12.

0 TECHNICAL SPECIFICATION AIR COMPRESSOR

12.1 SCOPE OF WORK ................................................................................................... 641

12.2 STANDARDS ............................................................................................................. 641
12.3 TECHNICAL REQUIREMENTS ............................................................................ 642
12.4 CONSTRUCTIONAL FEATURES OF THE COMPRESSOR ........................... 643
12.5 ELECTRICALS, INSTRUMENTATION AND CONTROLS ............................... 645
12.6 DATAS TO BE FURNISHED BY THE TENDERER:.......................................... 647
12.7 BATTERY LIMITS .................................................................................................... 648
12.8 SHOP INSPECTION AND TESTING ................................................................... 649
12.9 PAINTING AND SHIPMENT ................................................................................... 649
12.10 SITE FACILITIES .................................................................................................... 650
12.11 ERECTION AND COMMISSIONING................................................................... 650
12.13 PERFORMANCE GUARANTEE AND WARRANTY ........................................ 651
12.14 SAFETY AND ENVIRONMENTAL ASPECTS:- ................................................ 651
12.15 DATA TO BE FURNISHED BY THE TENDERER ............................................ 652
12.16 GENERAL ................................................................................................................ 652

Phanendra Kumar,

Territory Manager – Oil Free Air Simplex Infrastructure Limited

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 12.0 TECHNICAL SPECIFICATION
12.1 SCOPE OF WORK
This specification covers the technical requirements for design, supply, loading,
unloading, erection, testing & commissioning at site including defects liability
period of two years for Air Compressor with all accessories. The system shall
be of proven design and capable of actual field operation for the desired
materials without any difficulty or problem whatsoever. As such, the quality and
performance guarantee for compliance with this specification shall be the prime
responsibility of the successful tenderer.

The tenderer shall be thoroughly conversant with the specified requirements,

standards, quality and workmanship for trouble free operation of the equipment.

12.2 STANDARDS
The design, manufacture and testing of the equipment shall comply with the
latest editions of relevant standards.

EN: 1012 Compressors safety requirements.

EN 12076 Noise test code for compressors
IS: 11461 Safe Design and Construction of compressor

IS: 5456 Testing of Positive Displacement Compressor

IS: 5111 Testing of Refrigerant Compressor

IS: 7938 & IS 2825 /ASME Sec VIII Air Receiver for compressed air installation
IS: 4758 Methods of measurement of Noise emitted by
machines

Unless mentioned otherwise, all applicable codes and standards in their latest
editions as published by the Bureau of Indian Standards shall govern in respect
of design, workmanship and properties of materials and methods of testing. In
case where suitable Indian Standards are not available, generally accepted
codes and practices shall be adopted.

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 All equipment shall comply with the statutory requirements of the Govt. of India
and Government of Maharashtra. The equipment constructions and installation
shall conform to the provision of statutory and other regulations in force such as
the Indian Boiler Regulations, Indian Factories Act, Indian Explosives
Regulations, etc. Approval of drawings if required shall be arranged by the
successful contractor at no extra cost to the Purchaser.

In cases where the offer deviates from the specified standards, the tenderer shall
indicate clearly in his offer the reasons for deviation, standards proposed to be
adopted by him and the details thereof.

12.3 TECHNICAL REQUIREMENTS

The plant shall comprise of Oil Injected multi stage screw type compressor which
shall have a rated capacity of between 1150cfm to 1300cfm free air delivery on
wet basis at a working pressure of 10 bar.

Compressor shall have the integrated unit of Oil separator or connected to Oil
Separator unit capable to operate 1150cfm to 1300cfm.

Compressor shall be connected to the vertical air receivers of capacity 5m3

(5000litrs) at 10bar working pressure and bypass connections shall be provided
between compressors and air receivers to utilize as stand by units.

The Outlet nozzle of the air receivers shall be connected to the pre filters, capable to
operate with minimum air flow rate of 1150cfm to 1300cfm. There shall be complete
bypassing system with each pre-filter in order to maintain 100% redundancy.

Each out let of Pre-filter shall be connected to the Air Dryers, capable to operate
between minimum air flow rate of 1150cfm at working pressure of 10bar.

Each Outlet of dryer shall be connected to the post filters, capable to operate between
minimum air flow rate of 1150cfm at working pressure of 10bar. If the tenderer finds that
the sizes are not adequate the same shall be indicated in the offer.

The salient technical particulars are as below:

Capacity of each compressor - 1150cfm to 1300cfm

Effective working pressure - 10bar

Capacity of primary air receiver - 5m3

Capacity of Secondary air Receiver - 2m3

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 Dew point temperature - 20C

The Compressors, filters, driers, etc. are proposed to be located inside the
compressor room.
The contractor should indicate the space requirement in their offer for each items.

The contractor shall submit a properly dimensioned drawing indicating the layout of their
equipment in consonance with the general technical requirement mentioned in 5.3.1.

The size/capacity of the different pipes and ancillary fittings such as valves etc.
shall also be indicated clearly by the contractor in the drawing.

Foundation details shall be shown in a separate drawing.

12.4 CONSTRUCTIONAL FEATURES OF THE COMPRESSOR

The compressor shall be rigid, robust and of sturdy construction. It shall be

electric screw type. Details of this arrangement shall be explained in the offer.

Construction of the compressor shall be such that parts of the compressor which are
required to be maintained regularly shall be located as to be conveniently accessible.

Cooling system is to be specified. Air cooled system is preferred.

Safety Devices, Indicators and Gauges

The compressor plant shall be complete with discharge air pressure &
temperature gauges and other indicators & gauges as required. Details of all
safety devices provided on the compressor shall be explained in the offer.

Pressure gauges shall be calibrated to indicate simultaneously in bar and psi.

Component Details

Acoustic Canopy.

Compressor package shall be enclosed in a powder coated acoustic canopy with

sound absorbing material for limiting the noise level Canopy shall be under
positive pressure to ensure that there is no pressure drop at Suction Filter. The
installation shall be complete with anti-vibration mounts for Electric Motor &
Compressor unit. Cogged belts and pulley drive is suggested.

Air Intake/Pre-filter/Post filter.

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 Suitable filters, capable of filtering airborne particles shall be provided. The filter
shall possess high separation efficiency, good accumulation capacity, low air
resistance and mechanically strong. The filter elements shall be capable of being
easily cleaned for re-use. The method and criterion for cleaning of filter elements
shall be clearly specified by the contractor in his design.

Valves

Suction and delivery valves shall be of high durability and suitable for screw
compressors. The details of the safety arrangement shall be spelt out in the offer.
The valves shall be easily accessible for maintenance. Special design features of
the valves shall also be furnished in the design.

In addition to the above, other valves as considered necessary by the manufacturer

for efficient, continuous and safe working of the compressor shall be provided.
Function of these valves shall be explained in detail. Pre filter, air dryers, post filter
and air receivers shall have bypass connection with required number of valves in
order to replace each item for maintenance without affecting the transmission of air.

Air Receiver

The air receiver shall be built and tested in accordance with IS: 7938 and IS:
2825 /ASME Section VIII amended up-to-date. It shall be of the vertical
cylindrical, all welded design. The air receiver shall be supplied complete with
self-supporting mounting arrangement, manhole, safety valve, pressure gauge,
automatic drain trap, tapping and connection for air control regulation and inlet
and discharge connections. Details of anti-corrosion protection provided on the
inside and outside of the air receiver shall be furnished. The air receivers shall be
located outside of the buildings. The capacity of primary receiver is 5m 3 and
secondary receiver is 2m3. All the associated pipe fittings shall be included.

Motor Starter and Control Panel

The control panel for compressor shall be located at a suitable place outside the
enclosure of the compressor.
ACIL Comment: The control panel shall be inbuilt within the enclosure of the
compressor as a standard from Atlas Copco India Limited.

Air Dryer

The electrically heated air dryer shall be of refrigeration type capable of

automatic continuous operation. The unit shall be compactly designed and
cabinet enclosed to occupy minimum floor space, indoors.

Dryer Capability

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 The dryer shall receive oil free compressed air after filtration from oil carryover
upto 1 micron oil particles from the air receiver via an inline filter at specified
pressure and flow. It shall deliver completely moisture-free air with minimum
pressure loss and at a constant dew point.

Safety Features
The dryer shall incorporate, but not necessarily be limited to, the following
protective functions.

i) Excessive fluctuations of refrigerant pressure for the refrigeration compressor.

ii) Condensate over pressure
iii) Automatic turn off of power on air pressure loss in system with automatic
restart on repressurisation.

12.5 ELECTRICALS, INSTRUMENTATION AND CONTROLS

Instrumentation and Controls

The dryer shall be provided with sufficient controls and indicators to ensure
proper operation. These shall include, but not necessarily be limited to:-
a) Power on indication. Yes
b) Compressor on indication. No
c) Compressor loaded/unloaded. No (Not Applicable for Air Dryer)
d) Inlet air temperature. No
e) Air pressure. No
f) Dry air dew point. Yes
g) Outlet air temperature. No
h) Refrigerant pressure (high). No
i) Refrigerant pressure (low). No

The dryer shall undergo refrigeration system evacuation and charging prior to
shipment, including leak checks.

The unit shall also be given a running test and all instruments shall be calibrated prior to
dispatch. A copy of the running test report shall be submitted along with the unit.

Equipment
Contractor shall furnish the type and make of the equipment proposed to be
supplied along with necessary technical particulars for the same.

Noise Level
Noise level of the compressor without acoustic canopy shall not exceed 85 db (A)
(measured under field conditions at 1 m with a tolerance of + 3 db (A) when tested in

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 accordance with IS: 4758 or CAGI-PNEUROP/ANSI S1.13-1971. Contractor
shall furnish a certificate to this effect.

(BIDDER)
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 12.6 DATAS TO BE FURNISHED BY THE TENDERER:

A. COMPRESSOR:

1 Capacity of each compressor : 1326 cfm

2 Effective working pressure : 10 bar
3 Free Air Delivery : m3/min
4 Delivery pressure : bar
5 Drive motor Rating : hp
6 Drive motor nominal efficiency : %
7 Duty Cycle :
8 Full load current : Amps
9 Drive motor : RPM
10 Class of insulation(Drive motor) :

11 Fan motor Rating : Hp (If applicable)

12 Fan motor nominal efficiency : %
13 Total package input power at Zero : kW
flow
14 Total package input flow at rated : kW
capacity &full load operating
pressure
15 Specific package input power at : kW
rated capacity and full load operating
pressure
:
16 Operating noise level :
17 Compressor : RPM
18 Compressed air outlet temperature : oC

19 Size of suction flange : mm

20 Size of discharge flange : mm
21 Overall dimensions of compressor mm
including drive (mm)(LxBxH)

22 Type of filter :
23 Minimum size of airborne dust : microns
retained
24 GA drawing attached : Yes/No

B. AIR RECEIVER:

1. Type :
2. Volume :

3. Material of construction
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 4. Design pressure : bar
5. Test pressure : bar
6. Internal diameter :
7. Height (between tangents of dished ends) :
8. Over-all heights (in vertical) :
9. Wall thickness (mm)
Cylindrical portion:
Dished ends

10. Fabrication drawing : To be attached

C. AIR-DRYER :

1. Manufacturer :
2. Type :
3. Rated capacity at working pressure of 10bar : m3 min-1
4. Maximum effective pressure : bar
5. Air inlet temperature : oC

6. Ambient air temperature : oC

7. Dew point of dry air o
At working pressure : C
Referred to Atmosphere pressure : oC

8. Pressure drop through dryer at rated load : m bar

9. Safety devices provided. (To be detailed by the supplier)
10. Control systems: Detailed description of system offered for, dew point
temperature control and capacity regulation.
11. Gauge and indicators provided on control panel.
12. List of standard accessories provided
13. Special features, if any, of the air dryer offered

Note- If the above clauses are found inadequate for furnishing all necessary information
of the air dryer offered, the tenderer may append further information separately.

12.7 BATTERY LIMITS

Power

Power at 415 V 50 Hz will be made available at single point at the incoming

terminals of the Motor starter control panel separately for each compressor as
well as a Air drier unit. All further power distribution including Panels, Power
control cables, Motors, air drier heaters, earthing system etc. complete shall be
under the scope of the Compressor supplier.

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 Piping

All interconnecting piping with all accessories between the compressor, dryer
and receiver shall be in the scope of the Contractor.

12.8 SHOP INSPECTION AND TESTING

change or modifications as pointed out by the Purchaser/ Consultants during inspection

at no extra cost. The Supplier shall dispatch the equipment only after obtaining
clearance from the Purchaser/ Consultants. However, the Purchaser/Consultant
inspection and certification does not absolve the supplier of his responsibilities towards
the satisfactory operation and the guarantee/warranty of the system.

The manufacturer shall calibrate the equipment and conduct all tests required to ensure
that the equipment furnished shall conform to the requirements of the applicable codes
in presence of Purchaser/Consultant. All tests and test procedures proposed by the
manufacturer shall be submitted to the Purchaser/Consultant for his approval.

which the equipment is being manufactured or tested. The Purchaser/

Consultants shall be notified well in advance of the fabrication and major tests for
the purpose of general inspection and witnessing the tests.

All material used shall be of tested quality. The test certificate shall be made
available to t -
availability of test certificates, material shall be tested by the supplier at his own
cost, to establish conformance to the relevant standards.

The quality of fabrication work and welding shall be of the highest order in
accordance with the requirements of Indian standards.

Visual inspection for general workmanship and smoothness.

12.9 PAINTING AND SHIPMENT

All external surfaces shall be cleaned of loose substance and foreign material, e.g.
dirt, rust, scale, oil, grease, welding flux, etc. so that the zinc phosphate primer coat
adheres to the original metal surface. The work shall be carried out generally in
accordance with IS: 1477 (Part I) amended up to date. The surface shall be cleaned
either by sand blast to grade S.A.2.5 using graded sand or by acid pickling using
dilute sulphuric or hydrochloric acid followed by thorough rinsing with fresh water.
The prime coat shall be applied immediately after the surface preparation.

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 Supplemented by this specification.

The prime coats shall consist of two coat of Zinc phosphate` primer.

Finish painting shall consist of three coats of epox

specification.

Dry film thickness for each coat shall be about 25 microns and total dry film
thickness shall not be lower than 125 microns.

No shipment shall be made unless clear dispatch instructions are obtained from
pur

All projected parts shall be properly protected to avoid damage during transit.

Touch up painting for damaged coats doing transit / erection should be done by
the contractor .Prior painting proper cleaning of the damaged portions to be done.
Manufacturer’s standard paint shade and painting procedure shall be followed.
12.10 SITE FACILITIES

The bidder shall indicate clearly the work to be carried out at site and the procedure to be

For the work to be executed at site, electricity will be made available near the work
site. The Contractor shall ensure that the facilities are not misused or wasted.

Accommodation/transport of workmen and supervisors of the Contractor shall be

the responsibility of the contractor.

12.11 ERECTION AND COMMISSIONING

All equipment shall be erected by the contractor on the locations given on the
equipment layout drawing

Installation and commissioning of the complete system will be done by the

supplier. The Contractor must ensure that the system shall be working properly.

12.12 TIME OF COMPLETION

The period of the Contract shall commence from the date of receipt of Letter of
Intent (LOI/Notification of Award). The whole work under this Contract including

(BIDDER)
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 commissioning shall be completed in all respects within the time of completion specified
in the notice inviting tender from the date of commencement of the contract.

12.13 PERFORMANCE GUARANTEE AND WARRANTY

Contractor shall guarantee that all materials used for the equipment have been
submitted to regular acceptance procedure and free from any defect regarding
quality, form and appearance.

Any equipment, or its part not having been submitted to wrong operating service
or faulty manipulation and found defective during erection, test or during
operation, shall be repaired / replaced by the Contractor without delay and free of
cost within the guarantee period.

In case of defective equipment Purchaser / Consultant shall have the option to

repair/replace the equipment after intimating to the manufacturer, in order to
avoid time delay. In such an event, Purchaser / Consultant shall be entitled to
recover the cost of such repair / replacement from the Contractor.

The Contractor shall guarantee that upon completion of the satisfactory commissioning
and acceptance of the equipment by the purchaser, all portions thereof will be in
accordance with requirement of the contract and will be perfect as to design, materials,
workmanship etc. for a minimum period of one year from the date of provisional
acceptance of the equipment as per general conditions of contract.

The contractor shall further guarantee that during the guarantee period, he will
repair all defective equipment and replace all defective materials furnished or
installed under this contract, free of cost to the purchaser.

The performance of the systems as per the above requirement shall be

guaranteed for a minimum period of 12 months from the date of commissioning
or 18 months from the date of supply whichever is earlier.

The contractor shall ensure provision of sufficient quantity of commissioning

spares required for proper erection and commissioning of the equipment until
final acceptance following demonstration of performance guarantee.

Contractor shall furnish detailed specifications of the recommended lubricants, their

brand names and the quantity required for one-year consumption. The first fill of

12.14 SAFETY AND ENVIRONMENTAL ASPECTS:-

The total system should have adequate built-in precautions to prevent any fire or
explosive hazards.

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 Safety systems should be as per relevant IS codes.

The entire unit shall be fully enclosed and provision shall be given for easy repair
and maintenance of the machinery.

Emergency push button station shall be provided on the front side of the cabinet, which
can shut down all the operation of the compressor unit in case of any emergency.

12.15 DATA TO BE FURNISHED BY THE TENDERER

The tenderer shall submit all catalogues, leaflets, detailed technical specification, etc. for
the equipment. Drawings showing all the design, operational and maintenance features,
major dimensions, details of foundations including layout etc., shall be submitted along
with the offer. Technical data for individual items of equipment as per data sheet in
addition to details of all equipment within the battery limit shall be submitted along with
the tender. The tenderer shall also submit a general arrangement drawing and
approximate layout showing the space requirement etc.

Other Specifications and technical data to be furnished by the tenderer wherever

applicable

Data Sheets
G.A drawings
Drawings with dimensions of equipment
Equipment Layout Drawings with elevations
Equipment Specifications
Empty Weight
Foundation Drawings with load details of each equipment.
Safety devices provided.
Service and spare parts availability
Manufacturing and delivery schedule
List of customers to whom similar units have been supplied
Erection, Operation & Maintenance manual with detailed list of spare parts
Compliance Statement

12.16 GENERAL
The system or equipment mentioned above is indicative only. The tenderers are
advised to examine the feed materials and quote for a suitable equipment to
meet the performance requirement.

The equipment supplied shall be complete in all respects with all necessary
accessories required for operating.
The Purchaser reserves the right to procure all the items specified in the tender
or part thereof without assigning any reason.

(BIDDER)
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