Nc – Ng Paste

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Annexure – B TECHNO-COMMERCIAL SPECIFICATION FOR TENDER ENQUIRY FOR SUPPLY OF NC-NG PASTE PLANT, SINGLE BASE PROPELLANT PLANT AND TRIPLE BASE PROPELLANT & FLASH REDUCING DISC PLANT FOR PRODUCTION OF BIMODULAR CHARGES INCLUDING ASSOCIATED CIVIL WORKS AT O.F.NALANDA PROJECT, RAJGIR, BIHAR, INDIA VOLUME III TECHNICAL SPECIFICATIONS FOR THE THREE PLANTS : NC-NG PASTE PLANT, SINGLE BASE PROPELLANT PLANT AND TRIPLE BASE & FLASH REDUCING DISC PLANT Specification No. – SPCN/I/2016/OFN/BMCS APPENDIX-I TECHNICAL SPECIFICATION FOR SUPPLY, ERECTION & COMMISIONING OF PLANT AND MACHINERY INCLUDING ASSOCIATED CIVIL WORKS FOR PRODUCTION OF NC-NG PASTE AT O.F. NALANDA PROJECT, RAJGIR (BIHAR), INDIA Specification No. – SPCN/I/2016/OFN/BMCS/PASTE TABLE OF CONTENTS FOR APPENDIX I, VOLUME III VOLUME III PARA No. SUBJECT PAGE No. APPENDIX I NC-NG PASTE PLANT SPECIFICATIONS 1.0 Intent 1 2.0 Capacity of the plant 1 3.0 Description of requirement 1-4 3.1 4.0 Process Description Tools and fixtures 2-4 5 5.0 6.0 Testing Equipment Services / Utilities 5 5-6 Annexure I (Paste) Product specification 7-8 Annexure II (Paste) Raw material specifications 9-11 Annexure III (Paste) Block & Process Flow Diagram 12-16 Annexure IV (Paste) Equipment list 17-31 Annexure V (Paste) Accommodation statement 32 - 33 Annexure VI (Paste) Conceptual Plant Layout 34 Annexure VII (Paste) Contour Overlay on Plant Layout 35 REQUIREMENT - 1.0 NC/NG PASTE MANUFACTURING PLANT CAPACITY 900 MT/ANNUM ALONGWITH ASSOCIATED CIVIL WORKS. INTENT The present intent is for supply and installation of Nitroglycerine / Nitrocellulose paste manufacturing plant at Rajgir, Bihar India. The Plant shall be capable of producing NC/NG paste required for Bi-modular charge system. NC/NG Paste is obtained by mixing wet NC and Nitroglycerine along with chemical ingredient like ethyl centralite, candelilla wax and soda ash (for NG only) in a specially designed Plant and machinery to suit this purpose. 2.0 CAPACITY OF THE PLANT The plant will have a minimum output capacity of 900 MT/annum in 220 working days with a most modern PLC / automatic plant utilising minimum manpower and energy. The rated capacity of the plant has to be so designed so that the required output capacity of 900 MT/ annum as given above is achieved with the plant availability of minimum 80% of time with 80 % plant efficiency and wastage / rejection not more than 2 % on 1x8 hours shifts per day on continuous basis. The quality of the finished product will be as per the production specification enclosed as Annexure-I (Paste) The specification of raw material is also enclosed as Annexure-II (Paste). The plant supplier shall ensure that the plant and equipment offered as a whole is capable of producing under normal condition at full rated capacity and this should be demonstrated during commissioning / guarantee run both for main plant and separately for other utilities. 3.0 DESCRIPTION OF REQUIREMENT A brief description for paste making is given below. In addition to the above, process flow diagram (for reference purpose only) of the plant and an indicative list of main equipment with specification is enclosed at Annexure III (Paste) and Annexure IV (Paste) respectively. The vendor, if so desired, may change the process depending on his technology or for a better technology and submit the offer accordingly. In any case, the vendor shall submit along with the offer - process flow diagram, list of equipment and specifications of the offered equipment in the format of Annexure III (Paste) and Annexure IV (Paste) respectively including all other techno – commercial information as per the tender document. Vendor should specify the Capacity, quantity, Page 1 criticality of each equipments offered as per their technology. Hot stand- by for any equipment should also be specified. The vendor has to prove the capacity of the plant and quality of the products as given in the Annexure- I (Paste). 3.1 PROCESS DESCRIPTION 3.1.1 Transportation of NG and Weighing Nitroglycerine emulsion is transported from the Storage Section by means of ejector (Ej 43-10) into the receiving vessel (VE 49-10), from where it flows into the separator (SEP 50-10) in which the Nitroglycerine and transport water separates. The separated water flows to the labyrinth (LY 56-10) where any free Nitroglycerine separates from the water. The separated Nitroglycerine flows from the separator into a buffer tank (VE 51-10) from where it flows into the weighing vessel (VE 52 – 10). Upon reaching the correct mass of Nitroglycerine, a shut-off valve closes the supply pipe to the weighing vessel. The measured quantity of Nitroglycerine then flows into the transport vessel (VE 53-10) from where it is transported to tank (TK 63 – 10) in the Nitroglycerine Mixing plant by means of ejector (EJ 54-10). Nitroglycerine separated in the labyrinth is recovered by means of ejector (EJ 57-10), which transports it back to separator (SEP 50-10). Water accumulated in the labyrinth flows to the pressure vessel (TK 58–10) as well as wastewater vessel (VE 59-10) from where it is transported to the Wastewater Treatment plant by means of ejector (EJ 60-10). 3.1.2 NC-NG Paste Mixing Hot contaminated water is added to the tank (TK 61-10). Nitrocellulose is then added to the tank and stirred using stirrer (AG 61-11). Ethyl Centralite, which acts as a stabilizer on the Nitrocellulose, is added to the slurry and thoroughly mixed. This mixture is then stirred for a predetermined length of time, using agitator (AG 61-11) before pumping it to tank (TK 63-10) via pump (PP 62-10). In tank (TK 63-10), Nitroglycerine /water emulsion from the ejector (EJ 54-10) in the Weighing Plant is added while it is being stirred with agitator (AG 63-10). Hot contaminated water is added to both tanks TK 61-10 and TK 63-10. Upon completion of the mixing process, the paste slurry is then pumped by means of pump (PP 64-10) to the paste blending tank TK 65-10 or TK 68-10 in the Blending, Disintegration and Dewatering plant. Page 2 3.1.3 Blending, Disintegration and Dewatering Paste Blending Paste is received in approximately 500kg lots into the selected blending tank TK 65-10 / TK 68-11 by operating the splitter box connections in such a way that the open line between Tank 63-10 (Paste Mixing Room) and the blending tank is established. The agitator is run at a speed of 33 rpm. Once the required mass of paste has been mixed and transferred to the blender, the paste is homogenized by the agitator AG 65-11 and disintegrator PP 67-10. The paste slurry flows through the flush bottom valve via the blender pump PP 66-10, PP 66-30 to the disintegrator into an empty blender. The pump rate is 22.5 m3 per hour and the time needed for homogenization about 5 hours to 10 hours, dependant on the volume in the blender. When paste batches of greater than 15 000 kg (dry mass) are required, interblending of two blenders can be carried out. This will yield a paste batch of up to 30 000 kg. Inter blending is done by transferring the contents between blender. On completion of blending and homogenization paste samples are taken for laboratory analysis. If the paste does not conform to specification, provision is made for correction of the paste by pumping about 500kg of slurry back to the mixing tank TK 63-10 in the Paste Mixing Room. Additions of the necessary ingredients are made by utilizing the raw materials and semi-products facilities in H4. The addition batch is transferred to the blender and the whole cycle of homogenization, blending and interblending, where applicable, is carried out. If additions are greater than 100kg per mixer lot, the total addition is divided into suitable fractions and more than one addition made. The paste is subjected to Laboratory test. After approval, the paste is ready for dewatering. This is done by pumping (PP 66-10) the slurry into the launder that feeds the vacuum belt filter BFL 70-10. The recovered water storage tanks TK 68-10 & TK 68-20 are utilised for water received from the belt filter. The water is stored and re-used for paste mixing. The one tank (TK 68-10) is a dual-purpose tank utilised to receive paste from the two paste blenders or to store the recovered water from the process. Paste slurry can be agitated here, but transfer to either of the two paste blenders must first take place before the paste can be dewatered. The vacuum pump PP 75-10 is water-sealed unit with water supplied from the cooling tower CT 77-10. The vacuum pump is coupled to the filtrate receiver TK 71-10 where the Page 3 recovered water from the belt filter is collected. The filtrate pump PP 72-10 pumps the recovered water to the recovered water storage tanks from where the water is transferred by the recovered water pumps to the paste mixing building and the various pumps, blenders and vacuum belt filter in the paste blending building. De watering Paste slurry is pumped from the blenders via the launder on the vacuum belt filter for dewatering of the paste. This procedure yields about 1500kg dry mass of paste per hour. The vacuum belt filter has a corrugated rubber support belt with a cotton belt on top of the rubber belt. The rubber belt has holes in the slots through which vacuum is applied to the paste slurry. The filtrate is collected in a vacuum receiver from where it is transferred to the recovered water storage tanks for re-use in the process. The speed of the belt is variable to adjust for the required moisture content. The de watered paste falls through a chute in the floor to the ground floor section. Paste Loading The paste is collected into the paste bags connected to the outlet chute of the packaging table. The batch no., type of paste, mass and the date is recorded on a label that is attached to the bag. The filled bags are packed in a box pallet and transported to the paste magazine by a forklift truck. Internal moving of the box pallets is carried out by using the hand pump trolley. Quality assurance tests are carried out on the dewatered paste and six representative samples are taken and sent to the laboratory for full chemical analysis and moisture content. Disintegration The disintegration is used for paste homogenization. Lumpy materials in the paste cause non-homogeneity and the action of the disintegrator pump is to ensure fine dispersion and assist in blending operations. The high-speed rotation of the rotor in close tolerance with the stator sets up shear and sonic compression/decompression forces that result in colloidal dispersion of paste components. Page 4 The disintegrator is fed by the paste slurry pumps at a rate of 22.5 m3 per hour. The homogenization process can take up to 10 hours, according to the paste batch size. 4.0 TOOLS AND FIXTURES The plant supplied shall be tooled up. The offer shall be complete with tools, dies and fixtures (Refer Volume I para 4.0 (ii)) 5.0 TESTING EQUIPMENT, The technical bid should clearly indicate all the laboratory equipments, required for tests, including closed vessel tests that are to be conducted in relation to the production of NCNG paste, including online tests and laboratory tests, in a tabular form as given below. The item wise price breakup of these equipments is to be given in the price bids. The PRICE column in the table below should therefore be left blank in the technical bid. S.No. EQUIPMENT NAME A In process testing Equipments 1 2 … B PURPOSE No. of Equipment (Qty.) PRICE (including all taxes etc) Included in Offer ? (Y/N) Laboratory Equipments 1 2 ….. The provision of laboratory space is supplier’s responsibility. Also Refer Volume I Para 4.0 (iii). 6.0 SERVICES/ UTILITIES All the services/utilities required for production of NC-NG Paste, shall be designed, supplied and erected and their capacities proven. Refer to para 4.2 of Volume I of the specifications for Purchaser’s responsibility. Any special requirements of services by the plant, that is at variance with the provisions of the para 4.2 has to be included in the scope of supply and its cost included in the offer. Page 5 The vendor shall mention the guaranteed requirement of the following services for the plant offered, in the technical bid: (a) Steam (b) Water (c) Electricity (d) Compressed Air (e) Chilling Unit -------------------------------------------------------- Page 6 ANNEXURE (PASTE) ANNEXURE-I (Paste) (1/2) PRODUCT SPECIFICATION 1.0 Product Specification for M30 Propellant Paste (for TBP) The specification covers paste used in the manufacture of propellant M30. Description – The material shall consist of an intimate and uniform mixture of Nitrocellulose, Nitroglycerine and stabilizer in the form of a homogeneous paste, free from visible impurities, foreign matter and grit. Inspection Lot – An inspection lot shall consist of propellant paste from the same batch or blending operation, manufactured under conditions of production which are considered uniform and continuous. Sampling – Five representative samples of the de watered paste lot are to be taken and analyze for chemical and physical properties as specified below for evaluation of the individual results for acceptance or rejections. Properties - The material shall conform to the requirements as given below. Failure of any test result classified as a critical or major characteristic to comply with the chemical and physical requirement shall be cause for rejection of the inspection lot. SL. CHARACTERISTICS SPCN. LIMIT NO 1 Description : The material shall consist of an intimate and uniform mixture of nitrocellulose, nitroglycerine and stabilizer in the form of homogenous paste free from visible impurities, foreign matter and grit. 2 2.1 Properties Nitrocellulose (Pyro 51.9 to 53.5 12.6) % 2.2 Nitroglycerine % 43.8 – 45.0 2.3 Ethyl Centralite % 2.7 min. 3.1 max. 2.4 Heat Test at 65oC min 2.5 Energy value j/g 19 min. 5,000 – 5200 Note : All percentages are expressed as mass/ mass . All the laboratory test equipments required for above parameters are within the scope of supplier’s responsibility. Page 7 Annexure-I (Paste) (2/2) 2.0 Product Specification for Nitrocellulose / Nitroglycerine pastes for FRD The specification covers four types of Nitrocellulose / Nitroglycerine pastes used in the manufacture of propellants. Description – The material shall consist of an intimate and uniform mixture of Nitroglycerine Nitrocellulose CP2 and ethyl centralite in the form of a homogeneous paste, free from visible impurities, foreign matter and grit. Inspection Lot – An inspection lot shall consist of paste produced by one manufacturer under one set of operating conditions and blended to make the final product homogeneous. Sampling – Five representative samples of the de watered paste lot are to be taken and analyze for chemical and physical properties as specified below for evaluation of the individual results for acceptance or rejections. Properties - The material shall conform to the requirements as given below. Failure of any test result classified as a critical or major characteristic to comply with the chemical and physical requirement shall be cause for rejection of the inspection lot. Sl. No 1 Characteristics Specification Limit Classification of defects The material shall consist of an intimate and uniform mixture of nitroglycerine, nitrocellulose CP2 and ethyl centralite in the form of a homogenous paste, free from visible impurities, foreign matter and grit. Description 2. Properties 2.1 Nitrocellulose CP2 % 2.1.1 Grade P10 54.4 – 56.7 2.2 Nitroglycerine % 42.2- 44.2 2.3 Ethyl Centralite % 1.1 – 1.4 2.4 Candelilla wax % 0.1 min 2.5 Diethylphthalate % 2.6 Energy value J/g 2.7 Nitrogen content % 2.8 Heat Test min. 58/42P 5180-5320 15.02 19 Note : All percentages are expressed as mass/ mass . All the laboratory test equipments required for above parameters are within the scope of supplier’s responsibility. Page 8 Annexure-II (Paste) (1/3) RAW MATERIAL SPECIFICATION 1.0 Nitrocellulose 12.6 (pyro) SNo 1 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.0 SNo 1 2 2.1 2.2 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 CHARACTERISTICS LIMIT Description : The material shall consist of cellulose nitrate prepared from bleached cotton linters by mechanical nitration, in the form of white, milled fibres, free from grit, visible impurities and foreign matter. Properties Nitrogen as N % (Calculated on dry material free from 12.55 to 12.65 matter insoluble in acetone) Abel heat test at 65oC minutes 35 minimum. o Bergman & Junk test at 132 C mg N/g 1.25 max. Matter soluble in diethyl ether / ethyl alcohol 97 min. Total matter insoluble in acetone % 0.5 max. Fineness cc 70 to 105 Hoeppler viscosity (combustible components omitted) mPas 27 to 37 Alkalinity as CaCO3 % 0.20 to 0.50 Nitrocellulose (NC) 13.15 mechanical blend CHARACTERISTICS LIMIT Description:The material shall consist of homogeneous mixer of Nitrocellulose 12.6 N2 / Nitrocellulose 13.35 N2 ( conforming to this specification) Composition Nitrocellulose 13.35% 70- 80 % Nitrocellulose 12.6 ± 0.65% Remainder Properties Nitrogen content as N % (calculated on dry material free 13.05 to 13.25 from matter insoluble in acetone) Able heat test at 65.5OC minutes 35 minium Bergman test at 132oC mgN/g Hoeppler viscosity in pas Alkalinity as CaCO3 Total matter insoluble in acetone Total volatile matter ( if alcohol damped ) Moisture content ( if alcohol damped ) Moisture content if water wet NB : All percentages are expressed as mass/mass Page 9 1.5 max. 30 – 50 0.2- 0.5% 0.5% max. 27.5 – 32.4% 4.5% max. 25% min. Annexure-II (Paste) (2/3) 3.0 Nitrocellulose P10. The specification covers nitrocellulose used in the manufacture of nitrocellulose blend. The properties of nitrocellulose shall be as per the following specifications. SNO 1 2 2.1 2.2 2.3 2.4 2.4.1 2.4.2 2.5 2.6 2.7 2.8 2.9 4.0 SNo 1 2. 2.1 2.2 2.3 2.4 CHARACTERISTICS LIMIT Description: The material shall consist of Nitrocellulose prepared from cotton linters by mechanical process in the form of a thoroughly white, fibrous powder, free from grit, visible impurities and foreign matter. Properties P10 Nitrogen content as N % 12.43 to 12.57 Taliani test at 1350C , 87 minimum minutes . Viscosity at 200 C (Baume tube – 3% 57 to 117 mass per mass solution in 100% butyl acetate). MPas Stability Able heat test at 65.5 OC , minutes 35 Minimum o Bergman and Junk test at 132 C 1.25 max. mgN/g Matter soluble in ether/alcohol % 94 minimum Mineral matter % 0.4 % max. Alkalinity as CaCO3 % 0.10 to 0.50 Matter insoluble in acetone % 0.4 max. Setting test cm3 65 to 85 Nitroglycerine CHARACTERISTICS LIMIT Description: The material shall consist essentially of the trinitric ester of glycerol C3H5 ( N03) 3 in the form of a clear to pale yellow, oily liquid, free from visible impurities and foreign matter. Properties Abel heat test at 80oC 10 minimum. minutes Water content % 0.5 max. Alkalinity as NA2 CO3 % 0.005 max. Nitrogen as N % 18.4 min. Note : All percentages are expressed as mass/mass Page 10 Annexure-II (Paste) (3/3) 5.0 Ethyl centralite ( Carbamite) ( for use in the manufacture of propellants) Test No. 1. Test Limits 2. Description: The material shall consist essentially of diethyldiphenyl Urea CO (N C2H5. C6H5)2 in the form of a pale buff powder. Setting Point To lie within the range 71,7 to 72,5 0C. 3. Melting Test 4. 5. Volatile matter Ash Amines The material shall melt to a bright clear liquid free from scum and deposit. Not more that 0.1% (m/m) Not more that 0.1% (m/m) Not more that 0.1% (m/m) (i) Primary :Not more that 0.03% (m/m) as aniline (ii) Secondary :Not more that 0.10% (m/m) as ethylaniline 7 Acidity 8 Hydrolysable Chlorine compounds 6.0 Test No. 1. (iii) Tertiary :Not more that 0.05%(m/m) as diethylaniline. To phenolphtalein :Not more that 0.004% (m/m) as HCL Not more that 0.01% (m/m) as Cl2. Candelilla wax (for use in the manufacture of propellants) Test Limits Description 2 3 4 5 6 Volatile matter Setting point Total acidity Inorganic acidity. Saponification value 7 8 Ash Fineness of ash The material shall consist essentially of natural plant leaf wax and shall be clear, free from adulterants, grits, visible impurities and foreign matters. Not more than 1.5 % (m/m) Within the range of 630C to 680C. To phenolphthalein – not more than 22 mg KOH/g. To phenolphthalein –Nil To lie within the range of 45 to 65 mg KOH/g. Not more than 0.5% (m/m) Retained on 240 mesh BS – not more than 0.01% (m/m) Retained on 60 mesh BS sieve – Nil. Page 11 NC – NG PASTE Annexure III (Paste) (For reference purpose only.) Refer clause no. 3.0. Page 12 Annexure III (Paste) (1/4) For reference purpose only. Refer clause no. 3.0. Page 13 Annexure III (Paste) (2/4) For reference purpose only. Refer clause no. 3.1.1. Page 14 Annexure III (Paste) (3/4) For reference purpose only. Refer clause no. 3.1.2. Page 15 Annexure III (Paste) (4/4) For reference purpose only. Refer clause no. 3.1.3. Page 16 Annexure IV (Paste) (1/15) INDICATIVE EQUIPMENT LIST For reference purpose only. Refer clause no. 3.0.. 1.0 TRANSPORTATION OF NG & WEIGHING The following equipments are envisaged for the above operation: i) Receiving vessel (VE 49-10) ii) Nitroglycerine/Transport water separator (SEP 50-10) It is a vertical cylindrical type with top and bottom ends as domed shaped. Nominal Tank size Diameter = = 0.145 m3. 0.8 m. The material of construction is to meet AISI 304. Thickness of material Operating Temperature = = 3.0mm. 10 – 400C iii) Nitroglycerine Buffer Vessel (VE 51-10). iv) Weighing Vessel (VE 52-10) It is a vertical cylindrical type with top end domed shaped and bottom ends as conical. The material of construction is to meet AISI 304. Nominal Tank size Diameter Thickness of material Bottom end material / thickness Operating Temperature v) = = = = =1 0.195 m3. 0.8 m. 3.0mm. 5mm 0 – 400C Education vessel (VE 53-10). It is a vertical cylindrical type with top end domed shaped and bottom ends as conical. The material of construction is to meet AISI 304. Nominal Tank size Diameter Thickness of material Bottom end material / thickness Operating Temperature Page 17 = = = = = 0.225 m3. 0.8 m. 3.0mm. 5.0 mm 10 – 400C Annexure IV (Paste) (2/15) vi) Nitroglycerine Transfer Ejector (EJ 54-10) vii) Labyrinth (LY 56-10) It is a horizontal vessel with top and bottom ends as domed shaped. Nominal Tank size Length / Width = = 2.37 m3. 2.55 / 0.950 m. The material of construction is to meet AISI 304. Thickness of material Operating Temperature = = 3.0mm. 10 – 400C viii) Nitroglycerine /Transport Water ejector (EJ 57-10) ix) Pressure vessel (TK 58 –10) It is a vertical cylindrical vessel with top and bottom ends as domed shaped. Medium Nominal Tank size Diameter = = = Nitroglycerine slurry 0.80 m3. 0.92 m. The material of construction is to meet ST 42.1 UNI 5869. Operating pressure Test pressure Radiography Top, bottom end material thickness Shell material thickness Operating Temperature x) = = = = = = 600 kPag. 900 kPag 10% 5.0mm. 3.0 mm 10 – 400C Waste water vessel (VE 59-10) It is a vertical cylindrical type with top end flat and bottom end domed. Medium Nominal Tank size Diameter = = = Page 18 Waste Water. 0.77m3. 0.92 m. Annexure IV (Paste) (3/15) The material of construction is to meet AISI 304. Top end material thickness Bottom end material thickness Operating Temperature xi) 2.0 = = = 3.0mm. 5mm 10 – 400C Waste water Ejector (EJ 60-10). NC-NG PASTE MIXING The following equipment are envisaged for the above operation. i) Nitrocellulose slurry Tank (TK 61-10). It is a vertical cylindrical type with top and bottom ends as domed shaped. The material of construction is to meet AISI 304. Medium Nominal Tank size Diameter Operating temperature Design temperature Top end material thickness Bottom end material thickness ii) = = = = = = = Nitrocellulose slurry. 3.5 m3. 1.5 m. 650C 1000C 5.0mm. 5.0mm. Nitrocellulose Slurry Tank Agitator (AG 61-11). Process Fluid pH/Temperature Zone Classification Type Shaft Material Impeller material Seal Coupling Speed Mounting Motor Data - Speed Volts/Phase/Freq. Power Current Enclosure Coupling guard = = = = = = = = = = = = = = = = Page 19 Nitrocellulose slurry. Acidic / 650C Zone 2 1 Impeller, 4 Blade Vertical. AISI 304 AISI 304 Mechanical V- Belt drive 0 – 230 rpm. Vertical. 1450 rpm 415/3/50 0.75 kW 1.5 A IP55 Yes. Annexure IV (Paste) (4/15) iii) Nitrocellulose Slurry Pump (PP 62-10) Process Fluid Flow pH/Temperature Pressure head Zone Classification Type Shaft Material Impeller material Casing material Seal Coupling Speed Closed/ open impeller Motor Data - Power Current Speed Volts/Phase/Freq. Enclosure Coupling guard = = = = = = = = = = = = = = = = = = = Nitrocellulose slurry. 34 m3/hr. Acidic / 650C 145 kPa Zone 2 Gear Pump AISI 316 AISI 316 AISI 316 Mechanical Direct 1450 rpm. Gear. 5.5 kW 11 A 1450 415/3/50 IP54 Yes. iv) Paste mixing Tank (TK 63-10) It is a vertical cylindrical tankype with top and bottom ends domed shaped. Medium = Nominal Tank size = Diameter = Operating Pressure = Test Pressure = The material of construction = Top end material thickness = Bottom end material thickness = Operating temperature = Design Temperature = Agitator = Page 20 Paste Slurry 4.75 m3. 1.75 m. Hydrostatic 100 kPg AISI 304. 5.0mm. 5.0 mm 600C 1000C Yes Annexure IV (Paste) (5/15) v) Paste mixing Tank Agitator (AG 63-11). Process Fluid pH/Temperature Zone classification Type Shaft Material Impeller material Seal Coupling Speed Mounting Motor Data - Speed Volts/Phase/Freq. Power Current Enclosure Coupling guard vi) = = = = = = = = = = = = = = = = Nitrocellulose slurry Acidic / 600C Zone 2 1 Impeller, 4 Blade Vertical. AISI 304 AISI 304 Mechanical V- Belt drive 0 – 200 rpm. Vertical. 1450 415/3/50 1.5 kW 3A IP55 Yes. Paste mixing Pump (PP 64-10). Process Fluid Flow pH/Temperature Pressure head Zone Classification Type Shaft Material Impeller material Casing material Seal Coupling Speed Closed/ open impeller Motor Data - Power Current Speed Volts/Phase/Freq. Enclosure Coupling guard = = = = = = = = = = = = = = = = = = = Paste slurry 48 m3/hr. Acidic / 600C 350 kPa Zone 2 Gear AISI 316 AISI 316 AISI 316 Mechanical Direct 1450 rpm. closed. 11 kW 22 A 1450 415/3/50 IP55 Yes. Page 21 Annexure IV (Paste) (6/15) 3.0 a) BLENDING AND DISINTGRATION The following equipment are envisaged for the above operations. i) Blending Tank (TK 65-10). It is a vertical cylindrical tank. The material of construction is to meet AISI 304. Medium Nominal Tank size Diameter Design temperature Agitator Top end material thickness Bottom end material thickness = = = = = = = Water. 140 m3. 5.512 m. 1000C Yes. 5.0mm. 5.0mm. ii) Blending Tank Agitator (AG 65-11). Process Fluid pH/Temperature Pressure Zone Classification Type Shaft Material Impeller material Gear ratio Coupling Speed Mounting Motor Data - Volts/Phase/Freq. Power Current Speed Enclosure Coupling guard iii) = = = = = = = = = = = = = = = = = Nitroglycerine slurry. Acidic / - 20 to + 600C 700 kPa Zone 2 2 Impellers, 4 Blade Vertical. AISI 304 AISI 304 44:1 Direct. 33 rpm. Vertical. 415/3/50 22 kW 44 A 1450 IP55 Yes. = = = = = Nitroglycerine slurry 22.5 m3/hr Acidic / 350C Zone 2 N/A Blending Pump (PP 66-10) Process fluid Flow pH/Temperature Zone Classification Pressure head Page 22 Annexure IV (Paste) (7/15) Design temperature Type Shaft Material Impeller material Casing material Seal Coupling Speed Closed/ open impeller Motor Data - Power Current Speed Volts/Phase/Freq. Enclosure Coupling guard = = = = = = = = = = = = = = = 600C Gear AISI 316 AISI 316 AISI 316 Mechanical Direct 1450 rpm. Gears. 5.5 kW 11 A 1450 415/3/50 IP55 Yes. = = = = = = = = = = = = = = = = = = = = Nitroglycerine slurry 22.5 m3/hr Acidic / 350C Zone 2 N/A 600C Gear AISI 316 AISI 316 AISI 316 Mechanical Direct 1450 rpm. Gears. 5.5 kW 11 A 1450 415/3/50 IP55 Yes. iv) Blending Pump (PP 66-30). Process fluid Flow pH/Temperature Zone Classification Pressure head Design temperature Type Shaft Material Impeller material Casing material Seal Coupling Speed Closed/ open impeller Motor Data - Power Current Speed Volts/Phase/Freq. Enclosure Coupling guard Page 23 Annexure IV (Paste) (8/15) v) Disintegrating Pump (PP 67-10). Process fluid Flow pH/Temperature Zone Classification Pressure head Design temperature Type Shaft Material Impeller material Casing material Seal Coupling Speed Closed/ open impeller Motor Data - Power Current Speed Volts/Phase/Freq. Enclosure Coupling guard = = = = = = = = = = = = = = = = = = = = Nitroglycerine slurry 22.5 m3/hr Acidic / 350C Zone 2 N/A 600C Centrifugal AISI 316 AISI 316 AISI 316 Mechanical Flexible 1450 rpm. Closed. 5.5 kW 11 A 1450 415/3/50 IP55 Yes. vi) Recovered Water Tank No 1 (TK 68-10). It is a vertical cylindrical tank. Medium Nominal Tank size Diameter Operating Pressure Material Top end material thickness Bottom end material thickness Operating temperature Design Temperature Agitator = = = = = = = = = = Page 24 Water. 140 m3. 5.512 m. Hydrostatic AISI 304. 5.0mm. 5.0 mm 200C 300C Yes Annexure IV (Paste) (9/15) vii) Recovered Water Tank Agitator No 1 (AG 68-11). Process Fluid = pH/Temperature = Pressure = Zone Classification = Type = Shaft Material = Impeller material = Base = Gear ratio = Coupling = Speed = Mounting = Motor Data - Volts/Phase/Freq. = Power = Current = Speed = Enclosure = Coupling guard = Nitroglycerine slurry. Acidic / - 20 to + 600C 700 kPa g Zone 2 1 Impellers, 4 Blade Vertical. AISI 304 AISI 304 AISI 304 44:1 V - belt. 33 rpm. Top. 415/3/50 22 kW 44 A 1450 IP55 Yes. viii) Recovered Water Tank No 2 (TK 68-20). It is a vertical cylindrical tank. Medium = Nominal Tank size = Diameter = Operating Pressure = Material = Top end material thickness = Bottom end material thickness = Design Temperature = Agitator = Water. 140 m3. 5.512 m. Hydrostatic AISI 304. 5.0mm. 5.0 mm 1000C Yes ix) Recovered Water Pump No 1 (PP 69-10). Process fluid Flow pH/Temperature Pressure head Zone Classification Type Shaft Material = = = = = = = Page 25 Cold Water. 35 m3/hr Acidic / 20-500 C 320 kPa Zone 2 Centrifugal. Stainless steel. Annexure IV (Paste) (10/15) Impeller material Casing material Seal Coupling Speed Closed/ open impeller Motor Data - Power Current Speed Volts/Phase/Freq. Enclosure Coupling guard x) = = = = = = = = = = = = Stainless steel. Stainless steel. Mechanical Flexible 1450 rpm. Closed. 7.5 kW 15 A 1450 415/3/50 IP54 Yes. Recovered Water Pump No 2 (PP 69 – 20). Process fluid Flow pH/Temperature Pressure head Zone Classification Type Shaft Material Impeller material Casing material Seal Coupling Speed Closed/ open impeller Motor Data - Power Current Speed Volts/Phase/Freq. Enclosure Coupling guard = = = = = = = = = = = = = = = = = = = Page 26 Cold Water. 35 m3/hr Acidic / 20-500 C 320 kPa Zone 2 Centrifugal. Stainless steel. Stainless steel. Stainless steel. Mechanical Flexible 1450 rpm. Closed. 7.5 kW 15 A 1450 415/3/50 IP54 Yes. Annexure IV (Paste) (11/15) 3.0 b) DE-WATERING The following equipment are envisaged for the above operation. i) Vacuum Belt Filter (BFL 70-10) Medium = Flow pH/Temp. Zone Classification Material Motor Data - Power Current Speed Volts/Phase/Freq. Enclosure Coupling guard = = = = = = = = = = Nitro ester / Nitrocellulose slurry. 500 kg/hour Acidic/350C Zone 2 AISI 304 2.5 kW 5A 1450 415/3/50 IP55 Yes. ii) Filter receiver (TK 71-10) It is a vertical cylindrical tank with top and bottom ends domed shaped. Medium Nominal Tank size Diameter Material of construction Operating Pressure Top end material thickness Bottom end material thickness Operating temperature Design Temperature Agitator = = = = = = = = = = iii) Cloudy filtrate pump No.1 (PP 72-10) Medium = Flow = pH/Temperature = Pressure head = Zone Classification = Type = Shaft Material = Impeller material = Casing material = Seal = Coupling = Page 27 Vacuum filter Filtrate. 0.3 m3. 1.25 m. AISI 304. (-) 50 kPag 5.0mm. 5.0 mm 300C 500C No Vacuum filter filtrate. 20m3/hour Acidic / 300C 180 kPa Zone 2 Centrifugal AISI 304 AISI 304 AISI 304 Mechanical Flexible Annexure IV (Paste) (12/15) Speed Closed/ open impeller Motor Data - Power Current Speed Volts/Phase/Freq. Enclosure Coupling guard = = = = = = = = 1450 rpm. closed. 4.0 kW 8A 1450 415/3/50 IP55 Yes. iv) Scale - Capacity - 0-50 Kg., Stainless Steel. v) Vacuum Pump (PP 75-10). Process Fluid Flow pH/Temperature Pressure head Zone Classification Type Shaft Material Impeller material Casing material Seal Coupling Speed Closed/ open impeller Motor Data - Power Current Speed Volts/Phase/Freq. Enclosure Coupling guard = = = = = = = = = = = = = = = = = = = Air + Fluid 800 m3/hr. Acidic / 300C (-) 50 kPa Zone 2 Centrifugal Carbon Steel. Carbon Steel. Carbon Steel. Mechanical Flexible 1450 rpm. closed. 5.5 kW 11 A 1450 415/3/50 IP54 Yes. = = = = = = = = = Water 500 kg/hr. 400C 5oC Zinc sprayed mild steel. 0.75 kW 1.5 A 1450 415/3/50 vi) Cooling Tower (CT 77-10). Medium Flow Operating Temperature Differential Temperature Material Motor Data - Power Current Speed Volts/Phase/Freq. Page 28 Annexure IV (Paste) (13/15) Enclosure Coupling guard = = IP55 Yes. vii) Washing Water Circulating Pump (PP 78-10). Process Fluid Flow pH/Temperature Pressure head Zone Classification Type Shaft Material Impeller material Casing material Seal Coupling Speed Closed/ open impeller Motor Data - Power Current Speed Volts/Phase/Freq. Enclosure Coupling guard = = = = = = = = = = = = = = = = = = = Spillage and Filtrate. 7 m3/hr. Acidic / 250C N/A Zone 2 Centrifugal AISI 316 AISI 316 AISI 316 Mechanical Flexible 1450 rpm. closed. 2.2 kW 4.4 A 1450 415/3/50 IP54 Yes. Medium = Flow PH/Temperature Material Motor Data - Power Current Enclosure Speed Volts/Phase/Freq. Coupling Guard = = = = = = = = = Nitro Ester / Nitrocellulose Slurry 500 kg. / hr. Acidic/350 C AISI 304. 2.5 kW 5A IP 55 1450. 415/3/50 Yes. ix) Vacuum Belt Filter x) Filtrate Receiver It is a vertical cylindrical tank with top end and bottom end domed shaped. Medium Operating Pressure The material of construction Page 29 = = = Vacuum filter Filtrate. ( - ) 50 kPag AISI 304. Annexure IV (Paste) (14/15) Top end material thickness Bottom end material thickness Operating temperature Design Temperature Agitator = = = = = 5.0mm. 5.0 mm 300C 500C No = = = = = = = = = = = = = = = = = = Vacuum filter filtrate 20 m3/hr. Acidic / 300C 180 kPa Centrifugal AISI 304 AISI 304 AISI 304 Mechanical Flexible 1450 rpm. closed. 4.0 kW 8A 1450 415/3/50 IP55 Yes. = = = = = = = = = = = = = = = Air + Fumes 800 m3/hr. Acidic / 300C (-) 50 kPa Centrifugal Carbon Steel. Carbon Steel. Carbon Steel. Mechanical Flexible 1450 rpm. closed. 5.5 kW 11 A 1450 xi) Pump for vacuum filter filtrate. Process fluid Flow pH/Temperature Pressure head Type Shaft Material Impeller material Casing material Seal Coupling Speed Closed/ open impeller Motor Data - Power Current Speed Volts/Phase/Freq. Enclosure Coupling guard xii) Vacuum Pump Process Fluid Flow pH/Temperature Pressure head Type Shaft Material Impeller material Casing material Seal Coupling Speed Closed/ open impeller Motor Data - Power Current Speed Page 30 Annexure IV (Paste) (15/15) Volts/Phase/Freq. Enclosure Coupling guard = = = 415/3/50 IP54 Yes. = = = = = = = = = = = Water 500 kg/hr. 400C 5oC Zinc sprayed mild steel. 0.75 kW 1.5 A 1450 415/3/50 IP55 Yes. xiii) Cooling Tower . Medium Flow Operating Temperature Differential Temperature Material Motor Data - Power Current Speed Volts/Phase/Freq. Enclosure Coupling guard xiv) Re circulation Pump Process fluid Flow pH/Temperature Pressure head Type Shaft Material Impeller material Casing material Seal Coupling Speed Closed/ open impeller Motor Data - Power Current Speed Volts/Phase/Freq. Enclosure Coupling guard = = = = = = = = = = = = = = = = = = Spillage and filtrate 7 m3/hr. Acidic / 250C N/A Centrifugal AISI 316 AISI 316 AISI 316 Mechanical Flexible 1450 rpm. closed. 2.2 kW 4.4 A 1450 415/3/50 IP54 Yes Vendor should specify the Capacity, quantity, criticality of each equipments offered as per their technology. Hot stand- by for any equipment should also be specified. Page 31 ACCOMMODATION STATEMENT: NC – NG PASTE PLANT Technology Buildings Bldg. no. Building description Building size in (M) Total Floor Area (SQM) TR/Un Tr NEC kg Class Annexure V (Paste) Safety Distance (M) Special requirement (ref. safety regulation) SIQD PIQD OQD Elec. Fittings Fans/ Others AC/ Non AC Lightning protection 0213 Separation, weighing 12x6x4.5 72 VIFT 1500 1.1 28 66 275 Yes (FLP) Non AC Yes 0214 NC storage 10x10x4 100 Un Tr. - - - - - Yes (FLP) Non AC Yes 0215 NG-NC paste mixing 10x10x4.5 100 VIFT 1500 1.1 28 66 275 Yes (FLP) Non AC Yes 0216 Paste blending, disintegration, dewatering & loading / bagging 45x13x6 585 Un Tr. 5000 1.3 16 55 110 Yes (FLP) Non AC Yes 0217 Wet/Paste Storage, Maturing 15x10x4 + VARANDA 150 5000 1.1 40 140 380 Yes (FLP) Non AC Yes 0218 Wet/Paste Storage, Maturing 16X10X4 + VARANDA 150 One bldg. with two bays with RCC wall 5000 1.1 40 140 380 Yes (FLP) Non AC Yes 0219 Wet/Paste Storage, Maturing 17X10X4 + VARANDA 150 5000 1.1 40 140 380 Yes (FLP) Non AC Yes 0220 Wet/Paste Storage, Maturing 18X10X4 + VARANDA 150 One bldg. with two bays with RCC wall 5000 1.1 40 140 380 Yes (FLP) Non AC Yes 0221 Wet/Paste Storage, Maturing 19X10X4 + VARANDA 150 5000 1.1 40 140 380 Yes (FLP) Non AC Yes 0222 Wet/Paste Storage, Maturing 20X10X4 + VARANDA 150 One bldg. with two bays with RCC wall 5000 1.1 40 140 380 Yes (FLP) Non AC Yes 0223 Paste Centrifuge 20X10X4.5 200 VIFT 4000 1.1 41 140 380 Yes (FLP) Non AC Yes 0224 Paste rolling 20X10X4.5 200 VIFT 4000 1.1 41 140 380 Yes (FLP) Non AC Yes 0225 Sheet paste storage 15X10X4 150 NAT 10000 1.1 52 175 480 Yes (FLP) Non AC Yes Page 32 Remarks 0226 Sheet paste storage 15X10X4 150 NAT 10000 1.1 52 175 480 Yes (FLP) Non AC Yes 0227 Cleaning of Truck and Trays 23X6X4 138 Un. Tr. 30 1.1 10 18 275 Yes (DT) Non AC Yes Road work Drainage Sewerage Fencing Ventilation & air conditioning Bldg. and Road lighting Lighting protection Piping *REMARKS : DIMENSIONS / EXPLOSIVES LIMIT, CORRESPONDING SAFETY DISTANCES AND SPECIAL REQUIREMENT GIVEN ARE CONCEPTUAL.THE DETAILS GIVEN ABOVE ARE INDICATIVE AND FOR REFERENCE PURPOSE ONLY. PLANT SUPPLIER IS TO DESIGN BASED ON THEIR TECHNOLOGY. BIDDER SHOULD SUBMIT THE DETAILS OF TECHNOLOGY BUILDINGS AS PER THEIR OWN DESIGN IN THE ABOVE FORMAT. Page 33 Annexure VI (Paste) Page 34 Annexure VII (Paste) Page 39 of 153 Page 40 of 153 APPENDIX-II TECHNICAL SPECIFICATION FOR SUPPLY, ERECTION & COMMISIONING OF PLANT AND MACHINERY INCLUDING ASSOCIATED CIVIL WORKS FOR PRODUCTION OF SINGLE BASE PROPELLANT AT O.F. NALANDA PROJECT, RAJGIR (BIHAR), INDIA Specification No. – SPCN/I/2016/OFN/BMCS/SBP Page 41 of 153 VOLUME APPENDIX II PARA No. SUBJECT PAGE No. SINGLE BASE PROPELLANT PLANT SPECIFICATIONS 1.0 Intent 1 2.0 Capacity Of The Plant 1 3.0 Description Of Requirement 1-4 3.1 Process Description 1-4 4.0 Tools And Fixtures 5 5.0 Testing Equipment 5 6.0 Services/Utilities 5 Annexure I (SB) Product Specification 6-7 Annexure II (SB) Raw Material Specifications 8-11 Annexure III (SB) Block & Process Flow Diagram 12-19 Annexure IV (SB) Equipment List 20-37 Annexure V (SB) Accommodation Statement 38-39 Annexure VI (SB) Conceptual Plant Layout 40 Annexure VII (SB) Contour Overlay on Plant Layout 41 Page 42 of 153 REQUIREMENT: 1.0 SINGLE BASE PROPELLANT MANUFACTURING PLANT CAPACITY 340-MT PER ANNUM ALONG WITH ASSOCIATED CIVIL WORKS. INTENT The present intent is for supply and installation of Single Base Propellant manufacturing plant at Rajgir, Bihar, India. The plant shall be capable of producing Single Base Propellant required for Bi-modular Artillery charges. Single Base Propellant is obtained by incorporating alcohol wet NC with chemical ingredients like Dinitrotoluene, Diphenylamine, Dibutyl Phthalate and Pottasium Sulphate etc in specially designed Plant & Machinery to suit this purpose. 2.0 CAPACITY OF THE PLANT The plant will have a minimum capacity of 340 MT / annum in 220 working days with a most modern PLC/ automatic, plant utilising minimum manpower and energy. The rated capacity of the plant has to be so designed so that the required output capacity of 340 MT/ annum as given above is achieved with the plant availability of minimum 80% of time with 80% plant efficiency and wastage / rejection not more than 2 % on 2 x 8 hrs. shifts / day on continuous basis. The quality of finished Single Base Propellant grain will be as per the product specification enclosed at Annexure-I(SB). The specification of raw material with approx. limit is enclosed as Annexure-II (SB). The exact raw material specification will be disclosed to the successful bidder. The plant supplier shall ensure that the plant and equipment offered as a whole is capable of producing under normal condition at full rated capacity and this should be demonstrated during commissioning / guarantee run both for main plant and separately for other utilities. 3.0 DESCRIPTION OF REQUIREMENT SINGLE BASE PROPELLANT MANUFACTURING PLANT A brief description for manufacture of Single Base propellant is given below: In addition to the above, process flow diagram (for reference purpose only) of the plant and an indicative list of main equipment with specification is enclosed at Annexure-III (SB) and Annexure-IV (SB) respectively. However, if the vendor desires any changes in the process or a better technology, he can do so and submit the offer accordingly. Page 43 of 153 Page 01 In any case, the vendor shall submit along with the offer - process flow diagram, list of equipment and specifications of the offered equipment in the format of Annexure III (SB) and Annexure IV (SB) respectively including all other techno – commercial information as per the tender document. Vendor should specify the Capacity, quantity, criticality of each equipments offered as per their technology. Hot stand- by for any equipment should also be specified. The exact details in respect of product specifications and drawings etc. will be disclosed to the successful bidder after signing of non-disclosure agreement. The vendor has to prove the capacity of the plant and quality of the product. The approximate content of the ingredients are given in Annexure I (SB). 3.1 Process Description 3.1.1 INCORPORATION: The incorporators consist of a cast iron frame and trough, jacketed for coolant circulation to give a working temperature range of 110C – 150C in the machine. Each incorporator is fitted with two sigma type cast steel (non-sparking material) blades operating at strict clearance between the blades, shaft and trough. The blade speeds differ and are approx. 11 and 22 rpm respectively. Each machine has its own hydraulic pressure unit to open the lid and tilt bowl for unloading. The dehydrated alcohol wet Nitrocellulose together with other chemical ingredients required as per the formula are mixed into a dough with solvent comprising approx. two parts of ether to 1 part of alcohol by weight. Ingredients per Incorporator charge for propellants are as below: Nitrocellulose (Mechanical blend) is about 105 kg Dry mass. Other ingredients are Ether, Ethyl alcohol, Dinitrotoulene, Pottasium Sulphate, Diphenylamine, Dibutyl Phthalate and shredded rework. The approximate specifications are given in Annexure II (SB). Page 44 of 153 Page 02 3.1.2 Pressing and Cutting: Block Pressing After incorporation the colloidal mixture is formed into solid blocks by the application of hydraulic pressure in press. Bags of propellant dough from the incorporator are unloaded into the hoist to be transported to the top floor of the Block press compartment. The plunger of the press is lowered to the bottom of its stroke and carbon dioxide is hosed into the cylinder to displace the air. The dough is loaded into the cylinder and a solid rawhide disc is placed on top. The pressing operation is done from the control bay. The rawhide disc is removed and the block is loaded in a rubber bag to be transported to the final pressing room. Extrusion Pressing Two propellant blocks as obtained in the block press are loaded into the extrusion press cylinder in a carbon- dioxide atmosphere. The product is then extruded through a die assembly plate by applying pressure. The cord so extruded are guided through a cord distributor into a cord trolley and transported for cutting. Cutting The solvent wet extruded cords are transferred from the press room and fed directly into the single base cannon rotary cutting machine. The frequent inspection of the cut product is important to monitor the efficiency of the cutting press. Cut product are then collected in bags ( 25 kg. Max.) and bags are transported to the drying facilities. 3.1.3 Preliminary Drying: Single Base Propellants are subjected to a preliminary stoving process where the bulk of the solvent is removed. Solvent wet cut propellant is loaded onto cloths fitted in the drying troughs. The Propellant is spread uniformly to form a layer of uniform depth. During loading the doors of stove room are left open and cold air is blown into the room to reduce the concentration of solvent vapour in the room. A large shrinkage in volume of the Propellant grain takes place during drying and the temperature of solvent removal must be controlled very carefully, especially in the initial stage. After the drying cycle has been completed, live steam is introduced to lessen the risk of discharge of static electricity. Propellant is soaked with water through water sprays as a further precaution prior to unloading the propellant. The Propellant is loaded into bags and transferred to steeping house. Page 45 of 153 Page 03 3.1.4 Steeping: The hot water steeping forms a part of the solvent removal process. The bags of pre-dried propellant are loaded into the steeping tank. The tank is filled with water and brought upto required temperature using steam. The temperature is maintain by applying steam to the heating coils of the tank. When steeping is over, the hot water is drained and the bags with propellant are unloaded and transferred to the drying house for final drying. 3.1.5 Final Drying: On completion of steeping process, the propellant undergoes final drying process to reduce the total volatile solvents and moisture content to remain within the specification limit. Final drying operations is similar to preliminary drying and is done with similar equipment. 3.1.6 Blending: The uniformity of the finished product is ensure by sub and final blending. With the high cost of proofing it is important to size the final lot as large as can conveniently be handled during blending. For ease of control over the manufacturing process, the product as produced is weighed to 20 kg in canvas bag and blended is sublots of 1,000 kg. These quantities can change depending on the lot size of the charge, however, the quantity of propellant in the sublot should be a simple fraction ( one-tenth) of the final blend size. These sublots are homogenous and can thus be sampled and tested with confidence to enable the plant to make adjustment in case of offspecification material. When sufficient sublots conforming the specification have been accumulated, the final blend can be concluded. Blending takes place in a aluminium blending pan rotating at 16 rpm. 3.1.7 Solvent Recovery: Solvent laden air is extracted from the incorporator, Block pressing, Final pressing, Cutting room is drawn through ducting to a heating battery where the temperature of the air is raised to 430C . The heated air then passes through the extraction fan and is forced through an activated carbon absorption bed where the solvent is stripped from the air. The air is vented to the atmosphere through stack. The flow through the carbon bed is alternated every two hours with a 15 minutes steaming period where the entertained solvent are stripped and carbon bed is regenerated. The steam and solvent vapour rises, passing into a water-cooled condenser where liquefaction takes place. The liquid is drained to a condensate collecting tank from where it is pumped to the water treatment section. Page 04 Page 46 of 153 4.0 TOOLS AND FIXTURES The plant supplied shall be tooled up. The offer shall be complete with tools, dies and fixtures (Refer Volume I para 4.0 (ii)) 5.0 TESTING EQUIPMENT The technical bid should clearly indicate all the laboratory equipments, required for tests, including closed vessel tests that are to be conducted in relation to the production of Single Base Propellant, including online tests and laboratory tests, in a tabular form as given below. The item wise price breakup of these equipments is to be given in the price bids. The PRICE column in the table below should therefore be left blank in the technical bid. S.No. EQUIPMENT NAME A In process testing Equipments 1 2 … B PURPOSE No. of Equipment (Qty.) PRICE (including all taxes etc) Included in Offer ? (Y/N) Laboratory Equipments 1 2 ….. The provision of laboratory space is supplier’s responsibility. Also Refer Volume I Para 4.0 (iii) 6.0 SERVICES/ UTILITIES Refer to para 4.2 of Volume I of the specifications for Purchaser’s responsibility and Supplier’s scope of supply. Any special requirements of services by the plant, that is at variance with the provisions of the para 4.2 has to be included in the scope of supply and its cost included in the offer. All the services/utilities required for production of Single Base Propellant, shall be designed, supplied and erected and their capacities proven. The vendor shall mention the guaranteed requirement of the following services for the plant offered, in the technical bid: (a) Steam (b) Water (c) Electricity -------------------------------------------------------------------------------------------------------------------- Page 05 Page 47 of 153 ANNEXURE(SBP) Page 48 of 153 ANNEXURE-I (SB) (1/2) PRODUCT SPECIFICATION 1.0 Single Base Propellant The propellant shall be in the form of Cylindrical Granules, free from visible impurities. The propellant shall have seven longitudinal perforation one in the centre and six in the vertices of symmetrical hexagon The material composition, dimensions and ballistic properties of the propellant shall conform to the applicable requirements. The approximate values are given below: Inspection Lot - An inspection lot shall consist of one lot of propellant produced by one manufacturer under one continuous set of operating conditions and blended to make the final product homogenous. Nonconformance - Failure of any test result to comply with the requirements specified which will be disclosed to the successful bidder, may be cause of rejection. The approximate content of the ingredient & characteristic of the propellant are given below: SL. NO. CHARACTERISTIC LIMIT 1. Description The propellant shall be in the form of Cylindrical Granules, free from visible impurities. The propellant shall have seven longitudinal perforation one in the centre and six in the vertices of symmetrical hexagon. 2. 2.1 2.2 2.3 2.4 2.5 Composition ( on dry basis) Nitrocellulose (%) Diphenylamine (%) Dinitrotolluene (%) Dibutylphthalate (%) Potassium sulphate (%) 3. 3.1 3.2 3.3 Physical Properties Total Volatile matter (%) 1.0% approx. Energy (J/g) 3600 approx Methyl violet stability test at 1340C ( MTS) Complete discolouration to Solmon 50 approx pink 3.3.1 90% approx. 0.9% approx. 1.5% approx 4.0% approx. 1.5% approx Page 49 of 153 Page 06 3.3.2 3.4 Emission of brown fume Relative density (200C/200C 60 approx 1.55 approx 4. 4.1 4.2 4.3 4.4 Dimension of grains Average length (mm) Average web (mm) Average perforation dia (mm) Average diameter (mm) 5mm approx To be disclosed to the successful bidder To be disclosed to the successful bidder 4mm approx 5. 5.1 5.1.1 5.1.2 Ballistic properties In closed vessels (at 21± 20C) Relative dynamic vivacity Relative force 5.2 Dynamic Proof 5.2.1 5.2.2 Pressure Velocity 5.2.3 5.2.4 Range Accuracy Minimum Zone I 95 to 105 95 to 105 Firing M1/BT ERFB HE projectiles with a mass of 45.0 kg + 0.1 kg from a FH 77B 39 calibre gun in its first quarter. 40 MPa Zone I – 308 + 10 m/s (Approx. To be finalized after ongoing proof checks) Zone II – 458 + 10 m/s (Approx. To be finalized after ongoing proof checks) To be disclosed to the successful bidder To be disclosed to the successful bidder Note : All percentages are expressed as mass per mass. All the laboratory test equipments required for above parameters are within the scope of supplier’s responsibility. Page 07 Page 50 of 153 ANNEXURE-II (SB) (1/4) RAW MATERIAL SPECIFICATION 1.0 Nitrocellulose (NC) 13.15 mechanical blend SL.NO. CHARACTERISTICS LIMIT 1 Description The material shall consist of homogeneous mixer of Nitrocellulose 12.6 N2 /Nitrocellulose 13.4 N2 ( conforming to this specification) 2 Composition 2.1 2.2 Nitrocellulose 13.4 (Guncotton) % Nitrocellulose 12.6 (Pyro) % 3 Properties 3.1 Nitrogen content as N% 13.05 to 13.25 (calculated on dry material free from matter insoluble in acetone 3.2 Able heat test at 65.5OC 35 min 3.3 Bergman test at 132oC mgN/g 1.5 max. 3.4 Hoeppler viscosity in mPas 30 – 50 3.5 Alkalinity as CaCO3, % 0.2- 0.5 3.6 Total matter insoluble in acetone , % 0.5 max. 3.7 3.8 Total volatile matter (if alcohol 27.5 – 32.4 damped), % Moisture content (if alcohol damped), % 4.5 max. 3.9 Moisture content if water wet, % 70- 80 Remainder 25 min. Note : All percentages are expressed as mass/mass 2.0 Diphenylamine SL.NO. CHARACTERISTICS LIMIT 1. PROPERTIES 1.1 1.2 1.3 Setting point Moisture content Matter insoluble in ether / alcohol 52 OC Approx 0.5% (m/m ) Approx 0.02% (m/m) Approx 1.4 Matter insoluble in ethyl acetate 0.02% (m/m) approx Page 51 of 153 Page 08 1.5 1.6 Primary amines ( as aniline) 0.1% (m/m) approx Alkalinity of water extract to 0.005% (m/m) approx phenolphthalein ( as NaOH ) Acidity of water extract to 0.005% (m/m) approx phenolphthalein ( as HCl) Additional requirement on request for tender sample 1.7 1.8 1.9 Ash content 0.05% (m/m) Approx 1.10 Organic bases ( as aniline ) 0.25% (m/m) Approx 1.11 Sulphuric Acid test A colourless for pale green flourescent solution 1.12 Melting point To melt a clear pale yellow liquid. 3.0 DibutylPhthalate ( DBP) SL.NO. CHARACTERISTICS LIMIT 1. Appearance The material shall consist essentially of dibutyl ester of phthalic acid ( C6H4COOC4H9)2 in the form of colourless clear liquid free from visible impurities and foreign matter 2. Colour ( hazen unit) 50 max. approx 3 Refractive Index – n25/D 1.490 appro 4 Ester content 99 % approx 5 Ash content 0.01% approx. 6 Density at 25oC (KG / m3 1.040 approx 7 Acidity as C6H4(COOH)2 to 0.01% approx Phenelophkhalein 8. Water content 0.01% approx 9. Di- Isobutylphthalate 0.01% approx Note : All percentages are expressed as mass / mass. Page 09 Page 52 of 153 ANNEXURE-II (SB) (3/4) 4.0 Potassium Sulphate ( K2SO4) SL.NO. CHARACTERISTICS 1. Description 2 3 4 5. 6 7. 8 9 10 11 11.1 5.0 LIMIT The material shall essentially consist of potassium sulphate (K2SO4) in the form of white or near white crystalline power free from grit, foreign matter and visible impurities. Potassium Sulphate 99.0% approx Volatile matter 0.2% approx Matter insoluble in water 0.1% approx Ash ( larger than 63 m Nil Acidity as H2SO4 0.005% approx Alkalinity as KOH 0.005% approx Ammonium compound as 0.05% approx NH3 Material other than 0.5% approx Potassium as oxide Chloride as KCL 0.1% approx Fineness For process control purpose only Larger than 150 m 1.0% approx Dinitrotoulene ( DNT) SL.NO. CHARACTERISTICS LIMIT 1. DESCRIPTION 2. Setting point The material shall consist essentially of 2: 4 dinitrotollune (C6H3 ( N02) 2CH3 ) in the form of pale yellow crystal, flex of friable lump, free from grit, visible impurities and foreign matters. 66oC 3. Melting point To melt to a transparent yellow liquid free from scum and deposit. 4 Volatile matter Not more than 0.25% ( m/m) 5. Matter insoluble in Not more than 0.1% (m/m) toluene 6 Sulphated ash Not more than 0.05% (m/m) 7. Acidity To bromothymol blue – not more than 0.005% (m/m) as H2SO4 8. Alkalinity To Bromothymol blue - Nil. Note : All percentages are expressed as mass / mass Page 10 Page 53 of 153 ANNEXURE-II (SB) (4/4) 6.0 Ether (Diethyl Ether) SL.NO. CHARACTERISTICS LIMIT 1. DESCRIPTION The material shall essentially consist of diethyl ether ( C2H5OH ) in the form of clear colourless liquid free from suspended matter. 2. Relative humidity Approx 0.71 at 250C 3. Distillation range Not less than 95% volume / volume. Shall distil over below 360C at 760mm Hg. 4. Moisture Not more than 1.5% ( m/m ) 5. Residue on evaporation Not more than 0.005% (m/m) 6. Acidity To methyl red – not more than 0.002% (m/m) as H2SO4 7. Peroxides Nil 7.0 Ethanol (Ethyl Alcohol) SL.NO. CHARACTERISTICS LIMIT 1. DESCRIPTION The material shall essentially consist of ethyl alcohol ( C2H5OH ) in the form of a clear colourless liquid free from matter in suspension. 2. Properties 2.1 Relative density at 200C 0.814 2.2 Residue evaporation 0.01% m/m 2.3 Miscibility with water No opalescence 2.4 Alkalinity Nil 2.5 Acidity (as H2SO4 ) 0.005% (m/m) 2.6 Aldehydes & Ketone (as 0.10% (m/m ) CH3CHO ) Page 54 of 153 Page 11 ANNEXURE – III (SB) Page 55 of 153 For reference purpose only. Refer Clause 3.0. Page 12 ANNEXURE – III (SB) (1/7) For reference purpose only. Refer Clause 3.1.1. Page 56 of 153 Page 13 ANNEXURE – III (SB) (2/7) For reference purpose only. Refer Clause 3.1.2. Page 14 Page 57 of 153 ANNEXURE – III (SB) (3/7) For reference purpose only. Refer Clause 3.1.3. Page 15 Page 58 of 153 ANNEXURE – III (SB) (4/7) Page 59 of 153 For reference purpose only. Refer Clause 3.1.4. Page 16 ANNEXURE – III (SB) (5/7) For reference purpose only. Refer Clause 3.1.5. Page 17 Page 60 of 153 ANNEXURE – III (SB) (6/7) For reference purpose only. Refer Clause 3.1.6.. Page 61 of 153 Page 18 ANNEXURE – III (SB) (7/7) For reference purpose only. Refer Clause 3.1.7.. Page 19 Page 62 of 153 Annexure–IV(SB) (1/18) INDICATIVE EQUIPMENT LIST (For reference purpose only. Refer Clause 3.0.) INCORPORATION The following equipment are envisaged for the above operation. 1 Ether storage tank – TK 1-10 Type & Shape Medium Insulation Diameter (m) Operating Pressure (kPag) End Shape Agitator Nominal Tank size(m3) Material Total length (m) Operating temperature (0C) End material/thk(mm) Shell material/thk(mm) 2 Dibutylphthalate Measuring Tank Type & Shape Medium Insulation Diameter (m) Operating Pressure (kPag) End Shape Agitator Nominal Tank size(m3) Material Total length (m) Operating temperature (0C) End material/thk(mm) Shell material/thk(mm) 3 - HORIZONTAL ETHER YES 1.066 HYDROSTATIC - DOMED NONE 1.136 MILD STEEL 1.825 AMB - 5 3 - TK 2-10 - VERTICAL DIBUTYLPHTHALATE NONE 0.220 HYDROSTATIC - DOMED NONE 0.0183 MILD STEEL 0.480 AMB - 5 3 Ether Measuring Tank - TK 3-10 Type & Shape Medium - VERTICAL ETHER Page 20 Page 63 of 153 Annexure–IV(SB) (2/18) Insulation Diameter (m) Operating Pressure (kPag) End Shape Agitator Nominal Tank size(m3) Material Total length (m) Operating temperature (0 C) End material/thk(mm) Shell material/thk(mm) Sieve Basket No.1 - NONE 0.460 HYDROSTATIC - FLAT NONE 0.0150 COPPER 0.914 AMB - 5 3 - TK – 4 - 10 Type & Shape Medium Insulation Diameter (m) Operating Pressure (kPag) End Shape(bottom) Agitator Nominal Tank size(m3) Material Total height (m) Operating temperature (0 C) End material/thk(mm) Shell material/thk(mm) (v) Sieve Basket No.2 - VERTICAL ETHER & DBP NONE 0.355 HYDROSTATIC - CONICAL NONE 0.03 COPPER 0.304 AMB - 5 3 TK 4 – 20 Type & Shape Medium Insulation Diameter (m) Operating Pressure (kPag) End Shape(bottom) Agitator Nominal Tank size(m3) Material - VERTICAL ETHER NONE 0.355 HYDROSTATIC CONICAL NONE 0.03 COPPER Page 64 of 153 Page 21 Annexure–IV(SB) (3/18) Total height (m) Operating temperature (0 C) End material/thk(mm) Shell material/thk(mm) (vi) DBP Storage Tank Rotary Hand Pump Capacity(L/min) Material Viscosity Service Temperature(0C) Height (viii) Incorporator Capacity(kg) Shell working pressure Lid operation Material Jacket working pressure (bar) Test pressure(bar) Blade material Gear Box Ratio 0.304 AMB - 5 3 - VERTICAL DBP NONE 1.828 X 0.914 HYDROSTATIC - FLAT NONE 0.760 GALVANIZED MILD STEEL 0.457 AMB - 5 3 TK 5-10 Type & Shape Medium Insulation Length X Width (m) Operating Pressure (kPag) End Shape(bottom) Agitator Nominal Tank size(m3) Material Depth (m) Operating temperature (0 C) End material/thk(mm) Shell material/thk(mm) (vii) - PP 6-10 - 20 VARIOUS 20 CP @ 200C PUMPING OF DBP AMB 3.6 1PR 7-10 - 220 ATM HYDRAULIC CAST IRON/ AISI 304 3.5 - 5 CAST STEEL 13 : 1 Page 22 Page 65 of 153 Annexure–IV(SB) (4/18) Shaft material Coupling Output speed(rpm) 3.1 MOTOR DATA Power output (kw) Enclosure Frame Speed (rpm) Volts/Phase/Freq. Coupling guard - AISI 304 DIRECT 110 - 5.5 TEFC D160 M 1450 415/3/50 YES *Clearance between blades and end of troughs (maximum 1.7mm,minimum 1.6mm) Shaft clearance each side (maximum 0.09mm, minimum 0.06mm) Clearance between blades and sides of trough (maximum 0.8mm, minimum 0.7mm) Blade speed 11 & 22 rpm Hydraulic motor power output 2.2 Kw, speed 1450 rpm(power pack for incorporating tilting and lid opening). (ix) Sieve SE 7-20 Mesh size Sieve size 1 x b(m) Material (x) - BS8 & 60 MESH 0.812 X 0.730 BRASS, WOOD Discharge Trolley TR 8-10 Size(1xwxd) m Number of outlets Size of outlets 1xb(m) Material wheels Edging - (xi) Scale 1.245 X 0.762 X 0.200 5 0.2 X 0.2 AISI 304, TIMBER 4 X 150 MM O CASTORS DIA 12 MM ROD SC 9 –10 Capacity (kg) Material Platform Size (m) Service Temperature (oC) Accuracy (kg) - 0-17 AISI 304 L 0.500 X 0.500 BATCH WEIGHING AMB ± 0.01 Page 23 Page 66 of 153 Annexure–IV(SB) (5/18) (xii) Chiller Unit CH U 10-10 Type Refrigerant Cooling capacity Calorifier heating capacity MJ/h Circulating Water Pump Motor Power Output(Kw) Current(A) Enclosure Frame Speed (rpm) Volts/Phase/Freq. Coupling guard Process Water Pump Motor Power Output (Kw) Current (A) Enclosure Frame Speed (rpm) Volts/Phase/Freq. Coupling guard (xiii) Product Trolley Size (m) Material Service WATER COOLED SHELL & TUBE R22 (15 KG) 52200 kCal/h 97 1.5 3 T.E.F.C. D160M 2900 415/3/50 YES 1.5 3 T.E.F.C. D160 M 2900 415/3/50 YES - 1.220 X 0.800 TIMBER TRANSPORTING OF PRODUCT - 2200 3.3 1.98 X 1.53 X 2.08 - ELECTRIC ROPE OPERATED 10.67 - 4 8 IP 55 D160 M PRESSING & CUTTING 1. Goods Hoist Capacity (kg) Travel(m) Cage size (h X w X d) Type Speed(m/min) Motor Data Power output (kw) Current(A) Enclosure Frame Page 24 Page 67 of 153 Annexure–IV(SB) (6/18) Speed Volts/Phase/Freq. Coupling guard - (ii) Block Press BP 15-10 Manganese bronze ram working pressure low, .high(kPa) Manganese bronze ram test pressure (kPa) Powder cylinder diameter (m) Actuation Powder cylinder working pressure (kPa) Powder cylinder test pressure(kPa) Ram diameter(m) Motor for Hydraulic power pack Power output(kW) Current(A) Enclosure Speed Volts/Phase/Freq. Coupling guard (iii) BlockTrolley (iv) Size(m) Material Service Extrusion Press 1450 415/3/50 YES 1700, 24100 36200 0.298 HYDRAULIC 8600 13800 0.263 4 8 IP 55 1450 415/3/50 YES TR 16 10 - 1.220 X 0.800 TIMBER CONVEYING BLOCKS TO FINAL PRESS - 22000 - 2760 - 1.352 HYDRAULIC 36551 0.508 0.457 - 7.5 (2 OFF) EP 17-10 Working pressure high-low (kpa) Length of stroke(m) Actuation Test pressure(kpa) Hydraulic cylinder dia(m) Max press daylight(m) Motor for Hy.pack Power output(kW) Page 25 Page 68 of 153 Annexure–IV(SB) (7/18) Power output (kW) Current (A) Enclosure Speed Volts/Phase/Freq. Coupling guard (v) Eight channel Cord distributor Size(m) Material Operating pressure (vi) (vii) - Eight cone Trolley 4.0 (1 OFF) 38 IP 55 1450 415/3/50 YES CDR 18-10 - 11.6 X 0.6 X 1.44 COPPER, BRASS ATMOSPHERIC TR 19 –10 Size (m) - Material - 2.374 X 1.174 X 1.090 (L X B X H) WOOD Cannon Powder cutting machine (Motor) CM 20 – 10 Power output (kW) Current (A) Enclosure Mounting Speed Volts/Phase/Freq. Coupling guard - 1.5 3 IP 55 E182 1450 415/3/50 YES The Cannon Powder Cutting Machine is driven by a hydraulic power pack in a separate motor room. The cutting machine consists of a cutting disc with cutting blades which run against a cutting bar with holes to suit the cord diameter. The length of the cut is determined by the number of cutting blades and rollers connected by gear train. The speed of the machine may be varied by speed control valve. Cutting Machine requirements are as follows: Gear Blade Front Bar Back Bar Cutter Bar : 42 Tooth : 7 Blades. : 6.0 mm : 6.0 mm : 6.0 mm Page 26 Page 69 of 153 Annexure–IV(SB) (8/18) (viii) Scale SC 21 –10 Capacity (kg) Material Platform size Service (ix) (x) (x) - 0- 50 AISI 304 L 0.500 X 0.500(m X m) BATCH WEIGHING Size(m) - Temperature Accuracy(kg) Material Service - 2.222 X 1.016 X 0.914 ( L X B X H) AMB (±) 0.01 TIMBER TRANSPORT WET POWDER TO PREL.STOVE Wet Powder Trolley Air Filter Type Location Service FL 34 – 10 - Temperature - Fan FE 35 – 10 Type Service - CENTRIFUGAL AIR TO BE USED FOR DRYING OF DIES AND SIEVES. - 0.75 1.5 T.E.F.C. D213 1450 415/3/50 YES Motor Power output(KW) Current(A) Enclosure Frame Speed Volts/Phase/Freq. Coupling Guard (xii) WOVEN METAL MESH EXTERNAL FILTRATION OF AIR TO BE USED FOR DRYING OF DIES AND SIEVES. AMB Air Heater HE 36-10 Type Steam pressure required(bar) Service Temperature(0C) - STEAM HEATED EXTENDED SURFACE 6 DRYING OF DIES AND SIEVES 40 Page 27 Page 70 of 153 Annexure–IV(SB) (9/18) (xiii) Drying Hood HD 37 – 10 Size(m) Material Service Temperature(0C) - (xiv) Die Block cleaning tray Size(m) Material Service (xv) Wash water tank Type/shape Medium Insulation Diameter(m) Operating pressure(Kpag) Shell material/thk(mm) Nominal tank size(m3) Material Total height(m) Operating temperature End material(m)thk ( xvi) 0.900 X 0.600 X 0.900 GALVANIZED MILD STEEL DRYING OF DIES AND SIEVES 40 TR 38-10 1.070 SQ X 1.000 HIGH TIMBER CLEANING OF DIE BLOCKS - Caustic cleaning tank TK 40 –10 Type/shape Medium Insulation Diameter(m) Operating pressure(Kpag) Shell material/thk(mm) Nominal tank size(m3) Material Total height(m) Operating temperature End material(m)thk - (xvii ) Caustic Soda drum DRM 41 – 10 Type/shape Medium Insulation - VERTICAL WATER NONE 0.840 HYDROSTATIC 3 0.500 MILD STEEL 0.915 AMB 5 VERTICAL CAUSTIC SODA NONE 0.840 HYDROSTATIC 3 0.500 MILD STEEL 0.915 AMB 5 VERTICAL CAUSTIC SODA NONE Page 28 Page 71 of 153 Annexure–IV(SB) (10/18) Nominal tank size(L) Material (xviii) Caustic make up tank TK 42 - 10 Type/shape Medium Insulation Diameter(m) Operating pressure(Kpag) Shell material/thk(mm) Nominal tank size(m3) Material Total height(m) Operating temperature End material(m)thk (xix) Hoist 10 POLYTHENE - VERTICAL CAUSTIC SODA NONE 0.990 HYDROSTATIC 3 0.500 MILD STEEL 0.615 AMB 5 - 500 9 TROLLEY CHAIN OPERATED - WIRE BASKET DIA 0.68 X 0.38(DIE BLOCK) AISI 304 0.485 X 0.410 X 0.155(SIEVES) HT 43 –10 Capacity(kg) Lift speed(m/min) Type Operation (xx) Wire basket BKT 44-10 Type/shape Size(m) Material Size(m) (xxi) Wall mounted Extraction fan Type Impeller type Impeller diameter Service Motor power output(kw) Current(A) Speed Volts/Phase/Freq. FE 63 – 10 - CENTRIFUGAL 4 BLADE 400 MM EXTRACTION FAN 0.38 1 1450 415/3/50 Page 29 Page 72 of 153 Annexure–IV(SB) (11/18) 3.0 PRELIMINARY DRYING (i) (ii) (iii) (iv) FL 23 –10 Air filter Type Location Service - Temperature - Fan FE 24-10 Type Material Service - Motor power output(kw) Current(A) Enclosure Frame Speed(rpm) Volts/Phase/Freq. Coupling Guard - Air heater WOVEN METAL MESH EXTERNAL FILTRATION OF AIR TO BE USED FOR BATCH DRYING OF PROPELLANT POWDER. AMB CENTRIFUGAL MILD STEEL BATCH DRYING OF PROPELLANT POWDER 4 8 T.E.F.C. D213 1450 V - BELT DRIVE 415/3/50 YES HE 25 – 10 Type - Steam pressure required(bar) Service - Temperature(0C) - Drying trough - STEAM HEATED EXTENDED SURFACE TYPE 8-10 BATCH DRYING OF PROPELLANT POWDER 65 MAXIMUM HD 26 – 10 Capacity - Material Service - Temperature - 3700CFM AIR @ 75W.G 650C GALVANIZED MILD STEEL BATCH DRYING OF PROPELLANT POWDER 65 o C MAXIMUM Page 30 Page 73 of 153 Annexure–IV(SB) (12/18) (v) Trolley TR 27 - 10 Size(m) Material Service 4.0 - STEEPING/LEACHING (i) TK 28 – 10 Steeping tank Type/shape Medium Capacity(kg) Density(kg)/(dm3 ) Length,width(m) Operating pressure(kpag) Top end shape Bottom & shape Agitator Nominal tank size(m3) Material Total depth(m) Operating temperature Bottom end material/thk Shell material/thk (ii) Trolley - RECTANGULAR WATER 1820 DRY WEIGHT 1 2.300, 1.695 HYDROSTATIC FLAT FLAT NONE 5.0 AISI 304 1.220 950C MAX(STEAM HEATED) 3mm 3mm - 2.030 X 0.870 TIMBER TRANSPORTING OF PROPELLANT POWDER TR 29 – 10 Size(m) Material Service 5.0 2.030 X 0.870 TIMBER TRANSPORTING OF PROPELLANT FINAL DRYING The list of equipments with their specification is same as that of list of preliminary drying. Total no. of equipments (a) Air Filter (b) Fan, (c) Air heater (d) Stove Trough (e) Trolley - 5 FL 23 – 10 FE 24 – 10 FE 25 - 10 HD 26 – 10 TR 27 - 10 Page 31 Page 74 of 153 Annexure–IV(SB) (13/18) 6.0 BLENDING (i) Rotoclone 30 – 10 Motor power output (kw) Current(A) Enclosure (1PXX) Speed Volts/Phase/Freq. Coupling Guard - 3 6 1P55 1450V-BELT DRIVE 415/3/50 YES *4 inlet filters - material : Meld steel with cloth filters, Aluminium Ducting Diameter - 350mm (ii) (iii) (iv) Blender BLR 31 – 10 Capacity(kg) Material Gearbox Ratio Shaft Material Coupling Speed (rpm) Motor power output(kw) Current(A) Enclosure Frame Speed(rpm) Volts/Phase/Freq. Coupling Guard - 1000 ALUMINIUM To be designed AISI 304 FLUID DRIVE 16 7.5 15 T.E.F.C. D160M 960 415/3/50 YES Scale SC 32 – 10 Capacity(kg) Material Platform size(m) Service Temperature Accuracy(kg) - 0-50 AISI304L 0.3 X 0.3 WEIGHING AMB +-0.01 - 1000 WOOD TRANSPORTING 4 CASTORS Trolley Capacity(kg) Material Service Wheels TR 33 – 10 Page 75 of 153 Page 32 Annexure–IV(SB) (14/18) 7.0 SOLVENT RECOVERY (i) Extraction Fan (ii) (iii) FE 46 – 10 Type Capacity (m3/Hr.) Motor power output(kw) Current(A) Enclosure Frame Speed(rpm) Volts/Phase/Freq. Coupling Guard - Heat Exchanger/Vapour Heater HE 45 – 10 Type - Steam Pressure required(bar) Service - Temperature (0C) - Solvent Recovery Unit FAN, CENTRIFUGAL 5100 11 22 T.E.F.C. D213 2940 415/3/50 YES STEAM HEATED EXTENDED SURFACE TYPE 1.4 HEATING OF SOLVENT LADEN AIR 43 SRU 47 – 10 Size(L X B X H )m Absorbent type - 2.450 X 1.800 X 1.400 AG25 *This unit consists of a rectangular all welded 5mm thick mild steel casing with bolted tope cover 10mm thick. The unit is equipped with air operated valves & controllers. (iv) Condenser CD 48-10 and CD 48 – 20 Type Material - MULTIPASS SHELL & TUBE MILD STEEL There are two condensers of identical type with 60 tubes, 16mm outside diameter, 1.6mm thickness of wall mild steel tubing and the cooler with 40 similar tubes. (v) Condensate Tank Type/shape Medium Diameter(m) TK 49 – 10 - VERTICAL, CYLINDRICAL CONDENSATE 1.2 Page 33 Page 76 of 153 Annexure–IV(SB) (15/18) Insulation Operating pressure(kpag) Legs/feet Top end shape Bottom End shape Agitator Nominal Tank Size(m3) Material Total height(m) Operating pump Top End Material/thk Bottom End material/thk (vi) Cooling Tower Cooling Water Pump Process fluid Flow(m3/h) PH Zone classification Type Shaft material Casing material Impeller material Seal Base Temperature(0C) Pressure head(kpa) Pump size N/A ATM 4 FLAT CONICAL N/A 1.0 Mild steel 0.870 AMB 4 4 - WATER 6054 35 28 62 22 GLASS REINFORCED PLASTICS 7.5 15 IP54 FOOT 960 415/3/50 YES CT 50 – 10 Process fluid Heat capacity(MJ) Inlet Temperature(0C) Outlet Temperature(0C) Cooling water flowrate(m3/Hr.) Wet bulb temp(0C) Material Motor power (kw) Current (A) Enclosure Mounting Speed(rpm) Volts/Phase/Freq. Coupling Guard (vii) - - PP 51 – 10 - COOLING WATER 62.5 NEUTRAL NONE CENTRIFUGAL AISI316 CAST IRON BRONZE MECHANICAL MILD STEEL AMB 280 100 X 80 X 250 Page 77 of 153 Page 34 Annexure–IV(SB) (16/18) Coupling Speed(rpm) Inlet Flange(DN, PN) Outlet Flange (DN, PN) Closed/open Impeller Pump Motor Power Current(A) Enclosure Mounting Speed(rpm) Volts/Phase/Freq. Coupling Guard (viii) - FLEXIBLE 1450 NB 100 PN 10 NB 80 PN 10 OPEN 250 DIAMETER 7.5 15 IP54 FOOT 2890 415/3/50 YES - SHELL AND TUBE TYPE R22 1.5 - AISI 304 L 97.2 1.5 1.5 3 T.E.F.C. D160M 2900 415/3/50 YES 1.5 3 T.E.F.C. D160M 2900 415/3/50 YES Chiller Unit CHU 52 – 10 Type Refrigerent Circulating water pump power(kw) Material Calorifier Capacity(MJ/Hr.) Process water pump power(kw) CWP Motor power output(kw) Current (A) Enclosure Frame Speed(rpm) Volts/Phase/Freq. Coupling Guard PWP Motor power output(kw) Current (A) Enclosure Frame Speed (rpm) Volts/Phase/Freq. Coupling Guard Process water circuit : Heat exchanger APU paraflow H x U4 with stainless steel plate. (ix) Cooling water tank Process fluid Heat capacity(MJ) Inlet temp (0C) CT 53 – 10 - WATER 1471.9 35 Page 78 of 153 Page 35 Annexure–IV(SB) (17/18) Outlet temp (0C) Cooling water flow rate(m3/Hr.) Wet bulb temperature (0C) Material Motor power(kw) Current (A) Enclosure Speed(rpm) Volts/Phase/Freq. Coupling Guard 10. Cooling water pump - 28 44 22 GLASS REINFORCED PLASTIC 3 6 IP54 960 415/3/50 YES - COOLING WATER 44 NEUTRAL NONE CENTRIFUGAL AISI 316 CAST IRON AISI 316 MECHANICAL AISI 316 AMB 280 80 X 50 X 220 DIRECT 1450 NB80 PN10 NB50 PN10 OPEN 220 DIAMETER - N/A AISI 316 L - 5.5 11 IP54 FOOT 1450 415/3/50 YES PP 54 – 10 Process fluid Flow (m3/h) PH Zone classification Type Shaft Material Casting Material Impeller material Seal Base Temperature (0C) Pressure head (Kpa) Pump size Coupling Speed(rpm) Inlet Flange (DN, PN) Outlet Flange(DN, PN) Closed/open Impeller Pipeline data Pipe size(NB) Pipe material Pump Motor data Pump Motor power(KW) Current (A) Enclosure Mounting Speed (rpm) Volts/Phase/Freq. Coupling Guard Page 36 Page 79 of 153 Annexure–IV(SB) (18/18) (xi) Waste Water Pump Process fluid Flow (m3/h) PH Zone classification Type Shaft Material Casting Material Impeller material Seal Base Temperature (0C) Pressure head (Kpa) Pump size Coupling Speed(rpm) Inlet Flange (DN, PN) Outlet Flange(DN, PN) Closed/open Impeller Motor data Power (KW) Current (A) Enclosure Mounting Speed Volt/Phase/Freq. Coupling guard PP 56 – 10 - WASTE WATER 44 NEUTRAL NONE CENTRIFUGAL AISI 316 CAST IRON AISI 316 MECHANICAL AISI 316 AMB 280 80 X 50 X 220 DIRECT 1450 NB80 PN10 NB50 PN10 OPEN 220 DIAMETER - 1.1 2.2 1P54 Foot 1450 415/3/50 Yes ____________________________________________________________________________________ Vendor should specify the Capacity, quantity, criticality of each equipments offered as per their technology. Hot stand- by for any equipment should also be specified. Page 80 of 153 Page 37 ACCOMODATION STATEMENT – SBP PLANT Bldg. no. 0501 0502 0503 0504 0505 0506 0508 0519 0520 Building description Building size in (M) DB ATTENDENT / SECURITY CABIN UNIT OFFICE/ STAFF CHANGE ROOM/UNIT STORE EXCHANGE ROOM 6.46X5.46X3.5 CYCLE SCOORTER SHED FOR STAFF CYCLE SCOORTER SHED FOR IE’S NON-EXPLOSIVE STORES NON-EXPLOSIVE STORES + VARANDA INTERMEDDIATE STORAGE OF NC POWDER INTERMEDDIATE STORAGE OF NC POWDER ROAD WORKS Total Tr NECBuildings kg Class 1. NonTR/Un Technology Floor Area (SQM) 36 - - - ANNEXURE – V (SB) (1/2) Safety Distance (M) Special requirement (ref. safety regulation) SIQD PIQD OQD Elec. Fittings Fans/ Others AC/ Non AC Lightning protection - - - YES (FLP) FAN Non AC - - - - YES (O) FAN Non AC - 22X10X3.5 220 11X10X3.5 110 10X6.4 64 - - - - - 10X6.4 64 - - - - 20X10X3.5 200 - - - 20X10X4 200 - - 10X7.5X4 + 2.5 VARANDAH 100 Tr. / NAT 10X7.5X4 + 2.5 VARANDAH 100 Tr. / NAT YES (O) Non AC - YES (O) Non AC - - - YES (O) FAN Non AC - - - - YES (O) FAN Non AC YES - - - - YES (O) FAN Non AC YES 3000 1.1 35 105 320 YES (FLP) NO Non AC YES 3000 1.1 35 105 320 YES (FLP) NO Non AC YES DRAINAGE SEWERAGE FENCING VENTILATION AND AIR CONDITIONING Page 38 Page 81 of 153 Remarks ACCOMODATION STATEMENT – SBP PLANT 2. Technology Buildings Bldg. no. Building description Building size in (M) TR/Un Tr 10X10X4.5 Total Floor Area (SQM) 100 NEC kg - - Class Safety Distance (M) Special requirement (ref. safety regulation) SIQD PIQD OQD Elec. Fittings Fans/ Others AC/ Non AC Lightning protection - - - - YES (O) FAN Non AC YES 0507 SUB STATION 0509 20X10X4 200 NAT - - - - - YES (FLP) FAN Non AC YES 20X10X4 200 VIFT 1500 1.1 28 66 275 YES (FLP) YES 20X10X4 200 VIFT 1500 1.1 28 66 275 YES (FLP) AC YES 20X10X6 200 VIFT 4000 1.1 38 130 355 YES (FLP) AC YES 0513 PRELIMINARY DRYING 20X10X4 200 VIFT 3000 1.1 38 105 355 YES (FLP) Non AC YES 0514 PRELIMINARY DRYING 20X10X4 200 VIFT 3000 1.1 38 105 355 YES (FLP) Non AC YES 0515 WATER TREATMENT OF NC POWDER WATER TREATMENT OF NC POWDER AIR DRYING OF NC POWDER AIR DRYING OF NC POWDER BLENDING / PACKING OF NC POWDER 12X10X4 120 VIFT 3000 1.1 35 105 320 YES (DT) Non AC YES 12X10X4 120 VIFT 3000 1.1 35 105 320 YES (DT) Non AC YES 10X10X4 100 NAT 3000 1.1 35 105 320 YES (FLP) Non AC YES 10X10X4 100 NAT 3000 1.1 35 105 320 YES (FLP) Non AC YES 20X15X4 200 NAT 3000 1.1 35 105 320 YES (FLP) AS REQD AS REQD AS REQD AS REQD AS REQD AS REQD AS REQD AS REQD AS REQD AS REQD AC 0512 SCREENING/DEHYDRA TION (4 COMPARTMENT) (NON EXPLOSIVE) INCORPORATION / KNEEDING INCORPORATION / KNEEDING EXTRUSION /CUTTING Non AC YES 0510 0511 0516 0517 0518 0521 REMARKS : DIMENSIONS / EXPLOSIVES LIMIT, CORRESPONDING SAFETY DISTANCES AND SPECIAL REQUIREMENT GIVEN ARE CONCEPTUAL. PLANT SUPPLIER IS TO DESIGN BASED ON THEIR TECHNOLOGY. The details given above are indicative and for reference purpose only. VENDOR SHOULD SUBMIT THE DETAILS OF TECHNOLOGICAL BUILDINGS AS PER THEIR own DESIGN IN THE ABOVE FORMAT. Page 82 of 153 Page 39 Remarks ANNEXURE – VI (SB) Page 83 of 153 Page 40 ANNEXURE – VII (SB) Page 84 of 153 Page 41 APPENDIX-III TECHNICAL SPECIFICATION FOR SUPPLY, ERECTION & COMMISIONING OF PLANT AND MACHINERY INCLUDING ASSOCIATED CIVIL WORKS FOR PRODUCTION OF TRIPLE BASE PROPELLANT AND FLASH REDUCING DISCS AT O.F. NALANDA PROJECT, RAJGIR (BIHAR), INDIA Specification No. – SPCN/I/2016/OFN/BMCS/TBP Page 85 of 153 Volume Para No. Subject Page No. APPENDIX III TRIPLE BASE PROPELLANT & FLASH REDUCING DISC MANUFACTURING PLANT SPECIFICATIONS 1.0 Intent 1 2.0 Capacity of The Plant 1 3.0 Description of Requirement 2-7 3.1 3.2 4.0 5.0 6.0 Process Description For TBP Manufacture Process Description For FRD Manufacture Tools And Fixtures Testing Equipment Services / Utilities 3-5 5-7 8 8 8 Annexure I (TB) Product Specification For Triple Base 9-10 Propellant Annexure Ii (TB) Raw Material Specifications For TBP 11-13 Annexure Iii (Tb) Block & Process Flow Diagram For TBP 14-21 Annexure Iv (Tb) Indicative Equipment List for TBP 22-43 Manufacture Annexure IA (TB) Product Specification for Flash Reducing Discs 44 Annexure IIA (TB) Raw Material Specifications for FRD 45 Annexure IIIA (TB) Block & Process Flow Diagram for FRD 46-52 Annexure IVA (TB) Indicative Equipment List for FRD 53-59 Manufacture Annexure Drg.IA(TB) Drawing of Flash Reducing Discs 60 Annexure V Accommodation Statement 61-63 Conceptual Plant Layout Contour Overlay on Plant Layout 64 65 (TB) Annexure VI (TB) Annexure VIII (TB) Page 86 of 153 REQUIREMENT: 1. TRIPLE BASE MANUFACTURING PLANT CAPACITY 1500 MT PER ANNUM 2. FLASH REDUCING DISCS MANUFACTURING PLANT CAPACITY 18,00,000 DISCS PER ANNUM ALONG WITH ASSOCIATED CIVIL WORKS. 1.0 INTENT The present intent is for supply and installation of Triple Base Propellant and Flash Reducing Disc manufacturing plant at Rajgir (Bihar) India. The plant shall be capable of producing Triple Base Propellant required for Bi-Modular Artillery Charges, and also capable of producing Flash Reducing Discs for BMC M92 (1) A1 charges. Triple Base Propellant is obtained by incorporating three oxidizing agents viz Nitrocellulose, Nitroglycerine and Nitroguanidine in a solvent media using Alcohol and Acetone along with required chemical ingredients to suit the purpose. Flash Reducing Disc is obtained by vertical mill rolling of double base propellant to reduce moisture and to gelatinize into a consolidated sheet of material; cutting strips; and finally feeding into a punch machine to punch out the flash reducing disc. The double base propellant required for this, is obtained by incorporating Propellant paste, consisting of Nitrocellulose and Nitroglycerine, with Ethyl Centralite, Graphite, a stabilizer and a flame retardant. 2.0CAPACITY OF THE PLANT The plant will have a minimum capacity of 1500 MT/ANNUM of triple base propellant in 220 working days with a most modern PLC/automatic plant utilizing minimum manpower and energy. The rated capacity of the plant has to be so designed so that the required output capacity of 1500 MT/ annum as given above is achieved with the plant availability of minimum 80 % of time with 80% plant efficiency and wastage / rejection not more than 2 % on a 2 X 8 hrs. shifts/day on continuous basis The quality of finished triple base propellant grain will be as per the product specification enclosed at Annexure-I (TB). The specification of some of the raw materials enclosed at Annexure-II (TB). The specification of raw material with approx. limit is enclosed as Annexure-II (TB). The exact raw material specification will be disclosed to the successful bidder. In addition, the plant will also be capable of manufacturing a minimum of 18,00,000 Flash Reducing Discs per annum in 220 working days, with a most modern PLC/automatic plant utilizing minimum manpower and energy. The rated capacity of the plant has to be so designed so that the required output capacity of 18,00,000 FRD per annum as given above is achieved with the plant availability of minimum 80% of time with 80% of plant efficiency and wastage / rejection not more than 2 % on Page 01 Page 87 of 153 continuous basis. The quality of the finished Flash Reducing Disc will be as per product specification enclosed at Annexure-IA (TB) and Annexure Drg.-1A (TB). The specifications of raw materials for Flash Reducing Disc are enclosed in Annexure-IIA (TB). The specification of raw material with approx. limit is enclosed as Annexure-IIA (TB). The exact raw material specification will be disclosed to the successful bidder The plant supplier shall ensure the plant and equipments offered as a whole is capable of producing desired triple base propellant and Flash Reducing Discs under normal conditions at full rated capacity and this should be demonstrated during commissioning/guarantee run both for main plants and separately for other utilities. 3.0 DESCRIPTION OF REQUIREMENT A brief description for the manufacture of Triple Base Propellant is given in section 3.1 below and of Flash Reducing Discs at section 3.2 below. In addition to this, the process flow diagram (for reference purpose only) for Triple Base Propellant production is enclosed at Annexure III (TB), and for Flash Reducing Discs production at Annexure IIIA (TB). An indicative list of main equipment with specification is enclosed at Annexure IV (TB) for Triple Base manufacturing and at Annexure IVA (TB) for Flash Reducing Disc production. The actual number, type and capacities of equipments are based on the mass balance to be worked out by the plant designer for the capacities required. However, if the vendor desires any changes in the process or a better technology, he can do so and submit the offer accordingly. In case, the vendor feels that certain equipment being used for Triple Base manufacturing can also be used for Flash Reducing Discs manufacturing, and/or Single Base Propellant Manufacture, without effect on safety or capacity, he may indicate along with the plant being offered, the system of operation of the shared equipment/facilities, so as to get production as per stated capacity requirements within the overall time of operation stated above. In such case, it must be ensured for all common operations (shared equipment) that the extra handling is provided for in the design. In any case the vendor shall submit along with the offer – process flow diagram, list of equipments and their specifications of the offered equipment in the format of Annexure III (TB) and Annexure IV (TB) respectively, in addition to all other techno-commercial offers as per the tender document. The vendor has to prove the capacity and quality as given in the Annexure I (TB) and Annexure Drg. (TB) I (to be disclosed to the successful bidder after signing of non-disclosure agreement) for Triple Base propellant and Annexure IA (TB) and Annexure Drg. IA(TB) for Flash Reducing Discs. Vendor should specify the Capacity, quantity, criticality of each equipments offered as per their technology. Hot stand- by for any equipment should also be specified. Page 02 Page 88 of 153 3.1 Process Description for Triple Base Propellant Manufacturing 3.1.1 Paste Centrifuging During Paste Centrifuging, the moisture content is reduced from ca 40% to ca 18% NC-NG paste with 40% moisture content kept in paste bags are transported from the paste store to the top floor of the centrifuge house. The centrifuge and screw conveyor are set in motion and the paste is slowly fed through a screen into the trough of the screw conveyor. The centrifuge rotates on slow speed (50rpm) with basket filled with 100 + 5 kg. wet paste. The centrifuge is then operated at a maximum speed for 250 seconds to reduce the paste moisture content to 18%. The paste is then ploughed out of the centrifuge basket directing it down the discharge port into a crumbler. Here the paste is mechanically broken up and passed through a coarse screen into a discharge trolley fitted with bags to collect the material. The bags are removed from the trolley, open ends properly tied and fitted with labels to identify the paste lot details, mass, date and moisture content. The bags are then loaded on a trolley and transported to the paste store. Considerable quantity of dust produced during crumbling operation constitute a serious hazard and in no case should be allowed to accumulate. Moisture analysis of centrifuged paste is taken at least daily. 3.1.2 Paste Rolling Paste rolling is done to remove most of the moisture content from the composition and to start the gelatinisation of the Nitrocellulose so that a consolidated sheet of material is produced. The rolling mill used for the process has twin horizontal rollers, one of the roller has a smooth chromium plated surface and the other a very rough spark eroded steel surface. The mill is of the differential type so that a shearing and rolling effect is created within the material passing through the roll-nip. The temperature of the two rollers differ as to improve the sticking of the propellant composition to the rough roll. The rolling procedure is very basic. A pre-weighed mass paste is dropped from the feeding hopper into the nip between the rollers. The paste passes through the roll-nip and adheres to the rough colder roller. The moisture in the composition is volatilized and the heat together with the rolling effect produces a semi-gelatinised sheet with low moisture content. Control points of this operation are paste mass, roller temperature, roller gap and rolling time. At the end of the rolling period, a knife is operated to deflect the composition in sheet form off the rough roller. The rolled sheet is then torn into smaller strips by hand and placed in a clean, dry calico bag to be transported to the sheet paste store. Page 03 Page 89 of 153 3.1.3 Incorporation This is a complex process stage, if not done properly will have a significant effect on the physical, chemical and ballistic properties of the final product. The incorporators consist of stainless steel frame and trough jacketed for circulation of cold and hot water. Each incorporator is fitted with two contra rotating "SIGMA" type stainless steel blades operating at 25rpm for the front blade and 18 rpm for the rear bladed. Bowl tilting and lid movement is achieved hydraulically. A temperature control system consists of three water circuits, namely the process water circuit, the hot water circuit and the chilled water circuit. During incorporation, the ingredients added are:Shredded Paste Sheets; Nitroguinadine; Acetone; Alcohol; Graphite; Flame Retardant (Specification to be disclosed to the successful bidder); Plasticizer (Specification to be disclosed to the successful bidder). 3.1.4 Extrusion and Cutting The incorporated propellant mixture in the form of firm dough is transported in rubber bags to the press house. The product is raised in a hoist to the pressroom on the first floor and loaded in a carbon dioxide atmosphere into the charge cylinder. The product is then pre pressed at 200 bar. The charge cylinder is then submitted through 1800, transferring the product from the pre press position to the main press section. By applying pressure to the main ram the product is extruded through a filter plate and collected in a bin on the ground floor. The extrusion pressures are tentatively as below: - At Start - At 25%-75% - End - 180 to 250 bar 180 to 270 bar 200 to 270 bar Maximum permissible extrusion pressure during normal pressings is 300 bar Minimum permissible extrusion pressure is 150 bar. The drawing for the die plate assembly into which the die fits, is enclosed at Annexure Drg. II (TB). The filtered product is bagged and sent back to the press room for final extrusion using the same procedure except that the product is extruded through dies mounted in a die plate assembly. The extruded product is fed to a rotary cutting machine and the propellant grains are collected in aluminum pans. The cutting machine settings are tentatively as follows: Gear: 31 Tooth Blade: 2 blades Page 04 Page 90 of 153 After a short air-drying period the propellant is weighed and bagged for transporting to drying facilities. 3.1.5 Drying After cutting, the triple base propellant is allowed to dry naturally for at least three hours before it is bagged and transported to the drying facility. The propellant grains are then subjected to a drying cycle in a stoving process, where all the solvent and moisture is removed. The solvent wet product is loaded in to coarse mesh cloth fitted in the drying troughs. The propellant bags are positioned in the drying troughs to ensure good airflow through the propellant. During loading, the doors of the stove room are left open and cold air is blown in to the room to reduce the solvent vapor concentration. A large shrinkage in volume of grain takes place during drying and the temperature of solvent removal must be controlled very carefully, especially in the initial stages. After the drying cycle has been completed, steam is introduced for 3 minutes to lessen the risk of discharge of static electricity. The propellant is allowed to cool down to 350C and then the bags one unloaded for transporting to the blending facilities. 3.1.6 Blending Sub and final blending ensures the uniformity of the finished product. With the high cost of proofing, it is important to size the final lot as large as can be handled during blending. For case of control over the manufacturing process, the product, as it is produced, is weighed to 20 kg in canvas bags and blended in sublots of 1000 kg mass. These quantities can change depending on the lot size of the charges, however the quantity of the propellant in the sub-blend should be a simple fraction (i.e. one-tenth) of the final blend size. These sub-blends are homogeneous and can thus be sampled and tested with confidence to enable the plant to make adjustments in case of material which is out of specification. When sufficient sub-blends have been accumulated that conform to specification, the final blend can be concluded. Blending takes place in an aluminum 1-ton capacity blending pan rotating at 16 rpm. 3.2 Process Description for Flash Reducing Disc Manufacturing 3.2.1 Wet paste Storage The Nitroglycerine/Nitrocellulose water-wet paste is produced in large blends, which are substantially more than the production capability of flash reducing discs nd therefore require storage. The water-wet paste is stored at room temperature (minimum 13 degree Celsius) and time before processing is one to six weeks from the date of manufacture. Page 05 Page 91 of 153 3.2.1 Paste Centrifuging For safety reasons Nitroglycerine/Nitrocellulose paste is stored and handled in a water-wet condition. During Paste Centrifuging, the moisture content is reduced from 40% to 18% NC-NG paste which leaves the paste still relatively safe but sufficiently dry to be handled in subsequent operations. The bags of paste are transported from the paste store to the top floor of the centrifuge house. The centrifuge and screw conveyor are set in motion and the paste is slowly fed through a screen into the trough of the screw conveyor. With the centrifuge rotating on slow speed (50rpm) the basket filled with 100 + 5 kg wet paste. The centrifuge is then operated at a maximum speed for 250 seconds to reduce the paste moisture content to 18%. The paste is then ploughed out of the centrifuge basket directing it down the discharge port into a crumbler. Here the paste is mechanically broken up and passed through a coarse screen into a discharge trolley fitted with bags to collect the material. The bags are removed from the trolley, open ends properly tied and fitted with labels to identify the paste lot details, mass, date and moisture content. The bags are then loaded on a trolley and transported to the paste store. Considerable quantity of dust produced during crumbling operation constitute a serious hazard and in no case should be allowed to accumulate. The centrifuge cycle is directly related to the moisture content of the centrifuged paste. Samples for moisture analyses of the centrifuged paste are taken atleast daily, or whenever a new paste blend is centrifuged. 3.2.2 Homogenising and Mixing The centrifuged paste is homogenized in an incorporator so that the moisture content can be accurately determined, thus enabling a quantity of paste on a dry weight basis. A weighed out quantity of paste is rubbed by hand through a screen into the incorporator. The incorporator lid is closed and the paste is mixed for 20 minutes. The lid is opened again and three samples for moisture content are taken and sent to the laboratory. Once the moisture content of the paste is known, it is adjusted exactly to 18% by adding a calculated amount of water. The dry mass of other raw materials required are calculated and added to the paste in the incorporator. The incorporator load is mixed for another 50 minutes and unloaded into labeled plastic bags. The bags are then transported to the preliminary rolling facility or the wet paste store. 3.2.3 Preliminary Rolling The preliminary rolling stage in the process is to remove most of the moisture from the composition and to start the gelatinisation of the Nitrocellulose so that a consolidated sheet of material is produced. Page 06 Page 92 of 153 The rolling mill used for the process has twin horizontal rollers, one of the rollers has a smooth chromium plated surface and the other a very rough spark eroded steel surface. The mill is of the differential type so that a shearing and rolling effect is created within the material passing through the roll-nip. The temperatures of the two rollers differ as to improve the sticking of the propellant composition to the rough roll. The rolling procedure is very basic. A pre-weighed mass paste is dropped from the feeding hopper into the nip between the rollers. The paste passes through the roll-nip and adheres to the rough colder roller. The moisture in the composition is volatilized and the heat together with the rolling effect produces a semi-gelatinised sheet with low moisture content. The most important process parameters to control are paste mass, roller temperature, roller gap and rolling time. At the end of the rolling period, a knife is operated to deflect the composition in sheet form off the rough roller. The rolled sheet is wrapped in canvas and transported in a hot chest trolley to the finl rolling facility. 3.2.4 Final Rolling During the final rolling stage, the composition is fully gelatinized and the moisture content is reduced still further. The rolling mill used is of the vertical twin roll type. The rolls are made of steel with a polished surface. The rolls rotate at the same speed and are heated with hot water. The machine is fitted with a reciprocating feeding table, which automatically folds the sheet of composition double and returns it to roll nip after each pass through the mill. Three sheets from the preliminary mill is rolled through 40 passes and the sheet is turned through 90o every tenth pass. The required thickness of the final sheet is achieved by adjusting the roller gap. At the end of the rolling cycle the final sheet is passed through the edge trimmers to be trimmed to a pre-determined width. The sheet is received in the bin at the rear of the machine, rolled up, wrapped in a clean canvas sheet and placed in a hot trolley for transport to the punching facilities. 3.2.5 Punching and Packing The final rolled sheet of material is unrolled on a hot table, inspected for defects and cut into strips with a strip cutting machine. The strips are fed through a punching machine to form the flash reducing discs. The discs are measured and weighed to ensure physical conformance and packed in wooden boxes to be transported to the main magazines. Page 07 Page 93 of 153 4.0 TOOLS AND FIXTURES The plant supplied shall be tooled up. The offer shall be complete with tools, dies and fixtures (Refer Volume I para 4.0 (ii)) 5.0 TESTING EQUIPMENT, The technical bid should clearly indicate all the laboratory equipments, required for tests, including closed vessel tests that are to be conducted in relation to the production of NC-NG paste, including online tests and laboratory tests, in a tabular form as given below. The item wise price breakup of these equipments is to be given in the price bids. The PRICE column in the table below should therefore be left blank in the technical bid. S.No. EQUIPMENT NAME A In process Testing Equipments 1 2 … B PURPOSE No. of Equipment (Qty) PRICE (including all taxes etc) Included in Offer ? (Y/N) Laboratory Equipments 1 2 … The provision of laboratory space is supplier’s responsibility. Also Refer Volume I Para 4.0 (iii) 6.0 SERVICES/ UTILITIES Refer to para 4.2 of Volume I of the specifications for Purchaser’s responsibility. Any special requirements of services by the plant, that is at variance with the provisions of the para 4.2 has to be included in the scope of supply and its cost included in the offer. All such services/utilities required for production of Triple Base Propellant and Flash Reducing Discs, shall be designed, supplied and erected and their capacities proven. The vendor shall mention the guaranteed requirement of the following services for the plant offered, in the technical bid: (a) Steam (b) Water (c) Electricity (d) Compressed Air Page 08 Page 94 of 153 ANNEXURE (TB) Page 95 of 153 Annexure– I ( TB ) (1/2) PRODUCT SPECIFICATION Triple Base Propellant The propellant shall be in the form of cylindrical grains (rosette configuration) with seven longitudinal perforations and shall be Grey in colour. The material, composition, dimensions and ballistic properties of the propellant shall conform to the applicable requirements specified below. Inspection Lot - An inspection lot shall consist of one lot of propellant produced by one manufacturer under one continuous set of operating conditions and blended to make the final product homogeneous. Nonconformance – Failure of any test result to comply with the requirements specified below, may be cause of rejection. SL. CHARACTERISTIC LIMIT 1. Description The propellant shall be in the form of Cylindrical Grain (rosette configuration) with seven longitudinal perforations and shall be grey in colour. 2. Chemical and Physical Properties 2.1 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.1.8 Composition Nitrocellulose (%) Nitroglycerine (%) Nitroguanidine (%) Ethyl Centralite (%) Flame Retardant (%) Plasticizer (%) Graphite (%) Total volatile matter (%) 32 Approx 27 Approx 40 Approx 2 Approx 2 Approx 3 Approx 0.05 Approx 0.6 max. 2.2 Density at 210 C 1.64 min. 2.3 Methyl violet stability at 1200 C 2.3.1 Not within 40 2.3.2 Complete discolouration to salmon pink min Emission of brown fumes min 2.4 Energy 3750 to 4050 NO. g/cm3 J/g Not within 60 Page 09 Page 96 of 153 3 Dimensions 3.1 3.2 3.3 Average web (Wa) Average length (L) Average Diameter 4 Ballistic properties 4.1 4.1.1 4.1.2 In closed vessel Relative dynamic vivacity % Relative force 5 Dynamic Proof 5.1 Pressure at +60 oC (Mpa) 5.2 Velocity at +21 oC (m/s) 5.2.1 Standard Deviation (sample of 10) m/s 5.3 5.4 Range Accuracy mm mm mm To be disclosed to the successful bidder 21 approx 10 approx 95 to 105 95 to 105 Firing M1/BT ERFB HE projectiles with a mass of 45.0 kg + 0.1 kg from a FH 77B 39 calibre gun in its first quarter. Zone 5: maximum 420 Zone 3: 523+ 10 Zone 4: 664+ 10 Zone 5: 801+ 10 Max 6 To be disclosed to the successful bidder To be disclosed to the successful bidder Page 97 of 153 Page 10 Annexure-II (TB) (1/3) RAW MATERIAL SPECIFICATION FOR MANUFACTURE OF TRIPLE BASE PROPELLANT 1.0 PROPELLANT PASTE SL.NO 1 CHARACTERISTICS Description 2 2.1 2.2 2.3 2.4 2.5 Composition Nitrocellulose 12.6 (Pyro) % Nitroglycerine % Ethyl Centralite % O Heat test at 65 C min Energy value J/g 2.0 51.9 to 53.5 43.8 to 45.0 2.7 to 3.1 19 min 5000 to 5200 Ethyl centralite ( Carbamite) ( for use in the manufacture of propellants) Test No. 1. LIMIT The material shall consist of an intimate and uniform mixture of Nitrocellulose, nitroglycerine and stabilizer in the form of a homogeneous paste , free from visible impurities , foreign matter and grit. Test Limits 2. Description: The material shall consist essentially of diethyldiphenyl Urea CO (N C2H5. C6H5)2 in the form of a pale buff powder. Setting Point To lie within the range 71,7 to 72,5 0C. 3. Melting Test 4. 5. Volatile matter Ash Amines The material shall melt to a bright clear liquid free from scum and deposit. Not more that 0.1% (m/m) Not more that 0.1% (m/m) Not more that 0.1% (m/m) (i) Primary :Not more that 0.03% (m/m) as aniline (ii) Secondary :Not more that 0.10% (m/m) as ethylaniline 7 Acidity 8 Hydrolysable Chlorine compounds (iii) Tertiary :Not more that 0.05%(m/m) as diethylaniline. To phenolphtalein :Not more that 0.004% (m/m) as HCL Not more that 0.01% (m/m) as Cl2. Page 98 of 153 Page 11 Annexure-II (TB) (2/3) 3. ACETONE SL.NO. 1. CHARACTERISTICS Description LIMIT The material shall essentially consist of dimethyl Ketone in the form of clear colourless liquid free from suspended matter, deposits and visible impurities. 2. Properties 2.1 Relative density at 200 C 0.790 TO 0.792 2.2. 2.2.1 2.2.2 Distillation range at 101.3 k/Pa Initial boiling point 0 C Dry point 55.7 min 56.7 max. 2.3 Residue on evaporation 47 max 2.4 Permanganate test 120 min 2.5 Alkalinity to bromothymol blue Neutral 2.6 Acidity as CH3COOH mg/kg 20 Max 2.7 Alcoholic impurities not detectable 2.8 Water content % (m/m) max mg/kg 4.0 ETHANOL ( ETHYL ALCOHOL ) SL.NO. 1. CHARACTERISTICS Description 2. Properties 2.1 Relative density at 200C 2.2 Residue evaporation 2.3 Miscibility with water 2.4 Alkalinity 2.5 Acidity (as H2SO4 ) 2.6 Aldehydes & Ketone (as CH3CHO ) LIMIT The material shall essentially consist of ethyl alcohol ( C2H5OH ) in the form of a clear colourless liquid free from matter in suspension. 0.8140 (max.) 0.01% (max.) m/m No opalescence Nil 0.005% max. (m/m) 0.10% max. (m/m ) Page 99 of 153 Page 12 Annexure-II (TB) (3/3) 5.0 NITROGUANIDINE ( PICRITE ) CHARACTERISTICS 1. DESCRIPTION SPECIFICATION LIMITS The material shall consists essentially of Nitroguanidine, NH2C.(NH). NO2, in the form of a dry white crystalline powder free from lumps, grit and foreign matter. 2. PROPERTIES 2.1 Nitroguanidine content: 2.1.1 Type I 2.1.2 Type II %* 98.0 min 99.0 min 2.2 Crystal size (using Fisher Sub-sieve Sizer) (µm) 2.2.1 Class 1 2.2.2 Class 2 3.4 to 6.0 3.3 max 2.3 Volatile matter 2.4 Ash 2.5 Impurities,insoluble in water 2.6 Sulphates as Na2SO4 2.7 Acidity as H2SO4 2.8 pH of aqueous suspension 2.9 Surface pH 0.25 max 0.300 max. 0.200 max. 0.200 max. 0.060 max. 4.50 to 7.00 10.10 max. 6.0 GRAPHITE SL.NO. CHARACTERISTIC S 1. Description 2 2.1 Properties Water content % % % % % LIMIT The material shall essentially consist of Graphite in the form of a dark grey, fine ,flaky powder , free from grit, foreign matter and visible impurities. 0.5 % max. 2.2 Alkalinity to Nil phenolphthalein 2.3 Acidity to methyl Nil orange 2.4 Ash content 0.6% max. 2.5 pH of water extract 4.3 to 8.3 2.6 Free sulfur content 0.05 % max 2.7 Total sulfur content 0.05 % max 2.8 Particle size 96.0 min Smaller than 74 µm Note: All percentages are expressed as mass / mass Page 100 of 153 Page 13 ANNEXURE – III (TB) Page 101 of 153 For reference purpose only. Refer Clause 3.0.. Page 14 ANNEXURE – III (TB) (1/7) For reference purpose only Refer Clause 3.1.1.. Page 15 Page 102 of 153 ANNEXURE – III (TB) (2/7) Page 103 of 153 For reference purpose only. Refer Clause 3.1.1. Page 16 ANNEXURE – III (TB) (3/7) For reference purpose only. Refer Clause 3.1.3. Page 17 Page 104 of 153 ANNEXURE – III (TB) (4/7) For reference purpose only. Refer Clause 3.1.2. Page 18 Page 105 of 153 ANNEXURE – III (TB) (5/7) For reference purpose only. Refer Clause 3.1.4.. Page 19 Page 106 of 153 ANNEXURE – III (TB) (6/7) For reference purpose only. Refer Clause 3.1.5. Page 20 Page 107 of 153 ANNEXURE – III (TB) (7/7) For reference purpose only Refer Clause 3.1.6 Page 21 Page 108 of 153 Annexure-IV (TB) (1/22) INDICATIVE LIST OF UNIT OPERATION WISE EQUIPMENT FOR TRIPLE BASE PROPELLANT MANUFACTURE (For reference purpose only.) Refer clause 3.0 PASTE CENTRIFUGING 1. 2. TROLLEY FOR PASTE Size(m) - Material Service - GOODS LIFT Capacity (kg) Travel(m/Min.) Type Cage size (n X w X d)m Motor Power output (KW) Current (A) Enclosure Mounting Speed Volts/Phase/Freq. Coupling Guard 3. 2.222 Long,1.016 Wide,0.914 HIGH TIMBER TRANSPORTATION OF PRODUCT - 2200 3.3 ELECTRIC ROPE OPERATED 1.98 X 1.53 X 2.08 4 8 IP55 N/A 1450 rpm. 415/3/50 YES - 3.225 X 0.310 X 0.270 0.063 AISI304L 0.600 X 0.812 X 0.330 0.230 13 FLIGHTS AT 0.230M 20 : 1 AISI304 DIRECT 72.50 1.1 2 IP55 N/A 1450rpm 415/3/50 YES SCREW FEEDER Trough size (lXwXd)m Screw shaft dia (m) Material Hopper size (lXwXd)m Screw flight dia (m) Flight pitch Gear box Ratio Shaft Material Coupling Speed(rpm) Motor power out put (KW) Current(A) Enclosure Mounting Speed Volts/Phase/Freq. Coupling Guard Page 109 of 153 Page 22 Annexure-IV (TB) (2/22) 4. CENTRIFUGE Process fluid Max. charge wt (kg) Type Running speed (rpm) Loading/discharge Speed (rpm) Service Density (kg/m3) Basket dia (m) Basket depth (m) Outlet spout dia (m) Feeding time (s) Running time (s) Discharge time (s) Acceleration time (s) Deceleration time (s) Motor power output (kw) Current (A) Enclosure (IPXX) Mounting Speed Volts/phase/freq Classification (EXN) Coupling guard Drive Unit 5. : : : : NG-NC PASTE 136 (WET) SUSPENDED 900 : : : : : : : : : : : : : : : : : : : : 50 REDUCTION OF MOISTURE CONTENT 500 1.200 0.500 0.5 90 250 240 90 90 15 30 IP55 N/A 1450 415/3/50 N/A YES HYDRAULIC Inlet size (l x b) m Outlet size dia (m) Rotor Material Housing Material - Speed (rpm) Motor power output(kw) Current(A) Enclosure Mounting Speed (rpm) Volts/Phase/Freq. Coupling Guard - 0.6 X 0.6 0.50 AISI 304L GALVANIZED MILD STEEL FRAME & STAINLESS STEEL PLATE 170 5.5 11 IP55 N/A 1450 415/3/50 YES PASTE CRUMBLER *The crumbler is mounted to the outlet of the centrifuge with a hydraulic cylinder and locked in position by a hard wheel mechanism. Lifting/Lowering of the crumbler by means Page 23 Page 110 of 153 Annexure-IV (TB) (3/22) of a hydraulic power pack motor 0.75 KW. Crumbler drive shaft diameter -60mm motor 5.5 KW, V-belt drive between motor and gearbox to give a final speed of 170 rpm. 6. DISCHARGE TROLLEY Size (lxwxd)m Number of outlets Size of outlets (lxb) m Material Wheels Edging 7. - 1.245 X 0.762 X 0.200 5 0.2 X 0.2 AISI 304L, TIMBER 4 X 150MM DIA CASTORS DIA 12MM ROD - 0-50 AISI 304L 0.76 X 0.76 BATCH WEIGHING AMB ±0.01 - 2.20 LONG, 1.06 WIDE,0.90 HIGH TIMBER TRANSPORTATION OF PRODUCT Type Location Service - Temperature - WOVEN STEEL MESH EXTERNAL FILTRATION OF AIR TO BE USED FOR SPACE HEATING AMB - CENTRIFUGAL AIR HEATER EXTRACTION FAN 0.375 0.75 T.E.F.C. D213 1450 415/3/50 YES SCALE Capacity (kg) Material Platform size(m) Service Temperature (0C) Accuracy (kg) 8. TROLLEY Size(m) Material Service 9. 10. AIR FILTER FAN Type Service Motor power output(kw) Current (A) Enclosure Frame Speed (rpm) Volts/Phase/Freq. Coupling Guard Page 24 Page 111 of 153 Annexure-IV (TB) (4/22) 11. 12. AIR HEATER Type - Steam pressure reqd.(bar) Service Temperature (0C) - STEAM HEATED EXTENDED SURFACE TYPE 8-10 Space heating 30 MAXIMUM HYDRAULIC POWER PACK Type Power output(kw) Current(A) Enclosure Frame Service Pressure(bar) Speed (rpm) Volts/Phase/Freq. Coupling Guard - 3 STAGE 15 30 IP55 N/A 350 HIGH, 15 LOW 1450 415/3/50 YES PASTE ROLLING 1. 1. 2. PRODUCT TROLLEY Size (m) Material Service - 2.222 LONG, 1.016 WIDE, 0.914 HIGH TIMBER TRANSPORTATION OF PRODUCT SCALE Capacity (kg) Material Platform size (m) Service Temperature (0C) Accuracy (kg) - 0 - 50 AISI304L 0.76 X 0.76 BATCH WEIGHING AMB + 0.01 - NC/NG PASTE 6.4 HORIZONTAL 0.45 8:12:11 (FRONT) 12:12:13(REAR) 950C MAXIMUM ROLLING OF MATERIAL 250 (20% MOISTURE) ROLLING MILL Process fluid Charge weight (kg) Type Roller Diameter (m) Roller speed (rpm) Changeable Front Roller Temperature (0C) Service Density (kg/m3) - Page 112 of 153 Page 25 Annexure-IV (TB) (5/22) 3. Roller length (m) Roller finish - Rear Roller Temperature (0C) Rolling Mill Motor output (kw) Current (A) Enclosure Mounting Speed Volts/Phase/Freq. Coupling Guard - 0.900 CHROME PLATED FRONT), SPARK ERODED (REAR) 1050C MAXIMUM 26 50 IP55 N/A 1450 rpm 415/3/50 YES - 6.0 14200 80 82.1 1.200 0.900 200 MAX 10 - 25 - HOT WATER 34 NEUTRAL NONE GEAR PUMP AISI 316 AISI 316 BRONZE MECHANICAL 65 65 N/A N/A DIRECT 1450 NB50, PN10 NB50, PN10 OPEN, DIA-200MM 2.2 4 IP44 1450 rpm 415/3/50 YES ROLLER HEATING UNIT Steam Calorifier flowrate (m3/Hr.) Heat Transfer rate (w) Inlet Temperature (0C) Outlet Temperature(0C) Basket dia (m) Roller length (m) Inlet Pressure (kpa) Pressure Drop (kpa) PUMP Process fluid Flow (m3/Hr.) PH Zone classification Type Shaft Material Casing Material Impeller Material Seal Temperature (0C) Pressure Head (kpa) Delivery height(m) Suction height (m) Coupling Speed (rpm) Inlet Flange (DN,PN) Outlet Flange (DN, PN) Closed/open Impeller Motor Power (kwo) Current (A) Enclosure Speed Volts/Phase/Freq. Coupling Guard Page 113 of 153 Page 26 Annexure-IV (TB) (6/22) 4. 5. 6. 7. 8. DRENCHING TANK Type/shape Medium Density(kg/dm3) Diameter(m) Operating pressure(kPag) Top end shape Bottom end shape Agitator Nominal tank size(m3) Material Total length(m) Operating temperature Bottom end material/thk(mm) Shell material/thk(mm) : : : : : : : : : : : : : : VERTICAL WATER 1 1.500 HYDROSTATIC FLAT FLAT NONE 2.0 MILDSTEEL,ALUMINIUM SPRAYED 1.220 AMB 5 5 FUME EXTRACTION HOOD Material Diameter (m) Length (m) Service Temperature : : : : : MILDSTEEL,ALUMINIUM SPRAYED 0.390 3.200 FUMES EXTRACTION AMB EXTRACTION FAN Type Service Fan Motor power output(kw) Current(A) Enclosure Frame Speed Volts/Phase/Freq. Coupling guard - Centrifugal Extraction Fan 1.1 2 T.E.F.C. D213 1450rpm 415/3/50 YES AIR FILTER Type Location Servic - Temperature - WOVEN STEEL MESH EXTERNAL FILTRATION OF AIR TO USED FOR SPACE HEATING AMB FAN Type Service Fan Motor Power output(kw) Current(A) Enclosure Frame - CENTRIFUGAL SPACE HEATING 0.35 8 T.E.F.C. D213 BE Page 114 of 153 Page 27 Annexure-IV (TB) (7/22) Speed Volts/Phase/Freq. Coupling Guard 9. - 1450 rpm 415/3/50 YES Type - Steam pressure required (bar) Service Temperature (0C) - STEAM HEATED SURFACE TYPE 8 - 10 SPACE HEATING 65 AIR HEATER EXTENDED INCORPORATION 1. PRODUCT TROLLEY Size Material Service 2. 3. - 1.220 X 0.800 TIMBER TRANSPORTING OF PRODUCT. Material Service - AISI 304 L COMPLETE WITH 6 x 250MM DIA OUTLETS INTO BAGS. INCORPORATOR Capacity (Kg) Shell Working Pressure Lid Operation Front blade speed (rpm) Material Jacket Working Pressure(bar) Blade material Rear blade speed(rpm) ear box ratio Shaft material Coupling Speed(rpm) Motor power output (KW) Current(A) Enclosure Frame Speed Volts/Phase/Freq. Coupling Guard - 330 ATM HYDRAULIC 24 CAST IRON AISI304 3.5 STAINLESS STEEL 18 N/A AISI304 DIRECT N/A 15 30 T.E.F.C. D160M 1460 rpm 415/3/50 YES DISCHARGE TROLLEY *Clearance between blades and panel ends - 2.0 to 2.5 mm Page 28 Page 115 of 153 Annexure-IV (TB) (8/22) Clearance between blades and panel body - 2.0 to 2.5 mm Packed glands - Soft asbestos fibre packing impregnated with PTFE. Gear box - Planetary type, forgue limiting coupling complete with electric limit switch for stopping the motor in the event of overload. Jacket for prime cooling working pressure 345 Kpa, temp - 50C Jacket for water cooling working pressure 345 Kpa, temp-100C - 300C Jacket for water working pressure 345 Kpa, temp -500C The incorporators consist of stainless steel frame and trough jacketed for circulation of cold and hot water. Bowl tilting and lid movement is achieved hydraulically. A temperature control system, consisting of three water circuits, namely the process water circuits, hot water circuit and chilled water circuit is required for maintaining the temperature of the mix within the specified limit. 4. ETHER STORAGE TANK Type/shape Medium Insulation Diameter(m) Operating pressure(kpa g) End shape Agitator Nominal tank size (m3) Material Total Length(m) Operating temperature End material/thk(m) Shell material/thk(m) - HORIZONTAL ETHER YES 1.040 N/A DOMED NONE 1.00 AISI 304 L 1.220 AMB 8 6 - VERTICAL ETHER NONE 0.380 HYDROSTATIC FLAT NONE 0.085 AISI 304 L 0.74 AMB 5 3 5. ETHER MEASURING TANK Type/shape Medium Insulation Diameter (m) Operating pressure (Kpag) End shape Agitator Nominal Tank Size (m3) Material Total Length(m) Operating temperature End material/thk (mm) Shell Material thk (mm) Page 116 of 153 Page 29 Annexure-IV (TB) (9/22) 6. ACETONE TANK (STORAGE) Type/shape Medium Insulation Dia meter(m) Operating Pressing (kpa) End shape Agitator Nominal Tank size (m3) Material Total length (m) Operating temperature End material/thk(mm) Shell material/thk(mm) - HORIZONTAL ACETONE YES 1.770 N/A DOMED NONE 4.5 AISI 304 2.200 AMB 8 6 7. ACETONE MEASURING TANK Type/shape Medium Insulation Diameter(m) Operating pressure(K pag) End shape Agitator Nominal tank size(m3) Material Total length(m) Operating temperature End material/thk(mm) Shell material/thk(mm) - VERTICAL ACETONE NONE 0.380 HYDROSTATIC FLAT NONE 0.085 AISI 304 L 0.740 AMB 5 3 8. SCALE Capacity (kg) Material Platform Size (m) Service Temperature (0C) Accuracy (kg) - 0 - 17 AISI 304 L 0.500 X 0.500 BATCH WEIGHING AMB +0.01 9. AIR FILTER Type Location Service - Temperature - WOVEN STEEL MESH EXTERNAL FILTRATION OF AIR TO BE USED FOR SPACE HEATING. AMB Page 117 of 153 Page 30 Annexure-IV (TB) (10/22) 10. FAN Type Service Fan Motor power output(kw) Current(A) Enclosure Frame Speed Volts/Phase/Freq. Coupling Guard - CENTRIFUGAL SPACE HEATING 1.5 3 T.E.F.C. D213 1450 rpm 415/3/50 YES - 1.50 35 SPACE HEATING Type - Refrigerant Cooling Capacity(Kcal/h) Calorifier heating capacity MJ/h - WATER COOLED SHELL AND TUBE R 12 52200 97 11. AIR HEATER Working Pressure(kpa) Heating capacity(kw) Service 12. CHILLER UNIT 13. COOLING TOWER Fan type Delivery (m3/S) Fan Motor Size (KW) Material - AXIAL FLOW 3.5 2.0 GLASS RE INFORCED PLASTIC - CENTRIFUGAL WATER 20 ACIDIC NONE STAINLESS STEEL STAINLESS STEEL BRONZE MECHANICAL MILD STEEL PUMPING OF COOLING WATER 14. COOLING WATER PUMP Type Process fluid Flow (m3/hr.) PH Zone Classification Shaft material Casing material Impeller material Seal Base Plate Service Page 118 of 153 Page 31 Annexure-IV (TB) (11/22) Temperature Pressure head (Kpa) Delivery height(m) Suction height (m) Coupling Speed(rpm) Inlet Flange (DN,PN) Outlet Flange(DN,PN) Closed/Open Impeller Pump Motor Power output(KW) Current(A) Enclosure Frame Speed (rpm) Volts/Phase/Freq. Coupling Guard - AMB 220 N/A N/A DIRECT 1450 NB80 PN10 NB05 PN10 CLOSED 3 6 IP55 D213 2900 415/3/50 YES - 97 - 600 Type Process fluid Flow (m3/hr.) PH Zone Classification Shaft material Casing material Impeller material Seal Base plate Service - Temperature Pressure head(Kpa) Delivery height(m) Suction height(m) Pump size Coupling Speed (rpm) Inlet Flange (DN,PN) Outlet Flange (DN,PN) Closed/open impeller - CENTRIFUGAL WATER 20 ACIDIC NONE STAINLESS STEEL STAINLESS STEEL BRONZE MECHANICAL MILD STEEL PUMPING OF CHILLED HOT WATER PUMP AMB 120 N/A N/A N/A DIRECT 1450 NB65 PN10 NB50 PN10 CLOSED 15. CALORIFIER Calorifier heating Capacity MJ/h Steam Pressure (Kpa) 16. CIRCULATION WATER PUMP Page 119 of 153 Page 32 Annexure-IV (TB) (12/22) Motor Data Power Output Current (A) Enclosure Frame Speed Volt/Phase/Freq Coupling Guard KW - 1.5 3 IP55 D213 2900 rpm 415/3/50 Yes - SHELL AND TUBE 97.2 Type Process fluid Flow (m3/Hr.) PH Zone Classification Shaft material Casing material Impeller material Seal Box plate Service - Temperature Pressure Head(Kpa) Delivery Height(m) Suction Height(m) Pump size Coupling Speed (rpm) Inlet Flange (DN,PN) Outlet Flange (DN,PN) Closed/open Impeller Pump Motor power output(KW) Current (A) Enclosure Frame Speed (rpm) Volts/Phase/Freq. Coupling Guard - CENTRIFUGAL WATER 20 ACIDIC NONE STAINLESS STEEL STAINLESS STEEL BRONZE MECHANICAL MILD STEEL PUMPING OF HOT WATER AMB 120 N/A N/A N/A DIRECT 1450 NB65 PN10 NB50 PN10 CLOSED 1.5 3 IP55 D213 2900 415/3/50 YES 17. HEAT EXCHANGER UNIT Type Heating Capacity MJ/h 18. HOT WATER PUMP Page 120 of 153 Page 33 Annexure-IV (TB) (13/22) 19. COLD WATER PUMP Type Process fluid Flow (m3/Hr.) PH Zone Classification Shaft material Casing material Impeller material Seal Box plate Service Temperature Pressure Head(Kpa) Delivery Height(m) Suction Height(m) Pump size Coupling Speed (rpm) Inlet Flange (DN,PN) Outlet Flange (DN,PN) Closed/open Impeller Pump Motor power output(KW) Current (A) Enclosure Frame Speed (rpm) Volts/Phase/Freq. Coupling Guard Service - CENTRIFUGAL WATER 20 ACIDIC NONE STAINLESS STEEL STAINLESS STEEL BRONZE MECHANICAL MILD STEEL PUMPING OF HOT WATER AMB 120 N/A N/A N/A DIRECT 1450 NB65 PN10 NB50 PN10 CLOSED 1.5 3 IP55 D213 2900 415/3/50 YES PUMPING OF CHILLED WATER 20. METAL DETECTOR Tunnel opening size(w X h) m Maximum Sensitivity Conveyor belt size (l x w)m Drive Motor Power output(KW) Detection - Protection Classification Belt Type Belt speed - 600 X 200 IMMFE BALL 3.3 X 0.57 0.75 FERROUS/ NON FERROUS IP 65 NEMA 4 PLASTIC VARIABLE - VERTICAL 21. WATER EXPANSION TANK Type/shape Page 121 of 153 Page 34 Annexure-IV (TB) (14/22) Medium Insulation Diameter (m) Operating Pressure (Kpag) End shape Agitator Nominal Tank size (m3) Material Total length (m) Operating Temperature End Material/thk (mm) Shell Material/thk (mm) - WATER NONE 0.60 HYDROSTATIC FLAT NONE 0.23 AISI 304L 0.80 AMB 5 3 EXTRUSION AND CUTTING GOODS HOIST Capacity(Kg) Lift speed(m/min) Type Operation Motor power output(KW) Current(A) Enclosure Frame Speed Volts/Phase/Freq. Coupling guard BLOCK PRESS Process fluid Charge at (kg) Heating Vacuum Hydraulic cylinder diameter(m) Actuation Service - 500 9 RAIL PLATFORM HYDRAULIC 0.75 1.5 IP55 D80 1450 415/3/50 YES - SOLVENT IMPREGNATED NG, NC, NQ CHARGE CA 40 NOT REQUIRED NOT REIQUIRED 0.100 HYDRAULIC COMPRESSING OF PROPELLANT CHARGES IN TO A BLOCK AS PREPARATION FOR EXTRUSION PRESSING - Page 35 Page 122 of 153 Annexure-IV (TB) (15/22) Powder cylinger working Pressure(bar) Extrusion Ram speed(mm/s) Stroke length (m) Hydraulic Pressure(bar) Motor powder output(KW) Current (A) Enclosure Speed Volts/Phase/Freq. Coupling guard - 200 - 4 1.00 200 MAXIMUM 22 & 4 45 & 8 IP55 1450 415/3/50 YES *The press has two charge cylinders of diameter 300mm and can swivel through 1800 transferring the product from the loading and pre press section to the main pressing section. Hydraulic power pack three stage radial piston pump driven by 22 KW motor and low pressure pump driven by a 4 KW motor. The press is operated from a control room. TROLLEY Size Material Service 8 - 1.220 X 0.800 TIMBER TRANSPORTING OF COMPOSITION TO THE PRESS. - NOT REQUIRED NOT REQUIRED 0.450 HYDRAULIC 250 - 20 1.00 350 MAXIMUM 22 & 4 44 & 8 IP55 1450 415/3/50 YES EXTRUSION PRESS Heating Vacuum Hydraulic cyl.diameter(m) Actuation Powder cylinder Working pressure (bar) Extrusion ram speed(mm/min.) Stroke length(m) Hydraulic Pressure(bar) Motor power output(KW) Current (A) Enclosure Speed Volts/Phase/Freq. Coupling guard *The press has two charge cylinders of 300mm diameter and can swivel through 1800 transferring the product from the loading and pre press section to main press section. The hydraulic power pack consists of a three stage radial piston pump driven by a 22 KW motor. The low pressure pump is driven by a 4 KW motor. The press is operated from a control room. Page 123 of 153 Page 36 Annexure-IV (TB) (16/22) 9 CHUTE Service - Material - CONVEYING OF CORDS FROM PRESS TO CUTTING MACHINE. AISI 304L 10 POWDER CUTTING MACHINE Process fluid - Service - Motor power output(KW) Current(A) Enclosure Mounting Speed Volts/Phase/Freq. Coupling guard - EXTRUDED PROPELLANT CORDS CUTTING OF EXTRUDED PROPELLANT CORDS INTO SHORT LENGTH. 3 6 IP55 E182 1450 415/3/50 YES *Rotary cutting disc is equipped with two blades which pass across the face of a horizontal cutter bar through which the propellant cords are fed. The machine is hydraulically driven through a gear train to be able to cut the cords in a specific length. The machine is movable and may be positioned with in the limits of the flexible hydraulic system (Hoses). The cutting speed is variable by manually controlling the hydraulic valve. 11 TROLLEY Capacity(kg) Material Service - Number of Tray - 6 TIMBER ALUMINIUM TRANSPORTING CUT PRODUCT. 24 - 0-50 AISI 304 L 0.600 X 0.600 BATCH WEIGHING AMB + 0.01 - 2.222 LONG, 1.016 WIDE AND 0.914 HIGH 12 SCALE Capacity(kg) Material Platform size(m) Service Temperature Accuracy (kg) 13 PRODUCT TROLLEY Size (m) Page 37 Page 124 of 153 Annexure-IV (TB) (17/22) Material Service - TIMBER TRANSPORTING OF PRODUCT Type Location Service - Temperature - WOVEN STEEL MESH EXTERNAL FILTRATION OF AIR TO BE USED FOR SPACE HEATING. AMBIENT - CENTRIFUGAL SPACE HEATING 2.2 4 T.E.F.C. D 213 1450 415/3/50 YES Type - Steam pressure required (bar) Service Steam coil power output(kw) - STEAM HEATED, EXTENDED SURFACE TYPE. 6 SPACE HEATING 70 - 3 STAGE 350 HIGH, 15 LOW 22 45 1P55 N/A 1450 415/3/50 YES 4 8 1P55 N/A 1450 14 AIR FILTER 15. FAN Type Service Motor power output(kw) Current(A) Enclosure Frame Speed Volts/Phase/Freq. Coupling guard AIR HEATER 17 HYDRAULIC POWER PACK UNIT Type Service pressure(bar) (1) Motor power output(KW) Current(A) Enclosure Frame Speed Volts/Phase/Freq. Coupling guard (2) Motor power output(KW) Current(A) Enclosure Frame Speed Page 125 of 153 Page 38 Annexure-IV (TB) (18/22) Volts/Phase/Freq. Coupling guard - 415/3/50 YES Type Location Service - Temperature - WOVEN STEEL MESH EXTERNAL FILTRATION OF AIR TO BE USED FOR DRYING OF DIES AND SIEVES AMBIENT 18 AIR FILTER 19 FAN Type Service - Motor power output(kw) Current(A) Enclosure Frame Speed Volts/Phase/Freq. Coupling guard - CENTRIFUGAL AIR TO BE USED FOR DRYING OF DIES AND SIEVES. 0.75 1.5 T.E.F.C. D213 1450 415/3/50 YES 20 AIR FILTER Type - Steam pressure required(bar) Service - Temperature(0C) - STEAM HEATED EXTENDED SURFACE TYPE. 6 DRYING OF DIES AND SIEVES. 40 21 DRYING HOOD Size(m) Material Service - Temperature(0C) - 0.900 X 0.600 X 0.900 GALVANIZED MILD STEEL DRYING OF DIES AND SIEVES. 40 - 1.070 SQ X 1.000 HIGH TIMBER CLEANING OF DIE BLOCK. 22 TRAY (WOODEN) Size(m) Material Service Page 126 of 153 Page 39 ANNEXURE-IV (TB) (19/22) 23 WASH WATER TANK Type/shape Medium Insulation Diameter (m) Operating pressure(K Pag) Shell material/thk(mm) Nominal Tank size (m3) Material Total height(m) Operating Temperature End material/thk(m) - VERTICAL WATER NONE 0.840 HYDROSTATIC 3 0.500 MILD STEEL 0.915 AMB 5 24 CAUSTIC SODA CLEANING TANK Type/shape Medium Insulation Diameter (m) Operating pressure(K Pag) Shell material/thk(mm) Nominal tank size(m3) Material Total height (m) Operating temperature End material/thk(mm) - VERTICAL CAUSTIC SODA NONE 0.840 HYDROSTATIC 3 0.500 MILD STEEL 0.915 AMB 5 - VERTICAL CAUSTIC SODA NONE 0.990 HYDROSTATIC 3 0.160 MILD STEEL 0.610 AMB 5 - VERTICAL CAUSTIC SODA NONE 200 POLYTHENE 25 CAUSTIC SODA MAKE UP TANK Type/shape Medium Insulation Diameter (m) Operating pressure(K Pag) Shell material/thk(mm) Nominal tank size(m3) Material Total height (m) Operating temperature End material/thk(mm) 26 CAUSTIC DRUM Type/shape Medium Insulation Nominal Tank Size(m3) Material Page 40 Page 127 of 153 Annexure-IV (TB) (20/22) 27 TROLLEY HOIST Capacity (kg) - 1000 Type/shape Size (m) - Material Size (m) - WIRE BASKET DIA 0.68 X 0.38 ( DIE BLOCK ) AISI 304 0.485 X 0.410 X 0.155 (SIEVES) 28 CARRIER BASKET 29 EXTRACTION FAN Type Service - Motor power output(kw) Current(A) Enclosure Frame Speed Volts/Phase/Freq. Coupling guard - CENTRIFUGAL AIR TO BE USED FOR DRYING OF DIES AND SIEVES. 0.75 1.5 T.E.F.C. D213 1450 415/3/50 YES DRYING 30 PRODUCT TROLLEY Size (m) - 2.222 LONG, 1.016 WIDE, 0.914 HIGH. Material Service - TIMBER TRANSPORTING OF PRODUCT. - 1820 GALVANIZED MILD STEEL BATCH DRYING OF PROPELLANT. 65 MAXIMUM 3700 CFMAIR @ 75 WG, 650C 31 DRYING TROUGH 1 & 2 Capacity (kg) Material Service Temperature (0C) Fan capacity Page 41 Page 128 of 153 Annexure-IV (TB) (21/22) 32 AIR FILTER Type Location Service - Temperature - WOVEN STEEL MESH. EXTERNAL FILTRATION OF AIR TO BE USED FOR BATCH DRYING OF PROPELLANT. AMB 33 FAN Type Service - Fan motor power output (kw) Current(A) Enclosure Frame Speed Volts/Phase/Freq. Coupling guard - CENTRIFUGAL BATCH DRYING OF PROPELLANT. 4 8 T.E.F.C. D213 1450 415/3/50 YES 34 AIR HEATER Type - Steam Pressure required (bar) Service - Temperature(0C) - STEAM HEATED EXTENDED SURFACE TYPE. 8 - 10 BATCH DRYING OF PROPELLANT. 65 BLENDING 1. BLENDER Capacity (kg) Diameter (mm) Charge opening (mm) Drive shaft (mm) Material Max. Depth(mm) Discharge opening(mm) DRIVE Gearbox Data Ratio Shaft Coupling Speed (rpm) - 1000 2500 600 DIA 120 DIA ALUMINIUM 1240 400 DIA - 60:1 AISI 304 Fluid 16 Page 42 Page 129 of 153 Annexure-IV (TB) (22/22) Motor power output(kw) Current(A) Enclosure Frame Speed Volts/Phase/Freq. Coupling guard - 11 22 T.E.F.C. D160 M 960 415/3/50 YES NB : The drum is equipped with a copper ring and two carbon brushes to discharge any static electricity build up. 2. SCALE Capacity (kg) Material Platform size(m) Service Temperature Accuracy (kg) - 0 - 50 AISI 304 L 0.600 X 0.600 BATCH WEIGHING AMB + 0.01 Capacity (kg) Material Service - Wheels - 2000 WOOD TRANSPORT OF PROPELLANT. 4 CASTORS - 7.5 15 1P55 N/A V-BELT AND PULLEY DRIVE 1450 415/3/50 YES 3. TROLLEY 4. ROTOCLONE Power output (kw) Current(A) Enclosure Mounting Coupling Speed Volts/Phase/Freq. Coupling guard ___________________________________________________________________________ Vendor should specify the Capacity, quantity, criticality of each equipments offered as per their technology. Hot stand- by for any equipment should also be specified. Page 43 Page 130 of 153 Annexure– IA (TB ) (1/1) PRODUCT SPECIFICATION FLASH REDUCING DISC M92 (1) Inspection Lot: An inspection lot shall consist of one mixer load of Flash Reducing Disc produced by one manufacturer under one continuous set of operating conditions. Non-conformance: Failure of any test result to comply with the requirements specified below may be cause for rejection. Sl.No. 1. 2. CHARACTERISTIC SPECIFICATION LIMITS Description: The flash reducing disc shall be a flat circular disc free of foreign matters and cracks, which consists of double base propellant. CHEMICAL & PHYSICAL The physical and chemical properties shall PROPERTIES conform to the requirements as specified below: 2.1 NC-NG Paste % 49 Approx 49 This paste is 58% P10-type NC and 42% NG stabilised with Ethyl Centralite. 2.2 2.3 2.4 2.5 Ethyl Centralite Flame Retardant Graphite Stabilizer % % % % 1.5 Approx 40 Approx 1 Approx 10 Approx 2.6 Total volatile matter % 0.5 max 2.6 2.6.2 Methyl violet stability at 1200 C Complete discolouration to Salomon pink min Not within 40 Emission of brown fumes min Not within 60 3. 3.1 3.2 DIMENSIONS AND MASS Average thickness mm Mass gms 4. PACKAGING & MARKING 4.1 CONTAINER As per OFB QA provisions 4.2 MARKING As per OFB QA provisions 2.6.1 The dimensions of the flash reducing disc shall conform to the requirements specified in the drawing Annexure Drg. TB-1A *All percentages are expressed mass per mass basis. Page 44 Page 131 of 153 Annexure–IIA ( TB ) (1/1) RAW MATERIAL SPECIFICATION FOR FLASH REDUCING DISC MANUFACTURE 1. NC-NG PASTE Specification as specified for product specification of NC-NG Paste Plant. 2. Ethyl Centralite Specification as specified for raw materials for Triple Base Plant. 3. Graphite Specification as specified for raw materials for Triple Base Plant. 4. Flame Retardant To be disclosed to the successful bidder. 5. Stabilizer To be disclosed to the successful bidder. Page 45 Page 132 of 153 ANNEXURE – III A (TB) DOUBLE BASE PROPELLANT - WET PASTE STORAGE PROCESS BLOCK FLOW DIAGRAM For referencePage only.133 of 153 Page 46 ANNEXURE – III A (TB) (1/6) Page 134 of 153 For reference purpose only.Refer Clause 3.2.1.. Page 47 ANNEXURE – IIIA (TB) (2/6) For reference purpose only. Refer Clause 3.2.2.. Page 48 Page 135 of 153 ANNEXURE – IIIA (TB) (3/6) Page 136 of 153 For reference purpose only Refer Clause 3.2.3 . Page 49 ANNEXURE – IIIA (TB) (4/6) For reference purpose only.Refer Clause 3.2.1. Page 50 Page 137 of 153 ANNEXURE – III A (TB) (5/6) Page 138 of 153 For reference purpose only. Refer Clause 3.2.4. Page 51 ANNEXURE – IIIA (TB) (6/6) Page 139 of 153 For reference purpose only. Refer Clause 3.2.5. Page 52 Annexure-IVA (TB) (1/7) INDICATIVE EQUIPMENT LIST FOR FRD MANUFACTURE FLASH REDUCING DISC MANUFACTURING (For reference purpose only.) Refer Clause 3.0. PASTE CENTRIFUGING 1. TROLLEY: Size (l x w x d) m Material : : 1.245X0.762X0.200 TIMBER 2. GOODS LIFT : Specifications as indicated for Triple Base Propellant. 3. SCREW FEEDER : Specifications as indicated for Triple Base Propellant. 4. CENTRIFUGE : Specifications as indicated for Triple Base Propellant. 5. PASTE CRUMBLER : Specifications as indicated for Triple Base Propellant. 6. DISCHARGE TROLLEY: Specifications as indicated for Triple Base Propellant. 7. SCALE Specifications as indicated for Triple Base Propellant. 8. SPACE HEATING SYSTEM : Process fluid : STEAM Material : GALVANISED MILD STEEL Size (l x w x h )m : 0.890X0.660X1.000 Steam coil : 4 ROW Max. steam pressure (bar): 3.5 Ducting material : ALUMINIUM Ducting size (m) : 0.260X0.290, 0.508X0.200, 0.555X0.150 Steam coil size (m) : 0.380X0.635 Motor power output (kw): 0.375 Current (A) : 1.0 Enclosure (IPXX) : IP55 Mounting : N/A Speed : 1450 Volts/phase/freq : 415/3/50 Classification (EXN) : N/A Coupling guard : YES 9. HYDRAULIC POWER PACK NO-1: Specifications as indicated for Triple Base Propellant. 10. HYDRAULIC POWER PACK NO-2: Type : SINGLE STAGE Power output (kw) : 0.75 Current (A) : 1.5 Enclosure (IPXX) : IP55 : Page 53 Page 140 of 153 Annexure-IVA (TB) (2/7) Service pressure (bar) : Speed : Volts/phase/freq : Coupling guard : 15 1450 415/3/50 YES 3.2 HOMOGENISING AND MIXING 1. INCORPORATOR: Process fluid Charge weight(kg) Bowl material Blade type Service Density(kg/l) Cover material : : : : : : : Shaft material : Hydraulic power : output (kw) Volts/phase/freq : Pump output (l/min) : Pressure(bar) : Motor Power output (kw): Current (A) : Enclosure (IPXX) : Mounting : Speed : Volts/phase/freq : Classification (EXN) : Coupling guard : 2. 3. NITROGLYCERINE/NITROCELLULOSE PASTE 250 (INC 15% SOLVENT CONTENT) 18/10/MO STAINLESS STEEL SIGMA MIXING OF NC- NG PASTE WITH INGREDIENTS 0.66 18/10/MO STAINLESS STEEL, TITANIUM STABILISED CR-MO STAINLESS STEEL 1.5 415/3/50 2.5 160 5.5 11 IP55 N/A 1450 415/3/50 EXN YES DISCHARGE TROLLEY : Size (l x w x d )m : Number of outlets : Size of outlets (l x b )m: Material : Wheels : Edging : 1.245X0.762X0.200 5 0.2X0.2 AISI 304 L, TIMBER 4X150 M DIA CASTORS DIA 12MM ROD SCALE : Capacity (kg) Material Platform size(m) Service Temperature Accuracy(kg) 0-50 AISI 304 L 0.3X0.3 BATCH WEIGHING AMB ±0.01 : : : : : : Page 54 Page 141 of 153 Annexure-IVA (TB) (3/7) 4. TROLLEY : Size ( l x w x d )m Material 5. : : SPACE HEATING SYSTEM : 2.2X1.0X0.9 TIMBER Specifications same as indicated above PRELIMINARY ROLLING 1. ROLLING MILL 2. ROLLER HEATING UNIT: Specifications as indicated for Triple Base Propellant 3. DRENCHING TANK 4. FUME EXTRACTION HOOD: Material Diameter (m) Length (m) Service Temperature 5. :Specifications as indicated for Triple Base Propellant. : Specifications as indicated for Triple Base Propellant : : : : : MILD STEEL,ALUMINIUM SPRAYED 0.390 3.200 FUMES EXTRACTION AMB SPACE HEATING SYSTEM: Material : Size (l x w x h )m : Steam coil : Air flow rate(c.f/m) : Ducting material : Ducting size(m) : Steam coil size(m) : Air temperature : Motor power output (kw) : Current (A) : Enclosure (IPXX) : Mounting : Speed : Volts/phase/freq : Classification (EXN) : Coupling guard : GALVANISED MILD STEEL 0.890X0.660X1.000 4 ROW 915 ALUMINIUM 0.260X0.290, 0.508X0.200, 0.555X0.150 0.380X0.635 130C 0.375 1 IP55 N/A 1450 415/3/50 N/A YES 6. EXTRACTION FAN: Specifications as indicated for Triple Base Propellant 7. SCALE: Capacity (kg) Material Platform size(m) Service Temperature : : : : : 0-50 AISI 304 L 0.76 x 0.76 BATCH WEIGHING AMB Page 55 Page 142 of 153 Annexure-IVA (TB) (4/7) 8. 9. Accuracy(kg) : ±0.01 TROLLEY: Size (lxwxd)m Heating method Material Temperature (0C) : : : : 0.75 X 0.60 X 0.50 STEAM AISI 304L 95 HOT CHEST: Size (lxwxd)m Heating method Material Temperature (0C) : : : : 0.75 X 0.60 X 0.50 STEAM AISI 304L INSULATED 95 FINAL ROLLING 1. 2. HOT TROLLEY: Size (lxwxd)m Heating method Material Temperature (0C) : : : : 0.75 X 0.60 X 0.50 STEAM AISI 304L 95 ROLLING MILL; Process fluid Charge weight (kg) Service Density (kg/m3) Type Roller diameter (m) Roller speed (rpm) Front roller temp. Basket dia (m) Roller length (m) Roller finish Rear roller temp. Motor power output (kw) Current (A) Enclosure (IPXX) Mounting Speed Volts/phase/freq Classification (EXN) Coupling guard : : : : : : : : : : : : : : : : : : : : NC/NG PASTE 6.4 ROLLING OF MATERIAL 250 (20% MOISTURE) HORIZONTAL 0.45 12 AMB TO 105 0C 1.200 0.900 GROUND & CHROME PLATED AMB TO 1050C 26 54 IP55 N/A 1450 415/3/50 EXN YES 3. FUME EXTRACTION HOOD: Specifications as indicated above. 4. EXTRACTION FAN : Specifications as indicated for Triple Base Propellant Page 56 Page 143 of 153 Annexure-IVA (TB) (5/7) 5. DRENCHING TANK: 6. SPACE HEATING SYSTEM: Material : Size (l x w x h )m : Steam coil : Air flow rate(c.f/m) : Ducting material : Ducting size(m) : Steam coil size(m) : Air temperature : Motor power output (kw) : Current (A) : Enclosure (IPXX) : Mounting : Speed : Volts/phase/freq : Classification (EXN) : Coupling guard : 8. Specifications as indicated for Triple Base Propellant ROLL HEATING SYSTEM: Steam calorifier flowrate m3/hr.: Heat transfer rate (w) : Inlet temperature : Outlet temperature : Basket dia (m) : Roller length(m) : Inlet pressure (kPa) : Pressure drop (kPa) : Pump data : Process fluid : 3 Flow (m /hr) : pH : Zone classification : Type : Shaft material : Casing material : Impeller material : Seal : Temperature (0C) : Pressure head (kPa) : Delivery height (m) : Suction height (m) : Coupling : Speed (rpm) : Inlet flange (DN, PN) : Outlet flange (DN, PN) : GALVANISED MILD STEEL 0.890X0.660X1.000 4 ROW 915 ALUMINIUM 0.260X0.290, 0.508X0.200, 0.555X0.150 0.380X0.635 130C 0.375 1 IP55 N/A 1450 415/3/50 N/A YES 6.0 14200 800C 82.10C 1.200 0.900 200 MAX 10-25 HOT WATER 34 NEUTRAL NONE CENTRIFUGAL AISI316 AISI316 BRONZE MECHANICAL 65 65 N/A N/A DIRECT 1450 NB 50 PN 10 NB 50 PN10 Page 57 Page 144 of 153 Closed/Open impeller : OPEN DIA 200 MM Annexure-IVA (TB) (6/7) Motor power output (kw) Current (A) Enclosure (IPXX) Speed Volts/phase/freq Classification (EXN) Coupling guard 9. 10. : : : : : : : RECIPROCATING TABLE : Size (lxw)m : Drive method : Material : RECEIVING BIN : Size (lxwxd)m Material : : 2.2 4 IP44 1450 415/3/50 N/A YES 0.92 x 0.70 PNEUMATIC MILD STEEL & BRASS 1.0x0.6x0.5 AISI304 FULLY WELDED AND POLISHED WITH NO CAVITIES,ALL CORNER TO HAVE A RADIUS OF 25 MM PUNCHING AND PACKING 1. 2. 3. 4. HOT CHEST: Size (lxwxd) m Heating method Material Temperature : : : : 0.75 x 0.60 x 0.50 STEAM AISI 304L 950C STRIP CUTTER: Drive method Mounting Strip width(mm) Blade type Blade material : : : : : HYDRAULIC HOT TABLE 160 CIRCULAR TOOL STEEL HOT TABLE: Size (lxwxd)m Heating method Material Temperature : : : : 0.75 x 0.60 x 0.50 STEAM AISI 304L 950C DISC PUNCHING MACHINE: Material : Punching arm : VARIOUS HYDRAULIC The punching machine consists of two pillars a table with a female die, a hydraulic cylinder mounted on a cross piece with a male die and foot operated valve. The hydraulic power pack is powered by 1.5 k w electrical motor. Page 58 Page 145 of 153 Annexure-IVA (TB) (7/7) 5. SCALE: Capacity (kg) Material Platform size(m) Service Temperature Accuracy(kg) : : : : : : 0-1 AISI 304 L 0.32 x 0.25 BATCH WEIGHING AMB ±0.001 MICROMETER: Size (mm) Orientation Service Accuracy (µm) : : : : 0-25 BENCH METHOD THICKNESS MEASUREMENT 10 WOODEN BOX: Size (lxdxd) Material : : 0.90 x 0.75 x 0.4 WOOD 8. SPACE HEATING UNIT : As specified above 9. EXTRACTION FAN: Specifications as indicated for Triple Base Propellant 10. HYDRAULIC POWER PACK : Type : Power output (kw) : Current (A) : Enclosure (IPXX) : Service pressure (bar) : Speed : Volts/phase/freq : Classification (EXN) : Coupling guard : 6. 7. SINGLE STAGE 1.5 N/A IP55 100 1450 415/3/50 N/A YES ____________________________________________________________________________________ Vendor should specify the Capacity, quantity, criticality of each equipments offered as per their technology. Hot stand- by for any equipment should also be specified. Page 59 Page 146 of 153 Page 147 of 153 Annexure Drg. 1A (TB) Page 148 of 153 1. Page 60 Annexure V (TB) (1/3) ACCOMODATION STATEMENT – TBP PLANT 1. Bldg. no. 0601 0602 0603 0604 0605 0606 Building description Non Technology Buildings Building size in (M) Total Floor Area (SQM) TR/Un Tr NEC kg Class Safety Distance (M) DB ATTENDENT / SECURITY CABIN UNIT OFFICE/ STAFF CHANGE ROOM/UNIT STORE IE’s CHANGE ROOM 6.46X5.46X3. 5 22X10X3.5 36 Un. Tr. - 220 Un. Tr. - 11X10X3.5 110 Un. Tr. CYCLE SCOORTER SHED FOR STAFF CYCLE SCOORTER SHED FOR IE’S NON-EXPLOSIVE STORES 10X6.4 64 Un. Tr. - - - - - YES (O) Non AC - 14X6.4 90 Un. Tr. - - - - - YES (O) Non AC - 30X10X3.5 300 Un. Tr. - - - - - YES (O) Non AC - 1500 1.1 28 66 275 YES (FLP) Non AC YES 1500 1.1 28 66 275 YES (FLP) 1500 1.1 28 66 275 YES (FLP) Non AC YES SIQD PIQD OQD - - - - - - Special requirement (ref. safety regulation) - Elec. Fittings YES (O) Fans/ Others FAN - YES (O) FAN Non AC YES (O) FAN Non AC 0609A STORAGE OF NIGU BATCH 20X8X4 240 0609B -DO- 20X8X4 240 0609C -DO- 20X8X4 240 INGREDIENT PREPARATION AND STORAGE (NON – EXPL) STORAGE OF FINISHED POWDER STORAGE OF FINISHED POWDER STORAGE OF PARTIAL LOT 30X10X4 300 Unit risk one bldg. With 3 bays with RCC partition and NAT Un Tr. 16X11X4 + VARANDAH 12X7X4 + VARANDAH 16X11X4 + VARANDAH 176 Un. Tr. 15000 1.3 28 79 160 YES (FLP) 84 Un. Tr. 2000 1.3 10 41 65 YES (FLP) 176 Un. Tr. 15000 1.3 28 79 160 YES (FLP) 0611 0623 0624 0625 YES (FLP) FAN FAN (DT) AS REQD AS REQD AS REQD AC/ Non AC Non AC Lightning protection - Non AC YES Non AC YES Non AC YES ROAD WORK DRAINAGE SEWERAGE FENCING VENTILATION AND AIR CONDITIONING Page 149 of 153 Page 61 Remarks Annexure V (TB) (2/3) ACCOMODATION STATEMENT – TBP PLANT 2. Bldg. no. Building description 0607 SUB STATION 0608 PREPARATION OF NIGU BATCHES ACETONE STORAGE 0610 0612 Technology Buildings Building size in (M) Total Floor Area (SQM) TR/Un Tr NEC kg Class Safety Distance (M) 10X10X4.5 100 Un. Tr. - 20X8X4 80 VIFT 1500 OPEN AREA WITH PUMPING FACILITY 35X10X5 625 VIFT 350 VIFT 1500 1.1 28 66 275 YES (FLP) 35X10X5 350 VIFT 1500 1.1 28 66 275 YES (FLP) 20X8X4 200 VIFT 1500 1.1 28 66 275 YES (FLP) 50X15X7 750 VIFT 5000 1.1 41 140 380 YES (FLP) 50X15X7 750 VIFT 5000 1.1 41 140 380 YES (FLP) YES (DT) FLP YES (DT) FLP YES (DT) FLP YES (DT) FLP YES (DT) FLP YES (DT) FLP SIQD PIQD OQD - - - 1.1 28 66 - Elec. Fittings YES (O) Fans/ Others FAN AC/ Non AC Non AC 275 YES (FLP) AS REQD Non AC YES (FLP) 0615 INCORPORATOR/ KNEADING (3 IN-CORPORATOR) INCORPORATOR/ KNEADING (3 IN-CORPORATOR) INCORPORATION/KNEADING (2 INCORPORATOR) EXTRUSION 0616 EXTRUSION 0617 DRYING 30X10X4.5 300 Un. Tr. 10000 1.3 23 69 140 0618 DRYING 30X10X4.5 300 Un. Tr. 10000 1.3 23 69 140 0619 DRYING 30X10X4.5 300 Un. Tr. 10001 1.3 23 69 140 0620 DRYING 30X10X4.5 300 Un. Tr. 10002 1.3 23 69 140 0621 BLENDING 10X10X5 100 Un. Tr. 2000 1.3 10 41 65 0622 BLENDING 20X10X7 200 Un. Tr. 4000 1.3 15 51 92 0613 0614 Special requirement (ref. safety regulation) Non AC AS REQD AS REQD AS REQD AS REQD AS REQD AS REQD AS REQD AS REQD AS REQD AS REQD AS REQD Non AC Lightning protection YES YES YES YES YES AC YES AS REQD YES AS REQD YES Non AC YES Non AC YES Non AC YES Non AC YES Non AC YES Non AC YES Page 150 of 153 Page 62 Remarks ACCOMODATION STATEMENT – TBP PLANT Annexure V (TB) (3/3) Technology Buildings Bldg. no. Building description Building size in (M) Total Floor Area (SQM) TR/Un Tr NEC kg Class Safety Distance (M) 0626 GRAIN POWDER STORAGE 16 X 11 X 4 + VARANDAH 176 Un. Tr. 15000 1.3 28 79 160 Elec. Fittings YES (DT) 0627 GRAIN POWDER STORAGE 17 X 11 X 4 + VARANDAH 187 Un. Tr. 15000 1.3 28 79 160 YES (DT) AS REQD NON AC YES 0628 STORAGE OF FINISHED POWDER 16 X 11 X 4 + VARANDAH 176 Un. Tr. 15000 1.3 28 79 160 YES (DT) AS REQD NON AC YES 0629 FLASH REDUCING DISC BLDG 20 X 10 X 4 200 Tr. 800 1.1 23 48 275 YES (DT) AS REQD AC YES REMARKS : SIQD PIQD OQD Special requirement (ref. safety regulation) Fans/ Others AS REQD AC/ Non AC NON AC Lightning protection YES DIMENSIONS / EXPLOSIVES LIMIT, CORRESPONDING SAFETY DISTANCES AND SPECIAL REQUIREMENT GIVEN ARE CONCEPTUAL. PLANT SUPPLIER IS TO DESIGN BASED ON THEIR TECHNOLOGY. THE DETAILS GIVEN ABOVE ARE INDICATIVE AND FOR REFERENCE PURPOSE ONLY.VENDOR SHOULD SUBMIT THE DETAILS OF TECHNOLOGICAL BUILDINGS AS PER THEIR own DESIGN IN THE ABOVE FORMAT. Page 151 of 153 Page 63 Remarks Annexure VI (TB) ORDNANCE FACTORY NALANDA PROJECT SCALE BATTERY LIMIT AND LAY OUT 1:5000 OF TRIPLE BASE PROPELLANT PLANT SKETCH NO. Page 64 Page 152 of 153 Annexure VII (TB) Page 153 of 153 Page 65