Foundry Forge Plant
02/Steel Melting Shop
Subject: Complete scope of work and scope of supply with Technical
Specifications to design, supply, erection, commission and testing of EAFs(Two
40T) on turnkey basis
General:
The two new EAFs will replace two existing EAFs (one no has been closed down
and the other one is in running condition). The existing platform may be utilized as
per requirement.
The primary and secondary de-dusting system has to be designed to fit in the
existing building (The pollution level should not exceed the limit provided by state
government and union government standards). Also, the mechanized material
handling system for feeding additives has to be designed by utilizing the area
available in the shop.
The major technological facilities in the above shop are shown in the given Table.
Sl.
No.
1.
Facilities
Plant Configuration
Two EAF units
Existing
New facilities
60T EAF not in
operation will be
dismantled
40T EAF
30T (DEMAG) EAF
in operation will be
dismantled
40T EAF
N.B: The sequence of installation shall be as under:
(1) First 40 TON EAF (in place of 60 Ton EAF )
(2) Second 40TON EAF (in place of 30(DEMAG) EAF )
Scope of Supply
 Two (2) nos. of EAFs of 40ton capacity along with all Technological
Equipment, complete with mechanized material handling system primary
and secondary de-dusting system & associated auxiliary system as
required for completion of the system.
 Scrap boxes with stands for 40T EAF’s - 4 nos.
1
Design parameters
Capacity of scrap box: 28 m3 (by volume):4 nos.
Maximum Height of Box placed on Car: 4250 mm Max.
The scrap boxes shall be Cam Shell type arrangement. Each box shall
consist of trough with two integrated supporting pedestals. Trunnions for
suspension of the scrap box shall be provided in the upper part of the
supporting pedestals. The side walls of the box shall be externally
stiffened by means of the flat-bar steel edges.



























Refractory works for 2 nos of EAFs
Shop Electrics & Illumination.
Instrumentation
Automation level –II
Computer facilities as required
Application software for process control along with their installation and
commissioning
Proper drawings and documents
CCTV camera
All in-shop utilities and water system
(Zero discharge water system for furnaces)
Ventilation and Air Conditioning system
Fire Detection and Protection system
Lubrication & Hydraulics
Consumables and commissioning spares, etc.
Electric switch yard extension work
Ladle transfer car with load carrying capacity of 65T and emergency pulling
system
Automated and manual oxygen blowing facilities
2 Scrap box transfer cars with proper capacity
Automatic carbon injector system
Online temperature measurement system
Special tools and tackles
FES System
Technical specification part wise for all mechanical, Hydraulic, Electrical,
Refractory etc of all main auxiliary equipments (Hardcopies & Softcopies).
Operational & Maintenance manual in four sets (Hardcopies & Softcopies).
Furnace complete Drawing (Mechanical, Electrical & Hydraulic etc) in four
sets (Hardcopies & Softcopies).
Refractory Drawing in four sets.
Mechanized Material Handling System.
Test Certificates of all installed equipments and calibration certificate of
measuring instruments.
2


Total HT & LT electrical installations from 132KV switchyard upto new EAFs
in 02 Shop (Power Transformers (70 MVA approx.), Distribution
transformers, circuit breakers, Isolators, Lightening arresters, HT&LT
cables, Appropriate Protective equipment etc.) , measuring instruments
Two years operation and maintenance spares and insurance spares.
Complete equipment proper and accessories related to above mentioned
equipment.
Technological and operational parameters of EAF Units
The main parameters of 40T EAF unit will be as follows:
Sl no.
1
Description
Type of EAF
Parameters
Ultra high power EAF with water cooled roof,
water cooled side panels, Auto/Manual
carbon injector, Auto & Manual oxygen
lancing system, ferroalloy addition facility and
provision of EBT
1.100% scrap
2.50% scrap and 50% DRI/HBI
2
Charged Mix
3
4
Melting time with 100% 50 ± 5 minutes (Max) time from switch on to
scrap
time at which temperature achieve 1550 ± 5
ºC after complete melting
Transformer rating
30 MVA (Min)
5
Tapping of Steel
40T EAF with EBT provision
Steel grades(Products):
The steel grades proposed to be produced from two nos. of new EAFs units will be
Plain Carbon Steels, Alloy Steels, High alloy Steels as per applicable International
Standards as per Annexure I of specified heats (P≤0.003 should achieved in
furnace during oxidation period).
Scope of work:
Scope of work shall include civil work, design, foundation,erection and
commissioning and dismantling of existing structures (civil, mechanical and
electrical) to provide space for new furnaces and auxiliary equipment. The
dismantled parts should be transferred to the specific location allocated by HEC.
Scope of work shall also include design, engineering, transfer of process knowhow, manufacture/supply of all plant and equipment, procurement of bought out
items, assembly, inspection and testing, painting and packing, transportation,
materials, site storage, spares and consumables, minor hoisting and handling
equipment,
technological
structures,
refractories,
electrics
including
instrumentation and automation including Level II system, utilities,
3
lubrication/hydraulics, auxiliary facilities, technical services in India and abroad on
a fully co-ordinated basis, training of Purchaser’s personnel, erection, testing and
commissioning of all equipment / units demonstration of performance guarantees
and handing over along with related auxiliary facilities to HEC within stipulated
time schedule.
Total erection, commissioning & testing of new installations and cable layout (Both
HT&LT) from 132KV switchyard to new EAFs is in your scope including 70 MVA
transformer. The distance between 132KV switchyard (Bldg.26) to EAFs (02 Shop)
is 800 meters. (Approx.)
All the work should be completed within 18 months from date of placement of
order.
01. Soil Characteristics
Geotechnical investigation has not been carried out for the
proposed area. The successful tenderer shall have to carry out
Geotechnical investigation of the concerned area.
02. The major civil design involved for installation of the EAF shall
pertain mainly but not limited to the following areas:
i) Equipment foundations and facilities as required.
ii) Fume Extraction System
iii) Sub-station
iv) Civil works required for water supply, Fire fighting Facilities,
Compressed Air Facilities and Electrical Control Rooms as
necessary
v) Utility and services as necessary
vi) Roads, drainage and sewerage as required.
In addition to the facilities indicated above, design of all civil works other than
indicated above but required for system and completing this package are also
under Tenderer’s scope.
03. Tenderer is advised to visit the site and acquaint himself of the site
condition and collect all such data as may be necessary for preparation
of civil design and drawing.
1.
Training to be provided to nominated persons at site.
4