BASIC DESIGN CRITERIA OF FIELD CONTROL ELEMENTS (SENSORS) Field control elements included in the tenderer's scope of supply

shall conform to the following general design criteria: a) Dust proof conforming to NEMA 4/ IP65 b) Water proof conforming to NEMA 4/ IP65 c) Wiping action on contacts (self cleaning), encapsulated contacts are preferred d) Explosion proof where required e) Housing preferably made of metal Covers to be fitted easily, screws to be secured. Electronic equipment to be suitably protected against radio interference, as required. f) Resistant against vibration (contact pressure) g) Suitable for ambient temperature of - 20 degree to + 70 deg.C h) All potential free contacts shall be wired upto terminal block i) Current rating: Contacts (2 NO + 2 NC) Electronic Analogue 0.5 amp at 48 V DC (min.), 10 amp at 220 V AC (min.) - short circuit proof, protected from inductive voltage spikes, maximum inverse voltage &over voltage protection - 4 - 20 mA, galvanically isolated (against earth and power supply) - Local Analog digital display indication

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Mounting: By screws, mounting holes to be sealed, adequate mechanical protection to be included. The installation shall be done by the Tenderer. Connections: - Sensor type field elements to be supplied with min 10 mtrs long extension cable. - All others: Lug type connection

DESCRIPTION OF INDIVIDUAL CONTROL DEVICES AND EQUIPMENT Motion Detectors Will be a standardised proximity head fitted wherever possible to the final driven element of the machine. The Tenderer shall provide a hole metric M 6 (min. 20 mm) in the centre of the final drive shaft of the machine. The motion detector, controller as well as operating metal protrusion shall form a part of tenderers scope of supply. Necessary bracket for installation proximity and controller shall also form a part of tenderers scope of supply. Proximity Switches/Limit Switches Will be standardised proximity head type limit switches. The tenderer shall provide special mountings as may be required for an application. Application of this type of switch will be to chute gates, belt take-up, tripper positioning, valve position, clutch position, brake position and similar applications. Limit switches (2 NO + 2 NC) for diverter gates, actuator controlled valves, shut off valves etc. are part of the tenderers scope of supply. Level Detectors/Indicators Types of level detectors vary for individual applications. The tenderer shall provide specification, mounting device and typical drawing of preferred level detectors only. Level detectors for Bucket Elevator Boot, silos, hoppers, process bag filter hoppers, FK pump hopper, and cooler spillage hopper shall form a part of tenderers scope of supply. Ultrasonic level sensors are preferred for continuous level monitoring for hoppers and silos. Pressure, Flow and Temperature Switches/Sensors for Machine Protection Shall be supplied and installed by the tenderer to suit the individual application. Locally mounted, continuous monitoring devices with an isolated output 4 - 20 mA, 2-wire technique, external load upto 600 Ohm is required. For applications which require one set point only, switches with liquid filled (mercury type) or pressure operated contact systems can be applied. All transmitters shall be provided with locally mounted indicator.

Switches to be adjustable over full range and calibration scale visible with the case closed shall be ensured. The type of switch or sensor shall be subject to approval by the Purchaser. Flow element wherever required (Venturi, Orifice, piezzo rings ) shall be included in the scope. Temperature Detectors Temperature detectors (RTD, Pt 100 3 wire type including junction box) wherever specified or necessary for protection and monitoring like large process fan bearings, gearboxes etc. Thermocouple and smart temperature transmitters (with output signal 4-20 mA galvanically isolated) for cooler grate and cooler spillage hopper shall be tenderers scope of supply. Vibration Detectors Big fans, gear boxes, Mill and any other critical equipment shall be provided with vibration sensors for X-Y-Z Co-ordinates. The scope of supply of the tenderer include the sensor and the locally mounted transmitter (with output signal 4-20 mA galvanically isolated). Load Cells The tenderer shall supply the load cells of hermetically sealed design with field mounted electronic unit with local indication and circuitry giving 4-20 mA isolated output for remote display. The load cells shall also be supplied with brackets and expansion assemblies for other vessel. Copper straps shall be supplied along with to bridge-over each load cell to protect them from stray welding current. Special cable required between the load cell junction box and field mounted electronic unit shall be included by the Tenderer in addition to special cables required between load cells and junction boxes (Approx. 25 Meters). The load cell system shall be subject to approval by the Purchaser. Process Instrumentation Unless otherwise specified, the Tenderer shall provide mounting arrangements (brackets, holes, flanges, etc.) for process control and monitoring sensors specified for temperature, pressure, flow, position, etc. Location, size and type of arrangements to be subject to Purchaser approval. Valves/Dampers/Gates and Actuators On/off valves shall be included in the supply. Best quality equipment shall be provided. Valves shall be standardised and be subject to approval of the Purchaser. End limit and torque limit switches for valves shall be supplied by the tenderer with 2 NO + 2 NC Contacts. Control Valves and Actuators Solutions with variable speed drives (for pumps, critical large fans, etc.) are preferred to solutions with constant speed drive and control actuators. Where this is not possible, control valves and actuators and corresponding mechanical linkages shall be included by the Tenderer. Actuators and valves shall be standardised as much as possible. Motors shall be preferable of the 3-phase squirrel-cage type. The feedback element shall be 4 - 20 mA, galvanically isolated. Where required the feedback element shall be directly connected to the shaft. Actuator internal limit and torque switches shall generally be included. The pot shall be 1 K ohm & transmitter shall be mounted in the actuator. The position transmitter shall be 2 wire type and shall be suitable for 24 VDC from the plant control system. Actuator travel time and flow characteristic shall be adjusted to the specific application.

SCOPE OF C & I SUPPLY A documentation giving details of all special electrical devices included in the Tenderer' scope of supply (wiring diagrams, maintenance manual, special operating instructions, etc.) shall be provided. All types of elements will be subject for approval by the Purchaser/Consultant. Bag filter with solenoid valve shall be provided. Necessary safety switches like pressure switch for compressed air pressure monitoring and differential pressure transmitter for measuring DP across bag filter shall also supplied. Pressure regulator with Dial gauge indicator Manual valve in compressed air line header & Filter and moisture trap Pressure switch with 2 NO + 2 NC contact for external interlocking with 3A, 250 V AC ratings. Control cable between valve and junction box. Junction box for connection of solenoid valves. DP transmitter with profibus connectivity alongwith copper tubing. Set of hopper heating with thermostat (but without local panel) for 1/3rd bottom portion of hopper. For smaller filter heating pads shall be used. Bag house to be controlled through with their own PLC and shall be compatibility on profibus.