Requirements for a Design of OJSC MMK’s Production Facilities

		APPROVED BY: __________________ S. N. Ushakov, (date, signature) Chief Engineer, OJSC MMK

Requirements for a Design of OJSC MMK’s Production Facilities.

Blast Furnace Shop. Furnace #2. Technical Upgrading.

Dust Exhausting Plant for the Stock House.

Item No.	Basic design data and requirements	Parameters of the facility to be designed. Basic data and requirements
1	2	3
1	Basis for the design: (letter of instruction, contract)	Minutes No. GD-043 dated 08.02.2012
2	Type of construction (new construction, enlargement, revamping)	Technical upgrading
3	Number of engineering stages (one stage – detailed engineering; two stages – basic engineering; detailed engineering)	Detailed engineering documentation
4	Alternate and tender design requirements	None
5	Conditions on the construction site (climatic, seismic conditions)	To adopt climatic conditions under SNiP 2.01.07-85 To adopt seismic conditions under SNiP II-07-81
6	Key technical and economic parameters of the plant	The dust exhausting plant for the stock house including an electric filter and the automation flow distribution system which closes non-operating suction hoods. Continuous operating mode: 357 days Initial dust level: 12-15 g/m3 Final dust level: < 50 mg/m3 Dust parameters: - size range, µm 0-5 5-10 10-20 20-40 40-60 >60 % 2.5 4.2 18.5 49.0 16.5 11.3 - chemistry,% SiO2 Al2O3 Fe2O3 CaO MgO MnO 6.8 2.2 49.7 33.9 6.7 0.2 - bulk density: 1.92 t/m3 - tapped density: 1.98 t/m3 Dust shall be discharged dust-free from collecting bins to railway transport. Aspiration air consumption in sections of the charge delivery system of blast furnace #2 is given in Annex A.
7	Requirements for quality, ecological parameters and competitiveness of products	Parameters shall be in compliance with norms and standards which are in force in the Russian Federation.
8	Requirements for the process, a plant schedule	Operating mode: continuous, 8760 hours. Production cycle: completed, full cycle. Opening of valves of aspiration channels connected to the point of dust emissions prior to operation of process facilities (coke screen, hopper weighers for sinter, skip pit, hopper weighers of additives, additives conveyor, sinter fines conveyor, sinter fines conveyor (covering material)) and closing of such valves when the process is finished.
9	SOLUTIONS: ARCHITECTURAL-CONSTRUCTION SOLUTIONS, SPACE AND LAYOUT, AND DESIGN SOLUTIONS	Arrangement and layout of equipment subject to examinations of a manufacturer and a supplier of process equipment to be located in the current complex of BF#2. A final set and scope of technical upgrading to be stated at the stage of detailed engineering. Civil engineering, HVAC, fire alarm system, general and special-purpose electric lighting, integrated rooms, control pulpits are to be designed in compliance with Rules and Norms. - the fire alarm system is to be powered by Orion Pro including installation of the workstation in a control room of the BF shop. Integrated rooms where electrical equipment, Automatic PCS, automatic electric drives, instrumentation and control, Corporate Information System will be installed, are to be designed with specially equipped working places for repairs, service maintenance, and diagnosis of newly started-up lines. Air change rate in rooms is to be calculated. Additional installation of a required inlet and exhaust ventilation system is to be provided for. Tools, equipment and devices required for commissioning and further operation of started-up equipment are to be provided for in compliance with normative documents. Lifting and handling equipment, mechanical and automation equipment for execution of work and ensuring of the process are to be provided for. When developing designs, availability of all measuring devices in the state register of the Russian Federation is to be taken into consideration.
10	REQUIREMENTS FOR POWER GENERATION, POWER SUPPLY AND ELECTRICAL EQUIPMENT, INCLUDING AUTOMATION, CONTROL AND MEASURING SYSTEMS	POWER GENERATION Reliability categories of power supply: - I (key process facilities); - II (equipment supporting the process). Quality of electricity is under GOST 13109 – 97. It is required to design all types of electric current carriers within a scope which is sufficient for parameters of lines taking into consideration technical requirements for equipment #UGE/t dated 03.06.2008, specifications for power takeoff #UGE dated 17.11.2009. At substation #2 it is required: - to reinforce the ceiling and install a column under a 6 kV distribution unit; - to revamp a 0.4 kV local distribution board. The power supply system should be made from two independent, mutually redundant sources of electricity. Electrical network (up to 1 kV) of the automatic process and facilities control system - separate jam-resistant electrical network, three-phase, TN-S earthing system (five wires) - L 1, L 2, L 3, N, PE. It is required to exclude a non-authorized access to equipment, communication systems and hardware of the power supply system. Power supply for consumers (up to 1kV) to be provided from a 0.4 kV existing line including installation of automatic circuit breakers for LV switchgear 0.4/0.23 kV for newly designed equipment. Uninterrupted power lines for equipment of automatic PCS should be arranged from sources of uninterrupted power supply with a redundant system. Cables and equipment located in the constriction area should be transferred. It is required to place new process, mechanical, power, electrical equipment (power supply, electric drives, control, diagnosis, automation, inspection and measuring equipment) in axes and bays where current equipment and process is located. It is required to make a design of electrical equipment including Automatic PCS and a design of integration of control systems into current PCS and the Corporate Information System. It is required to develop a hardware and software complex for automation of contract and other equipment for the purposes of data transfer (air emissions control system) to external users. When designing an electrical part, it is required to make a self-powered earthing loop for equipment of Automatic PCS. AC motors with soft starters and stop devices are to be used. Siemens-based variable frequency motors are to be used for drives requiring speed control. It is required to use cross-linked polyethylene cables (over 1 kV) in a nonflammable sheath to be laid in air on cable-carrying steel structures. It is required to ensure accounting of utilities in cost centers. Devices to control flow rates of utilities (water, compressed air, gas, electricity) to be installed, collection of data from the stated devices, data processing and transfer to the information network of the shop to be provided. The following communications to be provided: - administrative telephone communications (automatic telephone station); - internal, control communication; - shop loudspeaker communication; - paging regulating communication; - CCTV. - interior and exterior lighting is to be designed using power-saving LED lamps. Interior lighting should be switched on and off by means of PLC and turn on/off time should be adjusted depending on light intensity in different cyclic periods of a year (summer-winter). POWER SUPPLY It is required to design all types of electric current carriers within a scope which is sufficient for parameters of lines taking into consideration technical requirements for equipment, specifications for power takeoff and technological connection to power networks. The design should not entail an increase in consumption of utilities.
11	Division into stages and start-up facilities	Not required
12	Environment protection measures
13	Safety and industrial hygiene requirements	In compliance with norms. Places of loading, screens, separators and conveyors are to be equipped with covers for dust catching and exhausting systems ensuring a dust level of 6 mg/m3 or less at workplaces and a dust level of 50 mg/m3 or less at the source of emissions.
14	Adaptation of production operations	Not required
15	Emergency prevention measures	Not required
16	R&D	Not required
17	Display materials	Not required
18	Source of financing	Capital expenditures
19	Annexes: - basis for capital expenditure for construction of the facilities; - a resolution of local executive authorities on a preliminary approval of the facilities’ location; - a building land allocation certificate and documents attached thereto; - technical requirements for connection of designed facilities to power supply sources, utility lines and systems; - data on public discussions of construction; - basic data on equipment, including tailor-made one; - documents received from local administration and state supervisory bodies, including: a description of social and economic environment, natural and environment conditions, data on existing sources of pollutants and other information in compliance with requirements of environment protection authorities, health and epidemiological conditions on the construction site; - available engineering surveys; - layouts of buildings and structures, underground and above-ground utility pipelines which are located on the construction site; - opinions and documents prepared in accordance with surveys of operating facilities, buildings and structures; - information about labor conditions on site; - requirements for layout of temporary buildings and structures, lifting and handling equipment, storage areas for construction materials; - other documents – a manning table	Not required Not required Not required 1.  Specifications for power takeoff #UGE dated 17.11.2009 2.  Technical requirements for electrical equipment dated 28.04.2012. Should the design requirements be changed, technical requirements for power takeoff are to be revised upon request of a company which designs such facility. Not required Not required Not required Not required Not required Not required Not required Not required Not required

A. V. Chevychelov,

Head of the BF Shop

APPROVAL SHEET

Regarding requirements for a design of OJSC MMK’s production facilities.

Blast furnace shop. Dust exhausting system for the stock house of furnace #2.

Head of the Shop A. V. Chevychelov

APPROVED BY:

Head of the Investment Department, OJSC MMK	A. Yu. Permyakov
Head of the Capital Construction Administration, OJSC MMK	A. I. Vasev
Chief Metallurgist, OJSC MMK	S. V. Prokhorov
Chief Power Engineer, OJSC MMK	Yu. P. Zhuravlev
Acting Head of the Maintenance and Repairs Centre, OJSC MMK	A. M. Chumikov
Deputy Chief Mechanical Engineer (power equipment), OJSC MMK	Yu. A. Petruk
Head of the Labour Safety Department, OJSC MMK	A. P. Sirotyuk
Head of the Railway Transport Administration	S. A. Ivanov
Director for Information Technology, OJSC MMK	D. S. Kaplan
Head of the Environment Protection Laboratory	O. F. Drobnyi
General Director, OJSC Magnitogorsk Gipromez	Yu. A. Tverskoy

Annex A

Aspiration air consumption in sections of the charge delivery system of blast furnace #2

Unit description	Number of dust aspiration points	Volume of air exhausted at one point, thousand m3/h	Total volume of exhaust air, thousand m3/h
Central Part Coke screen Head of additives and sinter fines conveyors Skip pit TOTAL	2 1 2	5 65 20	10 65 40 115
East Part Hopper weigher for sinter and additives Sinter and additives conveyor Horizontal sinter fines conveyor Vertical sinter fines conveyor TOTAL	4 4 4 1	7.5 5 5 3.75	30 20 20 3.75 73.75
West Part Hopper weigher for sinter and additives Sinter and additives conveyor Horizontal sinter fines conveyor Vertical sinter fines conveyor TOTAL GRAND TOTAL	10 12 10 1	7.5 5 5 3.75	75 60 50 3.75 188.75 377.5