RECLAIMER

1 Non Drive Wheel Assy. (Wheel & Shaft) No 1

2 Drive Wheel Assy (Wheel & Shaft) No 1

3 Bucket Wheel Drive Gear Box No 1


5 Boom Conveyor Gear Box [KCN-280] No 1

6 Slew Drive Gear Box No 1


8 Bucket Wheel Coupling No 1

9 Bucket Wheel Shaft No 1

10 Slew Bearing Assy. No 1

11 Boom Conveyor Drive Pulley (without


12 Hopper Feeder Tail Pulley (without Pillow

Block Assy) No 1


Page 263 of 286

Sl.

No. Description Unit Available Qty.

13 Hopper Feeder Head Pulley (without Pillow

Block Assy) No 1


15 Bucket Wheel Buckets No 4

16 Bucket Wheel Fluid Coupling No 1

17 Boom Conveyor Tail Pulley (without Pillow

block Assy) No 1

18 Belt Feeder Gear Box No 1

ELECTRICAL SPARES

1 Trailing Power Cable (610 Mtr.), 6.6 KV Grade Roll 2

2 Trailing Control Cable (610 Mtr.), 1.1 KV

Grade Roll 2

3 Trailing Control Cable (262 Mtr.), 1.1 KV

Grade Roll 1

5 PCRD Motor No 2

6 CCRD Motor No 1

8 ACB 2000 Amp. No 1

9 Cable 3C x 185 Sqmm. Mtr 202



13 Cable 4C x 50 Sqmm. (3.5 x 95Sqmm) Mtr 60

14 ACB 1000 Amp. No 1

15 CP 443-1 No 1

16 CP 441-1 No 1

19 CP 443 – 5 No 1

21 IM 461 – 3 No 1

22 Control Kit (EUA - 6150 - 6x) No 1

23 Power Supply Unit (EUS - 6150 - 1X) No 1

24 Earthing Truck Assy. 33 KV No 1

25 VCB Panel (HWX) 6.6 KV (2000 Amp.) No 2

26 VCB Panel (HWX) 6.6 KV (800 Amp.) No 1

27 VCB Panel (VCU) 6.6 KV (400 Amp.) No 2

28 VCB Panel (VMX) 6.6 KV (630 Amp.) No 1

29 Test Cabinets (6.6 KV) No 5

30 H.T Motor 6.6 KV (300 KW) No 1

31 H.T Motor 6.6 KV (350 KW) No 1

32 H.T Motor 6.6 KV (450 KW) No 1

33 Boom Conveyor Motor 150 KW For Stracker No 1

34 Boom Conveyor Motor 200 KW For Reclaimer No 1

35 Boom Conveyor Motor 200 Kw For Ship

Loader No 1


Page 264 of 286

APPENDIX-18

LIST OF OEMs FOR SPARE PROCUREMENT

Equipment / Machine OEM

M/s.

(a) Conveyor System (Mechanical):

Idler TRF Ltd. / Jana & Co.

Gear Box Elecon

Fluid Coupling Pembril Engineering Pvt. Ltd. / Premium

Spigoted Rigid coupling Birtley / L&T

Crowned toothed coupling Elecon

Scrapper Hosch / Usha Martin / Thejo Martin

Tramp metal magnet ERIEZ Magnetics

Electric hoist, Electrically operated trolley,

Manual Hoist, EOT Crane

Reva Industries Ltd.

Disc Brake Kateel Engineering industry

Sump pump Kirloskar Bros.

DG Set TIL Ltd.

Ventilation System C.Doctor & Co. (P) Ltd.

Arc Gate Hindustan Machine Tools

Take-up belt tensioning system Vankos

Plummer Block SKF / FAG

(b) Conveyor System (Electrical):

Belt weigher system Power build Ltd., Kolkata

HT Motors Crompton Greaves Ltd.

Illumination System Bajaj/ Crompton Greaves/ Havells

Hooter Kheraj Electrical Industries (P) Ltd.

Pull Cord, Belt sway, Zero speed, Take-up travel

limit switches, Tilt Switch

Jayashree Electron (P) Ltd., Pune

Rip Belt detector limit switches Davis Durvey, London

Local control station Teknic control gear (P) Ltd., Kolkata /Vaishno

Power & Control cable Cable corporation of India.

Fluid thermal limit switch BCH

Junction Box Exceltech

VVVF L&T Control & Automation (Yaskawa, Japan)

RRS Belt feeder Motor (LT) Crompton Greaves Ltd. / ABB

(c) Stacker / Reclaimer (Mechanical):

Long Travel SEW EURO Drive

PCRD / CCRD Electro Zavod

PCRD / CCRD Gear Box I C BAUER

Slew Clutch Coupling Flender / Siemens

Brake (Slew & Bucket Wheel) Bubenzer

Gear Box (Slew & Bucket Wheel) Flender / Siemens

Luff Hydraulic Vickers / Eaton

Boom Conveyor Gear box Flender / Siemens

Fluid coupling (Boom Conv. & Bucket Wheel) Voith

Idler TRF / Jana & Co.


Slew drag chain Electromac

Boom Conveyor Brake Kateel


Page 265 of 286


M/s.

Take-up component Enerpac

Maintenance Jacks Vankos

Wire rope Usha Martin

Plummer Block SKF / FAG

Centralised Lubrication System AFMC / CENLUB

(d) Stacker / Reclaimer (Electrical):

Long Travel SEW EURO Drive GmBH & Co.

Belt feeder motor NGEF

PCRD / CCRD Motor Bauer Geared motors, Germany

Slew Motor NGEF, Kolkata

Thruster brake Motor Bubenzer Bresmen, Germany

Hydraulic power pack motor Siemens

Boom Conveyor motor Siemens / Crompton Greaves

Bucket wheel motor Siemens / ABB

Bucket wheel brake motor Bubenzer Bresmen

Incremental encoder Rajdeep industrial products Ltd., pune

Anti Collision System Neo Tech Control System,Rajkot

HT Isolator A. Bond strand (P) Ltd., Chennai

Trailing cable Incab Industries Ltd./ Universal cables

Illumination system Crompton Greaves Ltd.

Transformer EMCO Transformer Ltd., Maharastra/

OTPL, Orissa

RIP Belt switch Communication and Control Engineering Co.

Ltd., Noltinghan

Belt weigher system Power build Ltd., Kolkata

VVVF Drives L&T-Control & Automation, Navi Mumbai

(Yaskawa, Japan)

PLC Siemens Ltd., Kolkata

Anemometer Lawrence and Mayo, New Delhi

Hooter & Flasher Siren Electrical, Kolkata/

Kheraj electrical industries (P) Ltd., Mumbai

Inductive Proximity switches, Tilt switches, Zero

speed switch

Jayashree Electro devices (P) Ltd., Pune

MCC Engineering Construction corporation

Local Control station Hotline switchgear & control, Delhi

Receptacles Control device, Kolkata

Cable tray Techofab manufacturing Ltd., Kolkata

Junction Box – HT Control device, Kolkata

Surge Weighing System(Reclaimer) Schenck Process /IPA Pvt Ltd.,Bengaluru

Control & Lighting JB Electrofabric Engineers, Kolkata

Cable reeling Drum (PCRD / CCRD) Electro Zavod (P) Ltd., Kolkata

Pull cord switch, Belt sway Jayashree Electro devices (P) Ltd., Pune

Complete electrical package Siemens Ltd., Kolkata

(e) Shiploader (Mechanical):

Long Travel, Boom Conveyor, Shuttle, Slew

Brake

Sigerland Bremsen

Long Travel Gear Box Getribebau Nord



Page 266 of 286


M/s.

Hydraulic component Rexroth / Bosch Rexorth

Boom Conveyor Gear Box Krupp Fordertechnik

Boom Conveyor Fluid coupling Voith

Shuttle Gear Box Krupp Fordertechnik

Slew Drive Bauer Esslingen

Central Lubrication System Delimon

Rail Clamp KF

(f) Shiploader (Electrical):

Boom Conveyor / Shuttle / Long Travel / Slew /

Hoisting gear motor

Crompton Greaves Ltd., Ahmednagar,

Maharastra

Thruster brake, ED-23/5, ED-50/6 Siegerland Bremsen Emde GmbH & Co.,

Germany

Inductive Proximity switches Schmersal / Jayashree Electron (P) Ltd., Pune

Tilt switch, speed switch, pull cord switch, belt

sway switch, heavy duty limit switch

Jayashree electron (P) Ltd., Pune

Absolute encoder TR Electronic GmbH Englishalde 6,

Trossingen

Local control station Teknic control gear (P) Ltd., Kolkata

Anemometer Lambrecht GmbH, Gohirgen / Lawrence and

Mayo, New Delhi

Cabin Glass wiper Casteels

Illumination system Bajaj, Crompton greaves, Havell’s

Hooter & Flasher Kheraj electrical industries (P) Ltd.,

Mumbai/Bajaj

VVVF Drives L&T-Control & Automation, Navi Mumbai

(Yaskawa, Japan)

PLC Siemens Ltd., Kolkata

Rail clamp hydraulic pump motor, Trimmer flap

kick-off motor

Siemens / Crompton greaves

Chute slew motor Bauer Gear Motors, Germany

EOT Crane Demag, Germany

PCRD, CCRD, WHRD Siemens

PCRD, CCRD, WHRD system Delachawx, 30 Avenue Brillant Savarin,

France

Pendulum Switch Ramsey Electrical

Auto lubrication pump system Delimon Fluthre GmbH, Germany

Remote Controller & their unit Theimeg Elektonikgerte GmbH & Co.,

Germany

Transformers 6.6 KV / 800 KVA Kirloskar power equipment Ltd., Pune/

OPTL, Orissa

Fire Alarm unit Electron Associates, Pune

Ladder type cable tray Debashish Industries, Kolkata

HT Isolator A. Bond strand (P) Ltd.

Trailing Cable Power cable corporation of India/ Universal

Cables


Page 267 of 286

g) Heavy Equipments (Mechanical):


M/s.

Payloader BL-40 Bharat Earth Movers Ltd.

Payloader BL-200 Bharat Earth Movers Ltd.

Hydra Crane ACE

Maintenance Vehicle TIL Ltd.

Belt Splicing Machine Shaw Almex India

DG Set ESSAB

(g) Substations (Eelctrical):

6.6 KV DOL starter panels / 6.6 KV HT feeder GEC Alsthom India Ltd., Kolkata/Areva

Vaccum contactors for 6.6 KV HT panels GEC Alsthom India Ltd., Kolkata/Areva

Motor protection relay GEC Alsthom India Ltd., Kolkata/Areva

All protection relays GEC Alsthom India Ltd., Kolkata/

Areva/Ashida electronics (P) Ltd.

Current transformer & Potential transformers Kappa electrical, Bangalore/ Emmess Control,

Chennai

Capacitors & Capacitor banks Meher capacitors (P) Ltd., Bangalore /

Schenider

Aux. plug & socket for 6.6 HT panels Allied electronics

Aux. contactors Siemens Ltd.

500 KVA DG Set TIL Ltd. / Kirloskar Electric Co. Ltd.

7.2 KV Indoor RVT Gyro Laboratories Pvt. Ltd., Mumbai

Ventilation system C. Doctor & Co. (P) Ltd.

Battery bank Exide Industries Ltd.

Package AC Blue Star

Window/Split AC Carrier/ LG/ Himgiri/ Blue Star

33 KV HT feeder Voltas/Schneider electric India (P) Ltd.

Automatic Voltage regulator relay, winding

temperature indicator for 20 mVA transformer

Pradeep Sales & Service, Mumbai

Transformers Alstom

Tap charges for 20 mVA transformer Easun-MR tap chargers (P) Ltd., Chennai

MCB’s MDS/Siemens/ C&S

LT ACB L&T

PLC Siemens Ltd.

DCDB Panel Electro Service India Ltd., Kolkata

LTMCC Panel L&T

ACDB Panel Exceltech.

(h) Others:

Welding material ESSAB / L&T / Advani Oerilikon / D&H /

Other reputed make

Steel Material(As per IS standard) SAIL / TISCO / Jindal / Vizag Steel

Conveyor Belt Phoenix Yule

Raw and Process water Pump Kirloskar Bros. Ltd

Raw and Process water Pump Motor Crompton Greaves Ltd., Ahmednagar,

Maharastra

All machines Operator Cabin Pagoda Industries


Page 268 of 286

APPENDIX-19

RECORD KEEPING & REPORT GENERATION FOR MANAGEMENT

INFORMATION SYSTEM:

OPERATION

Operation records / log books but not limited to the followings.

Sl.

No.

Ref Register

No. Description Purpose

Responsibility

PPT O& M

Contrac

tor

1 EM/MCHP/R-

01/17 Index Register

List of Registers & Files

maintained in MCHP

2 EM/MCHP/R-

02/17 Shift-in-Charge Register Information of shift in brief

3 EM/MCHP/R-

03/17 P.M.R. Log Book

4 EM/MCHP/R-

04/17 Ship-Loading Log Book

Ship particulars, shift wise

loading and stoppages

details.

5 EM/MCHP/R-

05/17 Receiving Log Book

Rake particulars, rake-wise

unloading in shift and

stoppages details.

6 EM/MCHP/R-

06/17

Status of Shipping Route

Register.

Pre inspection and Post

inspection of selected route

7 EM/MCHP/R-

07/17

Status of Receiving Route

Register.

Pre inspection and Post

inspection of selected route

8 EM/MCHP/R-

08/17

Operational Fault Register

(Mech.)

Details of Operational

faults (Mech. ) and

Analysis

9 EM/MCHP/R-

09/17

Operational Fault Register

(Elect. & Automation)

Details of Operational fault

(Elect. & Auto) and

Analysis

10 EM/MCHP/R-

10/17 MCL Log Book

Rake-wise unloading

timing, Oversize coal /

stoppages / wagon details.

11 EM/MCHP/R-

11/17

Capacitor Bank Operation

Register

Details of operation and

information from 132KV

substation.

12 EM/MCHP/R-

12/17

Overhead Electric Traction

line Isolator Operation

Register

Details of operation of

isolators and purpose.

13 EM/MCHP/R-

13 to 18 / 17

Machine log books

(ST#1, ST#2, RC#1, RC#2,

SL#1 & SL#2)

Details of running hours,

stoppages and other

important information

(shutdown) for calculation

availability.


Page 269 of 286

Sl.

No.

Ref Register

No. Description Purpose

Responsibility

PPT O& M

Contrac

tor

14 EM/MCHP/R-

19 / 17

Operation observations and

rectification Register (All

machines, substations and

conveyor system)

Details of observation and

remedial action.

15 EM/MCHP/R-

20 / 17

Malfunctioning / bypassing

of field, safety and

monitoring devices

Reason of mal functioning

and remedial action.

16 EM/MCHP/R-

21 / 17 Shut down Register Particulars of shutdown.

17. EM/MCHP/R-

22/ 17 Utility Log book

Details of operational data

of RWPH, PWPH, SWPH,

EWPH, HPPH, TSP &

Sprinklers.

18. EM/MCHP/R-

23/ 17 Cargo status Register.

Day-wise incoming and

outgoing of cargo ( plot and

party wise)

19 EM/MCHP/R-

24/ 17 RRS Log Book

Rake particulars, rake-wise

unloading in shift with

stoppage details.

20 EM/MCHP/R-

25/ 17

Rake Information Log

Book

Details of Rake Particulars

from Station to Station

(Showing Rake TRT)

OPERATION REPORTS BUT NOT LIMITED TO THE FOLLOWINGS.

Sl. No Type of

Reports Description Report No

Responsibility

Purpose PPT

O&M

Contra

ctor

A 1 Morning

Information

Report

Details of Receiving,

Shipping data & Major

maintenance works data

carried out from 06:00

previous day till 06:00 day.

EM/MCHP

/OPN/F-01

Information to

authorities.

B Daily Reports:

1 Daily Performance Report EM/MCH

P/OPN/F-

02

Internal

Analysis

Summary Abstract of Daily

performance of Receiving

& Shipping Stream

Rake Details Details of Rake particulars

handled in the day

Receiving

Stoppages

Details of stoppages in

Receiving stream during

the day

Shipping

Stoppages

Details of stoppages in

Shipping stream during the

day


Page 270 of 286

Rake TRT Details of Rake Turn

Around Time indicating

delays & Pie chart

Utilization of

RRS Details of Utilization of

RRS for the day showing

break-ups

Shipping

Stoppages

Abstract of Ship stoppages

Analysis for the month

2 Ministry

Report

MCHP Performance Report

(Shipping)

EM/MCH

P/OPN/F-

03

3 Penalty Report Shipping Penalty EM/MCH

P/OPN/F-

04

4 Railway

Report

Rake Indent to Railway EM/MCH

P/OPN/F-

05

5 Ship-loading

Performance

Ship-loading performance

analysis of completed

Vessel

EM/MCH

P/OPN/F-

08

Internal

Analysis &

Submission to

DM (MS),

PPT

6 Starting Order Starting order for

movement of Rakes from

RRS / Backloading Zone.

EM/MCH

P/OPN/F-

06

Sl. No Type of


Responsibility

Purpose PPT

O& M

Contra

ctor

C Weekly Reports:

1 Report on

delayed Rake

operation

Account of delay of rakes

beyond MCHP control

EM/MCH

P/OPN/F-

07

Submission to

TM, PPT

Sl. No Type of


Responsibility

Purpose PPT

O& M

Contra

ctor

Monthly Reports:

D 1 Monthly Ship-

loading

Performance

Ship-loading performance

analysis for the Month

EM/MCHP

/OPN/F-08

Internal

Analysis &

Submission

to DM(MS),

PPT

2 Cumulative

Receiving

Performance

Cumulative Month-wise

Receiving performance

analysis of Rakes

EM/MCHP

/OPN/F-09

Internal

Analysis &

Submission

to EE, P&D

Cell, PPT

3 Cumulative

Monthly

Report

Month-wise cumulative on

Rakes handled & ships

loaded, Average time and

Berthday output etc.

EM/MCHP

/OPN/F-10

Submission

to Dy. CEE


Page 271 of 286

4 Monthly Rake

Turn around

Report

Details of Rake operation

and delay time in different

accounts w.r.t to the fixed

norm.

EM/MCHP

/OPN/F-11

Submission

to Dy. CEE

& Internal

Analysis

5 Cumulative

Monthly Turn

Around Report

Month-wise Cumulative of

Turn Around Analysis

EM/MCHP

/OPN/F-12

Internal

Analysis

6 Non-

Conformance

Report

Details of Major break-

downs including

respective Corrective &

Preventive measures.

EM/MCHP

/OPN/F-13

Submission

to EE, P&D

Cell, PPT

7 Monthly

Availability &

Utilisation

Report

Availability & Utilisation

analysis w.r.t to previous

month & up to the month

previous year.

EM/MCHP

/OPN/F-14

Submission

to EE, P&D

Cell, PPT

8 Cumulative

monthly

unloading

performance

report w.r.t.

Oversize coal

Cumulative Month-wise

Analysis of unloading of

rakes w.r.t. presence of

Oversize coal.

EM/MCHP

/OPN/F-15

Internal

Analysis

9 9 Demurrage

Claim report

on account of

oversize coal

Consignee-wise Rakes

affected during the month

due to Oversize coal

EM/MCHP

/OPN/F-16

Submission

to TM, PPT

10 Report on

delay

operation

Stoppages Analysis of

delay in operation for Over

Size / Big Size coal

EM/MCHP

/OPN/F-17

11 Performance

Parameter

Comparison of Traffic

w.e.f to Previous Year /

Month of Receiving &

Shipping Stream

EM/MCHP

/OPN/F-18

12 MBO of

MCHP

Target Achievement of

Receiving & Shipping

Stream

EM/MCHP

/OPN/F-19

13 Result Frame

work

Achievement Parameter

w.r.t to Target.

EM/MCHP

/OPN/F-20


Page 272 of 286

Sl. No

Type of


Responsibility

Purpose PPT

O& M

Contra

ctor

Annual Reports:

E 1 Annual

Performance

Report

Shipping & Receiving

Analysis w.r.t. previous

two years

EM/MCHP

/OPN/F-21

CME, PPT

2 Record

Performance

Record performances this

year w.r.t. last year & last

record

Annual

Performance

Report

(Shipping)

Ships Loaded, berth-day,

availability - utilisation,

stoppages, records etc. for

the current year.

Annual

Performance

Report

(Receiving)

Rakes handled, Average,

availability - utilisation,

stoppages, records etc. for

the current year.

Statistics of

Shipping

Analysis

No. of Ships, Quantity,

berthday & stoppages w.r.t.

previous years.

Statistics of

Receiving

Analysis

No. of Rakes, Average,

back loaded rakes &

stoppages w.r.t. previous

years.

Abstract of

Monthly

Expenditure

Cost Per Ton & Operating

Ratio Analysis

2 Party-wise

Cargo handling

Analysis

Party-wise Rakes handled

& Ship-loading done w.r.t.

previous years since

inception.

EM/MCHP

/OPN/F-22


Page 273 of 286

MAINTENANCE:

Maintenance Records / Log books but not limited to the followings to be maintained by the

Contractor.

Sl.

No. Ref Register No.

Des

crip

tio

n

Dep

art

men

t

Equipment / machines /

systems Purpose

1. EM/MCHP/

MANT-R-01/17

Pre

ven

tiv

e

Mai

nte

nan

ce

Mec

han

ical

&

Str

uct

ura

l

ii) RRS,

iii) Pneumatic System,

iv) Arc gate

To be Recorded

i) Execution of work as per

preventive maintenance

schedule.

ii) Observation of PM

iii) Execution of work as per

observation.

iv) Execution of works as

per condition monitoring,

v) Execution of works as

per operational

observation.

vi) Execution of works as

per PPT observation.

vii) Execution of works as

per OEM observation.

viii) Any additional work

ix) Consumption of spares

(new, overhauling,

repair)

2. EM/MCHP/

MANT- R-02/17

All Machines including

structures.

3 EM/MCHP/

MANT- R-03/17


Conveyor Systems

including structures.

4 EM/MCHP/

MANT-R-04/17

i) Transfer Towers,

ii) Drive Towers

iii) Connecting Chutes,

iv) Tramp Magnet

5 EM/MCHP/

MANT-R-05/17

Track line Maintenance of

i) RRS,

ii) Stackers,

iii) Reclaimers

iv) Ship-loaders.

6 EM/MCHP/

MANT-R-06/17 Heavy equipments

7 EM/MCHP/

MANT-R-07/17

a) EOT cranes,

b) Electrical hoists & c)

Manual Hoists

8 EM/MCHP/

MANT-R-08/17

Pre

ven

tati

ve

Mai

nte

nan

ce

Ele

ctri

cal

& M

ech

an

ical

a) Ventilation System

b) Belt weighing System,

c) Sump pump,

d) 500 KVA D.G Set,

e) Fire detection & Fire

fighting System,

f) Earthing system

g) Air Conditioning

system of

i) PMR, ii) Canteen,

iii) Workshop,

iv) Amenity Building


Page 274 of 286

9 EM/MCHP/

MANT-R-09/17

a) Raw water Pump

house & pipeline,

b) Sewage system

c) Effluent system,

d) Portable Water System

e) Existing Dust Control

& Fire Fighting

system.

To be Recorded

i) Execution of work as

per preventive

maintenance schedule.

ii) Observation of PM

iii) Execution of work as

per observation.

iv) Execution of works as

per condition

monitoring,

v) Execution of works as

per operational

observation.

vi) Execution of works as

per PPT observation.

vii) Execution of works as

per OEM observation.

viii) Any additional work

ix) Consumption of spares

(new, overhauling,

repair)

10 EM/MCHP/

MANT-R-10/17 P

reven

tive

Main

ten

an

ce

Ele

ctri

cal

an

d A

uto

ma

tion

All Substations (9 nos) and

VVVF drive of RRS.

11 EM/MCHP/

MANT-R-11/17 All machines (6nos)

12 EM/MCHP/

MANT-R-12/17


Conveyor Systems.

13 EM/MCHP/

MANT-R-13/17

Illumination System of

i) Conveyors and

conveyor galleries

ii) Transfer / Drive

towers, tunnel.

iii) Rail Receival

Station

iv) Machines

v) Substations lighting

(Indoor and

Outdoor)

vi) High mast towers.

vii) Other buildings.etc

14 EM/MCHP/

MANT-R-14/17

Cathodic Protection System

15 EM/MCHP/

MANT-R-15/17

Automation and Control

i) PLC

ii) OP-37,

iii) Plant Monitoring

System

iv) Net working system.

16 EM/MCHP/

MANT-R-16/17

Lu

bri

cati

on

Lo

g B

oo

k

Mec

han

ical

& E

lect

rica

l

All equipments

Periodical lubrication of

different equipment of

machines and conveyors., etc

17 EM/MCHP/

MANT-R-17/17

Condit

ion M

onit

ori

ng

Mec

han

ical

, st

ruct

ura

l, E

lect

rica

l,

Auto

mat

ion

All major equipments

i) All machines

ii) All conveyors

iii) All Substations

iv) Plant Automation and

Control system.

v) Auxillary System

vi) Cathodic Protection

System. etc

To be recorded

i) Monitoring of condition

ii) Analysis of condition

iii) Course of Action

iv) Execution


Page 275 of 286

18 EM/MCHP/

MANT-R-18/17

Ov

erh

auli

ng

, M

ajor

Rep

air

Lo

g B

ook

Mec

han

ical

,

stru

ctura

l, E

lect

rica

l,

Au

tom

atio

n

All equipments

i) Reason for overhauling

/repairs

ii) Details of Overhauling/

major repairs

iii) Testing if any to ensure

its designated

parameters.

19 EM/MCHP/

MANT-R-19/17

His

tory

Bo

ok

Mec

han

ical

, st

ruct

ura

l,

Ele

ctri

cal,

Au

tom

atio

n i) All machines

ii) All conveyors

iii) All Substations

iv) Plant Automation

and Control system.

v) Auxillary System

vi) Cathodic Protection

System. etc

i) Recording major

works

ii) Modification date

with reason

iii) Major breakdown

rectification and fault

analysis

iv) Corrective action to

be taken to avoid

repetition of failure.

20 EM/MCHP/

MANT-R-20/17

Tes

ting a

nd C

alib

rati

on

Log b

ook

Mec

han

ical

, E

lect

rica

l,

Auto

mat

ion

i) Gauges, meters, wire

rope, handling tackles

ii) Lifting appliances

iii) Electrical measuring

and monitoring

instruments.

Previous schedule, Results of

tests and calibration, next

schedule.

21 EM/MCHP/

MANT-R-21/17

Unsc

hed

ule

d m

ainte

nan

ce

( O

per

atio

nal

Mai

nte

nan

ce)

Mec

han

ical

, E

lect

rica

l, A

uto

mat

ion

Receiving streams and

shipping streams

(Below 1 hr. Stoppage)

Operational faults and

immediate rectification

22 EM/MCHP/

MANT-R-22/17

Unsc

hed

ule

d m

ainte

nan

ce

( B

reak

dow

n M

ain

ten

ance

)

Mec

han

ical

, E

lect

rica

l,

Auto

mat

ion


shipping streams

(Above 1 hr. Stoppage)

i) Timing of breakdown

and nature of

breakdown

ii) Reason of breakdown

iii) Procedure of

rectification for critical

breakdowns.

iv) Complete analysis


Page 276 of 286

23 EM/MCHP/

MANT-R-23/17

Un

sch

edule

d m

ainte

nan

ce

( P

ost

-fau

lt M

ain

ten

ance

)

Mec

han

ical

, E

lect

rica

l,

Au

tom

atio

n


shipping streams

i) Reason for temporary

arrangement / bypass

of devices

ii) Corrective action

taken

24 EM/MCHP/

MANT-R-24/17

Ho

use

-kee

pin

g a

nd

Cle

anli

nes

s

Mec

han

ical

, E

lect

rica

l,

Au

tom

atio

n

Mechanized Coal handling

Plant Details of housekeeping

25 EM/MCHP/

MANT-R-25/17 Saf

ety

Mec

han

ical

, E

lect

rica

l,

Auto

mat

ion

Man & Machines

i) Weekly safety meetings.

ii) Safety violation and

enquiry.

iii) First aid facility

iv) PPE utilization

v) Checking of walkway,

handrails and safety

guards, etc & action

taken.

vi) Accident and reporting

the authority, Enquiry ,

delivery of

compensation.

26 EM/MCHP/

MANT-R-26/17

Civ

il a

nd

Ele

ctri

cal

Mai

nte

nan

ce

Buildings consist of

i) 9 nos of substations,

ii) amenity building,

iii) Change room,

iv) Compressor room,

v) Pump houses,

vi) Plant monitor room,

vii) Building at top &

down railway point,

viii) Tunnel,

ix) Watch tower building,

x) Workshop,

xi) Belt weighing room

near TT#8,

xii) Cable pits and yard

toilets, etc.

xiii) RRS & Feeder

xiv) Yard Toilet

xv) Transfer Tower pits &

etc.

Details of maintenance and

repair works.


Page 277 of 286

MAINTENANCE REPORTS BUT NOT LIMITED TO THE FOLLOWINGS.

Sl. No. Ref

Report No. Description

Dep

art

men

t

Purpose

1 EM/MCHP/

MANT-F-1/17 Daily work plan

Mec

han

ical,

Str

uct

ura

l, e

lect

rica

l an

d A

uto

mati

on

Planning of

i) Maintenance as per PMS

ii) Maintenance of Pending PM

iii) Observation of PM

iv) Observation of condition

monitoring

v) Critical observation

vi) Operational observation.

vii) PPT observation.

viii) OEM observation.

ix) Any additional work

2 EM/MCHP/

MANT-F-2/17 Daily work status

Execution status of previous day work

plan with information in brief.

3 EM/MCHP/

MANT-F-3/17 Daily check list

(i) Daily checking of all machines

and conveyors as per checklist.

(ii) Entry of any abnormalities.

4 EM/MCHP/

MANT-F-4/17

Weekly pending

job list (from

work plan)

Pending list of the planed jobs of

preceding week.

5 EM/MCHP/

MANT-F-5/17

Monthly pending

job list (work

plan)

Pending list of the planed jobs of

preceding month.

6 EM/MCHP/

MANT-F-6/17 Monthly status

Belt Weighers, Encoders, Safety

switches, Field devices & Monitoring

devices of all conveyors & machines.

7

EM/MCHP/

MANT-F-

07/17

Quarterly status

Gear box, Fluid coupling, Belt, Pulley,

Pumps, Motor Relays, Earth pits,

Breakers, Transformers, VVVF drive and

other vital equipments.

8

EM/MCHP/

MANT-F-

08/17

Monthly status

(i) Point to point communication

(ii) Profibus communication

(iii) Ethernet communication

(iv) Wireless Communication

9

EM/MCHP/

MANT-F-

09/17

Monthly status Illumination system & high mast tower

10

EM/MCHP/

MANT-F-

10/17

Yearly status of

structures

i) Replacement of corroded structural

points.

ii) Painting of structures.

11

EM/MCHP/

MANT-F-

11/17

Monthly status % of achievement of planned works

12

EM/MCHP/

MANT-F-

12/17

Monthly Major

Works Status

Major replacement / Repair of

equipment / component.


Page 278 of 286

STORES MANAGEMENT.

Maintenance of Record / Log books but not limited to the followings is under the

scope of the Contractor.

(a) Receipt & Issue Log Book

(b) Inventory of Critical Spares

(c) Master list

(d) Monthly report on status of Stores materials

(e) Monthly consumption report

(f) Annual report on Spares

(g) Indent file

(h) Purchase order file

ADMINISTRATION AND TRAINING ETC.

The maintenance of records but not limited to the followings is under the scope of

the Contractor.

(a) Manpower status

(b) Training particulars

(c) Programmes on Safety & Environment

(d) Recording on accidents

(e) Establishment records

(f) Labour & Welfare

(g) ISO requirement & compliance

(h) Compliance to Statutory bodies

`


Page 279 of 286

BILL OF QUANTITY (BOQ)

Tender Inviting Authority :Executive Engineer MCHP,E&M Department, PPT

Name of Work: Operation & Maintenance of Mechanised Coal Handling Plant

Contract No: EM/MCHP-19/17

Bidder Name :

PRICE SCHEDULE [BILL OF QUANTITY (BOQ)] (This BoQ template must not be modified/replaced by the bidder and the same should be uploaded after filling the relevent columns,

else the bidder is liable to be rejected for this tender. Bidders are allowed to enter the Bidder Name and Values only) N.B.: The above quoted price is inclusive .of all the taxes, duties, cess, etc..and all other incidentals like transport, insurance etc excluding.service tax.

Sl. No.

Item Description Qty. Units Estimated Rate for one year (12 months)

(in. Rs.)

RATE per month In Figures To be entered by the Bidder Rs. P

AMOUNT Rs. P

Figures For 12 months

In Words

1.00 Operation & Maintenance of Mechanised Coal Handling Plant

12 Month 62,79,59,586

2.00 One Time Mandatory Initial Works 1 LS 87,71,664

Total in Figures

0.0000 INR Zero Only

Quoted Rate in Words

INR Zero Only


Page 280 of 286

BOQ - BREAK-UP PRICE


Page 281 of 286

Annexure-I

BREAK UP PRICE

Sl. DESCRIPTION

RATE PER MONTH (In Indian Rupees)

AMOUNT FOR 12 MONTHS (In Indian Rupees)

In figures In figures

OPERATION & MAINTENANCE OF MECHANISED COAL HANDLING PLANT

A

Operation & Maintenance of Main System (Receiving & Shipping Stream)

(a) Operation & Maintenance of Main System - Receiving Stream

(i) Operation of Main System Receiving Stream

(excluding operation of 2nd

Receiving Stream)

0

(ii) Operation of 2nd

Receiving Stream 0

(iii) Maintenance of Main System - Receiving

Stream 0

Total of A(a) = Summation of a(i) to a(iii) 0 0

(b) Operation & Maintenance of Main System - Shipping Stream

(i) Operation of Main System - Shipping Stream 0 0

(ii) Maintenance of Main System - Shipping

Stream 0 0

Total of A(b) = Summation of b(i) and b(ii) 0 0

Total of A = A(a) +A (b) 0 0

B Operation & Maintenance of Auxiliary System 0 0

C Operation & Maintenance of Heavy Equipment 0 0

D Operation & Maintenance of Illumination System 0

E Maintenance of EOT Cranes, Electrical and Manual Hoists 0

F Maintenance of Cathodic Protection System 0

G Maintenance of Communication facility; i.e. intercom, VHF

communication etc. 0

H Maintenance of Buildings, Substations, Cable pits etc. 0

I Cleanliness/House Keeping including cleaning of debris

beneath the conveyor gallery & coal berth 0

J Painting of Plant 0

K Operation & Maintenance of existing Dust Control System 0 0

L One Time Mandatory Initial Works

(i) Revamping of Existing Dust Control System 0

(ii) Replacement of Civil Structurals of counter weight

sheeve pulley of R-7 & R-8. 0

(iii) Shifting of belt weigher from existing location 0

Total of L = Summation of L(i) to L(iii) 0

M Operation of ERP 0

GRAND TOTAL (Summation of Sl. A to M) : 0 0

GRAND TOTAL (Summation of Sl. A to M) in words :

NB: 1) The Total of the break-up prices as above should match with the total price quoted for item No.1 & 2 of BOQ.

2) The total of the Break-up Prices as above [summation of Sl. A to K & M( excluding L)] should match with the

price quoted for item No.1 of BOQ. Similarly, break-up price as above at Sl. L should match with the price quoted

for item No.2 of BOQ.

3).Bidders need to enter the rates in figure and grand total in words in green coloured cells.

4) Bidders shall advised to fill the break up price in the original given excel format and upload the same by converting

it into PDF

5) Bidders are advised to start filling the break up price starting from Annexure-II, III, IV, V and then I.

6) Total price quoted at item no.A(a)(iii) & A(b)(ii) corresponds to Annexure-II, B, corresponds to Annexure-III,C,

corresponds to Annexure-IV and K corresponds to Annexure-V.

Name of the Bidder :

Date :


Page 282 of 286

Annexure-II

BREAK UP PRICE Sl. DESCRIPTION RATE PER MONTH

( In Indian Rupees)

AMOUNT FOR

12 MONTHS

( In Indian Rupees)



A Operation & Maintenance of Main System (Receiving & Shipping Stream)

(a)(iii) Maintenance of Main System – Receiving Stream.

1 Stacker-1 0

2 Stacker-2 0

3 Substation # 1 0

4 Substation # 2 0

5 Substation # 3 0

6 Substation # 6 0

7 Conveyor-1A 0

8 Conveyor-1B 0

9 Conveyor-2A 0

10 Conveyor-2B 0

11 Conveyor-R3. 0

12 Conveyor-R4. 0

13 Conveyor-R5. 0

14 Conveyor-R6. 0

15 Conveyor-R7. 0

16 Conveyor-R8. 0

17 PLC Network comprising of 21 PLCs. 0

18 Rail Receival Station, Arc Gate and

Ventilation System.

0

19 Transfer Tower-TT1, connecting Chutes 0



22 Drive Tower –DT4, connecting Chutes 0

23 Drive Tower –DT5, connecting Chutes 0

24 Track-line Maintenance of Stacker-1 0

25 Track-line Maintenance of Stacker-2 0

26 Belt weighing System 0

27 Tramp Magnets 0

28 Compressors 0

Total of A (a)(iii) = summation of Sl. 1 to 28: 0 0

Total of A(a)(iii) in words


Page 283 of 286

Sl. DESCRIPTION

RATE PER

MONTH

( In Indian

Rupees)

AMOUNT FOR

12 MONTHS

( In Indian Rupees)


(b)(ii) Maintenance of Main System – Shipping Stream.

1 Reclaimer-1 0

2 Reclaimer-2 0

3 Shiploader-1 0

4 Shiploader-2 0

5 Substation # 4 0

6 Substation # 5 0

7 Substation # 7 0

8 Substation # 8 0

9 Substation # 9 0

10 Conveyor-S3. 0

11 Conveyor-S4. 0

12 Conveyor-S5. 0

13 Conveyor-S6. 0

14 Conveyor-S7. 0

15 Conveyor-S8. 0

16 Conveyor-S9. 0

17 Conveyor-S10. 0

18 Conveyor-S13. 0

19 Conveyor-S14. 0

20 Transfer Tower-TT6A, connecting Chutes 0

21 Transfer Tower-TT6B, connecting Chutes 0



24 Drive Tower –DT9, connecting Chutes,

moveable Trolley arrangement

0

25 Track-line Maintenance of Reclaimer-1 / 2 0

26 Track-line Maintenance of Shiploader-1 / 2. 0

27 Belt weighing System 0

28 Tramp Magnets 0

29 Up-keeping of Conveyor S-11 &

S-12 and Switch Bin 0

Total of A(b)(ii) = summation of Sl. 1 to 29: 0 0

Total A(b)(ii) in words

NB: 1) The Total of the break-up prices as above will reflect at item No.A(a)(iii) and A(b)(ii) of Annexure-I.

2)Bidders need to enter the rates in figure and total in workds in green coloured cells.

3) ) Bidders shall advised to fill the break up price in the original given excel format and upload the

same by conerting it into PDF.

Name of the Bidder :

Date :


Page 284 of 286

Annexure-III

BREAK UP PRICE

Sl. DESCRIPTION

RATE PER MONTH

( In Indian Rupees)

AMOUNT FOR

12 MONTHS

( In Indian Rupees)



B Operation & Maintenance of Auxiliary System.

1 Raw water Pump house

0

2. Raw water Pipe Line 0

3 Sewage system

0

4 Effluent system 0

5 Portable Water System

0

6 D.G set

0

7 Air Conditioner inside

MCHP Canteen & PMR.

0

Total of B = summation of Sl. 1 to 7: 0 0

Total of B in words

NB: 1) The Total of the break-up prices as above will reflect at item No.B of Annexure-I.

2) Bidders need to enter the rates in figure and total in words in green coloured cells.

3) Bidders shall advised to fill the break up price in the original given excel format and upload the same

by conerting it into PDF.

Name of the Bidder

Date :


Page 285 of 286

Annexure-IV

BREAK UP PRICE

Sl. DESCRIPTION RATE PER MONTH

(In Indian Rupees)

AMOUNT FOR 12 MONTHS

( In Indian Rupees)



C Operation & Maintenance of Heavy Equipment.

1 Hydra Crane-I

0

2 Hydra Crane-II

0

3 BL-200 Pay Loader

0

4 BL-40 Pay Loader

0

5 Maintenance Vehicle-I

0

6 Maintenance Vehicle-II

0

7 Maintenance Vehicle

DG set 0

Total of C=summation of Sl. 1 to 7: 0 0

Total of C in words

NB: 1) The Total of the break-up prices as above will reflect at item No.C of Annexure-I.

2)Bidders need to enter the rates in figure and words in green coloured cells.

3) Bidders shall advised to fill the break up price in the original given excel format and upload the same by

conerting it into PDF.

Name of the Bidder

Date


Page 286 of 286

Annexure-V

BREAK UP PRICE

Sl. DESCRIPTION RATE PER MONTH

(In Indian Rupees)

AMOUNT FOR

12 MONTHS

( In Indian Rupees)



K Operation & Maintenance of Existing Dust Control System.

1 Process Water Pump House

0

(a) Operation 0

(b) Maintenance of 04 nos.

pumps & its installation 0

Total of 1 = summation of (a) and (b): 0 0

2 RRS including High Pressure

Pump House 0

3 Both the Stackyard

Sprinklers

0

4 Sprinkling system at Transfer

Tower

0

5 Fire Fighting System

0

Total of K = summation of Sl. 1 to 5: 0 0

Total of K in words

NB: 1) The Total of the break-up prices as above will reflect at item No.K of Annexure-I.

2) Item at Sl.No.1(b) of above is meant for 04 times of maintenance of one no. pump

and its installation.

3)Bidders need to enter the rates in figure and total in words in green coloured cells.

4) Bidders shall advised to fill the break up price in the original given excel format and upload the

same by conerting it into PDF.

Name of the Bidder

Date :

Date post:	20-Jun-2018
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