design basis of coking coal beneficiation plant.pdf

8/10/2019 DESIGN BASIS OF COKING COAL BENEFICIATION PLANT.pdf

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BASIS OF DESIGN/OFFER


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BASIS OF DESIGN / OFFER COAL HANDLING SYSTEM

A. BASIS OF OFFER

The desired 1.8 MTPA Coking Coal Beneficiation System shall be as per Tender drawingNos.

Tender Drawings:

1 CET RN 3812 GL0 00 001 REV R=0 Layout Drawing

2 S&T/003 Surface Plan

3CET RN 3812 CC1 00 001 REVR=1

Process Flow Diagram

4CET RN 3812 CC1 00 002 REVR=0

Equipment Flow Sheet

5CET RN 3812 CC1 00 003 REVR=0

P&I Diagram

6 CET RN 3812 EE1 00 001 REV R=0 Overall Single Line Diagram

7 CET RN 3812 IN0 00 001 REV R=0 Automation System Configuration Diagram

B. BASIS OF DESIGN FOR PROPOSED CONVEYORS.

1. The conveyor power and tension will be calculated as per IS: 11592.

2. The drive motor rating of all conveyors will have a margin of 20% over Consumed

kW.

3. The bulk density of the material has been considered as:

Coal 0.8 t/m3for volumetric calculation.

1.2 t/m3for structural design.

4. Belting:

4.1 Top cover 6 mm for N/N

4.2 Bottom Cover 3 mm for N/N

4.3 Cover grade M-24


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4.4 Running tension < 80 % of allowable belt tension.

4.5 Type of belt N-N or EP for all conveyors

4.6 No. of Plies 5

5. Idlers: (Confirming to IS: 8598 1987, Reaffirmed in 1993)

5.1 Troughing Angle of Carrying idler 450 for all conveyors

5.2 Return Idlers Single Roll Flat Return Idler for Conveyor of Belt Width

less than 1000 mm andTwo Roll V return idlers with 100troughing angle

for Conveyors of Belt Width 1000 mm and above.

5.3 Roll Dia (OD)

Carrying / SACI: 152.4 mm for all conveyors. (Outer Dia.)

Return / SARI: 139.7 mm for all conveyors. (Outer Dia.)

Impact: 190 mm for all conveyors (Outer Dia.)

5.4 Tube material & thickness ERW tube, 4.5 mm (Min) thickness.

5.5 Bearing Seize Resistant /Single row deep groove ball bearing

5.6 Bearing Life 40,000 hrs B-10 life.

5.7 Bearing dia.

Carrying / SACI : 30 mm.

Impact : 30 mm.

Return / SARI : 25 mm.

5.8 Lubrication Life Lubrication type.

5.9 Idler Spacing

Carrying (Troughing) 1.0 m

Return 3.0 m

Carrying training / SACI

15.0 mReturn training / SARI 30.0 m

Impact Idler 300 mm(Min. 5 Nos. impact idlers shall be

provided at each feed point)

Transition Idlers 1 No. 200at Tail end and 1 No. 50,

200, 350each at Head end

5.10 Idler spacing at Convex Zone shall be 50% of the normal spacing specified

above.


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CONVEYOR DRIVE UNIT:

8 Reducers

8.1The gearbox mechanical rating shall be 1.5 times of consumed power at pulley shaft

or1.25 times of motor power, whichever is higher.

8.2For Motor Power Rating up to 15 kW Worm Gear Box shall be provided.

8.3For conveyor having motor kW above 15 kW, the type of gearboxes shall be helical

type. If required due to space constraint Bevel Helical Gearboxes shall also be used.

8.4All Inclined conveyors shall be provided with roller type holdback integral with

gearbox.

8.5Housing of the gearbox shall be made of Cast iron housing of FG 260 as per IS: 210.

9 High Speed Coupling

9.1Motor name plate rating up to 37 kW Tyre type Coupling

9.2Motor name plate rating above 37 kW to 200kW Traction Type Fluid Coupling.

9.3Motor name plate rating above 200 kW (HT motor) Delayed fill chamber type fluid

coupling

10Low Speed Coupling Gear coupling

11Brakes Electro hydraulic thruster brakes shall be provided on conveyors where

reduction in coasting time is required.

CONVEYORS STRUCTURAL

12Take up

12.1. Conveyors of length up to 30 m shall be provided with screw type take-ups and

conveyors of length above 40 m shall be provided with automatic take-ups

preferably vertical gravity take-up, wherever possible.

12.2. Conveyor of length between 30 m and 40 m, screw type take-up may be

considered if vertical gravity take-up is not possible to be provided.

12.3. Conveyors counter weight shall be made of 60% cast concrete block & balance in

cast iron block in steel box. Where RCC block counter weight cannot be

accommodated due to space problem, cast iron counter weight will be provided.

Weight of single piece of counterweight will not be more than 25 Kg.

13. Skirt Board Length of skirt board For single discharge, the length of the skirt

shall be minimum 4000 mm. In case of multiple feeding system, length of the skirt

shall be continuous covering all feed points. Skirt board top cover shall be 3.15

mm thk MS cover.The height of skirt shall be minimum 400 mm for 800 mm beltwidth, 450 mm for 1000 mm and 1200 mm belt widths and 500 mm for more than


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1200 mm belt width. Modular segmented type skirt board sealing system for

effective sealing against spillage and dust shall be provided. Steel liner MN STEEL

(IS:276 GRADE-1) of 10 mm thick shall be provided in the skirt which shall be

fixed by csk bolt. In feed zone, liners of full height shall be provided and beyond

feed zone, liner height shall be 200 mm. Skirt shall be made of 10 mm thick plate .

14. Belt Scrapers Primary external scraper shall be poly urethane blade and

secondary external scraper shall be sprung blade type (Tungsten tipped) at

discharge pulley shall be provided. For reversible conveyors the same shall be

provided at both the ends. One no. V-plough type internal scraper shall be

provided for each conveyor. Diagonal plough type scraper shall be provided for the

reversible type conveyor/feeder at both head and tail ends.

15. Deck Plate 3.15 mm thick Sheets shall be provided throughout the length of

Conveyor.MS deck plate of 3.15 mm thick shall be provided at every feed point up

to 3 m beyond the skirt length of all the conveyors. 6 m long deck plate from the

centre line of head pulley shall also be provided at the head end of all conveyors.

16. Conveyors stringer size: ISMC150 for Conveyors above 1000 mm Belt Width &

ISMC 125 for conveyors upto 1000 mm Belt Width.

17. Short support size: ISMC150 for Conveyors above 1000 mm Belt Width & ISMC125 for conveyors upto 1000 mm Belt Width.

18. Chutes:

18.1 Chute All the chute body shall beminimum 10 mm thick MS plate.Conveyor hood shall be made ofminimum 5 mm thick MS plate.

Hinged type inspection doorsminimum of 500 x 500 mm and

poke doors of 300 x 300 mmshall be provided, whereverrequired

Height of single piece of chuteshall not more than 2 meters

18.2 Liners Impact zone of all chutes shallbe lined with 60 mm thickrubber liner and sliding areaswith 30 mm thick ultra highmolecular weight polymer.

All clean coal chutes shall belined with SS-304 liner. Liners


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shall be provided at three (3)sides of chute plates for inclinedchute at all four (4) sides for

vertical chutes.

The size & shape of liner shall beprovided for easy handling andshall not exceed 20 kg/hour.

18.3 Valley Angle Valley angle of chute shall beminimum 60 degree.

Bin/ BunkerBin Bunker Details

Sl. No. Items Type/MOC

Coal

1. Raw coal silos Concrete silos

2. Ground ROM receivinghopper

Concrete hopper

3. Wagon tippler hopper Concrete hopper

4. Plant Surge hopper Structural

Liners for bin/bunker/pipelines/launders/catch pan

Sl. No. Items Liner Specification

1. Raw Coal handling chute 20 mm thick Hardox 450

2. Clean/Middling/Reject Coallump size (-) 13mm Impactzone

20 mm thick Hardox 450

3. Sliding/non impact zone 20 mm thick UHMWPE

4. Skirt 10 thick Mn Steel (IS:276 Part-I)

5. Wagon Tippler Hopper 45kg/m rail

6. Truck Dump Hopper 45kg/m rail7. 300T Hopper 1 meter bottom vertical portion &

all Conical portion 20mm thick.Hardox-450

8. Raw Coal Silo 1 meter bottom vertical portion &all Conical portion 20mm thick.Hardox-450

9. Media pipelines Cast basalt having shell thickness 8mm with surface coating of epoxy.

10. Launders Ceramic tiles (> 90% alumina)

11. Return pipelines & coalwater slurry line

HDPE (based on the suitability)


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CONVEYOR MOUNTED ELECTRICALS:

19. Pull Cord Switch. Pull cord switch of lock-out type shall be provided at a

regular interval of 25 m along each conveyor and on both sides for manual

tripping of drive motor under emergency. Minimum distance of switch shall be 5 m

from the head & tail end of conveyor.

20. Belt Sway Switch Belt sway switch shall be provided at both sides and at 50 m

interval along conveyor length to automatically stop the conveyor in case of

excessive sway of the belt. Minimum distance of switch shall be 10 m from the

head & tail end of conveyor.

21. Zero Speed Switch One for each conveyor at non drive pulley. Belt slip/zero

speed switch shall be provided at the tail end along the belt conveyor to

automatically stop the equipment in case of excessive slip of belt or snapping of

the belt.

22. Chute Blockage Switches Chute plug switch shall be provided for chutes and

hoppers handling fines. The chute plug switch shall be RF type.

.


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SCOPE OF WORK/SUPPLY


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SCOPE OF WORK / SUPPLY

Bengal Tools Ltd., Kolkata, India and Tangshan Guohua Technology Co. Ltd., Tangshan,

Hebei, China as consortium members jointly proposes to undertake design andengineering, manufacture/procurement, painting, packing, supply, unloading, storageand handling at site, construction, erection, testing, commissioning and demonstrationof performance guarantee of a coking coal beneficiation plant having capacity to treat1.80 MTPA raw coal to produce clean coal, middling, tailings and reject as per scope ofsupply on turnkey basis for M/s S&T Mining Company Pvt. Ltd. Kolkata, India atBhelatand, Dhanbad District of Jharkhand, India. The scope of supply shall consist ofthe following equipment/ item:

1) MECHANICAL

A.BELT CONVEYORS:

S.No.

Conv.No.

Qty.(Nos)

Beltwidth(mm)

ApproxConv. LengthAlong lengthper conveyor

(m)

Belt Speed(m/s)

CapacityR/D(TPH)

Remarks

New Belt Conveyors for proposed plant

1. BC-1 1 1800 40.00 2.50 1500/1800 Rail WagonUnloading

Circuit2. BC-2 1 1800 155.00 2.50 1500/1800

3 BC-3 1 1200 201.00 2.00 500/600 TruckDumpHopperCircuit4. BC-3A 1 1200 21.00 2.00 500/600

5. BC-4 1 1600 45.00 2.90 1500/1800

Raw CoalSilo

Feeding6. BC-4A 1 1600 105.00 2.90 1500/1800

7. TC-1 1 1800 77.00 2.90 1500/1800


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S.No.

Conv.No.

Qty.(Nos)

Beltwidth(mm)

ApproxConv. LengthAlong length

per conveyor(m)

Belt Speed(m/s)

CapacityR/D(TPH)

Remarks

8. BC-5 1 1000 55.00 2.00 500/600TertiaryCrushingCircuit &feed tomain

processplant

throughSurge

Hopper

9 BC-6 1 1000 106.00 2.00 500/600

10 BC-7 1 1000 11.00 2.00 300/360

11 BC-7A 1 1000 78.00 2.00 300/360

12 BC-8 1 1000 74.00 2.00 300/360

13 BC-9 1 1000 90.00 2.00 500/600

14 BC-10 1 1000 73.00 1.80 300/360

15 BC-11 1 800 45.00 2.00 200/240

Clean Coal

16 BC-12 1 800 186.00 2.00 200/240

17 BC-13 1 800 77.00 2.00 200/240

Middling18 BC-14 1 800 58.00 2.00 200/240

19 BC-15 1 800 130.00 2.00 200/240

20 BC-16 1 800 60.00 2.00 200/240 Rejects

21 BC-17 1 1600 168.00 3.20 1800/2160Middling/

Rejects


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S.No.

Conv.No.

Qty.(Nos)

Beltwidth(mm)

ApproxConv. LengthAlong length

per conveyor(m)

Belt Speed(m/s)

CapacityR/D(TPH)

Remarks

22 BC-18 1 1600 168.00 3.20 1800/2160

WagonLoadingCircuit

23 BC-19 1 1600 154.00 3.20 1800/2160

24 BC-20 1 1600 38.00 3.20 1800/2160

Belt Conveyors to be modified in the existing plant

1 BC-316 1 1600 3.20 1800/2160Existing

Conveyors2 BC-319 1 1600 3.20 1800/2160

Note: The conveyors will consist of the following:

Troughing, Troughing training, Flat Return /two roll V-return Idler, Return

Training, Transition, Impact idlers, as required.

Drive, tail, take-up, bend and snub pulleys complete with Double Row

Spherical Roller bearings and Plummer blocks, as required.

Belting: Heavy Duty Nylon- Nylon/ EP belting

Drive unit consists of Motors (HT & LT), worm/ helical gearbox (with integral

holdback for inclined conveyors), high speed, low speed coupling and

coupling guard.

Screw/ Gravity type take-up with Counter weight as specified in Basis of

Design.

One sprung blade type (Tungsten tipped) and one one poly urethane blade

belt scrapers at discharge pulleys and one no. V-plough type (internal

scraper shall be provided for each conveyor.

12 mm thick natural rubber lagging (shore hardness 35-450 on Scale A),

herringbone type except for Conveyors Nos. BC-1, BC-2, BC-17, BC-18,BC-

19, BC-20 which will be provided with 12 mm thick Ceramic Lagging and 10

mm thick plain rubber lagging for non-drive pulleys (shore hardness 35-


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450on scale A). Technological structure viz. Stringers, short post, head

frame, tail frame, skirt board, conveyor discharge chute.

Skirt board for all Conveyors as specified in Basis of Design.

B. CRITICAL EQUIPMENT:

S.No.

Equipments Specifications

1. Wagon Tippler

i) Quantity 1 (One) No.

ii) Capacity (Rated) 25 tips/ Hr

iii) Type Rota sideiv) Drive VSD Drive for tippling of wagons

2. Side Arm Charger


ii) Location At inhaul of WT

iii) Type of Traction Drag Chain Arrangement

iv) Capacity to Pull Capable of handling of gross load of140t

3. Apron Feeder


ii) Capacity (Rated) 1500 TPH

iii) Material Handled ROM (-) 600 mm

iv) Discharge BC-1

4. Lump Breaker

i) Type Moil point hammer with swivel armii) Quantity 1 (One) No.

iii) Drive Hydraulic

5. Vibrating Feeders

a) Pre MCCP Building

i) Quantity 6 (Six) Nos.

ii) Type Unbalanced Motor type

iii) Capacity 500 tph


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S.No.


iv) Location 1 No. below Raw Coal Receiving

Hopper and 5 Nos. below Raw CoalSilos

b) Post MCPP Building

i) Quantity 4 (Four) Nos.

ii) Type Unbalanced Motor type


iv) Location Below Middlings & Rejects Hopper

6. Primary Sizer

i) Type Sizer

ii) Quantity 1 (One) No.

iii) Capacity (Rated) 1500 tph

iv) Input Feed Size 600 mm nominal top size

v) Output Size (-) 200 mm

vi) Receives BC-2

vii) Discharges Secondary Sizer

7. Secondary Sizer

i) Type Sizer

ii) Quantity 1 (One) No.

iii) Capacity (Rated) 1500 tph

iv) Input Feed Size (-) 200 mm


vi) Receives Primary Sizer

vii) Discharges BC-4

8. Tertiary Crusher


ii) Type Impact Crusher


iv) Input Feed Size (-) 50 mm


vi) Receives Raw coal Classifying Screen Over

Product


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S.No.


vii) Discharges Classifying Screen 1 & 2

9. Classifying Screens

a) Classifying Screen 1


ii) Capacity 500 tph

iii) Aperture 13 mm

iv) Receives BC-6

vi) Discharges Over product on tertiary crusher

and under product on BC-9b) Clasiifying Screen 2



iii) Aperture 13 mm

iv) Receives BC-8

vi) Discharges Over product on BC-7 and underproduct on BC-9

10. Travelling Tripper



iii) Belt Width 1800 mm

iv) Location At conveyor TC-1

11. EOT Crane

i) Quantity 2 (Two) Nos.

ii) Type Double Girder Type

iii) Capacity 15 t & 20 t

iv) Location WT Complex & MCPP

v) Span 12.5 m at WT Complex & 20 m atMCPP

12. Rack & Pinion Gate

i) Quantity 6 (Six) Nos.

ii) Type Electrical actuator type withprovision of manual operation


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S.No.


iii) Location Below Raw Coal Silos & Surge

Hopper

13. Flap Gate


ii) Type Electrical actuator type withprovision of manual operation

iii) Location At tertiary Crusher House

14. Rod Gate

i) Quantity 5 (five) Nos.ii) Type Manual

iii) Location One Below WT Hopper & fourMiddlings & Reject Hoppers

15. Belt Weigh Feeder

i) Quantity 1 No.


16. Auto Sampler

i) Quantity 4 Nos.

ii) Type Automatic Coal Sampler

iii) Location At Conv. BC-10, 11, 13 & 16

17. Vibrating Screen -De-Sliming Screen, D&R Screen

a) Raw Coal De-Sliming Screen

i) Quantity 1 (One) Nos.

ii) Type Banana Type


iv) Aperture 1 mm

v) Dimension 3m x 6.1 m (Approx)

vi) Receives Plant Feed Conveyor

vii) Discharges

Over product To primary HM Blending Tank

Through Product To classifying cyclone sump

b) Primary HM Media Cyclone Clean Coal D&R Screen


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Sl.No.





iv) Aperture 1 mm

v) Dimension 2.4 m x 6.1 m (Approx)

vi) Receives HM Cyclone Overflow

vii) Discharges

Over product To clean coal centrifuge

Through Product To dilute sump

c) Primary HM Cyclone Reject D&R Screen




iv) Aperture 1 mm


vi) Receives HM Cyclone Underflow

vii) Discharges

Over product To secondary blending sump


d) Middlings D&R Screen




iv) Aperture 1 mm


vi) Receives Secondary HM Cyclone Overflow

vii) Discharges

Over product To middlings centrifuge


e. Reject DR Screen

i) Quantity 1 (One) No. used for Drain & Rinse



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Sl.No.



iv) Aperture 1 mm


vi) Receives Secondary HM Cyclone Underflow

vii) Discharges

Over product To reject conveyor


18. Heavy Media Cyclone

a) Primary Heavy Media Cyclone


ii) Type Scrolled evolute Type, 1000 mm dia


iv) Feed Size (-) 13 mm

v) Receives Primary HM Cyclone feed pump

vi) Discharges

Overflow To primary HM Cyclone overflowcollecting tank

Underflow To primary HM Cyclone underflowcollecting tank

b) Secondary HM Cyclone


ii) Type Scrolled evolute Type, 850 mm dia


iv) Feed Size (-) 13 mm

v) Receives Secondary HM Cyclone feed pump

vi) Discharges

Overflow To Secondary HM Cyclone overflowcollecting tank

Underflow To Secondary HM Cycloneunderflow collecting tank

19. Classifying Cyclone

a) Raw Coal Classifying Cyclone Cluster

i) Quantity 1 (One) Set


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S.No.


ii) Capacity (R/D) 100 tph/ 120 tph

iii) Size dia 350 mm

iv) Classification at 0.25 mm

v) Receives Classifying Cyclone Feed Pump

vi) Discharges

Overflow To flotation feed pump

Underflow To underflow collecting tank

b) TBS Product Cyclone

i) Quantity 2 (Sets) No.

ii) Capacity (R/D) 30tph/35 tph

iii) Size dia 350 mm

vi) Classification at 0.25 mm

v) Receives TBS Overflow

vi) Discharges

Overflow To flotation feed pump

Underflow To TBS Sieve Bend

20. Magnetite Separator

a) Primary & Secondary Magnetite Separator

i) Quantity 1 No. each

ii) Type Counter Rotation Type, self levelcontrolled wet drum magneticseparator

iii) Size Drum Size 915 mm dia x3000

longb) Magnetic Separator for Fresh Magnetite Charging


ii) Type Counter Rotation Type, self levelcontrolled wet

iii) Size Drum Size 915 mm dia

21. Coarse Coal Centrifuge

a) Clean Coal Centrifuge



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S.No.



iii) Basket Screen Aperture 0.35 mm

iv) Receives Clean Coal Screen over product

V) Discharges

Over Product To clean coal conveyor

Through Product To clean-up sump tank

b) Middlings Centrifuge



iii) Basket Screen Aperture 0.35 mm

iv) Receives Middlings D&R Screen Over Product

v) Discharges

Over Product To Middlings conveyor

Through Product To clean up coal conveyor

22. High Rate Thickener


ii) Capacity 20 tph

iii) Diameter 20 m

iv) Receives Tailings of flotation cells & pressurefilter effluent pump

v) Discharges

Overflow To clarified water tank

Underflow To pressure filter feed sump

23. Flotation Concentrate Filter Press

i) Quantity 1 (One) No

ii) Type Steel Frame & Chamber Type


iv) Receives Pressure filter feed pump

v) Discharges

Cake To clean coal conveyor

Filtrate To thickener


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S.No.


24. Teeter Bed separator/ Reflux Classifier

i) Quantity 1 (One) No

ii) Capacity 60 tph

iii) Feed Size (-) 1 to 0.25 mm

iv) Receives Classifying Cyclone underflow

v) Discharges

Overflow To TBS Product Sump

Underflow To TBS Reject Sump

25. Froth Flotation Cell


ii) Capacity 40 tph

iii) Feed Size < 0.25 mm

iv) Residence Time Minimum 10 minute

v) Receives Flotation Feed Pump

vi) Discharges

Clean Coal To flotation concentration sump

Tailings To thickener

26. High Frequency Screen for TBS Cleans & Rejects

i) Quantity 2 (Two) Nos.

ii) Capacity 40 tph

iii) Screen Aperture 0.35 mm

27. Metal Detector


ii) Type Coil Type

iii) Location On Conveyor BC-6

28. Magnetic Separators

a) In line Magnetic Separators


ii) Capacity 1000 gauss


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S.No.


iii) Location On Discharge of BC-2

b) Cross Belt Magnetic Separators

i) Quantity 2 (Two) No.

ii) Capacity 1000 gauss

iii) Location On conveyors BC-6 & BC-8

29. Belt Scales

i) Quantity 7 (Seven) Nos.

ii) Type Load Cell with microscopiccontroller

iii) Capacity variation 10 % to 120%

iv) Locations Conveyors BC-2. 3,10,11,13,16 &17

30. Electric & Manual Hoists

i) Quantity Lot

ii) Type Electric / Manual (As per requirement)

iii) Hoist Selection Basis Manual Hoist ->

To handle items up to 2000 kg.

Maximum Lift : up to 15 mtrs.

Electricl Hoist ->

To handle items beyond 2000 kg

Lift : More than 15 mtrs.NOTE: Hoist Schedule for the Various Location in CHP is furnished below and the

hoist required for the other areas can be referred in the detail list of equipment.


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LOCATIONELECTRIC

HOISTQTY.

MANUALHOIST

QTY.

WAGON TIPPLER HOUSE 5T 1 2T 1TP-1 3T 1 2T 1

TP-2 3T 1

TP-3 3T 1 2T 1

PRIMARY & SECONDARYCRUSHER HOUSE 15T 1 2T 1

8T 2

TP-4 3T 1 2T 1

TP-5 3T 1 2T 1

RAW COAL SILOS 5T 1 2T 1

2T 5SCREEN HOUSE 12T 1 2T 1

2T 1

TERTIARY CRUSHERHOUSE 12T 1 2T 1

SURGE HOPPER HOUSE 3T 1 2T 2

MCPP 8T 2

3T 1

TP-6 3T 1

TP-7(EXISTING)

TP-8 3T 1 2T 1

TP-9 3T 1 2T 1

3T 1

TP-10 3T 1 2T 1

TP-11 3T 1 2T 1

TOTAL 18 22


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2. UTILITIES

We have considered the following dust suppression systems at Wagon Tippler and the

adjacent Junction Houses prior to the MCPP as per plant layout:

1. DFDS-1 (Dry Fog Dust Suppression System) for all Dust Generation Points of

WAGON TIPPLER AREA, Primary & Secondary Crusher House, Reclaim Hopper

Area, and all Transfer Towers before Coal Washery.

2. DFDS-2 (Dry Fog Dust Suppression System) for all Dust Generation Points of all

transfer Towers after Coal Washery and Wagon Loading Station.

The intermediate Transfer Towers between Coal Washery and Middling Stockpile& Reject Stockpile will not in consideration of DFDS System.

Operation Logic For Dry Fog Type Dust Suppression System:

Consideration for DFDS System

Minimum 4 nos. DFDS Nozzle will be provided at each dust generation point.

2 nos. water pumps (1W + 1S) have been considered for each system.

2 nos. oil injected air cooled screw compressor (1W + 1S) has been considered for

each system.

The dry fog dust suppression system will consists of Vertical Centrifugal Pump

with Drive Motor (2 Pole), Air Compressor with Drive Motor, MCC, Local ControlPanel, Flow Activation Station, Pressure Regulating Unit, Nozzles, Nozzle

Headers, UBESS, Level Switch, Pressure Gauge, Pressure Switch, Differential

Pressure Switch, Gate Valves, Globe Valves, Check Valves, Ball Valves, Pressure

Relief Valves, Solenoid Valves, Air Release Valves, Drain (Ball) Valves & Duplex

Filter.

There are 2 water pumps (1W + 1S) for Dry Fog Dust Suppression System (DFDS)

will suck water from the RCC Water Storage Tank dedicated for DFDS System

and supply water to the Dry Fog Nozzles through Flow Activation Stations and

Pressure Regulating Units at different Transfer Points.

There are 2Screw Compressors (1W + 1S) for Dry Fog Dust Suppression System

(DFDS) will deliver compressed air to a Air Receiver from which air will supply to

the Dry Fog Nozzles through Flow Activation Stations and Pressure Regulating

Units at different Transfer Points.

Pump House shall have a MCC for the operation of Drive Motorsof Pumps and

Compressors.

The operation of above Pumps of DFDSS shall be interlocked with the Low Level

Switch of the respective Storage Tank, so that the Pumps for the entire Dust

Suppression System will run only when the water level at the respective Tank is

adequate. If the water level somehow falls and reaches the Low Low Level, the

water Pumps will trip automatically via signal of Low Low Levelof Level Switchin order to prevent dry running of the Pumps. Therefore care must be taken so


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that water level in the respective Storage Tank does not go below the Low Low

levelof the Level Switchto prevent automatic tripping of the Pumps.

There are two re-circulation by-pass lines with one having Pressure Relief Valve,

with an isolation Gate Valve and one having manually operated Globe Valve at

the common outlet line of Water Pumps of DFDS System for the purpose of re-

circulation of the water back to the RCC Water Tank when the respective Dust

Suppression System application points are not in operation.

Under Belt Electronic Speed Switches (UBESS) shall be used for selected

conveyors to get input signals of conveyors running on load. These signals shall

be interlocked with the operation of Solenoid Valves of Flow Activation Stations to

actuate the application points automatically only the conveyors will be moving

with load.

The Flow Activation Stations have provision for both manual and automatic

operation. In manual operation, the system becomes operational with selector

switch. In auto mode, the fogging operation starts on receiving a signal either

from a Respective UBESS or Flap gate limit switches installed at a strategic

location in the material Conveyor line or Potential Free Contact from the drive

motor of equipment as per requirements.

Each application point is provided with two numbers of spray bar assembly (One

for Water and other for Air) with Air Atomized Nozzles. FAScan be provided for a

single Application Point or more than one Application Points. FAS can be

connected to one or more PRU. A PRU is used to regulate the air and water

pressure for a group of headers.

The pressure switch in the respective building ensures the FAS that the solenoid

valves in the air and water lines are switched ON only when there is adequate air

pressure in the system. Each application point shall have a set of spray bar of air

and water. The nozzles shall be fixed at the discharge hoods/suction hoods and

shall be connected by flexible tubing with the headers. Each PRU shall have air

and water pressure regulators to ensure that the medium at the required

pressure is flowing through the nozzles.

Operation Logic for Starting of Pumps (DFDSS & PWDSS)

The waterPumpscan be started from MCC under following conditions.

Water level adequate signal from pre adjusted Low Levelset point of Level Switch.

Any one of the water pump out of two water pumps (1W + 1S) is selected.

Overload Relay (In pump starter panel) is not in tripped condition.

For Pump-1 & Pump-2 operation separate electrical interlock will be provided in

the MCC.

When pump-1 is in operation then Pump-2 will not in operation& vice versa.If any fault arises in the operation of Pump-1 then Pump-2 will startautomatically and vice versa.


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For the selection and operation of Compressor -1 & 2 the same logic will befollowed as followed by selection & operation of Pump-1 & Pump-2.

And, the water Pumps can be started from MCC (Pump Starter Panel) under followingconditions. Remote mode selected.

Local mode selected.

Start / Stop push button is pressed manually.

In local mode, the system can only be started on receiving local start permissive

command from control room. For the same, Local permissive indication lamp

shall be provided on the local panel.

Following signal should be generated once for any one of the two pumps running.

Pressure healthy signal from Pressure Switch at the common delivery line ofpumps.

Logic for Tripping of Pumps:

The water pumps shall trip while running, under any one of the following conditions, Water level touches the low- low level (preset) set point of level switch at the

Water Tank.

Signals from the Pressure switch at the common delivery line are not healthy.

General Considerations:

Incoming Power Supply up to DS MCC incomer at Pump House will be providedby Client.

All pipe will be ERW Carbon Steel as per IS:1239 (Part-1), Gr.- Heavy for Water

Pipe Lines and Medium for Compressed Air Line.

Pipes & = 65 NB will be Bevel Ends.

All valves up to 32 NB will be of F.C.S and Screwed Female Ends.

Valves of size 40 NB & above will be of Cast Iron with SS Internals and with

Flange Ends.

Duplex Filter will be placed in the common Suction Lineforboth DFDS System.

All Pumps & Compressors for DFDS-1 & 2 will be located in Raw Water Pump

House.

Water Tap Points for DWS, DFDSS 1&2 and Fire Hydrant System will be

provided by client at a distance of 50 meter from RCC Water Tank which is

located within 15 meter from Raw Water Pump House.

Fire Fighting system:

1. Water Source

The new built production and fire-fighting water tank and pump house willprovide water production and fire-fighting uses.

2. Water Consumption


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Municipal water consumption: the water consumption is 4.5m/d .Fire-fighting water consumption: 38 L/S, the total water consumption for a firedisaster will be 305 m.

The total quantity of makeup water for production is 0. 095 m3/ton of raw coaland 590 m/Day.

The recommended combined fire-fighting and process water tank is 1000

mhowever, a 1800 m3water tank is used as the client requires in tender.

Fire fighting water consumption: outdoor fire fighting water: 25 l/s,indoor fire fighting hydrant: 20 l/s, 3 hours duration for one fire disaster;water curtain system: 16l/s, fire duration time: 3 hours; automatic water spraysystem: 30 l/s, fire duration time: 1 hour.

Total 735m3

for one fire disaster

Water pressure:1. Production water makeup: 25m2. Municipal water line: 25m3. Fire fighting water pipe line: at least 65m

Dust Extraction ventilation & Air Conditioning System

Dust Extraction System

Introduction:

Dust Extraction system is used to extract the air bone dust generated due to thetransfer & loading & unloading of materials, activities like screening etc. in theIndustries. This air borne dust makes the nuisance inside the plant premises. Toeliminate these hazards from the working area Dust extraction system is one of theSolutions. Some of the equipments like Belt Conveyors Screen, Crusher, SiloVentilation needs a aspiration system to provide the equipment to work according tothe its designed working capacity & to avoid dusting.

Working Principal of DE system:

In this system the dust generated in the equipment like Belt conveyor Transfer points,

Screen, Dust generated due to Height of fall is being collected through the suction hood,Ducts, to the Bag filter .Air along with dust particles under suction or pressure entersthe lower portion i.e. hopper of the bag filter. The air travels through the filter bag,which retains the dust particles on surface of the bag, and the clean air passes outthrough bags and plenum to the outlet of Bag filter.Dust collected on the outside of the filter bags causes an increase in the pressuredifferential between dirty and clean airsides of the bag filter. To control the pressuredifferential across the bag filter, a sequential timer actuates a series of normally closedpulse valves at preset intervals causing them to open.A momentary rush of high-pressure air (5-6 bar g) flows from the compressed air headerto the blow tube and is expelled from the blow tube through nozzles at a high velocity(primary air flow). Air from each nozzle induces a secondary airflow the combined effect

of the primary and induced secondary air causes an instantaneous pressure rise on theclean side of the filter bags, causing a reverse flow air through the filter bags, thus


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dislodging the dust particles held on the outer surface of the bags. By this mechanism,the dust collected is released from the bags and falls into the hopper. From this hopperit is discharged through suitable device i.e. Rotary valve, screw conveyor.

Since only fraction of the total filter area of the bag filter is cleaned at any given time,continuous flow through the bag filter at rated capacities is assured.

The Volume calculation of the system is done with the reference of ACGIH norms.

Calculation Basis for Dust extraction system:1. Design of bag filter is done as per ACGIH norms.2. ON line cleaning bag filter Considered.3. Velocity of air inside the duct: 18-22 M/Sec.4. Intake velocity of air through hood: 1.5 -2 M/Sec.5. Emission Level shall be max. 10 mg/Nm3 at Outlet of stack.6. Bag filter material shall be 550 GSM with homopolymer bags.

7.

Bag filter cleaning arrangement shall be pulse jet compressed air system.8. Bag filter shall be designed for outdoor installation.9. Air to Cloth Ratio Considered 1.05 m3/min/m210.Max. Operating temperature considered 120 Deg C Considered for polyester

homopolymer bags.11.Pressure drop considered 150mmwg.12.Operation of DE system shall be started/ stopped from the local control panels

and interlocked with conveyor drives.13.Instrument grade compressed air pressure 6 -7 kg/cm2 for pulse cleaning of bag

filter will be provided from compressor house with air Receiver.14.Dust content at inlet and outlet of each bag filter will be minimum 10 gm/Nm3.15.The height of Stack shall be +3.0 mtr from nearest house.

Volume Calculation as per ACGIH Norms:

For Belt Conveyors:

1. Air quantity to be extracted is 2800 m3/hr. per meter of belt width for beltspeed more than 1.0 M/Sec. Additional exhaust at the back of chute of theloading conveyor of followingCapacity shall be provided wherever shown and possible as per layout formore than 3 ft. Fall:i) Belt width 300 mm to 900 mm : 1190 m3/hr.ii) Belt width above 900 mm : 1700 m3/hr.

2. Belt width 1000 mm considered. Belt Speed 2 m/s

For screen:

Air quantity to be extracted is 915 m3/hr. per sq. meter of top cover area. Screen(CS-1), size considered14.4 m2 & Screen (SC-2), size considered 8.64 m2

For Crusher:Air quantity to be extracted is 3600 m3/hr. per sq. meter of inlet opening. Inletopening considered2.7X 0.8 M x M

For Fan


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1. Fan Capacity calculated 10% more than the Calculated Volume of DE system.2. Noise level shall be 85 d BA from 1 m distance.3. Fan shall be SISW type Centrifugal fan with backward curved blades, simply

supported.

4. Fan RPM shall be max 1000 rpm Direct Coupled/Belt Driven.5. 10% margin considered on calculated volume for selection of fan volume.

Chimney:1. The height of Stack shall be +3.0 mtr from nearest house.2. Chimney/Stack shall be supported from nearest building.

For Bunker floor ventilation system

1. For bunker Floor ventilation system volume calculation 8 air change /hr

considered.2. Bunker floor length considered 60mtr.3. Axial Flow fan is considered for bunker floor ventilation system.

For Compressed air:1. Instrument quality air considered for bag filter pulsing.2. Instrument quality air calculation will be done on the basis of 3.4 Nm3/m2 of bag

Area.3. Compressor capacity shall be 1.25 times of the required compressed air flow

capacity.4. Dryer is also considered to get instrument quality air.5. Air Receiver shall be as per IS: 28256. Screw type air compressor air cooled oil Flooded.7. Motor speed shall be 2900 rpm.8. Noise level shall be 85 dBA from 1 mtr distance.9. Capacity of compressed air shall be approximately 140 cfm, Pressure 8.5

Kg/cm2.

Location Considered for Dust Extraction System:1. Screen House : Capacity of Bag Filter: 45000 m3/Hr2. Tertiary Crusher House : Capacity of Bag filter : 22500 m3/Hr

Major Equipment involved in the DE system

1 Filter bags Polyester Homopolymer Bags.2 Cages GI3 Centrifugal fan (backward curved) IS2062, gr. A

4 3 PH-motor for centrifugal fan Standard

5 Inlet damper for centrifugal fan IS2062, gr. A

6 Suction hoods Is-2062gr.A 5 mm Thk

7 Manual & motorised damper Is-20620 gr.A 5 mm Thk

8 Sequential controller Standard

9 Solenoid operated pulse valve Standard

10 DP switch Standard

11 Pressure switch Standard

12 Rotary Air lock valve IS:2062 gr.A


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13 Bag filter housing IS:2062 gr.A 5 mm Thk

14 Bag filter hopper IS:2062 gr.A 5 Thk

15 Plenum IS:2062 gr.A3.15 mm

Thk

15 Screw conveyor IS:2062 gr.A

16 Ducting & bends IS:2062 gr.A5 MM

THIK

17 Stack IS:2062 gr.A5 MM

THIK

18Air compressor(screw type, air cooled, oil flooded ) Standard

19 Air dryer (refrigerated type) Standard

20 Air receiver IS:2062 gr.AAs per IS:2825,

Ventilation System:

Description for Mechanical (Tunnel) Ventilation System:

Push-pull type mechanical ventilation system shall be provided in the undergroundportion of building & conveyor tunnels, cable tunnel, cable vaults to eliminate stagnantcontaminated air & produce a continuous flow of fresh air inside the tunnel. The airquantity for mechanical ventilation system shall be estimated either based on theequipment heat load or adequate air change, whichever is higher. The system consistsof a fresh supply air arrangement (push type) & a exhaust air arrangement (pull type) tomaintain a healthy atmosphere inside the tunnel. Centrifugal fan is considered forsupply of fresh air inside the system. Axial type fan is considered for extraction ofcontaminated or polluted air from the system. Supply air is distributed inside the tunnelby supply air duct. At regular interval supply air grill with VCD shall be provided in thesupply air duct to distribute the supply air inside the underground building. Polluted orcontaminated air is sucked from the underground building by exhaust air grill placed at

regular interval in the exhaust air duct.


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Design Considerations:Mechanical Ventilation System:

a.

Supply air system:i) Underground area: No of air changes considered 15 /hr.ii) Velocity Maintained in the supply air duct & fan outlet shall not exceed 12

m/s.iii) Velocity through grill shall be 3-4 m/siv) Fan shall be Centrifugal type, backward curved vanes for supply of fresh air.

a. Face velocity considered in the HDPE panel filter shall be 2-2.25 m/s.HDPE filter shall be 3Ply having efficiency 90% down to 10 micron.

v) Velocity in branch duct shall be 6-8 m/svi) Ducting : GI sheet ducting (IS:655:2008 & IS:277)vii) Grills: GI sheet construction with volume control dampers and double

directional louvers. Spacing ofGrills: 5m (max)viii) Duct support shall be as per IS: 655:2008

b. Exhaust air system:i) Underground area: No of air changes considered 7 /hr.ii) Axial type fan for exhaust of contaminated air.iii) Velocity maintained in the exhaust air duct shall not exceed 6-8 m/siv) The Velocity of air sucked in the exhaust air grill shall be 3-4 m/sv) Ducting : GI sheet ducting (IS:655 & IS:277)vi) Grills: GI sheet construction with volume control dampers and double

directional louvers. Spacing of

Grills: 5m (max)vii) Duct support shall be as per IS: 655:2008

c. Major Equipments involved in Mechanical Ventilation system:

Sr. No. Equipments MOC

1 Centrifugal Type Supply Air Fan IS: 2062 Gr. A

2 Axial Type Exhaust air Fan IS: 2062 Gr. A

3 Panel Type Air Filter at Inlet of Supply Fan HDPE, 3 PLY , 610x610x50,efficiency 90% down to 10micron.

4 3 Ph, AC motors For Supply Fan ,4 pole Standard5 3 Ph, AC motors For Exhaust Fan, 4 pole Standard

6 INLET DAMPER AT CENTRIFUGAL FAN INLET GI

7 SUPPLY AIR DUCT (RECTANGULAR TYPE) GI

8 EXHAUST AIR GRILL (RECTANGULAR TYPE) GI

9 DUCT SUPPORT FOR SUPPLY & EXHAUST IS:2062

10 SUPPLY AIR GRILL WITH VCD GI

11 EXHAUST AIR GRILL (FIXED TYPE) GI

12 RAIN PROTECTION COWL WITH BIRDSCREEN FOR EXHAUST FAN

GI

13 FIRE DAMPER(FUSIBLE LINK TYPE) GI


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Pressurized Ventilation System at MCC / Switchgear room & Exhaust Ventilationsystem in Battery RoomIntroduction:

Pressurized ventilation system shall be provided in the MCC room to make the roompressurized & prevent the in rushed dusty air to entre inside the room. Tube axial typefan is used to supply the air through air duct & supply grill. This Fan draw the air fromthe atmosphere though panel filter. Panel type air filter is used at the inlet of fan toprevent dust to deliver inside the room. Gravity type wall mounted damper is providedto exhaust the excess amount of air from the mcc room. This gravity damper shall openwhen the pressure inside the room exceed the value of 2-3 mmwg above atmosphericpressure. Thus as the name implies, the air pressure above atmosphere shall bemaintained inside the room. As the air pressure inside the room is more thanatmospheric pressure there shall be rise in temperature inside the room limited to 2-3deg c above outside air temperature. Fire damper fusible link type shall be provided at

the inlet of the room to prevent fire hazard inside the room.For Battery room exhaust ventilation is used to extract the contaminated air.

General Consideration for Dry Pressurized Ventilation :

i) No of air change considered for supply of fan shall be 15/hr.ii) Rise in temperature inside the room is 2-3 deg c.iii) Gravity damper shall be used to make the room pressurized.iv) Fan volume is decided by air change method or heat load calculation Method

whichever is higher.v) Velocity in the duct shall be max.10 m/svi) Velocity of air at supply grill shall be 3-4 m/s

vii) Velocity of air at gravity louver shall be 5 m/sviii) Filter face velocity shall be 2-2.25 m/s

Codes & Standard:

CODE DESCRIPTION

IS-655:2008 : METAL AIR DUCT (GI)IS-3588: 1987 : SPECIFICATION OF ELECTRICAL AXIAL FLOW FANIS-277-2003 : GALVANISED STEEL SHEETSUL-555 : FIRE DAMPER

Major Equipment Involved in the System:

EQUIPMENTS MOC

INLET FILTER : HDPE TYPECENTRIFUGAL FAN : IS: 2062MOTOR FOR FAN : STANDARDBIFURCATED TYPE TUBE AXIAL FAN : IS-2062/AL CASTAIR DUCT SUPPLY AIR : GIGRILL WITH VCDRAIN TROTECTION COWL/BIRD SCREEN : GIFIRE DAMPER : GI

PROPELLER FAN : AL DIE CAST/MS


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Ventilation Location:Dry Pressurized Ventilation:

i) HT MCC Room

ii) LT MCC RoomExhaust Ventilation:

i) Battery Room

Air Conditioning System for PLC/CONTROL ROOM:

Introduction:Air Conditioning system shall be considered for PLC cum control room, computer room,Office room . It is designed considering equipment heat load, solar heat load, heat gaininto the room adequate number of air changes etc. to maintain a uniform temperature &relative humidity within the air conditioned areas.Air Conditioner- Package type water cooled, Non Ductable Hi wall mounted split Type

air conditioner is considered.

Design Considerations:Indoor condition considered 232 C & 555 %Fresh Air Intake: Minimum 1.5 air change per hour.Occupancy considered 4 NosLighting load considered 1 Watt/ft2 of room area.

Major equipments involved in the system:

Sl.

No.

Equipments MOC

1 Package Air Conditioner Standard

2 Hi Wall Mounted Spilt Air Conditioner Standard

3 Horizontal Split Casing Pump Standard

4 Cooling Tower (Induced Draft type) FRP Type

5 Duct & its supporting structure GI/MS(As per IS:655:2008)

6 Fire Damper GI

7 Insulation for Duct Resin bonded glass Wool (24Kg/m3, 50Thk.) Cladding30G GI sheet

8 Acoustic Insulation 5 Mtr of the supply air duct,

material : Fiber Glass Wool ofDensity 48 Kg/m3

Codes & standards:

Sr. No Indian standard (IS) Title

1 IS:3588 Specification for electrical axial flow fans

2 IS:2312 Propeller type ac ventilation fans

3 IS:4894 Centrifugal fans

4 IS 1391 (PART 2) : 1992 Split air conditioners

5 IS: 8148:1976 Package air conditioner

Air conditioning location:


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i) PLC/ Control Room: Package Air Conditionerii) Office Room: Hi Wall Mounted Split Air Conditioner

3) ELECTRICAL

Power distribution:

CHP power distribution has been considered as per basic Overall power distributiondiagram Drg. No- CET RN 3812 EE1 00001, Rev-0.

As per the above document a detail Overall SLD has been generated and attached forreference.Power at 11 kV will be made available by the Purchaser at take over point within 100metres from MRSS proposed to be installed by BTL. Purchaser will establish 11kVgantry structure to terminate two 11 kV feeders of Panther ACSR overhead conductorover LA & string insulators. Purchasers 11 kV Gantry will be considered as the TakeOver Point (TOP).

The scope of work will commence from tapping 11 kV power from TOP and feeding to11 kV Switch board at MRSS. The Power from TOP will be drawn over 11KV Isolator(G.O.D), LA &11 kV(E) XLPE cables and thereby to 11 kV indoor switch board to beestablished for feeding entire Beneficiation Plant loads over 11/3.3/0.415kV powerdistribution system.

One no. 11 kV/3.3 kV HT substation with 2 nos. 11/3.3 kV transformers and

associated 3.3 kV switch board will be provided in the MRSS to cater to the motorloads having ratings above 160 kW. Adequate number of Load Centre Substations(LCSS) each comprising of 2 nos. 11/0.433 kV transformers with associated LTswitchboard to feed power supply to various LT loads of the plant will be included inscope of work. Supply, laying and termination (at both ends) of 11kV cable from the11kV Gantry Structure (TOP) up-to 11 kV Switchboard at MRSS shall be in the scopeof work. Similarly supply, laying and termination (at both ends) of 11kV cable fromthe11 kV Switchboard at MRSS to 11/3.3kV HV substation/HV MCC and 11/0.433kVLT substations will be included in the scope.Supply, laying and termination (at both ends) of 3.3 kV cable from HT motors to 3.3 kVswitch board will be under the scope.

HT load will be feed from 11KV switch board to 11KV/3.3KV transformer&11KV/0.433V transformer as per single line diagram. All HT motor load will be feedfrom client 3.3KV switch gear up to motor which are mentioned in attached single linediagram.


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Following switch gears are considered for HT load distribution:

Sl. ITEM DESCRIPTION Qty. Unit

1 11 kV, 1250A,26.3KA/3 sec, three-phase outdoor, triple-pole, off-circuit gang operated vertically mounted, singlebreak type isolator with manual earth switch onoutgoing side

2 No

2 11kV LA,26.3KA/3 sec, Station Class complete withsurge arrestor and insulating base. Class-1

2 Set

3 Trifurcating cable box for terminating 11KV HT cables 2 No

4 11 kV, 26.3 kA for 3s switch board consisting of two (2)incoming VCBs, one (1) bus coupler VCB and outgoingVCB feeders each provided with imploding type LA, along

with bus and cable earthing VCB. 11 kV switch boardwill operate on Automatic Bus Transfer (ABT) basedsystem.

1 Set

5 11 kV Circuit Breaker control Panel, comprising relay &metering cubicle for the above.

1 Set

6 110V DC plante type lead acid battery of adequatecapacity along with battery charger and 110V DCDB for11 kV & 3.3kV equipment at MRSS & HT s/s

1 No

7 11/0.433 kV, 2MVA ONAN, Dyn11 transformer ofsuitable rating for auxiliary power supply and dedicatedlighting load of the complete plant

4 Nos.

811/0.433 kV, 1.6MVA ONAN, Dyn11 transformer ofsuitable rating for auxiliary power supply and dedicatedlighting load of the complete plant

4 Nos.

9 11/3.45 kV, ONAN, 1.5MVA, Dyn11 power transformerwith all fittings and accessories.

2 Nos.

10 11/0.433kV, ONAN, 1.0 MVA, Dyn11 lightingtransformer with all fittings and accessories.

1 No.

11 3.3 kV neutral grounding resistor and transformerneutral isolator panel.

2 Nos.

12 3.3 kV, 36KA/3sec.1600A draw out type HT MCC forvarious HT motors. The two (2) I/C VCBs & B/C VCB,O/G VCB will operate on ABT based system. All motorfeeders (10 no) will be provided with LA & R-C snubbercircuit.

1 Set

Al the above item will be considered as per specification doc. NoCET/26/RN/3812/TS/CC/01/R=1 which short description are as follows.

11 kV Switchboard:

The switchgear distribution boards will generally comprise horizontally operated, floormounted heavy duty circuit-breakers for incoming, outgoing and bus-sectionalizing

circuits as required. The enclosure protection class of the switchgear will be IP4X.


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The cubicle will be CRCA sheet steel of 2 mm for non-load bearing members and 2.5mmfor load bearing members.

The cast resin insulated Line & Bus PTs will be mounted on independent draw out typecarriages in separate panels.

Each cubicle will have lockable doors for the VCB compartment & meteringcompartment. The switchboard will be natural cooled.Non-magnetic removable bottom base plate will be provided in each chamber for cableentry.

The bus bars will be made of electrolytic grade copper & Raychem sleeved and runthroughout the length of the distribution board.Service, Test and Isolated positions of the circuit breakers will be achieved with thefront door closed.

Automatic safety shutters will be provided over the isolating contacts in the stationaryportion and will be so designed that the busbar compartment is completely segregatedfrom the breaker/PT compartment for all positions of the circuit breaker/PT.

HT Motor Control Centre (HT MCC) for 3.3 kV Motors:

3.3kV HT MCC will have two (2) incomers and one (1) bus coupler breaker (VCB) withprotective relay. The cubicles will be totally sheet steel enclosed, dust and vermin-proof,floor mounting type indoor. Incoming and bus coupler circuit-breakers will be providedwith CT operated numerical relay having non-directional inverse definite minimum timelag (IDMTL) over current and earth fault protection along with instantaneous overcurrent element along with time delay relay. Anti-pumping relay, trip circuit supervision

relay, master trip relay and auxiliary relays will be provided as a standard feature ofbreaker control. ABT scheme will be adopted for HT MCC as indicated in the 3.3kVswitchboard.Each outgoing motor feeder will basically comprise HRC fuse and high voltage vacuumcontactor mounted on a draw-out unit for isolation. Vacuum contactor will bemechanically held (latched) type.Circuit breakers and motor feeders will be provided with trip-neutral-close (TNC) springreturn control switch in HV MCC and the same will be mounted on its low voltagecompartment.Minimum degree of enclosure protection for the HV MCC will be IP4X.

The HT MCCs will be provided with copper busbars.

11KV HT isolator:

Description of Isolating Panel- Pole Mounted Off load isolator with Earth switchStandard followed in design, manufacture and Testing- IEC 60129/IS 9921

Type Designation: DFT

Rated current: 1250A

Supply Voltage and Frequency: 11KV50Hz

Rated operation/Insulation voltage: 12KV Insulation level

One minute power frequency withstand voltage: 1.2/50ms

Impulse withstand voltage: 28/32KVrms,75/85KV peak

Min Clearance in air (mm)Phase to Phase: 229Phase to earth: 178


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Rated short time withstand current: 25KA/3sec

Finish Hot dip galvanized Approx. isolator weight: 250Kg.

Type of Support insulators: Porcelain

No. of poles: Three Rated continuous current: 1250A

Installation: Outdoor, pole mounted type

11/3.3 kV Sub-station Power Transformer:

Basic requirements are given in General Design Features of Power Transformer.However, the power transformer and accessories will comply with the following:

Three-phase power transformer (Dyn11) will be supplied with:Winding & oil temperature indicator with alarm/trip contact, additionally remotesignaling for winding & oil temperature.

ii) Pressure relief valveiii) Buchholz relay

Basic features of the transformers:

i) Primary voltage. 11 kVii) Secondary voltage. 3.45 kViii) Rated power output will be furnished by the EPC vendoriv) Type of cooling. ONANv) Tapping. 7.5% with steps of 2.5% off load

Transformer will be installed outdoor suitably designed along with all safety features(e.g. HVWS-if required).

Neutral earthing Arrangement:

A full capacity neutral terminal will be brought outside the tank and provided with abushing CT with dual ratio 1000-500/5A, 15 VA, 5P20 for standby earth faultprotection. The neutral point after CT connection will be bifurcated. One of the leadsafter bifurcation will be connected to a suitable terminal for solid earthing via two (2)knife switches, by 1.1 kV, 1/C, 630 sq mm Al. PVC or 1/C, 300 sq mm Cu PVC cable toearth stations as specified. The other lead will be taken inside LV box through a bushingand provided with a suitable terminal for neutral connection

Neutral earthing isolator.

11/0.433 kV Distribution Transformer:

The 415V load centre substations will be fed from 11/0.433 kV distributiontransformer.Distribution transformers will be selected from sizes 1600 kVA/2000 kVA. Maincharacteristics are:

Transformer type: Oil filled

Cooling class: ONAN

Winding vector group: Dyn11

Installation: Outdoor

Primary off-load tap changer: 5% @2.5% by step


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Sub-station power transformers will be sized based on consumed loads in operation.Stand-by and spare feeders will not be considered in transformer sizing. The

transformer capacity will be designed such that in the case of outage of one transformer,the other healthy transformer is not loaded beyond 80%.The transformers will bedesigned, constructed and tested in accordance with the applicable sections of the latestrevision of relevant Indian Standard (IS), Indian Electricity Acts & Codes equivalent IECstandards. For isolation of load centre transformers, load breaks isolators along withLPT panel will be considered. If transformers are not in the vicinity of HT switch gear.VCB with protection along with LPT will be provided.

110V DC Battery with charger& DCDB:

110V Plant type lead acid battery system will be provided for control and monitoring of

the 11 kV and 3.3 kV switchboards located in two different substations. Each set willhave redundant battery charger circuit but batteries will be common. Each charger willoperate on float-cum-boost mode. The float cum booster charger will be rated to cater tothe trickle changing current of batteries as well as the boost charging (2 rate) of a fullydischarged battery and continuous load on DC bus including 20% margin. The boostcharger will be rated to charge the battery from fully discharged condition to chargedcondition within 8 hours. DC distribution boards will be provided.

LT load distribution:

LT load will be supplied from 2 nos. 11KV/433V, 1600KVA transformer for WT system &fire fighting system, 2 nos. 11KV/433V 2000KVA transformer for conveying& others

auxiliary system.In this regards one dedicated PCC will be considered for supplying LT load to Conveyingsystem MCC, DS MCC , PDB as per SLD. Required rating bus duct will be consideredfrom transformer secondary to PCC incomer & PCC outgoing to MCC Incomer .

Following switchgears are considered for LT load distribution:


1 4000A LT Bus duct for ELB-1 between 11/.433KVTransformer & PCC

2 Nos.

2 2000A, LT Bus duct for WT PCC 2 Nos.

3 3200A LT Bus duct for MCC Conveying system 2 Nos.

4 PCC for ELB-1 1 No.5 PCC for WT 1 No.

6 MCC for Coal Handling Part Conv. & Aux. load.MCCs - Conventional, Non-draw-out type, Singlefront, Motor Control Centres (MCC) with twoincomers & one bus-coupler

1 No

7 MCC for DS SYSTEMMCCs Conventional, Non-draw-out type, Singlefront, Motor Control Centres (MCC) with twoincomers & one bus-coupler

1 No


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8 MCC-5 FIRE FIGHTINGMCCs Conventional, Non-draw-out type, Single

front, Motor Control Centres (MCC) with twoincomers & one bus-coupler

1 No

9 PDB for coal handling area 1 No.

10 VFD for apron feeder. 1 Set

Al the above item will be considered as per specification doc. NoCET/26/RN/3812/TS/CC/01/R=1 which short description are as follows.

LT SWITCHGEAR (PCC/MCC):

Industrial, floor mounted, self-supporting, sheet steel enclosed, compartmentalized non-

draw out type 415V motor control centre will be adopted. The bus bars as well as theincoming circuit breaker/outgoing MCCB will be capable of withstanding a throughfault current of 50 kA for 1 second. Sheet steel thickness will generally be 2 mm& nonload bearing member 1.6 mm. Generally MCCB will be provided for motor and powerfeeders in 415V MCC. MPCB will be provided for power feeder rated up-to 10A andmotor feeders rated up-to 3.7kW. Ammeter and selector switch along with currenttransformer will be considered for incomer.

The low-voltage switchgear will be PCC& Motor Control Centres of totally enclosed, self-supporting, floor mounted, compartmentalized, single front, type construction. Theswitchboard will be a sheet steel-clad low-voltage distribution board with doorinterlocking facility. Local/remote selector switch will be provided in the PCC/MCC.

Power distribution boards:

Single front, non draw-out type, modular construction, having one incomer will beprovided for loads like welding sockets, maintenance cranes, hoists, power supplyfeeders to repair shop, laboratory, admin building, utility aux load etc.MCCB will be used as power isolating cum short circuit protection device for alloutgoing feeders.

The power distribution boards (PDBs) are generally intended for distribution of power tovarious consumers in the plant area and will be suitable for 415V, 3-phase, 4 wire,50Hz. The distribution boards will be of cubicle type having incoming & outgoing draw-out ACB/MCCB units.

Degree of Protection will be IP-54.Cubicle type power distribution boards will be totally enclosed, dust & vermin proof in 2mm thick sheet steel construction, housing draw out Air Circuit Breakers and MCCBswith O/C, S/C & E/F protection. The cubicle will be floor mounting type and will bedust and vermin proof generally conforming to IP-54 with multitier compartmentalarrangement.

The bus bars will be of aluminium and will have continuous current rating same as thatof the incoming ACB/MCCB and will be suitable to withstand without damage the effectof maximum short circuit current of 50 kA RMS for one (1) second.


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415 V Bus ducts:

Three phase and neutral, nonsegregated bus duct with 3 mm thick aluminium alloy

enclosure will be provided up to 15 meter length for connection between the transformersecondary and the 415 V switch board. Material for the bus bar will be aluminium. Thedegree of protection for enclosure will be IP54.Suitable adapter chamber will be provided for terminating the bus-duct on toswitchgear. Matching flanges will be provided at both ends of the bus-duct run. Flexibleterminal connectors will be provided for termination at transformer and switchgearends. Expansion type joints will be provided in the bus-duct sections to take care ofvariation in lengths due to variation in temperature.Busbars inside the enclosure will be supported on insulators of required voltage grade.

The number and spacings of insulators will be so selected that the bus bars will becapable of withstanding the dynamic forces set up under rated through fault conditions.

The bus-duct enclosure will be provided with earthing terminals at both ends forconnection to the station earthing system. A continuous aluminium earth bus will beprovided throughout the length of the bus-duct.Bus-ducts will be provided withcomplete supporting structures, as required. Sections of bus-ducts installed outdoorswill be supported from ground while indoor sections will be supported from ceilingand/or wall.Seal-off wall bushings will be provided where the bus- duct enters a building from itsoutdoor run.

LT Variable Speed AC Drives for apron feeder:

The VVVF will be of pulse width modulation (PWM) type with open loop frequency

control to keep the ratio of voltage to frequency (V/f) constant throughout the speedrange to maintain constant motor torque.

The VVVF will comprise incoming fuse unit, dry type line reactor, threephase diodebridge, inverter unit, load side contactor/isolator and current limiting choke whererequired.

The PWM inverter will have fully digital microprocessor based regulation and controlsystem with suitable interfaces for instruments and signals. The microprocessor willcarry out all the functions required from unit including triggering protection, self-diagnostic and operator interface. Suitable programming and debugging unit will beprovided. Display of faults, alarms, as well as diagnostic messages will be available inplain text on the operator panel of the cubicle.

All faults, not limited to the following, will be detected, annunciated and protectivemeasures will be initiated accordingly. First fault annunciation will be provided.

Power supply(Line - O/C, O/V, U/V)

Drive faults(Fuse blown, cooling fan stop, device over temperature, instant O/C, overload)

Motor faults


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The boards will be of industrial, totally enclosed dust-proof, wall mounted, sheet steelcubicle design.

The boards will have welded back and sides and gasketed hinged door at the front withdoor handle and suitable locking devices. For boards with incoming MCCB (I) the accessto the operating handle will be from the front of the cubicle without opening the frontdoor. Operating knobs of outgoing MCBs will be accessible only after opening the frontdoor of the cubicle. Protective insulated cover plate will be provided inside the cubicle toshroud all the live parts with only the operating knobs of the MCBs protruding outsidethe cover plate. Adequate space will be provided within the board to facilitatetermination of incoming and outgoing cables. The boards will be factory wired andassembled.

HT & LT Motor for conveyor drive:

The Electric motors has been considered Squirrel Cage induction type in horizontal footmounted design, totally enclosed fan cooled with IP-55 degree of protection. All themotors will be provided with Class F insulation, temperature rise limited to class-Blimit over an ambient temperature of 50deg .The motors will be provided with a terminalblock on the side which can be rotated through 360deg in steps of 90deg. All the motorswill be provided with two earth connections. The ratings of all motors will be as per thedrive list furnished with mech. Motor has been considered as per technical specificationdoc. No CET/26/RN/3812/TS/CC/01/R=1& S&TMCPL/DB-ELE-001, clause no-5.0

H.T Power cables:

The H.T power cables will be 6.6KV (UE) grade ,stranded Almunium conductor withextruded XLPE insulated, each phase having screening by a semi conducting material ,with Extruded PVC inner sheath ,G.I. strip / wire armoured having over all ExtrudedPVC sheathing (Type-ST-1) with oxygen index not less than 29. HT power cable hasbeen considered from purchasers switch gear room to proposed CHS MCC room (NearWT-3).

L.T Power cables:

LV Power Cable has been considered 1100 V grade, single/multi-core, strandedaluminium conductor, XLPE insulated, extruded FRLS PVC, inner sheathed of type ST-2,galvanized single round steel wire/strip armoured and with outer sheath made ofFRLS PVC compound of type ST-2. The cables used for DC system will be of single core

type. Minimum conductor cross section of power cables shall be 4 Sq.mm.

Control cables:

Control cables have been considered 1100V grade, multicore, minimum 1.5 sq.mmcross section, stranded copper conductor having 7 strands, PVC insulated, inner FRLSPVC sheathed of type ST-1, galvanized steel wire armoured and outer sheath made ofFRLS PVC compound of type ST-1. In situations where accuracy of measurement orvoltage drop in control circuit, warrant, higher cross sections as required will be used.For all the CT & PT cables, minimum 2.5 sq.mm cables will be used.

Instrumentation cables:


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SlNo.

Location Normal LightingEmergencyLighting

6

HT Switchgear room

/MRSS 2X40W FTL

7Switchyard & alloutdoor areas

250W HPSV

In addition with above road lighting will be considered for material handling area up to1200 meter by 10 meter lighting pole with fixture at 30 meter interval to achieverequired lux level.

6 nos. High mast has been considered for ground hopper stock pile& reject stock pilearea for yard lighting.

Cabling, Earthing and Lighting Protection:

Cabling has been considered for the above cable including laying by different size cabletray, separate cable tray has been considered for Power cable, control cable &instrument cable. Required size conduit has been considered for field instrumentlooping and termination purpose. Cable laying, termination has been considered as perspecification.Earthing & Lightning protection system has been considered as per specification doc.No CET/26/RN/3812/TS/CC/01/R=1 & S&TMCPL/DB-ELE-001, clause no-5.0Earthing material has been considered in various areas in CHP system are as follows:

SlNo. Equipment Earth conductor aboveground level

1 Earth Pit 40mm dia MS Rod

2 Main earth grid 75X10 mm GS flat

33.3KV Switchgear/415VSwitchgear/11/3.45 KV Trafo

40X6 mm GS flat

4 11KV Switchgear

5 11/0.433 Transformer, 2MVA 65X8 mm GS flat

6 LT Motors (160-200KW) 50X6 mm GS flat

7 LT Motors (110KW to 132KW) 40X6 mm GS flat

8 LT Motors (15KW to 90KW) 25X6 mm GS flat

9 LT Motors (3.7KW to 11KW) 16 Sqmm stranded Wire

10Control panels & Controldesk

50 Sq mm stranded

11 PB Station/JB 6 Sq mm stranded

12Columns,structures,cabletrays & busduct enclosures

50X6 mm GS flat

13Crane,rails,rail tracks & othernon-current carrying metalparts

25X6 mm GS flat

14 Earth Pit for lightning 25X6 mm GS flat

15 Down-Comer 25X6 mm GS flat

16 Electronic Earth Pit17 VVVF/DCDB/UPS/PLC 1CX25 Sqmm Cu. Wire


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Electrics for Equipment Wagon tippler & side arm charger, hoist, elevator, tripperetc.

All electrics for Wagon tippler & side arm charger, hoist, elevator, tripper etc. has beenconsidered as per equipment standard application and specification which details canbe given during detail engineering stage.

Instruments:Safety Switches (ZSS/PCS/BSS):

Zero Speed Switch:

Each conveyor will be provided with industrial duty non-contact type

proximity type zero speed switch along with its electronic controller ofprotection class conforming to IP55. The electronic unit will haveprovision to receive auxiliary power at 110V AC and generate potentialfree 1 NO + 1 NC contact each rated for 10A at 110 Volt. The electronicunit will have provision to adjust time delay for contact actuation as wellas dropping of relay to avoid nuisance tripping. The switch will besupplied with special cable between sensor and the electronic unit. Theproximity switch shall be suitably designed to sense with a gap up to 20mm.

Pull Chord Switch:

Pull cord switch will be provided in conveyor gallery @ 25minterval along walkway onboth sides. The pull cord switches will be industrial, heavy-duty types, enclosed in adust and vermin proof cast iron, cast aluminium box. The switches will be operable inboth directions with automatic locking arrangement in the operated position and will bemanually reset type. The pull cord switches will have 2 NO + 2 NC contacts each rated10 A at 110 V and will be complete with parallel running pull wire and associatedaccessories. The degree of protection for enclosure of pull cord switches will be IP65.

Belt Sway Switch:

Belt sway switches will be provided along conveyor @ 50 m interval on both sides with aminimum of 1-pair for each conveyor. Belt sway switches will be industrial, heavy dutytype, housed in a dust and vermin proof cast iron, cast aluminium box with indirectacting mechanism such that the belt does not come in direct contact with the switchelement. The switches will have 2 NO + 2 NC auxiliary contacts each rated for 10A at110 V AC. The degree of protection for enclosure will be IP65.

Limit Switch:

Heavy-duty type limit switches will be provided for automatic reversal of shuttleconveyor as well as stoppage during over travel. The same will be provided with 2 NO +2 NC auxiliary contact of 10 A rating at 110V. The degree of protection for enclosure willbe IP:65. Heavy-duty proximity type positioning switches, with sensing distance to suit

the application, will be provided for automatic positioning of the carriage of reversible


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shuttle conveyor. The switches will be 3 wire type with leakage current below 10 mA andsuitable for signal exchange with PLC system.

Chute jamming switch:

Chute jamming indication will be needed for automatic stoppage ofupstream/downstream conveyors through tilt switch which will be located at the exitside of the chute. The tilt switch will be actuated when material flow on conveyor isnormal to tilt the probe of the tilt switch 15 degrees or more from its vertical position.

The mercury switch will get tilted regardless of the direction of tilt and the NO contact ofthe switch will close. When there is no material flow from the chute, thus indicatingchute jammed condition, the NO contact will open and will generate a signal to PLCsystem to trip the conveyor. The probe will be adequately protected against mechanicaldamage. The control unit will be suitable for outdoor installation with degree of

protection IP 54. Green (normal) and Red (alarm) indicating lamps will be provided onthe front panel of the control unit. There will be provision for adjustable time delay toprevent stoppage of conveyors in case of momentary tilting of the probe.110 V AC, 5 A, 2NO, 2 NC contacts will be made available for interlocking/alarm. Alternatively,ultrasonic/ microwave operated switch inside the chute may be adopted, wherespecified in TS.

Temperature transmitter

The said transmitter will be considered for each HT motor bearing and winding RTDapplication as per specificationIndividual JB will be considered for transmitter housing of each HT motor as per RTD &

BTD application. The signal will be transmit up to DCS (employer scope) by the help ofrespective PLC &RIO panel.

Level Measurement System

Radar type continuous level measuring system will be provided at the top of bins &silos. The system will comprise of probe & electronics unit. The probe will contain aninner active section and an outer shield section. The electronics unit will consist ofoscillator, detector, etc. The design consideration is as follows:

Probe materials :SS with PTFE or Ceramic as per requirement

No. of points : As per requirement Range : As required

Output : 4-20 mA DC with 600 ohms load

Alarm output : Potential free contact for High, Low level

Operating temp.: 0-70 oC

Power supply : 230V, 50Hz AC

Mounting : Flanged connection at top of Covers/side walls.

Enclosure : As per IPSS : 2-07-001-87

Belt Weighing System

Microprocessor based system for Belt Weigher system will provide mA signal output forthe coal feed to be connected to DCS of CHP.


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On conveyors to record the quantity of coal received in the plant and quantity ofcoal conveyed.

Boom conveyor of SCR to record quantity coal available in stockpile and alsoreclaiming rate.

The belt scale is considered as load cell type and of continuous operating. Provisions forlocal and remote measurement of instantaneous through put, totalling, local signallingof load limits of conveyors will be provided. Control of sampler, signals for remoteindication and overload alarm will be given in the belt scale. Suitable device for testingthe accuracy by test weights will be provided. The belt scales will be of electronicmicroprocessor type. Weigh scales will be of multi-idler type.

Vibration Monitoring System for each Crusher:

Vibrating monitoring system is considered for the ring granulator type Crushers tosense and for indication of vibration of the equipment and transmission of the sensedsignal to the Control room for indication of alarm and tripping in case of anyabnormality of the equipment.

We have considered simple Vibration Monitoring System for total 2 Nos. of Crusher(both its Driving End & Non Driving End location and in Horizontal & Vertical location).

The output from the Two Sensors would be fed in to the Dual Channel Monitor, whichprovides a continuous display, Alarm-Alert Relay and 4-20 mA Output. This transmitteris a dual channel one and the output could be fed in to the CHP DCS. We have alsoconsidered a buffer output using handheld portable data collector for further analysis of

the data.

Individual control panel will be considered for each system.

Automation System

Level-1 Automation System:

The proposed instrumentation & automation system will comprise of PLC systems (PLC),primary & secondary instruments and field devices.

i) Automation system for Pre & Post Material Handling facilitiesii) Automation system for Wagon Tippler houseiii) Integration among automation system of Material Handling facilities, Main

Coal Processing Plant, Wagon Tippler system.

Automation system for each area will be achieved through dedicated PLC system housedin respective control room along with Human Machine interface (HMI), Operator stations(OS), Engineering stations, system cabinet, input/output subsystem, communicationsub system, peripherals etc. for execution of sequential operation & logic control, PID,process monitoring & supervision, data acquisition, historical trending and logging.Each PLC system will be complete with necessary application software, system software& communication Software. Each PLC system will have redundancy with respect to

CPU, power supply & communication modules with hot standby feature. Necessaryhardware will be considered for bringing all signals from different areas to PLC system.


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All control loops will also be achieved in the PLC system. PLC system will be consideredas per said specification & requirement.

UPS with Battery Backup:

UPS system (minimum 2x10 KVA) in parallel redundant mode & single phase 220 V acwith neutral grounded output and sealed maintenance free battery will be providedcatering the need of Instrumentation &Automation system, PLC, Fire Detection & Alarmsystem, voice communication system, EPABX, PA system & CCTV system. The UPS willbe installed in A/C environment in or near the Control Rooms. The purchaser willprovide two feeders of 440V AC 3 phase, 4 wire input supply. The UPS will be designedsuch that it is loaded up to 60% of the capacity. The Bidder will generate two feeders of440V, 4 wire AC input along with manual changeover scheme for input supply toUPS.UPS failure will be displayed in the Operator station of PLC.

The UPS will be provided with servo controlled voltage stabilizer (SCVS) in the by-passline with static switch. Further, static by-pass line should have selector switch formanual by pass of the UPS& SCVS system in case of maintenance of UPS. The output ofthe UPS will be suitable for 230 V AC, 50 Hz with voltage and frequency variationlimited to +1% and +0.5% respectively or better. Necessary potential free contact will beprovided for alarm and status contacts to be hook up to respective automationsystem.UPS distribution board will be provided with 20% spare feeders. DPMCB withsuitable rating will be provided at each of the feeders including the spare ones..Metal Detector /Magnetic separator

The above equipment has been considered as per flow diagram with specification whichE & I part control panel has been considered. Necessary IO hook up provision has beenkept inside the control panel. Signal will be transmitted from respective control panel upto PLC/ RIO panel.

Instrument for DE & DS system

Following instrument will be considered for DE & DS system for various locations as perscope which detail will be submitted along with P & ID diagram during the time of detailengineering.1. Pressure switch, 2. Displacer type level 3. Sequential controller, 3.Pulse valveAll the instrument associated with DE & DS system will be considered as per saidspecification & requirement.

Plant telephone system:The Automatic telephone exchange and allied equipment along with the required cablingnetwork are intended for providing internal communication inside the plant as well asfor external communication beyond the plant. It will consist of one number EPABXsystem with 4x64 line capacity and line cards for 192 extensions including powersupply equipment along with rechargeable Battery bank, operator console and MainDistribution Frame (MDF). The system will be complete with standard telephones 48 nosand necessary telephone cable network for the subscribers within the plant officebuilding & control room buildings. The exchange will be equipped with required

hardware and software to interface with the Loudspeaker Intercommunication system(LSIS)/ Public Address (PA) system of the respective shop.


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The above system will be considered as per specification doc. NoCET/26/RN/3812/TS/CC/01/R=1, clause- no 3.6.5

VHF voice communication system:

The VHF communication system will be used to provide instantaneous audiocommunication facility among control rooms & plant personnel. System will beconsidered as per specification doc. No CET/26/RN/3812/TS/CC/01/R=1, clause- no3.6.6

Closed circuit television (CCTV) system:

Supervision & monitoring system will be provided for process monitoring and

functioning of equipment from a central location by installing CCTV system. This systemwill assist in monitoring various areas on a continuous basis from a central location andfor taking timely action in the event of any dysfunction.

Main Features of CCTV system will be as follows:

Remote control facility

Recording of events

Motorized pan & tilt head (as required)

Centralized viewingThe CCTV system will consist of cameras to view the respective area along with monitorsfor viewing independent areas. The monitors shall be housed in the main control room.

The facility for recording the events as historical events with time limit of storage will be

provided in the system.

System will be considered as per specification doc. No T/26/RN/3812/TS/CC/01/R=1,clause- no 3.6.8

Loudspeaker communication system:Two Channel Open Line Page Party type Loudspeaker Communication system (PA) forestablishing reliable and quick communication amongst various sections of themanufacturing complex comprising of the following:

1) Thirty (30) nos. of wall/desk mounted subscriber stations with required no. of horn /

cone type loudspeaker and other accessories as per requirement.

2) Required quantities of armoured signal cable, control cable and mains cable withcabling accessories, junction boxes, PDBs as per requirement.

3) Any other accessory or equipment as required for the proper functioning of the abovementioned loudspeaker communication system.


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4) STRUCTURAL WORK:

4.1 TECHNOLOGICAL STRUCTURES

SNO.

Description QTY. Location

1Stringer, Short post, Head and

Tail pulley frame & Guide columnfor Vertical gravity take-up.

Lot

Stringer will be made of ISMC150 forConveyors above 1000 mm Belt Width& ISMC 125 for conveyors up to 1000mm Belt Width.Short posts shall be made of ISMC150 for Conveyors above 1000 mmBelt Width & ISMC 125 for conveyors

upto 1000 mm Belt Width.

2

design basis of coking coal beneficiation plant.pdf

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