IN LINE MAGNETIC SEPARATOR (ILMS}/ SUSPENDED ELECTRO MAGNET & METAL

DETECTOR

IN LINE MAGNETIC SEPARATOR (ILMS)/ SUSPENDED ELECTRO MAGNET:

Scope Of Work

• The scope of work of the Tenderer shall include design, engineering, manufacture,
fabrication, assembly, testing and inspection, packing, dispatch, transportation, delivery
FOR Purchaser's site, unloading, handling and storage at site, insurance during storage,
erection supervision, testing, inspection, commissioning, guarantee testing and handing
over to the client including all electrics and standard accessories of In Line Magnetic
Separator (ILMS)/ Suspended Electro Magnet along with standard electrics, metal
down comer chute as covered under this part of the specification and to make the system
complete.

The scope of the Tenderer shall be deemed to include all such items which although are
not specifically mentioned in the specification, but are needed to make the equipment
complete in all respect for its safe, reliable, efficient and trouble free operation.

• The scope of supply and services of the Tenderer for In Line Magnetic Separators/
Suspended Electro Magnets shall include the following:

a) Mechanical

- Each equipment shall be complete in all respect including, its drive units, cables,
safety switches, structural, mechanical and other standard accessories.

- Provision of necessary fixtures, supporting angles, ropes, turnbuckles and brackets

required for mounting and supporting the equipment.

b) Electricals

• The control panel for all functions & controls for ILMS shall be supplied with adequate no.
of I/Os for integrating with system PLC & sufficient length of cables for monitoring the
panel at suitable place on the wall/ floor of building.

• All fixing bolts and nuts including foundation bolts shall be included in the scope of supply
of Tenderer.
• Two years maintenance spares.

• Insurance spares.

• Commissioning spares as required during testing and commissioning of the equipment.

• Required quantity of initial fill of oil, grease, lubricants, hydraulic fluid, transformer oil
etc. and other consumables which are necessary for cleaning/ flushing including erection,
testing and commissioning the equipment shall be in the scope of supply of the Tenderer.

• Necessary tools and tackles for each equipment required for maintenance, testing or
inspection of the equipment.

• The scope of work shall stand supplemented by such details as are given m this
specification, tender drawing, and instruction to the Tenderer, General Conditions of
Contract (GCC), or any other part of the document.

TECHNICAL SPECIFICATION

• General

Inline Magnetic Separators shall be provided for continuous and automatic extraction
and discharge of tramp magnetic pieces from coal being discharged from conveyors as
specified. The sets shall be complete in all respects with motor, drives, magnets, cleated
belts with back - up non magnetic S.S. support plate, belts, hoppers, chutes, tramp-iron
boxes and all electrical ancillaries like control panels etc. Inline Suspended Magnetic
Separator (ILMS) shall be provided for picking up tramp magnetic pieces buried under
material burden from moving Conveyor as specified.

For Suspended Electro Magnets, suspension of magnet shall be done from a monorail
with the help of a Manual Hoist of suitable capacity. The monorail of the hoist shall be
planned such that occasional discharge of tramp iron can be at a safe place outside the
conveyor at a convenient location. The main suspension arrangement shall be provided
with turn buckles for adjustment of operating height. Lifting eyes shall be provided on
magnet for required suspension system.

In addition to suspension arrangement, additional safety wire ropes shall be provided for
supporting the magnet in case of main suspension system failure. Suspended Magnet
shall be complete with magnet with a suitable non-magnetic face plate, electrics
 (electrical panel, cables etc.) and any other item to make the system complete.

After all suspended magnets, a metal detector shall be installed over the conveyor which
shall detect any metallic pieces which could not be picked up by the magnet. In case of
detection, the conveyor shall be tripped with suitable audio-visual warning at the central
control room/ desptacher.

General Technical Specification

All the suspended magnets shall be suspended over the conveyor by electric hoist of
suitable capacity. A 500mm dia pipe chute shall be provided in the building for disposal
of metal pieces picked up by the magnet.

• Codes & Standards

The design, manufacture, inspection and testing of In line Magnetic Separators /

Suspended Electro Magnets shall comply with all the currently applicable statutes,
regulations and safety codes in The Magnetic Separators shall conform to the latest
edition of standards and codes. Other internationally acceptable standards/codes, which
ensure equal or higher performance than those specified, shall also be accepted. Nothing
in this specification shall be construed to relieve the contractor of the required statutory
responsibility.

• Equipment Specification

Magnet core material shall be pure annealed iron or equivalent high permeability
magnetic material. The coil shall be of anodised aluminium foil / strip with class 'H'
insulation, to limit the absolute temperature of the winding to 140 deg. centigrade. The In
line Magnetic Separators / Suspended Electro Magnets shall be air cooled and if
required separate cooler fan has to be provided. The rectifier shall be of silicon bridge
rectifier type only.

The 'Force Index' i.e. the product of flux density in gauss and rate of change of flux
density w.r.t. distance, at the bottom of falling material trajectory shall be 100,000 (gauss
x gauss/inch) minimum in hot condition for mounting height of 400 mm. However, the
strength of the magnet shall not be less than 1000 gauss in hot running condition at 400
mm distance. The minimum strength of the magnet shall be 1000 gauss at the specified
mounting height at the centre of Belt width. Bidder shall to select magnet width to suit
above. The width of the magnet shall be minimum 200mm wider than the width of the
belt.

Mounting height of 400 mm shall be taken between top of conveyor belt or bottom of
falling material trajectory and the surface of magnetic separator belt. Characteristic curve
of magnet with the value of flux density varying between 50 mm to face of conveyor belt
 shall be provided. The cross section of magnet shall be suitably designed to provide
sufficient area for magnetising the coil effectively covering full cross section of the
discharge material. The In line Magnetic Separators shall be located such that it picks-
up tramp iron from coal trajectory after it has been discharged from head pulley.

The tramp magnetic pieces buried under coal picked up by the magnetic separator shall
be discharged suitably to ensure that it falls into the tramp iron chute, which shall be

provided upto ground level. The tramp iron chute shall be of minm. 6thk MS plates. All
conveyors with magnetic separator at head end shall have non-magnetic Stainless
pulleys (shell & diaphragm), however, for magnetic separators located other than the
discharge end, the idlers likely to be in zone of magnetic field shall be made of stainless
steel. The liners on discharge chute of ILMS shall be of non - magnetic stainless steel
material only.

For ILMS, the motor and the gear reduction unit for driving the in-line belt shall be
adequate sized with minimum 20% margin to avoid any over loading during operation.
Suitable zero speed switch shall be provided. No Chain/belt drives shall be accepted.

The belt shall be designed to withstand high temperature at the bottom of the magnet and
any serious damage due to the impact of the sharp edges of the tramp iron. The belt shall
be provided with rubber cleats spaced suitably. The belt shall be of fire resistant grade.
Side rollers shall be provided to keep the belt aligned.

The idlers and the pulleys supporting the belt shall be manufactured to the best
engineering practices and shall conform to relevant Indian Standards

Material to be separated as tramp iron by ILMS:

The maximum weight of 50 Kg having 'LID' 5 of iron or steel piece

of any shape (except sphere) below the material heap of 250 mm.

MS round bar with 'LID' 5

MS Bolt 'L' = 5 X Diameter.
MS Nuts with Diameter 'LID' 10 mm

• Construction Requirement
The ILMS units shall be supported by suitable structural member from the top by taking
support from the operating floor beams with turn buckle arrangement to facilitate the
necessary adjustments during operation.
 ON/OFF control push buttons with indicating lamps shall be provided at the local station.
Suitable arrangements shall be provided in the magnet for keeping the coil of the magnet
dry from atmospheric condensation when the magnetic separator is not in use.

Documentation
List of drawings /data to be submitted along with tender

a) General arrangement drawing with bill of material of equipment showing overall dimension, motor
kW (if any), drive & suspension arrangement etc. alongwith details of limit switches, load data,
weight etc.
b) Supplier's name for components catalogues for these items shall be furnished.
c) List of commissioning spares proposed by the Tenderer.
d) List of recommended spares for two years maintenance of plant and equipment along with
itemised price.
e) List of tools and tackles to be supplied with the plant and equipment.
f) Duly filled up questionnaire given

2. List of drawings /data to be submitted by successful tenderer

a) General arrangement drawing with bill of material of equipment showing overall dimension, motor
kW (if any), drive & suspension arrangement etc. alongwith details of limit switches, load data,
weight etc.

b) Supplier's name for components catalogues for these items shall be furnished.

c) List of commissioning spares proposed by the Tenderer.

d) List of recommended spares for two years maintenance of plant and equipment along with
itemised price.

e) List of tools and tackles to be supplied with the plant and equipment.

QUESTIONNAIRE

Type & Quantity ILMS / Suspended Magnet

Suspension device
Location of ILMS / Suspended Magnet:
Force index (As defined earlier)

Gauss strength of magnet at the specified mounting height Mounting height

Weight of total assembly
Magnetic Separator belt (for ILMS)

(i) Drive Unit

(ii) Belting

(iii) Discharge
Tramp Iron Items
(i) MS cube of 20 mm size

(ii) Brake shoe of Railway Wagon (Cast Iron15 Kg.)

(iii) MS plate of 250 x 250 x 100 mm size.

(iv) Shovel Teeth and spikes.

(v) MS round bar of 50 kg with LID ratio not exceeding 5
Control

Magnetic Cooling system

Location of silicon rectifier unit
MOC of magnet core
MOC of coil

MOC of insulating medium

MOC of pulley shell
MOC of diaphragm
MOC of idler
METAL DETECTOR

Scope Of Work

The scope of work of the Tenderer shall include design, engineering, manufacture, fabrication, assembly,
testing and inspection, packing, dispatch, transportation, delivery FOR Purchaser's site, unloading,
handling and storage at site, erection supervision, testing, inspection, commissioning, guarantee testing
and handing over to the client including all electrics / electronics / microprocessors and standard
accessories of Metal Detector as covered under this specification.

The scope of the Tenderer shall be deemed to include all such items which although are not specifically
mentioned in the specification, but are needed to make the equipment complete in all respect for its safe,
reliable, efficient and trouble free operation.

• The scope of supply and services of the Tenderer shall include the following:

a) Mechanical

- Each equipment shall be complete in all respect including, its drive units, cables, safety switches,
structural, mechanical and other standard accessories, sand hoppers, markers etc.

- Provision of necessary fixtures, supporting angles and brackets required for mounting and
supporting the equipment.

The Tenderer shall also include supervision services at site during erection, testing and commissioning
of the equipment supplied by them.

b) Electricals

• Necessary hooter I light indicators / alarms and panel with sufficient I/Os for interconnection with PLC

• All fixing bolts and nuts including foundation bolts shall be included in the scope of supply of
Tenderer.

• Two years maintenance spares.

• Commissioning spares as required during testing and commissioning of the equipment.

• Insurance spares.

• Required quantity of initial fill of oil, grease, lubricants, hydraulic fluid etc. and other
consumables which are necessary for cleaning/ flushing including erection, testing and
commissioning the equipment shall be in the scope of supply of the Tenderer.

• Necessary tools and tackles for each equipment required for maintenance, testing or
inspection of the equipment. The list of such tools and tackles shall be furnished and
included in offer.

• Statutory approval wherever required shall be taken by the Tenderer for the equipment
being supplied by them from relevant state/ central authorities.

• The scope of work shall stand supplemented by such details as are given in this
specification, tender drawing, and instruction to the Tenderer, General Conditions of
Contract (GCC), General Technical Specification (GTS) or any other part of the
document.

TECHNICAL SPECIFICATION

• Codes & Standards

The design, manufacture, inspection and testing of Metal Detectors shall comply with all
the currently applicable statutes, regulations and safety codes in the locality where the
equipment is to be installed. The Metal Detectors shall conform to the latest edition of
standards/codes, which ensure equal or higher performance than those specified, shall
also be accepted. Nothing in this specification shall be construed to relieve the contractor
of the required statutory responsibility.

• Equipment Specification
Metal detectors shall have high reliability with enough sensitivity to detect 25 mm aluminium sphere below
the burden of material. It shall also detect other metals like brass, copper, stainless steel, manganese steel,
bars, scraps etc.

The equipment shall have provision for automatic static calibration with adjustable sensitivity.

Metal detectors shall be completely solid state using latest state of art technology. It shall be suitable for
50°C ambient and RH of 100%. The search sensor shall be protected from rain and direct sunlight by means
of a non metallic covering other than wood. Control unit shall have adjustable controls for sensitivity,
ON/OFF push buttons, reset table operation counter, audio-visual alarms local remote selector switch and all
other

necessary controls for trouble free operation of metal detector. It shall be suitable for
mounting on wall, column, structure, etc. with IP-65 degree of protection. It shall be
constructed from FRP of thickness not less than 2 mm.

The metal detectors shall also have the following features:

► The coils shall be protected against being struck by an oversized material/ coal.

► In order to counteract interference from external sources such as motors, lighting

and radio-transmitters, and to nullify the effect of climate changes/ aging, dual
receiver coils are to be used.

► In order to allow passing of metal belt fasteners without giving alarm and at the
same time detection tramps, suitable arrangements shall be provided.

► In case a few non-magnetic idlers or non magnetic deck plates are required, the
bidder shall provide these. However, these shall be metallic. Wood shall not be
used.

► LED display of COAST COUNT to indicate the number of pieces of tramp iron
detected since last reset shall be provided so that the operator is alerted for the
pieces of tramps, if any, between tramp marker and coil before restoring conveyor.

► TOTAL COUNT, which is not resettable, shall also be provided on the same LED
display on demand.
► The location of tramp metal pieces shall be indicated by liquid colour spray / sand
bag marker I as agreed by purchaser.

► Construction Requirement

Fiber glass enclsosure (with IP-65 degree of protection) shall be provided for
all type of coils.

Suitable tramp metal markers shall be provided.

Local control panel shall be provided with IP-65 degree of protection.

1. Documentation

List of drawings /data to be submitted along with tender

a) General arrangement drawing with bill of material of equipment showing overall dimension and
details.

b) Supplier's name for components & catalogues for these items.

c) List of commissioning spares proposed by the Tenderer.

d) List of recommended spares for two years maintenance of plant and equipment.

e) List of tools and tackles to be supplied with the plant and equipment.

f) Duly filled up questionnaire.

g) The Tenderer has to furnish one copy of the specification drawing duly signed by him as a token
of acceptance along with the list of deviation from tender documents.

2. List of drawings /data to be submitted by the successful tender

a. General arrangement drawing with bill of material of equipment showing

 overall dimension & details.

b. Supplier's name for components & catalogues for these items shall be furnished.

c. List of commissioning spares proposed by the Tenderer.

d. List of recommended spares for two years maintenance of plant and

equipment along with itemised price.

e. List of tools and tackles to be supplied with the plant and equipment.