carr1.

0 PLANT WATER SYSTEM

1.1 The plant water system starts from receiving of water at the Raw Water
Reservoir. Water will be conveyed from existing raw water supply line to the new
Raw Water Reservoir. Concrete twin compartment reservoir of approximate 1800m3
capacity has been envisaged as plant raw water storage which is equivalent to
4hours storage requirement along with 2hrs dedicated storage for fire water.
The scheme for plant water system has been presented in Proposed Scheme for Plant
Water System drawing no. TCE.11311A -610-FD-1000.
The quality of raw water is mentioned in Annexure-1.

1.2 Make-up Water Requirement

For the proposed plant, water is required for the process plant, drinking,
sanitation and other miscellaneous uses like canteen, safety shower, etc. The
individual water demand for the proposed plant is being tabulated below.
Parameter Units Value
Total Process Water Demand on the plant m3/hr 370
Raw Water makeup from existing supply line m3/hr 290
Reclaimed water from existing Reclaimed Water Pond. m3/hr 120
Filtered Water m3/hr 28
Potable water m3/hr 3
Soft water m3/hr 3

1.3 Battery Limit

The battery limit / terminal points for water system have been shown in Proposed
Scheme for Plant Water System drawing no. TCE.11311A -610-FD-1000.

1.4 System Description

The plant water system consists of the following sub systems.

1.4.1 Make-up Water System

It is envisaged that the makeup water for the process plant is taken from the Raw
Water Reservoir and necessary arrangements (pumps, piping and others) for the same
is mentioned in the flow diagram TCE.11311A -610-FD-1000.
Raw water is required for make-up water to Process Water Tank, Dust Suppression,
high pressure line flushing, filter cloth washing etc.

1.4.2 Filtration Unit

Filtered water is required for gland sealing, Softening Plant, drinking purpose,
etc. Filtration Unit consists of Filter Feed Pumps, Dual media Filters, Filtered
Water Storage Tank and all associated piping along with other necessary
arrangement. Raw water will be fed to the Dual Media Filter through Filter Feed
Pumps. Filtered water produced from filtration unit will be stored in Filter water
Storage tank of capacity 200 cum.

1.4.3 Potable Water System

Part of Filtered Water from Filtration Unit will be stored in Potable Water Storage
Tank. Sodium Hypochlorite solution will be dosed in the tank for disinfection
purpose. Potable Water will be distributed via Potable Water Pumps for use in
ablutions, drinking, washing and other uses in office, canteen and kitchen and for
use in safety showers.

1.4.4 Gland Seal Water

Filtered water from Filtered Water Storage tank shall be used for gland sealing.
Two (2) nos. Seal water Pumps have been envisaged for this purpose.

1.4.5 Softening Plant

Soft water is required for Mill bearing cooling. Softening Plant will consist of
Softener Feed Pumps, Softener unit, Soft Water Storage Tanks and necessary pumping.
Softening Plant will be fed water from Filtered Water Storage Tank.

1.4.6 Fire Water System

For fire water system, dedicated compartment to store volume offire water
equivalent to 2 hours pumping capacity of main fire water pump is kept in the Raw
Water cum Fire Water Reservoir. The fire water system will be provided with pumps,
piping network and other associated facilities as per the appropriate TAC/ NFPA
codes. Fire water pumps comprising 1 no. motor driven pump (273 m3/hr capacity and
88 mWc head) 1 no. diesel engine driven pump (273 m3/hr capacity and 88 mWc head),
2 nos. jockey pumps (10.8 m3/hr capacity and 95 mWc head) will be installed in the
fire water pump house. External fire hydrant system will be provided around all
buildings/ facilities. Internal hydrant shall be provided for storied buildings and
basements. Automatic High Velocity Water Spray (HVWS) system will be provided to
protect large oil filled transformers. Generally the oil filled transformer
capacity 10 MVA and above or oil storage capacity more than 2000 litre shall be
protected by HVWS system. Medium Velocity Water Spray (MVWS) system will be
provided for Hydraulic/
lubricating oil cellar, Major Cable vaults in electrical buildings. LHS cable shall
also be provided for along with cable vaults. Water based automatic activated
medium expansion foam based protection systems will be provided for Oil Storage
Tanks. Inert gas flooding system will be provided for server rooms/ PLC rooms/
Battery rooms and chemically corrosive areas. Potable fire extinguisher will be
provided inside all buildings as per the guidelines laid down in the latest edition
of TAC.

1.5 Capacity of Major Facilities

List of Major facilities of plant water system are given in table below:
Sl No. Description Capacity/ Size of facilities
1. Raw Water cum Fire Water Reservoir About 1800 m3 capacity water
storage tank including fire water storage requirement.
2. Process Plant supply pumps 2 nos. (1W+1S) pumps of each of capacity
410 m3/hr flow and 50 mWC head (to distribute water from Reservoir to various
consumption points within Process plant).
3. Filter Feed Pumps 2 nos. (1W+1S) pumps of each of capacity 35 m3/hr
flow and 40 mWC head (to supply raw water to Dual Media Filter).
4. Dual Media Filters 2 Nos. of Pressure filters each of capacity 35
m3/hr along with backwash arrangement.
5. Filtered Water Storage Tank CS, filter water storage tank of capacity
200 m3.

6. Seal Water Pumps 2 nos. (1W+1S) pumps of each of capacity 25 m3/hr

flow and 80 mWC head (to distribute gland sealing water to various consumption
points within Process plant).
7. Potable Water System CS with internal epoxy painted, Potable water
storage tank of capacity 25 m3.
2 nos. (1W+1S) pumps of each of capacity 5 m3/hr flow and 55 mWC head (to
distribute water from Storage tank to various consumption points within Process
plant).
NaOCl dosing system for disinfection (tanks and dosing pumps).
8. Softening Plant 2 nos. (1W+1S) Softener Feed Pumps of each of
capacity 5 m3/hr flow and 20 mWC head to supply filtered water to Softener Unit.
2 nos. Na+based Softener Unit each of capacity 5m3/hr.
Brine Solution Tank and dosing pumps for regeneration of Softener Unit.
2 nos. (1W+1S) Soft water Supply Pumps of each of capacity 5 m3/hr flow and 30 mWC
head to supply Soft water to Cooling Tower at Mill area.
9. Fire fighting tank and pump
house with fire network
RCC Fire water tank ( included within Raw water reservoir) of about 600 m3
capacity with pump house
consisting of following pumps:
Fire Pumps of each of capacity 273 m3/hr flow and 88 mWC (1 no. Motor driven and 1
no. diesel driven).
- 2 nos. (1W+1S) Jockey Pumps of each of capacity 10.8 m3/hr flow and 95 mWC.

1.6 Major Equipment Design Criteria

1.6.1 Horizontal Pumps

i. All Small size pumps of capacity less than 200 m3/hr will be selected of
back-pull type with end suction and top discharge type.
ii. Required NPSH at duty point will be at least one (1) meter less than the
available NPSH.
iii. For Horizontal pumps, vibration level in the pumps will be limited to the
specified limit provided by Hydraulic institute Standards (HIS). The overall
vibration level shall be as per zones A and B of ISO 10816-1.
iv. Mechanical seal has been considered in for critical application pumps.
v. 100 % stand-by (1W +1S) pumps have been considered in each type/group of
horizontal pumps.
1.6.2 General Requirement of Pumps ( Horizontal And Vertical)
i. Head Calculation of Pumps
For estimating friction head in pressure pipe flow Hazen-Williams equation is used.
V = 0.849 x C x R 0.63 x S 0.54�.....Hazen-Williams formula for pressure loss
calculation
Where
V = Velocity in m/s
C = Hazen William constant for pipe
R = Hydraulic radius of pipe in meter = Internal Diameter/4
S = Head loss in meter per meter run of pipe
The accuracy of estimating friction head in piping system depends on selecting the
correct surface roughness coefficient. The condition of the interior surface of the
pipe varies by pipe material and over time with use, age, and the effects of
corrosion / erosion. �C� value of 100 has been considered for calculation of head
of pumps.
ii. 10 % margin will be considered in dynamic head for arriving the pump head.
iii. Motor rating of Pumps:
Minimum Motor rating for Motors of the all pumps will be large of followings:
a) 16 % margin on the power requirement of pump at rated duty point.
b) 10 % margin on the maximum input power requirement of entire pump characteristic
curve (within any operating point between maximum and minimum resistance curves.).
iv. The shut-off head will be at least 115% of the differential head.
v. Hydro test pressure on casing will be 1.5 times maximum discharge head or
twice differential head whichever is higher. (Maximum discharge head
vi. = shut-off head + maximum suction head). Hydro test pressure testing will be
done for at least 30 minutes.
vii. The critical speed of the pumps will be not less than 130% of the normal
operating speed of the pump
viii. The noise level will not exceed 85 dBA measured at 1 m from the outline of
pump set.
ix. All pumps, except for back-pull out type, will be provided with flexible
coupling. Back-pull out type pumps will be provided with spacer type coupling.

1.6.3 Filtration Plant

Design of Pressure Filters will be based on the following parameters:

a) Maximum Design Surface Flow rate : 15 m3/m2/hr.

b) Backwash rate : 25 m3/m2/hr.

c) Air scouring rate : 40 Nm3/m2/hr.

d) Backwash Interval : Will be determined by differential pressure
across DMF or 24 hrs of operations.
e) Free board : 80%
f) Guaranteed quality of Filtered water at design rated flow rate :
1NTU

1.6.4 Softener Unit

a) Each Softener is sized based on 5 m3/hr net flow rate.
b) The Softener unit shall be capable of treating the specified input influent
water of hardness 200 ppm, to meet the effluent water quality of hardness as 50
ppm.
c) Surface flowrate shall be considered as 40 m3/m2/hr.
d) Softener vessel shall b designed as per IS 2825 or ASME Sec VIII Dev 1.

1.6.5 Water Storage Tank

i. Drain Valve and over flow lines will be provided in each tank.
ii. Tank will be with suitable cover to reduce the evaporation loss and protect
from external environment.
iii. MOC of tanks will be as follows :
Sl No. Description MOC
1. Raw Water cum Fire Water Reservoir RCC construction
2. Filtered Water Storage Tank CS
3. Potable Water Storage Tank CS with epoxy painted
4. Soft Water Storage Tank CS

1.6.6 Disinfection /Chlorination System

a. FRP NaOCl Dosing Tank will be provided.
b. Reciprocating type dosing pumps will be provided.
c. Carbon steel with food grade epoxy paint potable water tank will be provided
for storing the filter water.
d. Horizontal Potable Water Pumps will be provided to pump water from tank to
distribution.

1.6.7 Pipeline
i. Design Pressure
Design pressure will be the maximum expected pressure to which the system may be
subjected. Maximum expected pressure for a system placed in the discharge line of a
pump will be based on the shut-off head of the pump plus static head at pump
suction, if any.
ii. Design Temperature
Design temperature will be 10 Deg C higher than the maximum temperature that any
part of the system is likely to attain in course of operation. The design
temperature will be finalized based on maximum ambient temperature.
iii. Design Velocity
Pipe lines ying 1.0 PLANT WATER SYSTEM

1.1 The plant water system starts from receiving of water at the Raw Water
Reservoir. Water will be conveyed from existing raw water supply line to the new
Raw Water Reservoir. Concrete twin compartment reservoir of approximate 1800m3
capacity has been envisaged as plant raw water storage which is equivalent to
4hours storage requirement along with 2hrs dedicated storage for fire water.
The scheme for plant water system has been presented in Proposed Scheme for Plant
Water System drawing no. TCE.11311A -610-FD-1000.
The quality of raw water is mentioned in Annexure-1.

1.2 Make-up Water Requirement

For the proposed plant, water is required for the process plant, drinking,
sanitation and other miscellaneous uses like canteen, safety shower, etc. The
individual water demand for the proposed plant is being tabulated below.
Parameter Units Value
Total Process Water Demand on the plant m3/hr 370
Raw Water makeup from existing supply line m3/hr 290
Reclaimed water from existing Reclaimed Water Pond. m3/hr 120
Filtered Water m3/hr 28
Potable water m3/hr 3
Soft water m3/hr 3

1.3 Battery Limit

The battery limit / terminal points for water system have been shown in Proposed
Scheme for Plant Water System drawing no. TCE.11311A -610-FD-1000.

1.4 System Description

The plant water system consists of the following sub systems.

1.4.1 Make-up Water System

It is envisaged that the makeup water for the process plant is taken from the Raw
Water Reservoir and necessary arrangements (pumps, piping and others) for the same
is mentioned in the flow diagram TCE.11311A -610-FD-1000.
Raw water is required for make-up water to Process Water Tank, Dust Suppression,
high pressure line flushing, filter cloth washing etc.

1.4.2 Filtration Unit

Filtered water is required for gland sealing, Softening Plant, drinking purpose,
etc. Filtration Unit consists of Filter Feed Pumps, Dual media Filters, Filtered
Water Storage Tank and all associated piping along with other necessary
arrangement. Raw water will be fed to the Dual Media Filter through Filter Feed
Pumps. Filtered water produced from filtration unit will be stored in Filter water
Storage tank of capacity 200 cum.

1.4.3 Potable Water System

Part of Filtered Water from Filtration Unit will be stored in Potable Water Storage
Tank. Sodium Hypochlorite solution will be dosed in the tank for disinfection
purpose. Potable Water will be distributed via Potable Water Pumps for use in
ablutions, drinking, washing and other uses in office, canteen and kitchen and for
use in safety showers.

1.4.4 Gland Seal Water

Filtered water from Filtered Water Storage tank shall be used for gland sealing.
Two (2) nos. Seal water Pumps have been envisaged for this purpose.

1.4.5 Softening Plant

Soft water is required for Mill bearing cooling. Softening Plant will consist of
Softener Feed Pumps, Softener unit, Soft Water Storage Tanks and necessary pumping.
Softening Plant will be fed water from Filtered Water Storage Tank.

1.4.6 Fire Water System

For fire water system, dedicated compartment to store volume offire water
equivalent to 2 hours pumping capacity of main fire water pump is kept in the Raw
Water cum Fire Water Reservoir. The fire water system will be provided with pumps,
piping network and other associated facilities as per the appropriate TAC/ NFPA
codes. Fire water pumps comprising 1 no. motor driven pump (273 m3/hr capacity and
88 mWc head) 1 no. diesel engine driven pump (273 m3/hr capacity and 88 mWc head),
2 nos. jockey pumps (10.8 m3/hr capacity and 95 mWc head) will be installed in the
fire water pump house. External fire hydrant system will be provided around all
buildings/ facilities. Internal hydrant shall be provided for storied buildings and
basements. Automatic High Velocity Water Spray (HVWS) system will be provided to
protect large oil filled transformers. Generally the oil filled transformer
capacity 10 MVA and above or oil storage capacity more than 2000 litre shall be
protected by HVWS system. Medium Velocity Water Spray (MVWS) system will be
provided for Hydraulic/
lubricating oil cellar, Major Cable vaults in electrical buildings. LHS cable shall
also be provided for along with cable vaults. Water based automatic activated
medium expansion foam based protection systems will be provided for Oil Storage
Tanks. Inert gas flooding system will be provided for server rooms/ PLC rooms/
Battery rooms and chemically corrosive areas. Potable fire extinguisher will be
provided inside all buildings as per the guidelines laid down in the latest edition
of TAC.

1.5 Capacity of Major Facilities

List of Major facilities of plant water system are given in table below:
Sl No. Description Capacity/ Size of facilities
1. Raw Water cum Fire Water Reservoir About 1800 m3 capacity water
storage tank including fire water storage requirement.
2. Process Plant supply pumps 2 nos. (1W+1S) pumps of each of capacity
410 m3/hr flow and 50 mWC head (to distribute water from Reservoir to various
consumption points within Process plant).
3. Filter Feed Pumps 2 nos. (1W+1S) pumps of each of capacity 35 m3/hr
flow and 40 mWC head (to supply raw water to Dual Media Filter).
4. Dual Media Filters 2 Nos. of Pressure filters each of capacity 35
m3/hr along with backwash arrangement.
5. Filtered Water Storage Tank CS, filter water storage tank of capacity
200 m3.

6. Seal Water Pumps 2 nos. (1W+1S) pumps of each of capacity 25 m3/hr

flow and 80 mWC head (to distribute gland sealing water to various consumption
points within Process plant).
7. Potable Water System CS with internal epoxy painted, Potable water
storage tank of capacity 25 m3.
2 nos. (1W+1S) pumps of each of capacity 5 m3/hr flow and 55 mWC head (to
distribute water from Storage tank to various consumption points within Process
plant).
NaOCl dosing system for disinfection (tanks and dosing pumps).
8. Softening Plant 2 nos. (1W+1S) Softener Feed Pumps of each of
capacity 5 m3/hr flow and 20 mWC head to supply filtered water to Softener Unit.
2 nos. Na+based Softener Unit each of capacity 5m3/hr.
Brine Solution Tank and dosing pumps for regeneration of Softener Unit.
2 nos. (1W+1S) Soft water Supply Pumps of each of capacity 5 m3/hr flow and 30 mWC
head to supply Soft water to Cooling Tower at Mill area.
9. Fire fighting tank and pump
house with fire network
RCC Fire water tank ( included within Raw water reservoir) of about 600 m3
capacity with pump house
consisting of following pumps:
Fire Pumps of each of capacity 273 m3/hr flow and 88 mWC (1 no. Motor driven and 1
no. diesel driven).
- 2 nos. (1W+1S) Jockey Pumps of each of capacity 10.8 m3/hr flow and 95 mWC.

1.6 Major Equipment Design Criteria

1.6.1 Horizontal Pumps

i. All Small size pumps of capacity less than 200 m3/hr will be selected of
back-pull type with end suction and top discharge type.
ii. Required NPSH at duty point will be at least one (1) meter less than the
available NPSH.
iii. For Horizontal pumps, vibration level in the pumps will be limited to the
specified limit provided by Hydraulic institute Standards (HIS). The overall
vibration level shall be as per zones A and B of ISO 10816-1.
iv. Mechanical seal has been considered in for critical application pumps.
v. 100 % stand-by (1W +1S) pumps have been considered in each type/group of
horizontal pumps.
1.6.2 General Requirement of Pumps ( Horizontal And Vertical)
i. Head Calculation of Pumps
For estimating friction head in pressure pipe flow Hazen-Williams equation is used.
V = 0.849 x C x R 0.63 x S 0.54�.....Hazen-Williams formula for pressure loss
calculation
Where
V = Velocity in m/s
C = Hazen William constant for pipe
R = Hydraulic radius of pipe in meter = Internal Diameter/4
S = Head loss in meter per meter run of pipe
The accuracy of estimating friction head in piping system depends on selecting the
correct surface roughness coefficient. The condition of the interior surface of the
pipe varies by pipe material and over time with use, age, and the effects of
corrosion / erosion. �C� value of 100 has been considered for calculation of head
of pumps.
ii. 10 % margin will be considered in dynamic head for arriving the pump head.
iii. Motor rating of Pumps:
Minimum Motor rating for Motors of the all pumps will be large of followings:
a) 16 % margin on the power requirement of pump at rated duty point.
b) 10 % margin on the maximum input power requirement of entire pump characteristic
curve (within any operating point between maximum and minimum resistance curves.).
iv. The shut-off head will be at least 115% of the differential head.
v. Hydro test pressure on casing will be 1.5 times maximum discharge head or
twice differential head whichever is higher. (Maximum discharge head
vi. = shut-off head + maximum suction head). Hydro test pressure testing will be
done for at least 30 minutes.
vii. The critical speed of the pumps will be not less than 130% of the normal
operating speed of the pump
viii. The noise level will not exceed 85 dBA measured at 1 m from the outline of
pump set.
ix. All pumps, except for back-pull out type, will be provided with flexible
coupling. Back-pull out type pumps will be provided with spacer type coupling.

1.6.3 Filtration Plant

Design of Pressure Filters will be based on the following parameters:

a) Maximum Design Surface Flow rate : 15 m3/m2/hr.

b) Backwash rate : 25 m3/m2/hr.

c) Air scouring rate : 40 Nm3/m2/hr.

d) Backwash Interval : Will be determined by differential pressure

across DMF or 24 hrs of operations.
e) Free board : 80%
f) Guaranteed quality of Filtered water at design rated flow rate :
1NTU

1.6.4 Softener Unit

a) Each Softener is sized based on 5 m3/hr net flow rate.
b) The Softener unit shall be capable of treating the specified input influent
water of hardness 200 ppm, to meet the effluent water quality of hardness as 50
ppm.
c) Surface flowrate shall be considered as 40 m3/m2/hr.
d) Softe1.0 PLANT WATER SYSTEM
1.1 The plant water system starts from receiving of water at the Raw Water
Reservoir. Water will be conveyed from existing raw water supply line to the new
Raw Water Reservoir. Concrete twin compartment reservoir of approximate 1800m3
capacity has been envisaged as plant raw water storage which is equivalent to
4hours storage requirement along with 2hrs dedicated storage for fire water.
The scheme for plant water system has been presented in Proposed Scheme for Plant
Water System drawing no. TCE.11311A -610-FD-1000.
The quality of raw water is mentioned in Annexure-1.

1.2 Make-up Water Requirement

For the proposed plant, water is required for the process plant, drinking,
sanitation and other miscellaneous uses like canteen, safety shower, etc. The
individual water demand for the proposed plant is being tabulated below.
Parameter Units Value
Total Process Water Demand on the plant m3/hr 370
Raw Water makeup from existing supply line m3/hr 290
Reclaimed water from existing Reclaimed Water Pond. m3/hr 120
Filtered Water m3/hr 28
Potable water m3/hr 3
Soft water m3/hr 3

1.3 Battery Limit

The battery limit / terminal points for water system have been shown in Proposed
Scheme for Plant Water System drawing no. TCE.11311A -610-FD-1000.

1.4 System Description

The plant water system consists of the following sub systems.

1.4.1 Make-up Water System

It is envisaged that the makeup water for the process plant is taken from the Raw
Water Reservoir and necessary arrangements (pumps, piping and others) for the same
is mentioned in the flow diagram TCE.11311A -610-FD-1000.
Raw water is required for make-up water to Process Water Tank, Dust Suppression,
high pressure line flushing, filter cloth washing etc.

1.4.2 Filtration Unit

Filtered water is required for gland sealing, Softening Plant, drinking purpose,
etc. Filtration Unit consists of Filter Feed Pumps, Dual media Filters, Filtered
Water Storage Tank and all associated piping along with other necessary
arrangement. Raw water will be fed to the Dual Media Filter through Filter Feed
Pumps. Filtered water produced from filtration unit will be stored in Filter water
Storage tank of capacity 200 cum.

1.4.3 Potable Water System

Part of Filtered Water from Filtration Unit will be stored in Potable Water Storage
Tank. Sodium Hypochlorite solution will be dosed in the tank for disinfection
purpose. Potable Water will be distributed via Potable Water Pumps for use in
ablutions, drinking, washing and other uses in office, canteen and kitchen and for
use in safety showers.

1.4.4 Gland Seal Water

Filtered water from Filtered Water Storage tank shall be used for gland sealing.
Two (2) nos. Seal water Pumps have been envisaged for this purpose.

1.4.5 Softening Plant

Soft water is required for Mill bearing cooling. Softening Plant will consist of
Softener Feed Pumps, Softener unit, Soft Water Storage Tanks and necessary pumping.
Softening Plant will be fed water from Filtered Water Storage Tank.
1.4.6 Fire Water System
For fire water system, dedicated compartment to store volume offire water
equivalent to 2 hours pumping capacity of main fire water pump is kept in the Raw
Water cum Fire Water Reservoir. The fire water system will be provided with pumps,
piping network and other associated facilities as per the appropriate TAC/ NFPA
codes. Fire water pumps comprising 1 no. motor driven pump (273 m3/hr capacity and
88 mWc head) 1 no. diesel engine driven pump (273 m3/hr capacity and 88 mWc head),
2 nos. jockey pumps (10.8 m3/hr capacity and 95 mWc head) will be installed in the
fire water pump house. External fire hydrant system will be provided around all
buildings/ facilities. Internal hydrant shall be provided for storied buildings and
basements. Automatic High Velocity Water Spray (HVWS) system will be provided to
protect large oil filled transformers. Generally the oil filled transformer
capacity 10 MVA and above or oil storage capacity more than 2000 litre shall be
protected by HVWS system. Medium Velocity Water Spray (MVWS) system will be
provided for Hydraulic/
lubricating oil cellar, Major Cable vaults in electrical buildings. LHS cable shall
also be provided for along with cable vaults. Water based automatic activated
medium expansion foam based protection systems will be provided for Oil Storage
Tanks. Inert gas flooding system will be provided for server rooms/ PLC rooms/
Battery rooms and chemically corrosive areas. Potable fire extinguisher will be
provided inside all buildings as per the guidelines laid down in the latest edition
of TAC.

1.5 Capacity of Major Facilities

List of Major facilities of plant water system are given in table below:
Sl No. Description Capacity/ Size of facilities
1. Raw Water cum Fire Water Reservoir About 1800 m3 capacity water
storage tank including fire water storage requirement.
2. Process Plant supply pumps 2 nos. (1W+1S) pumps of each of capacity
410 m3/hr flow and 50 mWC head (to distribute water from Reservoir to various
consumption points within Process plant).
3. Filter Feed Pumps 2 nos. (1W+1S) pumps of each of capacity 35 m3/hr
flow and 40 mWC head (to supply raw water to Dual Media Filter).
4. Dual Media Filters 2 Nos. of Pressure filters each of capacity 35
m3/hr along with backwash arrangement.
5. Filtered Water Storage Tank CS, filter water storage tank of capacity
200 m3.

6. Seal Water Pumps 2 nos. (1W+1S) pumps of each of capacity 25 m3/hr

flow and 80 mWC head (to distribute gland sealing water to various consumption
points within Process plant).
7. Potable Water System CS with internal epoxy painted, Potable water
storage tank of capacity 25 m3.
2 nos. (1W+1S) pumps of each of capacity 5 m3/hr flow and 55 mWC head (to
distribute water from Storage tank to various consumption points within Process
plant).
NaOCl dosing system for disinfection (tanks and dosing pumps).
8. Softening Plant 2 nos. (1W+1S) Softener Feed Pumps of each of
capacity 5 m3/hr flow and 20 mWC head to supply filtered water to Softener Unit.
2 nos. Na+based Softener Unit each of capacity 5m3/hr.
Brine Solution Tank and dosing pumps for regeneration of Softener Unit.
2 nos. (1W+1S) Soft water Supply Pumps of each of capacity 5 m3/hr flow and 30 mWC
head to supply Soft water to Cooling Tower at Mill area.
9. Fire fighting tank and pump
house with fire network
RCC Fire water tank ( included within Raw water reservoir) of about 600 m3
capacity with pump house
consisting of following pumps:
Fire Pumps of each of capacity 273 m3/hr flow and 88 mWC (1 no. Motor driven and 1
no. diesel driven).
- 2 nos. (1W+1S) Jockey Pumps of each of capacity 10.8 m3/hr flow and 95 mWC.

1.6 Major Equipment Design Criteria

1.6.1 Horizontal Pumps

i. All Small size pumps of capacity less than 200 m3/hr will be selected of
back-pull type with end suction and top discharge type.
ii. Required NPSH at duty point will be at least one (1) meter less than the
available NPSH.
iii. For Horizontal pumps, vibration level in the pumps will be limited to the
specified limit provided by Hydraulic institute Standards (HIS). The overall
vibration level shall be as per zones A and B of ISO 10816-1.
iv. Mechanical seal has been considered in for critical application pumps.
v. 100 % stand-by (1W +1S) pumps have been considered in each type/group of
horizontal pumps.
1.6.2 General Requirement of Pumps ( Horizontal And Vertical)
i. Head Calculation of Pumps
For estimating friction head in pressure pipe flow Hazen-Williams equation is used.
V = 0.849 x C x R 0.63 x S 0.54�.....Hazen-Williams formula for pressure loss
calculation
Where
V = Velocity in m/s
C = Hazen William constant for pipe
R = Hydraulic radius of pipe in meter = Internal Diameter/4
S = Head loss in meter per meter run of pipe
The accuracy of estimating friction head in piping system depends on selecting the
correct surface roughness coefficient. The condition of the interior surface of the
pipe varies by pipe material and over time with use, age, and the effects of
corrosion / erosion. �C� value of 100 has been considered for calculation of head
of pumps.
ii. 10 % margin will be considered in dynamic head for arriving the pump head.
iii. Motor rating of Pumps:
Minimum Motor rating for Motors of the all pumps will be large of followings:
a) 16 % margin on the power requirement of pump at rated duty point.
b) 10 % margin on the maximum input power requirement of entire pump characteristic
curve (within any operating point between maximum and minimum resistance curves.).
iv. The shut-off head will be at least 115% of the differential head.
v. Hydro test pressure on casing will be 1.5 times maximum discharge head or
twice differential head whichever is higher. (Maximum discharge head
vi. = shut-off head + maximum suction head). Hydro test pressure testing will be
done for at least 30 minutes.
vii. The critical speed of the pumps will be not less than 130% of the normal
operating speed of the pump
viii. The noise level will not exceed 85 dBA measured at 1 m from the outline of
pump set.
ix. All pumps, except for back-pull out type, will be provided with flexible
coupling. Back-pull out type pumps will be provided with spacer type coupling.

1.6.3 Filtration Plant

Design of Pressure Filters will be based on the following parameters:

a) Maximum Design Surface Flow rate : 15 m3/m2/hr.

b) Backwash rate : 25 m3/m2/hr.

c) Air scouring rate : 40 Nm3/m2/hr.

d) Backwash Interval : Will be determined by differential pressure
across DMF or 24 hrs of operations.
e) Free board : 80%
f) Guaranteed quality of Filtered water at design rated flow rate :
1NTU

1.6.4 Softener Unit

a) Each Softener is sized based on 5 m3/hr net flow rate.
b) The Softener unit shall be capable of treating the specified input influent
water of hardness 200 ppm, to meet the effluent water quality of hardness as 50
ppm.
c) Surface flowrate shall be considered as 40 m3/m2/hr.
d) Softener vessel shall b designed as per IS 2825 or ASME Sec VIII Dev 1.

1.6.5 Water Storage Tank

i. Drain Valve and over flow lines will be provided in each tank.
ii. Tank will be with suitable cover to reduce the evaporation loss and protect
from external environment.
iii. MOC of tanks will be as follows :
Sl No. Descriptio1.0 PLANT WATER SYSTEM

1.1 The plant water system starts from receiving of water at the Raw Water
Reservoir. Water will be conveyed from existing raw water supply line to the new
Raw Water Reservoir. Concrete twin compartment reservoir of approximate 1800m3
capacity has been envisaged as plant raw water storage which is equivalent to
4hours storage requirement along with 2hrs dedicated storage for fire water.
The scheme for plant water system has been presented in Proposed Scheme for Plant
Water System drawing no. TCE.11311A -610-FD-1000.
The quality of raw water is mentioned in Annexure-1.

1.2 Make-up Water Requirement

For the proposed plant, water is required for the process plant, drinking,
sanitation and other miscellaneous uses like canteen, safety shower, etc. The
individual water demand for the proposed plant is being tabulated below.
Parameter Units Value
Total Process Water Demand on the plant m3/hr 370
Raw Water makeup from existing supply line m3/hr 290
Reclaimed water from existing Reclaimed Water Pond. m3/hr 120
Filtered Water m3/hr 28
Potable water m3/hr 3
Soft water m3/hr 3

1.3 Battery Limit

The battery limit / terminal points for water system have been shown in Proposed
Scheme for Plant Water System drawing no. TCE.11311A -610-FD-1000.

1.4 System Description

The plant water system consists of the following sub systems.

1.4.1 Make-up Water System

It is envisaged that the makeup water for the process plant is taken from the Raw
Water Reservoir and necessary arrangements (pumps, piping and others) for the same
is mentioned in the flow diagram TCE.11311A -610-FD-1000.
Raw water is required for make-up water to Process Water Tank, Dust Suppression,
high pressure line flushing, filter cloth washing etc.

1.4.2 Filtration Unit

Filtered water is required for gland sealing, Softening Plant, drinking purpose,
etc. Filtration Unit consists of Filter Feed Pumps, Dual media Filters, Filtered
Water Storage Tank and all associated piping along with other necessary
arrangement. Raw water will be fed to the Dual Media Filter through Filter Feed
Pumps. Filtered water produced from filtration unit will be stored in Filter water
Storage tank of capacity 200 cum.

1.4.3 Potable Water System

Part of Filtered Water from Filtration Unit will be stored in Potable Water Storage
Tank. Sodium Hypochlorite solution will be dosed in the tank for disinfection
purpose. Potable Water will be distributed via Potable Water Pumps for use in
ablutions, drinking, washing and other uses in office, canteen and kitchen and for
use in safety showers.

1.4.4 Gland Seal Water

Filtered water from Filtered Water Storage tank shall be used for gland sealing.
Two (2) nos. Seal water Pumps have been envisaged for this purpose.

1.4.5 Softening Plant

Soft water is required for Mill bearing cooling. Softening Plant will consist of
Softener Feed Pumps, Softener unit, Soft Water Storage Tanks and necessary pumping.
Softening Plant will be fed water from Filtered Water Storage Tank.

1.4.6 Fire Water System

For fire water system, dedicated compartment to store volume offire water
equivalent to 2 hours pumping capacity of main fire water pump is kept in the Raw
Water cum Fire Water Reservoir. The fire water system will be provided with pumps,
piping network and other associated facilities as per the appropriate TAC/ NFPA
codes. Fire water pumps comprising 1 no. motor driven pump (273 m3/hr capacity and
88 mWc head) 1 no. diesel engine driven pump (273 m3/hr capacity and 88 mWc head),
2 nos. jockey pumps (10.8 m3/hr capacity and 95 mWc head) will be installed in the
fire water pump house. External fire hydrant system will be provided around all
buildings/ facilities. Internal hydrant shall be provided for storied buildings and
basements. Automatic High Velocity Water Spray (HVWS) system will be provided to
protect large oil filled transformers. Generally the oil filled transformer
capacity 10 MVA and above or oil storage capacity more than 2000 litre shall be
protected by HVWS system. Medium Velocity Water Spray (MVWS) system will be
provided for Hydraulic/
lubricating oil cellar, Major Cable vaults in electrical buildings. LHS cable shall
also be provided for along with cable vaults. Water based automatic activated
medium expansion foam based protection systems will be provided for Oil Storage
Tanks. Inert gas flooding system will be provided for server rooms/ PLC rooms/
Battery rooms and chemically corrosive areas. Potable fire extinguisher will be
provided inside all buildings as per the guidelines laid down in the latest edition
of TAC.

1.5 Capacity of Major Facilities

List of Major facilities of plant water system are given in table below:
Sl No. Description Capacity/ Size of facilities
1. Raw Water cum Fire Water Reservoir About 1800 m3 capacity water
storage tank including fire water storage requirement.
2. Process Plant supply pumps 2 nos. (1W+1S) pumps of each of capacity
410 m3/hr flow and 50 mWC head (to distribute water from Reservoir to various
consumption points within Process plant).
3. Filter Feed Pumps 2 nos. (1W+1S) pumps of each of capacity 35 m3/hr
flow and 40 mWC head (to supply raw water to Dual Media Filter).
4. Dual Media Filters 2 Nos. of Pressure filters each of capacity 35
m3/hr along with backwash arrangement.
5. Filtered Water Storage Tank CS, filter water storage tank of capacity
200 m3.
6. Seal Water Pumps 2 nos. (1W+1S) pumps of each of capacity 25 m3/hr
flow and 80 mWC head (to distribute gland sealing water to various consumption
points within Process plant).
7. Potable Water System CS with internal epoxy painted, Potable water
storage tank of capacity 25 m3.
2 nos. (1W+1S) pumps of each of capacity 5 m3/hr flow and 55 mWC head (to
distribute water from Storage tank to various consumption points within Process
plant).
NaOCl dosing system for disinfection (tanks and dosing pumps).
8. Softening Plant 2 nos. (1W+1S) Softener Feed Pumps of each of
capacity 5 m3/hr flow and 20 mWC head to supply filtered water to Softener Unit.
2 nos. Na+based Softener Unit each of capacity 5m3/hr.
Brine Solution Tank and dosing pumps for regeneration of Softener Unit.
2 nos. (1W+1S) Soft water Supply Pumps of each of capacity 5 m3/hr flow and 30 mWC
head to supply Soft water to Cooling Tower at Mill area.
9. Fire fighting tank and pump
house with fire network
RCC Fire water tank ( included within Raw water reservoir) of about 600 m3
capacity with pump house
consisting of following pumps:
Fire Pumps of each of capacity 273 m3/hr flow and 88 mWC (1 no. Motor driven and 1
no. diesel driven).
- 2 nos. (1W+1S) Jockey Pumps of each of capacity 10.8 m3/hr flow and 95 mWC.

1.6 Major Equipment Design Criteria

1.6.1 Horizontal Pumps

i. All Small size pumps of capacity less than 200 m3/hr will be selected of
back-pull type with end suction and top discharge type.
ii. Required NPSH at duty point will be at least one (1) meter less than the
available NPSH.
iii. For Horizontal pumps, vibration level in the pumps will be limited to the
specified limit provided by Hydraulic institute Standards (HIS). The overall
vibration level shall be as per zones A and B of ISO 10816-1.
iv. Mechanical seal has been considered in for critical application pumps.
v. 100 % stand-by (1W +1S) pumps have been considered in each type/group of
horizontal pumps.
1.6.2 General Requirement of Pumps ( Horizontal And Vertical)
i. Head Calculation of Pumps
For estimating friction head in pressure pipe flow Hazen-Williams equation is used.
V = 0.849 x C x R 0.63 x S 0.54�.....Hazen-Williams formula for pressure loss
calculation
Where
V = Velocity in m/s
C = Hazen William constant for pipe
R = Hydraulic radius of pipe in meter = Internal Diameter/4
S = Head loss in meter per meter run of pipe
The accuracy of estimating friction head in piping system depends on selecting the
correct surface roughness coefficient. The condition of the interior surface of the
pipe varies by pipe material and over time with use, age, and the effects of
corrosion / erosion. �C� value of 100 has been considered for calculation of head
of pumps.
ii. 10 % margin will be considered in dynamic head for arriving the pump head.
iii. Motor rating of Pumps:
Minimum Motor rating for Motors of the all pumps will be large of followings:
a) 16 % margin on the power requirement of pump at rated duty point.
b) 10 % margin on the maximum input power requirement of entire pump characteristic
curve (within any operating point between maximum and minimum resistance curves.).
iv. The shut-off head will be at least 115% of the differential head.
v. Hydro test pressure on casing will be 1.5 times maximum discharge head or
twice differential head whichever is higher. (Maximum discharge head
vi. = shut-off head + maximum suction head). Hydro test pressure testing will be
done for at least 30 minutes.
vii. The critical speed of the pumps will be not less than 130% of the normal
operating speed of the pump
viii. The noise level will not exceed 85 dBA measured at 1 m from the outline of
pump set.
ix. All pumps, except for back-pull out type, will be provided with flexible
coupling. Back-pull out type pumps will be provided with spacer type coupling.

1.6.3 Filtration Plant

Design of Pressure Filters will be based on the following parameters:

a) Maximum Design Surface Flow rate : 15 m3/m2/hr.

b) Backwash rate : 25 m3/m2/hr.

c) Air scouring rate : 40 Nm3/m2/hr.

d) Backwash Interval : Will be determined by differential pressure

across DMF or 24 hrs of operations.
e) Free board : 80%
f) Guaranteed quality of Filtered water at design rated flow rate :
1NTU

1.6.4 Softener Unit

a) Each Softener is sized based on 5 m3/hr net flow rate.
b) The Softener unit shall be capable of treating the specified input influent
water of hardness 200 ppm, to meet the effluent water quality of hardness as 50
ppm.
c) Surface flowrate shall be considered as 40 m3/m2/hr.
d) Softener vessel shall b designed as per IS 2825 or ASME Sec VIII Dev 1.

1.6.5 Water Storage Tank

i. Drain Valve and over flow lines will be provided in each tank.
ii. Tank will be with suitable cover to reduce the evaporation loss and protect
from external environment.
iii. MOC of tanks will be as follows :
Sl No. Description MOC
1. Raw Water cum Fire Water Reservoir RCC construction
2. Filtered Water Storage Tank CS
3. Potable Water Storage Tank CS with epoxy painted
4. Soft W1.0 PLANT WATER SYSTEM

1.1 The plant water system starts from receiving of water at the Raw Water
Reservoir. Water will be conveyed from existing raw water supply line to the new
Raw Water Reservoir. Concrete twin compartment reservoir of approximate 1800m3
capacity has been envisaged as plant raw water storage which is equivalent to
4hours storage requirement along with 2hrs dedicated storage for fire water.
The scheme for plant water system has been presented in Proposed Scheme for Plant
Water System drawing no. TCE.11311A -610-FD-1000.
The quality of raw water is mentioned in Annexure-1.

1.2 Make-up Water Requirement

For the proposed plant, water is required for the process plant, drinking,
sanitation and other miscellaneous uses like canteen, safety shower, etc. The
individual water demand for the proposed plant is being tabulated below.
Parameter Units Value
Total Process Water Demand on the plant m3/hr 370
Raw Water makeup from existing supply line m3/hr 290
Reclaimed water from existing Reclaimed Water Pond. m3/hr 120
Filtered Water m3/hr 28
Potable water m3/hr 3
Soft water m3/hr 3

1.3 Battery Limit

The battery limit / terminal points for water system have been shown in Proposed
Scheme for Plant Water System drawing no. TCE.11311A -610-FD-1000.

1.4 System Description

The plant water system consists of the following sub systems.

1.4.1 Make-up Water System

It is envisaged that the makeup water for the process plant is taken from the Raw
Water Reservoir and necessary arrangements (pumps, piping and others) for the same
is mentioned in the flow diagram TCE.11311A -610-FD-1000.
Raw water is required for make-up water to Process Water Tank, Dust Suppression,
high pressure line flushing, filter cloth washing etc.

1.4.2 Filtration Unit

Filtered water is required for gland sealing, Softening Plant, drinking purpose,
etc. Filtration Unit consists of Filter Feed Pumps, Dual media Filters, Filtered
Water Storage Tank and all associated piping along with other necessary
arrangement. Raw water will be fed to the Dual Media Filter through Filter Feed
Pumps. Filtered water produced from filtration unit will be stored in Filter water
Storage tank of capacity 200 cum.

1.4.3 Potable Water System

Part of Filtered Water from Filtration Unit will be stored in Potable Water Storage
Tank. Sodium Hypochlorite solution will be dosed in the tank for disinfection
purpose. Potable Water will be distributed via Potable Water Pumps for use in
ablutions, drinking, washing and other uses in office, canteen and kitchen and for
use in safety showers.

1.4.4 Gland Seal Water

Filtered water from Filtered Water Storage tank shall be used for gland sealing.
Two (2) nos. Seal water Pumps have been envisaged for this purpose.

1.4.5 Softening Plant

Soft water is required for Mill bearing cooling. Softening Plant will consist of
Softener Feed Pumps, Softener unit, Soft Water Storage Tanks and necessary pumping.
Softening Plant will be fed water from Filtered Water Storage Tank.

1.4.6 Fire Water System

For fire water system, dedicated compartment to store volume offire water
equivalent to 2 hours pumping capacity of main fire water pump is kept in the Raw
Water cum Fire Water Reservoir. The fire water system will be provided with pumps,
piping network and other associated facilities as per the appropriate TAC/ NFPA
codes. Fire water pumps comprising 1 no. motor driven pump (273 m3/hr capacity and
88 mWc head) 1 no. diesel engine driven pump (273 m3/hr capacity and 88 mWc head),
2 nos. jockey pumps (10.8 m3/hr capacity and 95 mWc head) will be installed in the
fire water pump house. External fire hydrant system will be provided around all
buildings/ facilities. Internal hydrant shall be provided for storied buildings and
basements. Automatic High Velocity Water Spray (HVWS) system will be provided to
protect large oil filled transformers. Generally the oil filled transformer
capacity 10 MVA and above or oil storage capacity more than 2000 litre shall be
protected by HVWS system. Medium Velocity Water Spray (MVWS) system will be
provided for Hydraulic/
lubricating oil cellar, Major Cable vaults in electrical buildings. LHS cable shall
also be provided for along with cable vaults. Water based automatic activated
medium expansion foam based protection systems will be provided for Oil Storage
Tanks. Inert gas flooding system will be provided for server rooms/ PLC rooms/
Battery rooms and chemically corrosive areas. Potable fire extinguisher will be
provided inside all buildings as per the guidelines laid down in the latest edition
of TAC.

1.5 Capacity of Major Facilities

List of Major facilities of plant water system are given in table below:
Sl No. Description Capacity/ Size of facilities
1. Raw Water cum Fire Water Reservoir About 1800 m3 capacity water
storage tank including fire water storage requirement.
2. Process Plant supply pumps 2 nos. (1W+1S) pumps of each of capacity
410 m3/hr flow and 50 mWC head (to distribute water from Reservoir to various
consumption points within Process plant).
3. Filter Feed Pumps 2 nos. (1W+1S) pumps of each of capacity 35 m3/hr
flow and 40 mWC head (to supply raw water to Dual Media Filter).
4. Dual Media Filters 2 Nos. of Pressure filters each of capacity 35
m3/hr along with backwash arrangement.
5. Filtered Water Storage Tank CS, filter water storage tank of capacity
200 m3.

6. Seal Water Pumps 2 nos. (1W+1S) pumps of each of capacity 25 m3/hr

flow and 80 mWC head (to distribute gland sealing water to various consumption
points within Process plant).
7. Potable Water System CS with internal epoxy painted, Potable water
storage tank of capacity 25 m3.
2 nos. (1W+1S) pumps of each of capacity 5 m3/hr flow and 55 mWC head (to
distribute water from Storage tank to various consumption points within Process
plant).
NaOCl dosing system for disinfection (tanks and dosing pumps).
8. Softening Plant 2 nos. (1W+1S) Softener Feed Pumps of each of
capacity 5 m3/hr flow and 20 mWC head to supply filtered water to Softener Unit.
2 nos. Na+based Softener Unit each of capacity 5m3/hr.
Brine Solution Tank and dosing pumps for regeneration of Softener Unit.
2 nos. (1W+1S) Soft water Supply Pumps of each of capacity 5 m3/hr flow and 30 mWC
head to supply Soft water to Cooling Tower at Mill area.
9. Fire fighting tank and pump
house with fire network
RCC Fire water tank ( included within Raw water reservoir) of about 600 m3
capacity with pump house
consisting of following pumps:
Fire Pumps of each of capacity 273 m3/hr flow and 88 mWC (1 no. Motor driven and 1
no. diesel driven).
- 2 nos. (1W+1S) Jockey Pumps of each of capacity 10.8 m3/hr flow and 95 mWC.

1.6 Major Equipment Design Criteria

1.6.1 Horizontal Pumps

i. All Small size pumps of capacity less than 200 m3/hr will be selected of
back-pull type with end suction and top discharge type.
ii. Required NPSH at duty point will be at least one (1) meter less than the
available NPSH.
iii. For Horizontal pumps, vibration level in the pumps will be limited to the
specified limit provided by Hydraulic institute Standards (HIS). The overall
vibration level shall be as per zones A and B of ISO 10816-1.
iv. Mechanical seal has been considered in for critical application pumps.
v. 100 % stand-by (1W +1S) pumps have been considered in each type/group of
horizontal pumps.
1.6.2 General Requirement of Pumps ( Horizontal And Vertical)
i. Head Calculation of Pumps
For estimating friction head in pressure pipe flow Hazen-Williams equation is used.
V = 0.849 x C x R 0.63 x S 0.54�.....Hazen-Williams formula for pressure loss
calculation
Where
V = Velocity in m/s
C = Hazen William constant for pipe
R = Hydraulic radius of pipe in meter = Internal Diameter/4
S = Head loss in meter per meter run of pipe
The accuracy of estimating friction head in piping system depends on selecting the
correct surface roughness coefficient. The condition of the interior surface of the
pipe varies by pipe material and over time with use, age, and the effects of
corrosion / erosion. �C� value of 100 has been considered for calculation of head
of pumps.
ii. 10 % margin will be considered in dynamic head for arriving the pump head.
iii. Motor rating of Pumps:
Minimum Motor rating for Motors of the all pumps will be large of followings:
a) 16 % margin on the power requirement of pump at rated duty point.
b) 10 % margin on the maximum input power requirement of entire pump characteristic
curve (within any operating point between maximum and minimum resistance curves.).
iv. The shut-off head will be at least 115% of the differential head.
v. Hydro test pressure on casing will be 1.5 times maximum discharge head or
twice differential head whichever is higher. (Maximum discharge head
vi. = shut-off head + maximum suction head). Hydro test pressure testing will be
done for at least 30 minutes.
vii. The critical speed of the pumps will be not less than 130% of the normal
operating speed of the pump
viii. The noise level will not exceed 85 dBA measured at 1 m from the outline of
pump set.
ix. All pumps, except for back-pull out type, will be provided with flexible
coupling. Back-pull out type pumps will be provided with spacer type coupling.

1.6.3 Filtration Plant

Design of Pressure Filters will be based on the following parameters:

a) Maximum Design Surface Flow rate : 15 m3/m2/hr.

b) Backwash rate : 25 m3/m2/hr.

c) Air scouring rate : 40 Nm3/m2/hr.

d) Backwash Interval : Will be determined by differential pressure

across DMF or 24 hrs of operations.
e) Free board : 80%
f) Guaranteed quality of Filtered water at design rated flow rate :
1NTU

1.6.4 Softener Unit

a) Each Softener is sized based on 5 m3/hr net flow rate.
b) The Softener unit shall be capable of treating the specified input influent
water of hardness 200 ppm, to meet the effluent water quality of hardness as 50
ppm.
c) Surface flowrate shall be considered as 40 m3/m2/hr.
d) Softener vessel shall b designed as per IS 2825 or ASME Sec VIII Dev 1.

1.6.5 Water Storage Tank

i. Drain Valve and over flow lines will be provided in each tank.
ii. Tank will be with suitable cover to reduce the evaporation loss and protect
from external environment.
iii. MOC of tanks will be as follows :
Sl No. Description MOC
1. Raw Water cum Fire Water Reservoir RCC construction
2. Filtered Water Storage Tank CS
3. Potable Water Storage Tank CS with epoxy painted
4. Soft Water Storage Tank CS

1.6.6 Disinfection /Chlorination System

a. FRP NaOCl Dosing Tank will be provided.
b. Reciprocating type dosing pumps will be provided.
c. Carbon steel with food grade epoxy paint potable water tank will be provided
for storing the filter water.
d. Horizonta1.0 PLANT WATER SYSTEM

1.1 The plant water system starts from receiving of water at the Raw Water
Reservoir. Water will be conveyed from existing raw water supply line to the new
Raw Water Reservoir. Concrete twin compartment reservoir of approximate 1800m3
capacity has been envisaged as plant raw water storage which is equivalent to
4hours storage requirement along with 2hrs dedicated storage for fire water.
The scheme for plant water system has been presented in Proposed Scheme for Plant
Water System drawing no. TCE.11311A -610-FD-1000.
The quality of raw water is mentioned in Annexure-1.

1.2 Make-up Water Requirement

For the proposed plant, water is required for the process plant, drinking,
sanitation and other miscellaneous uses like canteen, safety shower, etc. The
individual water demand for the proposed plant is being tabulated below.
Parameter Units Value
Total Process Water Demand on the plant m3/hr 370
Raw Water makeup from existing supply line m3/hr 290
Reclaimed water from existing Reclaimed Water Pond. m3/hr 120
Filtered Water m3/hr 28
Potable water m3/hr 3
Soft water m3/hr 3

1.3 Battery Limit

The battery limit / terminal points for water system have been shown in Proposed
Scheme for Plant Water System drawing no. TCE.11311A -610-FD-1000.

1.4 System Description

The plant water system consists of the following sub systems.

1.4.1 Make-up Water System

It is envisaged that the makeup water for the process plant is taken from the Raw
Water Reservoir and necessary arrangements (pumps, piping and others) for the same
is mentioned in the flow diagram TCE.11311A -610-FD-1000.
Raw water is required for make-up water to Process Water Tank, Dust Suppression,
high pressure line flushing, filter cloth washing etc.

1.4.2 Filtration Unit

Filtered water is required for gland sealing, Softening Plant, drinking purpose,
etc. Filtration Unit consists of Filter Feed Pumps, Dual media Filters, Filtered
Water Storage Tank and all associated piping along with other necessary
arrangement. Raw water will be fed to the Dual Media Filter through Filter Feed
Pumps. Filtered water produced from filtration unit will be stored in Filter water
Storage tank of capacity 200 cum.
1.4.3 Potable Water System
Part of Filtered Water from Filtration Unit will be stored in Potable Water Storage
Tank. Sodium Hypochlorite solution will be dosed in the tank for disinfection
purpose. Potable Water will be distributed via Potable Water Pumps for use in
ablutions, drinking, washing and other uses in office, canteen and kitchen and for
use in safety showers.

1.4.4 Gland Seal Water

Filtered water from Filtered Water Storage tank shall be used for gland sealing.
Two (2) nos. Seal water Pumps have been envisaged for this purpose.

1.4.5 Softening Plant

Soft water is required for Mill bearing cooling. Softening Plant will consist of
Softener Feed Pumps, Softener unit, Soft Water Storage Tanks and necessary pumping.
Softening Plant will be fed water from Filtered Water Storage Tank.

1.4.6 Fire Water System

For fire water system, dedicated compartment to store volume offire water
equivalent to 2 hours pumping capacity of main fire water pump is kept in the Raw
Water cum Fire Water Reservoir. The fire water system will be provided with pumps,
piping network and other associated facilities as per the appropriate TAC/ NFPA
codes. Fire water pumps comprising 1 no. motor driven pump (273 m3/hr capacity and
88 mWc head) 1 no. diesel engine driven pump (273 m3/hr capacity and 88 mWc head),
2 nos. jockey pumps (10.8 m3/hr capacity and 95 mWc head) will be installed in the
fire water pump house. External fire hydrant system will be provided around all
buildings/ facilities. Internal hydrant shall be provided for storied buildings and
basements. Automatic High Velocity Water Spray (HVWS) system will be provided to
protect large oil filled transformers. Generally the oil filled transformer
capacity 10 MVA and above or oil storage capacity more than 2000 litre shall be
protected by HVWS system. Medium Velocity Water Spray (MVWS) system will be
provided for Hydraulic/
lubricating oil cellar, Major Cable vaults in electrical buildings. LHS cable shall
also be provided for along with cable vaults. Water based automatic activated
medium expansion foam based protection systems will be provided for Oil Storage
Tanks. Inert gas flooding system will be provided for server rooms/ PLC rooms/
Battery rooms and chemically corrosive areas. Potable fire extinguisher will be
provided inside all buildings as per the guidelines laid down in the latest edition
of TAC.

1.5 Capacity of Major Facilities

List of Major facilities of plant water system are given in table below:
Sl No. Description Capacity/ Size of facilities
1. Raw Water cum Fire Water Reservoir About 1800 m3 capacity water
storage tank including fire water storage requirement.
2. Process Plant supply pumps 2 nos. (1W+1S) pumps of each of capacity
410 m3/hr flow and 50 mWC head (to distribute water from Reservoir to various
consumption points within Process plant).
3. Filter Feed Pumps 2 nos. (1W+1S) pumps of each of capacity 35 m3/hr
flow and 40 mWC head (to supply raw water to Dual Media Filter).
4. Dual Media Filters 2 Nos. of Pressure filters each of capacity 35
m3/hr along with backwash arrangement.
5. Filtered Water Storage Tank CS, filter water storage tank of capacity
200 m3.

6. Seal Water Pumps 2 nos. (1W+1S) pumps of each of capacity 25 m3/hr

flow and 80 mWC head (to distribute gland sealing water to various consumption
points within Process plant).
7. Potable Water System CS with internal epoxy painted, Potable water
storage tank of capacity 25 m3.
2 nos. (1W+1S) pumps of each of capacity 5 m3/hr flow and 55 mWC head (to
distribute water from Storage tank to various consumption points within Process
plant).
NaOCl dosing system for disinfection (tanks and dosing pumps).
8. Softening Plant 2 nos. (1W+1S) Softener Feed Pumps of each of
capacity 5 m3/hr flow and 20 mWC head to supply filtered water to Softener Unit.
2 nos. Na+based Softener Unit each of capacity 5m3/hr.
Brine Solution Tank and dosing pumps for regeneration of Softener Unit.
2 nos. (1W+1S) Soft water Supply Pumps of each of capacity 5 m3/hr flow and 30 mWC
head to supply Soft water to Cooling Tower at Mill area.
9. Fire fighting tank and pump
house with fire network
RCC Fire water tank ( included within Raw water reservoir) of about 600 m3
capacity with pump house
consisting of following pumps:
Fire Pumps of each of capacity 273 m3/hr flow and 88 mWC (1 no. Motor driven and 1
no. diesel driven).
- 2 nos. (1W+1S) Jockey Pumps of each of capacity 10.8 m3/hr flow and 95 mWC.

1.6 Major Equipment Design Criteria

1.6.1 Horizontal Pumps

i. All Small size pumps of capacity less than 200 m3/hr will be selected of
back-pull type with end suction and top discharge type.
ii. Required NPSH at duty point will be at least one (1) meter less than the
available NPSH.
iii. For Horizontal pumps, vibration level in the pumps will be limited to the
specified limit provided by Hydraulic institute Standards (HIS). The overall
vibration level shall be as per zones A and B of ISO 10816-1.
iv. Mechanical seal has been considered in for critical application pumps.
v. 100 % stand-by (1W +1S) pumps have been considered in each type/group of
horizontal pumps.
1.6.2 General Requirement of Pumps ( Horizontal And Vertical)
i. Head Calculation of Pumps
For estimating friction head in pressure pipe flow Hazen-Williams equation is used.
V = 0.849 x C x R 0.63 x S 0.54�.....Hazen-Williams formula for pressure loss
calculation
Where
V = Velocity in m/s
C = Hazen William constant for pipe
R = Hydraulic radius of pipe in meter = Internal Diameter/4
S = Head loss in meter per meter run of pipe
The accuracy of estimating friction head in piping system depends on selecting the
correct surface roughness coefficient. The condition of the interior surface of the
pipe varies by pipe material and over time with use, age, and the effects of
corrosion / erosion. �C� value of 100 has been considered for calculation of head
of pumps.
ii. 10 % margin will be considered in dynamic head for arriving the pump head.
iii. Motor rating of Pumps:
Minimum Motor rating for Motors of the all pumps will be large of followings:
a) 16 % margin on the power requirement of pump at rated duty point.
b) 10 % margin on the maximum input power requirement of entire pump characteristic
curve (within any operating point between maximum and minimum resistance curves.).
iv. The shut-off head will be at least 115% of the differential head.
v. Hydro test pressure on casing will be 1.5 times maximum discharge head or
twice differential head whichever is higher. (Maximum discharge head
vi. = shut-off head + maximum suction head). Hydro test pressure testing will be
done for at least 30 minutes.
vii. The critical speed of the pumps will be not less than 130% of the normal
operating speed of the pump
viii. The noise level will not exceed 85 dBA measured at 1 m from the outline of
pump set.
ix. All pumps, except for back-pull out type, will be provided with flexible
coupling. Back-pull out type pumps will be provided with spacer type coupling.

1.6.3 Filtration Plant

Design of Pressure Filters will be based on the following parameters:

a) Maximum Design Surface Flow rate : 15 m3/m2/hr.

b) Backwash rate : 25 m3/m2/hr.

c) Air scouring rate : 40 Nm3/m2/hr.

d) Backwash Interval : Will be determined by differential pressure

across DMF or 24 hrs of operations.
e) Free board : 80%
f) Guaranteed quality of Filtered water at design rated flow rate :
1NTU

1.6.4 Softener Unit

a) Each Softener is sized based on 5 m3/hr net flow rate.
b) The Softener unit shall be capable of treating the specified input influent
water of hardness 200 ppm, to meet the effluent water quality of hardness as 50
ppm.
c) Surface flowrate shall be considered as 40 m3/m2/hr.
d) Softener vessel shall b designed as per IS 2825 or ASME Sec VIII Dev 1.

1.6.5 Water Storage Tank

i. Drain Valve and over flow lines will be provided in each tank.
ii. Tank will be with suitable cover to reduce the evaporation loss and protect
from external environment.
iii. MOC of tanks will be as follows :
Sl No. Description MOC
1. Raw Water cum Fire Water Reservoir RCC construction
2. Filtered Water Storage Tank CS
3. Potable Water Storage Tank CS with epoxy painted
4. Soft Water Storage Tank CS

1.6.6 Disinfection /Chlorination System

a. FRP NaOCl Dosing Tank will be provided.
b. Reciprocating type dosing pumps will be provided.
c. Carbon steel with food grade epoxy paint potable water tank will be provided
for storing the filter water.
d. Horizontal Potable Water Pumps will be provided to pump water from tank to
distribution.

1.6.7 Pipeline
i. Design Pressure
Design pressure will be the maximum expected pressure to which the system may be
subjected. Maximum expected pressure for a system placed in the discharge line of a
pump will be based on the shut-off head of the pump plus static head at pump
suction, if any.
ii. Design Temperature
Design temperature will be 10 Deg C higher than the maximum temperature that any
part of the system is likely to attain in course of operation. The design
temperature will be finalized based on maximum ambient temperature.
iii. Design Velocity
Pipe lines l Potable Water Pumps will be provided to pump water from tank to
distribution.

1.6.7 Pipeline
i. Design Pressure
Design pressure will be the maximum expected pressure to which the system may be
subjected. Maximum expected pressure for a system placed in the discharge line of a
pump will be based on the shut-off head of the pump plus static head at pump
suction, if any.
ii. Design Temperature
Design temperature will be 10 Deg C higher than the maximum temperature that any
part of the system is likely to attain in course of operation. The design
temperature will be finalized based on maximum ambient temperature.
iii. Design Velocity
Pipe lines ater Storage Tank CS

1.6.6 Disinfection /Chlorination System

a. FRP NaOCl Dosing Tank will be provided.
b. Reciprocating type dosing pumps will be provided.
c. Carbon steel with food grade epoxy paint potable water tank will be provided
for storing the filter water.
d. Horizontal Potable Water Pumps will be provided to pump water from tank to
distribution.

1.6.7 Pipeline
i. Design Pressure
Design pressure will be the maximum expected pressure to which the system may be
subjected. Maximum expected pressure for a system placed in the discharge line of a
pump will be based on the shut-off head of the pump plus static head at pump
suction, if any.
ii. Design Temperature
Design temperature will be 10 Deg C higher than the maximum temperature that any
part of the system is likely to attain in course of operation. The design
temperature will be finalized based on maximum ambient temperature.
iii. Design Velocity
Pipe lines n MOC
1. Raw Water cum Fire Water Reservoir RCC construction
2. Filtered Water Storage Tank CS
3. Potable Water Storage Tank CS with epoxy painted
4. Soft Water Storage Tank CS

1.6.6 Disinfection /Chlorination System

a. FRP NaOCl Dosing Tank will be provided.
b. Reciprocating type dosing pumps will be provided.
c. Carbon steel with food grade epoxy paint potable water tank will be provided
for storing the filter water.
d. Horizontal Potable Water Pumps will be provided to pump water from tank to
distribution.

1.6.7 Pipeline
i. Design Pressure
Design pressure will be the maximum expected pressure to which the system may be
subjected. Maximum expected pressure for a system placed in the discharge line of a
pump will be based on the shut-off head of the pump plus static head at pump
suction, if any.
ii. Design Temperature
Design temperature will be 10 Deg C higher than the maximum temperature that any
part of the system is likely to attain in course of operation. The design
temperature will be finalized based on maximum ambient temperature.
iii. Design Velocity
Pipe lines ner vessel shall b designed as per IS 2825 or ASME Sec VIII Dev 1.

1.6.5 Water Storage Tank

i. Drain Valve and over flow lines will be provided in each tank.
ii. Tank will be with suitable cover to reduce the evaporation loss and protect
from external environment.
iii. MOC of tanks will be as follows :
Sl No. Description MOC
1. Raw Water cum Fire Water Reservoir RCC construction
2. Filtered Water Storage Tank CS
3. Potable Water Storage Tank CS with epoxy painted
4. Soft Water Storage Tank CS

1.6.6 Disinfection /Chlorination System

a. FRP NaOCl Dosing Tank will be provided.
b. Reciprocating type dosing pumps will be provided.
c. Carbon steel with food grade epoxy paint potable water tank will be provided
for storing the filter water.
d. Horizontal Potable Water Pumps will be provided to pump water from tank to
distribution.

1.6.7 Pipeline
i. Design Pressure
Design pressure will be the maximum expected pressure to which the system may be
subjected. Maximum expected pressure for a system placed in the discharge line of a
pump will be based on the shut-off head of the pump plus static head at pump
suction, if any.
ii. Design Temperature
Design temperature will be 10 Deg C higher than the maximum temperature that any
part of the system is likely to attain in course of operation. The design
temperature will be finalized based on maximum ambient temperature.
iii. Design Velocity
Pipe lines water, chemicals, air etc. should be sized on the following velocities:
Velocity in m/sec
Sl No. Description Pipe Size
Below 50 mm 50-150 mm 200 mm & above
a) Pump Suction for Water - 1.2-1.5 1.2-1.5
b) Pump Discharge for Water 0.8-1.0 1.2-1.8 1.5-2.5
c) Pump suction for chemical solution 0.8-1.2 0.8-1.3 -
d) Pump discharge for chemical solution 1.2-1.4 1.3-1.5 -
e) Compressed air below 2 kg./sq.m (g) 10-15 10-20 10-25
f) Compressed air [ 2 kg./sq.m (g) & above] 10-20 10-25 15-25

iv. Velocity consideration in Gravity Flow

Pipe line under gravity flow shall be restricted to a flow velocity of 1 m/sec
generally. Channels under gravity flow shall be sized for a maximum flow velocity
of 0.6 m/sec.
v. Velocity consideration in raw water pipeline will be generally kept between
1.1 to 2.5 m/s, which depends on the size, length, MOC, static head, terminal point
head etc.
vi. Material of Construction
The MOC of pipe for different application is tabulated below:
Service Recommended Material
Raw Water/Clarified water/ Filtered Water Carbon steel
Slurry line Cast Iron/ Ductile Iron- Cement mortar lined pipes / HDPE/GRP
Instrument Air/Service Air/Potable Water Galvanized Steel
Waste water HDPE/ GRP / MS Rubber lined
vii. Corrosion allowance of 1.5 mm will be considered in thickness while selecting
final thickness of pipeline.
viii. Air release valves will be provided at the peaks of pipelines at suitable
interval.
ix. Drain Valves will be provided in lower points at some interval to facilitate
the cleaning and maintenance of pipeline during shut down.

1.6.8 Valves
Valves will be of hand operated, gear operated or motor operated depending up on
the application and under the guidance of applicable standard like IS, ASME etc.

1.6.9 Fire Fighting System

i. The fire water tank shall be RCC construction and situated above ground. Two
(2) nos. of horizontal centrifugal firewater pumps (One electric motor driven and
one diesel engine driven) will supply water to fire water system network. Design
considers maximum one pump (electric motor driven) is in operation and the diesel
engine driven pump remaining as standby. 2 Nos. of Jockey pumps will be provided
along with the main fire pumps.
ii. The booster pumps will also start automatically when the header pressure at
the discharge of fire water pumps falls below a pre set value.
iii. Design Criteria
a. Hazard class will be considered as per TAC guideline.
b. The fire pumps, jockey pumps, their drive motors and diesel engines complete
with fuel systems, piping, fittings and valves will be designed as per TAC
guideline.
c. Fire water pump houses shall be provided with required nos. of electric motor
driven flooded suction, horizontal centrifugal (split casing) pump sets, diesel
engine driven pump sets and vertical turbine type jockey pump to cater to the needs
of the water based fire-fighting system an independent fire fighting network with
all associated electric, instrumentation piping handling and hoisting facilities
etc. shall be provided in line with the TAC requirement. Also a wet riser ring
main shall be provided which will cover the complete plant complex.
d. All fire pumps shall be of identical design based on spares interchange
ability criteria.
iv. Hydrant protection system
a. Fire hydrant system shall be provided as per TAC guideline, considering the
plant as ordinary hazard.
b. Interval between two consecutive hydrants shall be maximum 45 meter.
c. Internal hydrant shall be provided on all the floors of the buildings.
d. Hydrant system shall be hydraulically so designed that a minimum pressure of
3.5 Kg/cm2g is available at the farthest and highest hydrant valves/landing valves.
e. Water monitor shall be provided if the target height is more than 15 meter.
f. Suitable orifice plates shall be provided for the hydrant valves to limit the
pressure wherever required and suitably designed orifice plates shall also be
provided at the tap-off for spray, sprinkler and water curtain systems to obtain
required pressure as per TAC rules. Orifice plates shall be supplied and erected at
no additional cost to the PURCHASER
g. Line sizing shall take care of future needs as indicated in the enquiry
document. Pressure drop calculations shall be based on Hazen William constant C of
100 for cast iron pipes and 120 for steel pipes
h. External fire hydrants shall not be located less than 2 m or more than 15 m
from major buildings and structures.
i. Fire escape hydrants at each landing of staircase shall be provided for
elevated buildings/structures.
v. Fixed water based spray protection system
a. HVW spray system
� Design water spray density of 10.2 LPM/m� of protected area shall be
considered as per TAC.
� Quartzoid bulb detectors located at strategic points around the protected
equipment/zone are provided as per TAC.
� One deluge valve shall be provided for each protected area.
� Spray nozzles shall be of stainless steel construction and provided with
integral strainers.
b. MVW spray system
� Cable galleries/Cable vaults are provided with MVW spray system.
� Fire detection system for cable galleries/cable vaults shall consist of both
spot type heat detectors and photoelectric type smoke detectors provided in
suitable combination. A single run of digital LHS cable shall also be provided
running along top, bottom and alternate length of intermediate cable trays.
Detection system over each zone shall be covered by cross zoning method to avoid
false alarm. Automatic activation of a particular spray system will be initiated by
simultaneous detection by at least one heat detector and one photoelectric smoke
detector in the respective zone. In the event of fire, the detection system will
initiate an alarm at the main fire alarm panel located in central control room and
simultaneously activate the deluge valve of the spray systems.
vi. Inert gas flooding system
� Proprietary inert gas shall be used for inert gas flooding system.
� The centralized inert gas flooding system shall be designed considering the
single largest protected volume.
� Required number of pressure reducing stations shall be provided in the gas
manifold for gas pressure reduction from cylinder pressure to required gas flooding
pressure.
� The inert gas flooding system and its components shall be designed and
installed as per NFPA standard 2001�� Clean agent fire extinguishing systems�.
� The cylinder rack shall be designed to accommodate sufficient number of inert
gas cylinders so that the largest protected volume can be flooded.
vii. Portable fire extinguishers
� The portable fire extinguishers shall be TAC approved and BIS stamped.
� Portable hand-held fire extinguishers as well as trolley-mounted
extinguishers shall be provided at indoor hose stations in addition to other key
locations including BFP Lube Oil Coolers and Turbine Bearing oil Area. The
extinguishing agent shall be selected based on the fire hazards encountered in the
immediate area. The location and quantity of the portable fire extinguishers will
confirm to TAC guidelines.
� Operating conditions for portable fire extinguishers shall be displayed on
the face of each individual extinguisher.
� Following types of portable fire extinguishers and safety equipment are
envisaged to be used:
� Dry chemical.
� Carbon dioxide.
� Water carbon dioxide.
� Foam.
1.7 Layout consideration
The layout of the Plant Water System consists the following units/buildings:

a) Raw Water cum Fire water Reservoir.

b) Filtration Unit
c) Softener Unit
d) Filtered Water Storage Tank.
e) Potable Water Storage Tank.
f) Fire Water cum Common Pump House.
Process Water Make-up Pumps, Filter Feed Pumps, Seal Water Pumps, Filtered Water
Supply Pumps, filter backwash Pumps and Potable Water Pumps shall be housed in the
Common pump house adjacent to the Raw Water cum Fire water Reservoir. The pump
house will be equipped with Crane of suitable capacity and electrically operated.
Proper maintenance spaces will be provided in between the pumps/equipment. For
operators ease access platform will be provided wherever necessary.
Fire Water Pumps and Jockey Pumps shall be located in a separate area within Common
Pump House.
Filtration Unit along with backwash air blowers shall be located outdoor. Filtered
Water and Potable Water Storage tank shall be located beside Raw Water Reservoir.
The overall layout will also take care of handling and installation of various
equipment including road layout.

2.0 COMPRESSED AIR SYSTEM

The compressed air system will meet the requirement of Air Blower for Floatation
unit, instrument air for the control of various pneumatically operated instruments
and service air for Filter Press, DFDS and general plant services for the proposed
plant. This DBR provides the design basis for compressed air system including Air
Blowers and air compressors (both SA & IA) with auxiliaries.

2.1 Compressed Air Requirement

2.2 System Description

2.2.1 Flotation Blower Air

The flotation air blowers supply air to all flotation cells. Two (2) nos. Blowers
(positive displacement type) will be operating on one running and one stand-by
basis. The air will be distributed to the flotation cells via a ring main and
headers. Blowers will be located in an isolated sound-proof room.

2.2.2 Plant Air

Three (3) nos. (2W+1S) oil free (non-lubricated), multistage, water cooled, skid
mounted, direct driven, rotary dry screw Compressors have been envisaged along with
suction filter (with silencer), inter cooler, after cooler, lubricating oil system
and all associated accessories & auxiliaries for meeting the total air requirement
for both Plant Service Air and Instrument Air. The capacity of each Air Compressor
shall be 500 Nm3/hr.
The plant service air from the compressor will be stored in Service Air Receiver
(Capacity 5 m3) for further distribution within process plant.
The instrument air is dried and filtered and then stored in the instrument air
receiver. One (1) no. Refrigeration type Air Dryers has been envisaged for
providing moisture free instrument air with all interconnecting piping, valves,
fittings etc. One (1) no. Instrument Air receiver (capacity 2 m3) has been
considered.

2.2.3 Filter Press High Pressure Air

Tower press filters required high pressure compressed air. The high pressure
air is used to perform a cake squeeze in the filter chamber to remove more
filtrate.
In the second stage, high pressure compressed air is required to blow air
through the solids for final dewatering before discharging the filter cake.
One (1) no. Air Receivers of capacity 5 m3 have been considered for the Filter
Press.

2.3 Major Equipment Design Criteria

2.3.1 Air Compressor

A. The Air compressor is designed to take care of total service air and
instrument air requirement. The capacity of each instrument air compressor would be
500 NM3/min with delivery pressure of 8.5 Kg/cm2 (g) at the outlet of after cooler.
The pressure drop from air compressor to air dryer outlet shall be restricted to
0.5kg/cm� (g). The air quantity indicated in terms of Nm3/min is for dry air only.
The following formula shall be used for converting the measured air quantity in
terms of free air delivery (FAD) with respect to the design atmospheric condition
at site to standard atmospheric condition.
V / V1 = {(P1-P) x 288.6} / {(273+t) x 1.033}
Where
V = Capacity referred to standard atmospheric condition of 15.6 ?C ambient
temperature and 1.033 kg/cm2 atmospheric pressure, Nm3/min.
V1 = Capacity referred to prevailing atmospheric condition, i.e. FAD, m3/min.
t = Prevailing ambient temp. in oC
P1 = Prevailing atmospheric pressure (kg/cm2).
P = Partial pressure of water vapour in the atmosphere for the prevailing
ambient temperature and relative humidity (kg/cm2).
Each compressor would be designed to deliver the free air delivery (FAD) capacity
at the required delivery pressure.
B. Compressors will be provided with acoustic enclosures to reduce the noise
level.
C. Performance tests for capacity for Compressor shall be as per BS:726/BS:1571
Part- II/IS:5456 or equal.
D. The Compressor�s capacity will be designed for 450 C DBT and 60% RH at
atmospheric pressure at site.
E. Compressors to be designed for continuous, load unload and on-off mode of
operation.
F. Noise level would be limited to 85dB(A) to a reference of 0.0002microbar when
measured at a 1.5m above the floor and 1m away from equipment enclosure.
G. Continuous Motor rating at 500C ambient will be at least ten (10) percent
above the maximum load demand of the driven equipment under the entire operating
range.
H. Cooling of compressor, intercooler, after-coolers shall be done by filtered
water.
I. The suction filter (with silencer) shall preferably be of dry type with
replaceable cartridge filter element. Filter efficiency shall be 99.97%@ 2micron
dust size and 90%@ 0.5micron. Intake shall have a weather cowl or a bird screen.
J. Satisfactory parallel operation of air compressors shall be ensured without
any uneven load sharing, undue vibration, noise.
K. Vibration limit shall be 40 micron (measured at top & bottom of main bearing)
(Anti vibration arrangement shall be provided).
L. The materials of various components of the compressor shall conform to the
applicable BIS / BS/ ASTM/ DIN standard or any other reputed standards.
M. Design code of Construction for Intercooler and After cooler should be as per
TEMA Class �C� and MOC of the after cooler is Shell: C.I.Gr.260.
N. TEFC squirrel cage induction type motor for the compressor (Direct driven)
with Class F insulation, temperature rise limited to Class B, IP 55.
O. Site data : -
a) Annual Mean Temperatures : 50 deg C (max.)
6 deg C (min.)
b) Humidity : 91% (max)
18% (min)
c) Altitude: 422.5 m
2.3.2 Air Dryers

Air drying plant shall be of refrigerant (close-loop Freon circuit) type. The
Air Dryer shall be free-standing, floor mounted type. 2 x 100% prefilter and 2 x
100% after filter located upstream and downstream of the drier respectively shall
be designed to remove foreign particles from the air stream.
The quality of outlet air from the Air Dryer shall be as follows:

a) Dew point at the outlet of the air dryer will be (-) 22 Deg C at atmospheric
pressure.
b) Dust particle size in the instrument air will be limited to one (1) micron.
c) Oil free or with a maximum oil content of 0.01 ppm.
d) Contaminants: No corrosive hazardous, toxic or flammable materials.
e) Quality of dry outlet air shall conform to Instrument Society of American
Standard S7.3�Quality Standard for Instrument Air�

2.3.3 Air Receiver

The air receivers will be vertical self-supporting cylindrical vessels with

supporting legs for resting on their foundation.
The air receiver shall be designed for a pressure & temperature of 10 kg/cm2 (g) &
500C and shall have a hydraulic test pressure of 15 kg/cm2 (g).
Air Receiver design code shall be ASME Sec. VIII Div 1 or IS: 2825 & IS 7938,
MOC- IS: 2002 Gr.2A & shall be provided gasketted inspection manhole of minimum 500
mm diameter. Opening shall not pierce any seam & shall be as far as possible away
from any welded seam.
The installation of all the Air Receivers shall be outdoor.
2.4 Layout consideration
The Plant Air Compressors and Air Dryer shall be located in a separate room within
Process Plant Building. All Air Receivers shall be installed outdoor.
Air Compressor for Filter Press shall be located in Filter press Building.

3.0 DUST SUPPRESSION SYSTEM

For dust control in the proposed plant, Dry Fog Dust Suppression (DFDS)/Water
Sprinkler Dust Suppression System (DS) have been envisaged.
The scope of the dust suppression system is to control the dust by Dry Fog Dust
Suppression System or Water Sprinkling System depending upon the site condition as
mentioned below:
A. Dry fog dust suppression system (DFDS) at the transfer & receiving points of
Sag Mill Feed Conveyors.
B. Water sprinkler dust suppression (DS) system for Crushed Ore Stockpile.
The details of the area where dust suppression system will be provided have been
enlisted in the following table:
Area Dust suppression points Type of Dust Suppression System
SAG Mill Feed Conveyor Apron Feeder Discharge Points (4 nos.) DFDS
Transfer Tower Transfer point of Sag Mill Feed Conveyor 1 DFDS
Receiving Point of Sag Mill Feed Conveyor 2
DFDS
Crushed Ore Stockpile Stockpile DS

3.1 System Description

Water for the dust suppression systems will be sourced from the Process Water pump
discharge header. Industrial grade/clarified water @1-2 bar at the nozzle is
required for the system. The volume of water is decided based on number of
application points and the area to be covered.
Compressed air @6 bar at the nozzle is required for the system. The volume of
compressed air is decided based on number of application points and the area to be
covered.
3.1.1 Dry Fog Dust Suppression System

The DFDS system will include spray bar assemblies fitted with dual-fluid air driven
acoustic oscillator atomizing nozzles, pressure regulating units, and flow
activation stations for ON-OFF control of the system and instrumentation for auto
operation.
The DFDS system will be equipped with local control panel for controlling the dust
suppression through signal exchange.
Solenoid valves will be mounted on each spray nozzle header for DFDS system at
material transfer points. These will be interlocked with conveyor operation so that
spray of water and compressed air take place when conveyor is running with
material.
The compressed air requirement for the DFDS system shall be taken from plant
service water line. The compressed air supply system for DFDS systems will be
complete with Air receivers and all fittings such as safety valves, drain
connections with auto condensate trap and bypass valve, vent connections and all
inlet and outlet connections with companion flanges, supporting arrangement, access
platforms, instruments etc.
3.2 Major Equipment Design Criteria

3.2.1 Spray bar assembly

The spray bar assemblies will be manufactured from stainless steel tubing drilled
and tapped for connection of nozzle adapters. A specially designed and selected
dual fluid atomizing nozzle (stainless steel construction) will be fitted into each
of the adapters. These nozzles will be fitted with acoustic oscillators for
atomizing the water into droplets of micronic size. Each spray bar will be provided
with mounting brackets and flexible hoses for connection to the air and water
pipeline.
3.2.2 Pressure regulating unit (PRU)

Pressure regulating units will be provided to control flow and pressure of air and
water in the system. The pressure regulating unit will consist of diaphragm type
pressure regulator with pressure gauge and ball valve for isolation of air and
water line. The operator will be able to adjust both the air and water pressures
independently to change the fog characteristics to obtain optimum dust suppression
results depending on the site requirements. The pressure regulators will be
installed in a metallic enclosure with inspection door with rubber sealing
arrangement. Flexible hose will be provided for connection of PRU to the air and
water pipeline. The number of pressure regulating units will depend upon the
position / elevation of spray bars. The number of nozzles operating from one PRU
will not exceed 8.
3.2.3 Flow activation stations (FAS)

The flow activation station will consist of solenoid valves in air and water lines,
pressure switch in the airline and selector switch and indication lamps as noted
below. Isolation ball valves will be provided in the air and water line. All
equipment will be installed in a metallic enclosure with inspection door with
rubber sealing arrangement. Flexible hoses will be provided with each flow
activation stations (FAS) for connection to air and water pipeline.
The "ON-OFF" control of the fogging system will be through the flow activation
station (FAS) with facility for both manual and auto mode. A three-position
selector switch will be provided to select the mode of operation. The switch when
energized will open the electric solenoid valves, which will permit compressed air
and water to enter into the pressure regulating units and spray bars.
In addition, a pressure switch will be installed in the airline to ensure that air
and water solenoid valves are energized only when sufficient air pressure is
available in the line. This will ensure that the system cannot operate without
sufficient air pressure to the nozzles and reduces the chance of un-atomized water
to pour into the dust source. Flow activation will have indication for:
- System ON
- System OFF due to lower air pressure

4.0 WASTE WATER MANAGEMENT

Waste water generated from the proposed plant shall be mainly categorised as
process plant waste and sanitary waste.
Waste water generated from different process plant unit shall be sent to the
tailing pit for further transfer to the existing tailing dam.
Sanitary water shall be collected from different buildings and treated in STP plant
for further reuse.

4.1 Processing Plant Waste water

The processing plant wet circuit would generate tailings from thickeners
contaminated with sulphate, lead and cyanide due to use of processing chemicals
e.g. copper sulphate, zinc sulphate, sodium ethyl xanthate, sodium cyanide and
frother in flotation as flocculation and depressant reagents. The contaminated
tailings of about 55% solids concentration would be pumped to the existing tailings
storage reservoir at a distance of about 3.5 km from the processing plant.
Adequate number of Sump Pit with sump pumps shall be provided as strategic
locations to transfer the waste water to the tailing pit.

4.2 Sewage Treatment Plant

Sanitary waste from different plant buildings will be collected and further treated
in Sewage Treatment Plant. Package STP has been envisaged in this purpose of
capacity 10m3/day. Treated water from STP will be used for general washing, Road
Cleaning, gardening etc.

4.2.1 System Description

Sewerage system shall be so designed to connect the discharge from the buildings to
the centralised STP which will be located within the plot boundary. Sewage from the
toilets of various buildings shall be collected to the inspection chambers through
pipes located outside the buildings. The sewer line shall be connected from one
inspection chamber/manhole to others and finally discharge to STP by gravity flow.
Manholes, inspection chambers shall be located suitably on the sewer line at every
bend, junction, and point of change in slope or diameter and on straight sections
of lower diameter pipes at intervals not exceeding 15meters and higher diameter
pipes at interval not exceeding 30meters for cleaning purpose. These shall be
constructed with RCC, considering easy access, maintenance and safety.
The external sewerage system pipes shall be of either uPVC, stoneware or RCC Non-
pressure pipes of minimum 200mm diameter. Adequate sizes and gradients shall be
provided to take care of minimum and maximum flow conditions, self cleansing
velocity (0.6m/s) requirements, as well as to minimize scouring effect and to
maintain below scouring velocity (2.2m/s).
Gravity sewer from trunk sewer line shall be discharged to inlet chamber,followed
by screen chamber and wet well of lifting station. The sewage water shall be
collected in the wet well of lifting station from there sewage water shall be
pumped to bar screen of sewage treatment plant. The capacity of STP shall be 10
cum/day of Rotating Biological Contactor (RBC) technology for the proposed plant.
A rotating biological contactor or RBC is a biological treatment process used in
the treatment of wastewater following primary treatment. The primary treatment
process removes the grit and other solids through a screening process followed by a
period of settlement. The RBC process involves allowing the wastewater to come in
contact with a biological medium in order to remove pollutants in the wastewater
before discharge of the treated wastewater to the environment. A rotating
biological contactor is a type of secondary treatment process. It consists of a
series of closely spaced, parallel discs mounted on a rotating shaft which is
supported just above the surface of the waste water. Microorganisms grow on the
surface of the discs where biological degradation of the wastewater pollutants
takes place.

4.2.2 The STP shall consist the following major units/ facilities:
a) Bar screen
b) Oil and grease trap
c) Equalization tank
d) Primary Sedimentation tank
e) Aerator
f) Secondary Sedimentation tank
g) Sludge holding tank
h) NaOCL dosing tank
i) Filtered Feed Water Tank
j) Filter press
k) Mulitigrade filter (MGF)
l) Activated carbon filter (ACF)
m) Treated water tank

4.3 Central Monitoring Basin

Treated Water form STP and strom water with plant area will be transferred & stored
in Central Monitoring Basin. The purpose of basin is to neutralize the combined
effluent before disposal and reuse. The basin will be designed for 7 days storage
capacity.