BASIS OF DESIGN/OFFER1|Page 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 drawing Nos. Tender Drawings: 1 CET RN 3812 GL0 00 001 REV R=0 Layout Drawing 2 S&T/003 Surface Plan 3 4 5 B. CET RN 3812 CC1 00 001 REV R=1 CET RN 3812 CC1 00 002 REV R=0 CET RN 3812 CC1 00 003 REV R=0 Process Flow Diagram Equipment Flow Sheet 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 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/m3 for volumetric calculation. 1.2 t/m3 for 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 2|Page 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 45 0 for all conveyors 5.2 Return Idlers Single Roll Flat Return Idler for Conveyor of Belt Width less than 1000 mm and Two Roll „V‟ return idlers with 10 0 troughing 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 m Return 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. 200 at Tail end and 1 No. 50, 200, 350 each at Head end 5.10 Idler spacing at Convex Zone shall be 50% of the normal spacing specified above. 3|Page 5.11 Two (2) Nos. Self Cleaning Type Rubber Disc Return Idlers Shall be provided at Discharge pulley. 5.12 Eight (8) Nos. Machined Idlers shall be provided for Belt Scale Location 5.13 Four (4) Nos. Non-Magnetic Idlers shall be provided at Tramp Iron Separator 5.14 One (1) No. Inverted V-Return Idler shall be provided at Tail and Head end. 6. Pulleys (Face width as per IS: 8531 – 1986, Reaffirmed in 1993) 6.1 Pulley shell thickness: 12 mm (minimum) for all conveyors. Non Drive pulley 10 mm (minimum) for all conveyors. Drive Pulley 6.2 Pulley lagging: Drive Pulley Non-drive Pulley 12 mm thick natural rubber lagging (shore hardness 35-4 5 on Scale „A‟), herringbone except Conveyors Nos. BC-1, BC-2, BC-17, BC18,BC-19, BC-20 which will be provided with 12 mm thick Ceramic Lagging. 10 mm thick plain natural rubber lagging for all non-drive pulleys (shore hardness 35-45 on scale „A‟). 6.3 All pulleys shall be connected to the shaft through key arrangement 6.4 Pulley shaft deflection at hub shall be maximum 5 minutes. 6.5 Pulley Shaft material shall be Class- IV, IS-1875, up to 150 mm and 40Cr1MO28, IS-1570 above 6.6 Pulley Shell Material shall be MS conforming to IS: 2062. 6.7 Pulley Hub Material shall be Cast Steel Gr. II, IS-1030 6.8 Pulley Diaphragm Material shall be MS conforming to IS: 2062. 6.9 Bearing Type: Double row self aligning spherical roller bearings 7 6.10 Bearing Life: 40000 Hrs 6.11 Type of sealing: Double labyrinth with synthetic sealing. Plummer Blocks The pulley shaft shall be supported on heavy duty; split type Plummer blocks of 4 bolts construction. 4|Page 8 CONVEYOR DRIVE UNIT: Reducers 8.1 The gearbox mechanical rating shall be 1.5 times of consumed power at pulley shaft or1.25 times of motor power, whichever is higher. 8.2 For Motor Power Rating up to 15 kW Worm Gear Box shall be provided. 8.3 For 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. 8.4 All Inclined conveyors shall be provided with roller type holdback integral with gearbox. 8.5 Housing of the gearbox shall be made of Cast iron housing of FG 260 as per IS: 210. 9 High Speed Coupling 9.1 Motor name plate rating up to 37 kW Tyre type Coupling 9.2 Motor name plate rating above 37 kW to 200kW Traction Type Fluid Coupling. 9.3 Motor name plate rating above 200 kW (HT motor) Delayed fill chamber type fluid coupling 10 Low Speed Coupling Gear coupling 11 Brakes Electro hydraulic thruster brakes shall be provided on conveyors where reduction in coasting time is required. CONVEYORS STRUCTURAL 12 Take 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 belt width, 450 mm for 1000 mm and 1200 mm belt widths and 500 mm for more than 5|Page liner height shall be 200 mm. Chutes: 18.15 mm thick shall be provided at every feed point up to 3 m beyond the skirt length of all the conveyors. For reversible conveyors the same shall be provided at both the ends. Skirt shall be made of 10 mm thick plate.15 mm thick Sheets shall be provided throughout the length of Conveyor. Liners All clean coal chutes shall be lined with SS-304 liner. Diagonal plough type scraper shall be provided for the reversible type conveyor/feeder at both head and tail ends. In feed zone. liners of full height shall be provided and beyond feed zone.1 Chute All the chute body shall be minimum 10 mm thick MS plate. V-plough type internal scraper shall be provided for each conveyor. Liners 6|Page . MS deck plate of 3. Hinged type inspection doors minimum of 500 x 500 mm and poke doors of 300 x 300 mm shall be provided. 6 m long deck plate from the centre line of head pulley shall also be provided at the head end of all conveyors. Deck Plate 3. Short support size: ISMC 150 for Conveyors above 1000 mm Belt Width & ISMC 125 for conveyors upto 1000 mm Belt Width. One no. Conveyors stringer size: ISMC 150 for Conveyors above 1000 mm Belt Width & ISMC 125 for conveyors upto 1000 mm Belt Width. wherever required 18. 15. 16. 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. 18.2 Height of single piece of chute shall not more than 2 meters Impact zone of all chutes shall be lined with 60 mm thick rubber liner and sliding areas with 30 mm thick ultra high molecular weight polymer. Conveyor hood shall be made of minimum 5 mm thick MS plate.1200 mm belt width. 17. 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. Modular segmented type skirt board sealing system for effective sealing against spillage and dust shall be provided. Hardox-450 Cast basalt having shell thickness 8 mm with surface coating of epoxy. The size & shape of liner shall be provided for easy handling and shall not exceed 20 kg/hour. 18.shall be provided at three (3) sides of chute plates for inclined chute at all four (4) sides for vertical chutes.3 Valley Angle Valley angle of chute shall be minimum 60 degree. Hardox-450 1 meter bottom vertical portion & all Conical portion 20mm thick. Media pipelines 1. Plant Surge hopper Structural Concrete hopper Liners for bin/bunker/pipelines/launders/catch pan Sl. 2. Launders Return pipelines & coal water slurry line 7|Page 20 mm thick UHMWPE 10 thick Mn Steel (IS:276 Part-I) 45kg/m rail 45kg/m rail 1 meter bottom vertical portion & all Conical portion 20mm thick. Items Liner Specification 20 mm thick Hardox 450 20 mm thick Hardox 450 3. Raw Coal handling chute Clean/Middling/Reject Coal lump size (-) 13mm Impact zone Sliding/non impact zone Skirt Wagon Tippler Hopper Truck Dump Hopper 300T Hopper 8. Ground ROM receiving hopper Wagon tippler hopper 4. Items Type/MOC Coal Raw coal silos Concrete silos Concrete hopper 3. 5. Bin/ Bunker Bin Bunker Details Sl. 10. 6. 7. No. 11. 1. 4. Raw Coal Silo 9. Ceramic tiles (> 90% alumina) HDPE (based on the suitability) . 2. No. 21. Pull Cord Switch. 20. hoppers handling fines. Zero Speed Switch One for each conveyor at non drive pulley. 8|Page . 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.CONVEYOR MOUNTED ELECTRICALS: 19. Minimum distance of switch shall be 5 m from the head & tail end of conveyor. 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. Chute Blockage Switches Chute plug switch shall be provided for chutes and 22. 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. . The chute plug switch shall be RF type. Minimum distance of switch shall be 10 m from the head & tail end of conveyor. SCOPE OF WORK/SUPPLY 9|Page . China as consortium members jointly proposes to undertake design and engineering. painting. Conv. India and Tangshan Guohua Technology Co.00 2.00 2. Tangshan. Ltd. unloading.00 2. BC-4A 1 1600 105.00 2. TC-1 1 1800 77. India at Bhelatand. erection. BC-4 1 1600 45. BC-1 1 1800 40. tailings and reject as per scope of supply on turnkey basis for M/s S&T Mining Company Pvt.50 1500/1800 2.80 MTPA raw coal to produce clean coal..00 2. commissioning and demonstration of performance guarantee of a coking coal beneficiation plant having capacity to treat 1.90 1500/1800 10 | P a g e Truck Dump Hopper Circuit Raw Coal Silo Feeding . storage and handling at site. Kolkata. construction. No.00 2. supply. manufacture/procurement. middling. Qty.90 1500/1800 7.SCOPE OF WORK / SUPPLY Bengal Tools Ltd.00 500/600 4. Ltd. BC-2 1 1800 155.00 2. testing.00 500/600 5. packing.50 1500/1800 3 BC-3 1 1200 201.. (Nos) Belt width (mm) Approx Conv. BC-3A 1 1200 21. The scope of supply shall consist of the following equipment/ item: 1) MECHANICAL A. Dhanbad District of Jharkhand. BELT CONVEYORS: S. India. Kolkata.90 1500/1800 6. Hebei. No. Length Along length per conveyor (m) Belt Speed (m/s) Capacity R/D (TPH) Remarks Rail Wagon Unloading Circuit New Belt Conveyors for proposed plant 1. 00 200/240 Remarks Tertiary Crushing Circuit & feed to main process plant through Surge Hopper Clean Coal 16 BC-12 1 800 186.00 2.00 2.00 1. Qty.00 3. BC-5 1 1000 55. Length Along length per conveyor (m) Belt Speed (m/s) Capacity R/D (TPH) 8.00 300/360 12 BC-8 1 1000 74. (Nos) Belt width (mm) Approx Conv.S.00 200/240 19 BC-15 1 800 130.00 2.00 200/240 17 BC-13 1 800 77.00 500/600 9 BC-6 1 1000 106.00 300/360 11 BC-7A 1 1000 78.00 500/600 14 BC-10 1 1000 73. No.00 2.20 1800/2160 Middling/ Rejects 11 | P a g e Middling .00 2.00 2. Conv.00 2. No.00 2.00 2.00 2.80 300/360 15 BC-11 1 800 45.00 2.00 300/360 13 BC-9 1 1000 90.00 500/600 10 BC-7 1 1000 11.00 2.00 200/240 20 BC-16 1 800 60.00 200/240 Rejects 21 BC-17 1 1600 168.00 200/240 18 BC-14 1 800 58. (Nos) Belt width (mm) Approx Conv. herringbone type except for Conveyors Nos.00 3.20 1800/2160 BC-20 1 1600 38.20 1800/2160 Note: Existing Conveyors The conveyors will consist of the following: Troughing. bend and snub pulleys complete with Double Row Spherical Roller bearings and Plummer blocks. tail. Belting: Heavy Duty Nylon. take-up. Flat Return /two roll V-return Idler.00 3. Impact idlers.Nylon/ EP belting Drive unit consists of Motors (HT & LT). No. 12 mm thick natural rubber lagging (shore hardness 35-450 on Scale „A‟). Transition. low speed coupling and coupling guard. high speed.S. V-plough type (internal scraper shall be provided for each conveyor. 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- 12 | P a g e . Drive. Troughing training. BC-1.BC19. Screw/ Gravity type take-up with Counter weight as specified in Basis of Design.00 3. Length Along length per conveyor (m) Belt Speed (m/s) Capacity R/D (TPH) 22 BC-18 1 1600 168. BC-17. Return Training. worm/ helical gearbox (with integral holdback for inclined conveyors). One sprung blade type (Tungsten tipped) and one one poly urethane blade belt scrapers at discharge pulleys and one no. Conv. as required.20 1800/2160 BC-19 1 1600 154. No.20 1800/2160 2 BC-319 1 1600 3. as required.20 1800/2160 23 24 Remarks Wagon Loading Circuit Belt Conveyors to be modified in the existing plant 1 BC-316 1 1600 3. BC-18. BC-2. Qty. 1. Vibrating Feeders a) Pre MCCP Building i) Quantity ii) Type iii) Capacity 13 | P a g e . Unbalanced Motor type 500 tph i) Type ii) Quantity iii) Drive 5. Stringers. CRITICAL EQUIPMENT: S. head frame. Apron Feeder i) Quantity 1 (One) No. 25 tips/ Hr iii) Type Rota side iv) Drive VSD Drive for tippling of wagons i) Quantity 1 (One) No. short post. Hydraulic 6 (Six) Nos. Skirt board for all Conveyors as specified in Basis of Design. No. Lump Breaker Moil point hammer with swivel arm 1 (One) No. skirt board. Technological structure viz. conveyor discharge chute. B. ii) Location At inhaul of WT iii) Type of Traction Drag Chain Arrangement iv) Capacity to Pull Capable of handling of gross load of 140t ii) Capacity (Rated) 2. tail frame. ii) Capacity (Rated) 1500 TPH iii) Material Handled ROM (-) 600 mm iv) Discharge BC-1 4.450on scale „A‟). Equipments Specifications Wagon Tippler i) Quantity 1 (One) No. Side Arm Charger 3. Equipments No. below Raw Coal Silos 4 (Four) Nos. below Raw Coal Receiving Hopper and 5 Nos. Primary Sizer i) Type ii) Quantity vii) Discharges 7. iii) Capacity (Rated) 1500 tph iv) Input Feed Size (-) 200 mm v) Output Size (-) 50 mm vi) Receives Primary Sizer BC-4 1 (One) No. iv) Location Specifications 1 No.S. Unbalanced Motor type iii) Capacity 1000 tph iv) Location Below Middlings & Rejects Hopper Sizer 1 (One) No. Secondary Sizer i) Type ii) Quantity vii) Discharges 8. Tertiary Crusher i) Quantity ii) Type 14 | P a g e . iii) Capacity (Rated) 1500 tph iv) Input Feed Size 600 mm nominal top size v) Output Size (-) 200 mm vi) Receives BC-2 Secondary Sizer Sizer 1 (One) No. Impact Crusher iii) Capacity 300 tph iv) Input Feed Size (-) 50 mm v) Output Size (-) 13 mm vi) Receives Raw coal Classifying Screen Over Product b) Post MCPP Building i) Quantity ii) Type 6. 11.S. ii) Capacity 300 tph iii) Aperture 13 mm iv) Receives BC-8 vi) Discharges Over product on BC-7 and under product on BC-9 i) Quantity 1 (One) No. Double Girder Type iii) Capacity 15 t & 20 t iv) Location WT Complex & MCPP v) Span 12. Electrical actuator type with provision of manual operation 9. Travelling Tripper EOT Crane i) Quantity ii) Type 12. vii) Discharges Specifications Classifying Screen 1 & 2 i) Quantity 1 (One) No. Equipments No. ii) Capacity 1500 tph iii) Belt Width 1800 mm iv) Location At conveyor TC-1 2 (Two) Nos. ii) Capacity 500 tph iii) Aperture 13 mm iv) Receives BC-6 vi) Discharges Over product on tertiary crusher and under product on BC-9 i) Quantity 1 (One) No.5 m at WT Complex & 20 m at MCPP 6 (Six) Nos. Classifying Screens a) Classifying Screen 1 b) Clasiifying Screen 2 10. Rack & Pinion Gate i) Quantity ii) Type 15 | P a g e . 1 m (Approx) vi) Receives Plant Feed Conveyor Over product To primary HM Blending Tank Through Product To classifying cyclone sump ii) Type vii) Discharges b) Primary HM Media Cyclone Clean Coal D&R Screen 16 | P a g e . Automatic Coal Sampler At Conv. ii) Capacity 300 tph 4 Nos. iii) Location 13. Banana Type iii) Capacity 300 tph iv) Aperture 1 mm v) Dimension 3m x 6. BC-10. Electrical actuator type with provision of manual operation At tertiary Crusher House Flap Gate i) Quantity ii) Type iii) Location 14. Rod Gate i) Quantity ii) Type 5 (five) Nos. Specifications Below Raw Coal Silos & Surge Hopper 1 (One) No. D&R Screen a) Raw Coal De-Sliming Screen i) Quantity 1 (One) Nos.S. 13 & 16 iii) Location 15. 16. Belt Weigh Feeder Auto Sampler i) Quantity ii) Type iii) Location 17. Vibrating Screen -De-Sliming Screen. 11. Equipments No. Manual One Below WT Hopper & four Middlings & Reject Hoppers i) Quantity 1 No. Banana Type iii) Capacity 150 tph iv) Aperture 1 mm v) Dimension 2.1 m (Approx) vi) Receives HM Cyclone Underflow Over product To secondary blending sump Through Product To dilute sump 1 (One) Nos.Sl.4 m x 6.1 m x 6. i) Quantity Specifications 1 (One) Nos. Equipments No. Reject DR Screen i) Quantity ii) Type 17 | P a g e . Banana Type iii) Capacity 200 tph iv) Aperture 1 mm v) Dimension 2.1 m (Approx) vi) Receives HM Cyclone Overflow Over product To clean coal centrifuge Through Product To dilute sump ii) Type vii) Discharges c) Primary HM Cyclone Reject D&R Screen i) Quantity 1 (One) Nos.1 m (Approx) vi) Receives Secondary HM Cyclone Overflow Over product To middling‟s centrifuge Through Product To dilute sump 1 (One) No. used for Drain & Rinse Banana Type ii) Type vii) Discharges d) Middlings D&R Screen i) Quantity ii) Type vii) Discharges e.4 m x 6. Banana Type iii) Capacity 200 tph iv) Aperture 1 mm v) Dimension 2. 850 mm dia iii) Capacity 160 tph iv) Feed Size (-) 13 mm v) Receives Secondary HM Cyclone feed pump Overflow Underflow To Secondary HM Cyclone overflow collecting tank To Secondary HM Cyclone underflow collecting tank ii) Type vi) Discharges 19. Scrolled evolute Type. 1000 mm dia iii) Capacity iv) Feed Size 210 tph (-) 13 mm v) Receives Primary HM Cyclone feed pump Overflow Underflow To primary HM Cyclone overflow collecting tank To primary HM Cyclone underflow collecting tank vii) Discharges Over product Through Product 18.1 m (Approx) vi) Receives Secondary HM Cyclone Underflow To reject conveyor To dilute sump 1 (One) No.Sl. Scrolled evolute Type. Classifying Cyclone a) Raw Coal Classifying Cyclone Cluster i) Quantity 18 | P a g e 1 (One) Set . Heavy Media Cyclone a) Primary Heavy Media Cyclone i) Quantity ii) Type vi) Discharges b) Secondary HM Cyclone i) Quantity 1 (One) No.1 m x 6. iii) Capacity Specifications 150 tph iv) Aperture 1 mm v) Dimension 2. Equipments No. S. ii) Capacity (R/D) Specifications 100 tph/ 120 tph iii) Size dia 350 mm iv) Classification at 0.25 mm v) Receives Classifying Cyclone Feed Pump Overflow To flotation feed pump Underflow To underflow collecting tank 2 (Sets) No. Equipments No. 30tph/35 tph iii) Size dia 350 mm vi) Classification at 0. Coarse Coal Centrifuge a) Clean Coal Centrifuge i) Quantity 19 | P a g e . self level controlled wet drum magnetic separator iii) Size Drum Size ≥ 915 mm dia x3000 long b) Magnetic Separator for Fresh Magnetite Charging i) Quantity ii) Type iii) Size 21. 1 (One) No. self level controlled wet Drum Size ≥ 915 mm dia 1 (One) No. each Counter Rotation Type. Magnetite Separator a) Primary & Secondary Magnetite Separator i) Quantity ii) Type 1 No.25 mm v) Receives TBS Overflow Overflow To flotation feed pump Underflow To TBS Sieve Bend vi) Discharges b) TBS Product Cyclone i) Quantity ii) Capacity (R/D) vi) Discharges 20. Counter Rotation Type. S.35 mm iv) Receives Clean Coal Screen over product Over Product To clean coal conveyor Through Product To clean-up sump tank i) Quantity 1 (One) No. Equipments No. High Rate Thickener v) Discharges 23. ii) Capacity Specifications 150 tph iii) Basket Screen Aperture 0.35 mm iv) Receives Middlings D&R Screen Over Product Over Product To Middlings conveyor Through Product To clean up coal conveyor i) Quantity 1 (One) No. ii) Capacity 150 tph iii) Basket Screen Aperture 0. Flotation Concentrate Filter Press i) Quantity 1 (One) No Steel Frame & Chamber Type iii) Capacity 30 tph iv) Receives Pressure filter feed pump Cake To clean coal conveyor Filtrate To thickener ii) Type v) Discharges 20 | P a g e . ii) Capacity 20 tph iii) Diameter 20 m iv) Receives Tailings of flotation cells & pressure filter effluent pump Overflow To clarified water tank Underflow To pressure filter feed sump V) Discharges b) Middlings Centrifuge v) Discharges 22. No. High Frequency Screen for TBS Cleans & Rejects i) Quantity 2 (Two) Nos. Coil Type On Conveyor BC-6 i) Quantity 1 (One) No. ii) Capacity 40 tph 0. ii) Capacity 40 tph iii) Feed Size < 0. Equipments Specifications Teeter Bed separator/ Reflux Classifier i) Quantity 1 (One) No ii) Capacity 60 tph iii) Feed Size (-) 1 to 0. 24.25 mm iv) Residence Time Minimum 10 minute v) Receives Flotation Feed Pump Clean Coal To flotation concentration sump Tailings To thickener v) Discharges 25. Metal Detector i) Quantity ii) Type iii) Location 28.S.25 mm iv) Receives Classifying Cyclone underflow Overflow To TBS Product Sump Underflow To TBS Reject Sump i) Quantity 1 (One) No. Magnetic Separators a) In line Magnetic Separators 21 | P a g e . Froth Flotation Cell vi) Discharges 26. ii) Capacity 1000 gauss iii) Screen Aperture 27.35 mm 1 (One) No. 3. ii) Capacity 1000 gauss iii) Location On conveyors BC-6 & BC-8 7 (Seven) Nos. Equipments No.13.10. Load Cell with microscopic controller 10 % to 120% 29. 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. 22 | P a g e . Electricl Hoist -> To handle items beyond 2000 kg Lift : More than 15 mtrs. Belt Scales i) Quantity ii) Type iii) Capacity variation iv) Locations Conveyors BC-2.11.S.16 & 17 i) Quantity Lot ii) Type Electric / Manual (As per requirement) iii) Hoist Selection Basis Manual Hoist -> 30. Maximum Lift : up to 15 mtrs. Electric & Manual Hoists To handle items up to 2000 kg. iii) Location Specifications On Discharge of BC-2 b) Cross Belt Magnetic Separators i) Quantity 2 (Two) No. 1 1 1 1 2T 2T 1 1 2T 1 1 2 1 1 1 2T 1 TP-4 TP-5 RAW COAL SILOS 15T 8T 3T 3T 5T SCREEN HOUSE 12T 1 2T 2T 2T 2T 2T 2T 1 1 1 5 1 1 12T 3T 8T 3T 3T 1 1 2 1 1 2T 2T 1 2 3T 3T 1 1 3T 3T 1 1 18 2T 2T 3T 2T 2T 1 1 1 1 1 22 LOCATION WAGON TIPPLER HOUSE TP-1 TP-2 TP-3 PRIMARY & SECONDARY CRUSHER HOUSE TERTIARY CRUSHER HOUSE SURGE HOPPER HOUSE MCPP TP-6 TP-7(EXISTING) TP-8 TP-9 TP-10 TP-11 TOTAL ELECTRIC HOIST QTY.MANUAL HOIST QTY. 5T 3T 3T 3T 23 | P a g e . The intermediate Transfer Towers between Coal Washery and Middling Stockpile & Reject Stockpile will not in consideration of DFDS System. Ball Valves. DFDS-2 (Dry Fog Dust Suppression System) for all Dust Generation Points of all transfer Towers after Coal Washery and Wagon Loading Station. water pumps (1W + 1S) have been considered for each system. so that the Pumps for the entire Dust Suppression System will run only when the water level at the respective Tank is adequate. Primary & Secondary Crusher House. Globe Valves. Pressure Relief Valves. Nozzle Headers. and all Transfer Towers before Coal Washery. 2. 2 nos. MCC. DFDS Nozzle will be provided at each dust generation point. Pressure Regulating Unit. Pressure Switch. Local Control Panel. Air Release Valves. If the water level somehow falls and reaches the Low Low Level .2. Therefore care must be taken so 24 | P a g e . Differential Pressure Switch. Gate Valves. Reclaim Hopper Area. Solenoid Valves. Air Compressor with Drive Motor. The dry fog dust suppression system will consists of Vertical Centrifugal Pump with Drive Motor (2 Pole). Flow Activation Station. Nozzles. UBESS. Operation Logic For Dry Fog Type Dust Suppression System: Consideration for DFDS System Minimum 4 nos. 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. the water Pumps will trip automatically via signal of ‘Low Low Level’ of Level Switch‟ in order to prevent dry running of the Pumps. Drain (Ball) Valves & Duplex Filter. The operation of above Pumps of DFDSS shall be interlocked with the ‘Low Level Switch’ of the respective Storage Tank. 2 nos. Pump House shall have a MCC for the operation of Drive Motors of Pumps and Compressors. 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. 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. Level Switch. Pressure Gauge. Check Valves. DFDS-1 (Dry Fog Dust Suppression System) for all Dust Generation Points of WAGON TIPPLER AREA. oil injected air cooled screw compressor (1W + 1S) has been considered for each system. A PRU is used to regulate the air and water pressure for a group of headers. Each application point is provided with two numbers of spray bar assembly (One for Water and other for Air) with Air Atomized Nozzles. When pump-1 is in operation then Pump-2 will not in operation& vice versa. 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 water Pumps can be started from MCC under following conditions. 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 recirculation of the water back to the RCC Water Tank when the respective Dust Suppression System application points are not in operation. Any one of the water pump out of two water pumps (1W + 1S) is selected. The nozzles shall be fixed at the discharge hoods/suction hoods and shall be connected by flexible tubing with the headers. 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. Each application point shall have a set of spray bar of air and water. the system becomes operational with selector switch. Under Belt Electronic Speed Switches (UBESS) shall be used for selected conveyors to get input signals of conveyors running on load. 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. 25 | P a g e . Overload Relay (In pump starter panel) is not in tripped condition. In auto mode. FAS can be connected to one or more PRU. Water level adequate signal from pre adjusted Low Level set point of Level Switch. If any fault arises in the operation of Pump-1 then Pump-2 will start automatically and vice versa. FAS can be provided for a single Application Point or more than one Application Points. that water level in the respective Storage Tank does not go below the ‘Low Low level’ of the ‘Level Switch’ to prevent automatic tripping of the Pumps. The Flow Activation Stations have provision for both manual and automatic operation. For Pump-1 & Pump-2 operation separate electrical interlock will be provided in the MCC. In manual operation. 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. For the selection and operation of Compressor -1 & 2 the same logic will be followed as followed by selection & operation of Pump-1 & Pump-2. Pressure healthy signal from Pressure Switch at the common delivery line of pumps.C. 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. General Considerations: Incoming Power Supply up to DS MCC incomer at Pump House will be provided by Client. Duplex Filter will be placed in the common Suction Lineforboth DFDS System. In local mode.S and Screwed Female Ends. Local mode selected. the system can only be started on receiving local start permissive command from control room. All Pumps & Compressors for DFDS-1 & 2 will be located in Raw Water Pump House. Following signal should be generated once for any one of the two pumps running. Water Consumption 26 | P a g e . 2. Remote mode selected. And. the water Pumps can be started from MCC (Pump Starter Panel) under following conditions. Start / Stop push button is pressed manually. Gr.. Pipes <& = 50 NB will be GI & Screwed ends. „Local permissive‟ indication lamp shall be provided on the local panel. Logic for Tripping of Pumps: The water pumps shall trip while running. All valves up to 32 NB will be of F. All pipe will be ERW Carbon Steel as per IS:1239 (Part-1). For the same. Water Tap Points for DWS. under any one of the following conditions. Valves of size 40 NB & above will be of Cast Iron with SS Internals and with Flange Ends. Signals from the Pressure switch at the common delivery line are not healthy. Water level touches the low.low level (preset) set point of level switch at the Water Tank. Water Source The new built production and fire-fighting water tank and pump house will provide water production and fire-fighting uses.Heavy for Water Pipe Lines and Medium for Compressed Air Line. Fire Fighting system: 1. Pipes >& = 65 NB will be Bevel Ends. fire duration time: 1 hour. thus 27 | P a g e . water curtain system: 16l/s.Municipal water consumption: the water consumption is 4. Some of the equipment‟s like Belt Conveyors Screen.5m³/d . 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 the transfer & loading & unloading of materials. activities like screening etc. To control the pressure differential across the bag filter. in the Industries. and the clean air passes out through bags and plenum to the outlet of Bag filter. Working Principal of DE system: In this system the dust generated in the equipment like Belt conveyor Transfer points. indoor fire fighting hydrant: 20 l/s. Total 735m3 for one fire disaster Water pressure: 1. This air borne dust makes the nuisance inside the plant premises. fire duration time: 3 hours.e. The total quantity of makeup water for production is 0. Fire fighting water consumption: outdoor fire fighting water: 25 l/s. The air travels through the filter bag. The recommended combined fire-fighting and process water tank is 1000 m³，however. Dust collected on the outside of the filter bags causes an increase in the pressure differential between dirty and clean airsides of the bag filter. hopper of the bag filter. which retains the dust particles on surface of the bag. a 1800 m3 water tank is used as the client requires in tender. Municipal water line: 25m 3. the total water consumption for a fire disaster will be 305 m³. 3 hours duration for one fire disaster. to the Bag filter .Air along with dust particles under suction or pressure enters the lower portion i. causing a reverse flow air through the filter bags. Fire-fighting water consumption: 38 L/S. automatic water spray system: 30 l/s. 095 m 3/ton of raw coal and 590 m³/Day. A momentary rush of high-pressure air (5-6 bar g) flows from the compressed air header to the blow tube and is expelled from the blow tube through nozzles at a high velocity (primary air flow). Ducts. Production water makeup: 25m 2. Dust generated due to Height of fall is being collected through the suction hood. Screen. Crusher. a sequential timer actuates a series of normally closed pulse valves at preset intervals causing them to open. Air from each nozzle induces a secondary airflow the combined effect of the primary and induced secondary air causes an instantaneous pressure rise on the clean side of the filter bags. To eliminate these hazards from the working area Dust extraction system is one of the Solutions. Silo Ventilation needs a aspiration system to provide the equipment to work according to the its designed working capacity & to avoid dusting. 9. Velocity of air inside the duct: 18-22 M/Sec. Design of bag filter is done as per ACGIH norms. Since only fraction of the total filter area of the bag filter is cleaned at any given time. screw conveyor. Bag filter material shall be 550 GSM with homopolymer bags. 11. Screen (CS-1). Belt width 1000 mm considered. size considered 8. Pressure drop considered 150mmwg. 2.e. 14.5 -2 M/Sec. Max. Air quantity to be extracted is 2800 m3/hr.0 mtr from nearest house. Instrument grade compressed air pressure 6 -7 kg/cm2 for pulse cleaning of bag filter will be provided from compressor house with air Receiver. 10 mg/Nm3 at Outlet of stack. 7. Volume Calculation as per ACGIH Norms: For Belt Conveyors: 1. From this hopper it is discharged through suitable device i. The Volume calculation of the system is done with the reference of ACGIH norms. per meter of belt width for belt speed more than 1.64 m2 For Crusher: Air quantity to be extracted is 3600 m3/hr. Rotary valve. continuous flow through the bag filter at rated capacities is assured. Operating temperature considered 120 Deg C Considered for polyester homopolymer bags. Emission Level shall be max. 2. Bag filter shall be designed for outdoor installation. meter of inlet opening. 4. By this mechanism. 13. meter of top cover area.7X 0.05 m3/min/m2 10. per sq. Calculation Basis for Dust extraction system: 1. Additional exhaust at the back of chute of the loading conveyor of following Capacity shall be provided wherever shown and possible as per layout for more than 3 ft.8 M x M For Fan 28 | P a g e . per sq. The height of Stack shall be +3. Bag filter cleaning arrangement shall be pulse jet compressed air system. 5. Fall: i) Belt width 300 mm to 900 mm : 1190 m3/hr. size considered 14. the dust collected is released from the bags and falls into the hopper. Inlet opening considered 2. 8. ii) Belt width above 900 mm : 1700 m3/hr. Air to Cloth Ratio Considered 1. Operation of DE system shall be started/ stopped from the local control panels and interlocked with conveyor drives. 15.0 M/Sec. 12.4 m2 & Screen (SC-2). Intake velocity of air through hood: 1. ON line cleaning bag filter Considered. Dust content at inlet and outlet of each bag filter will be minimum 10 gm/Nm3.dislodging the dust particles held on the outer surface of the bags. 3. Belt Speed 2 m/s For screen: Air quantity to be extracted is 915 m3/hr. 6. 7. Dryer is also considered to get instrument quality air. 2. GI IS2062. 3. Fan RPM shall be max 1000 rpm Direct Coupled/Belt Driven. 2. Axial Flow fan is considered for bunker floor ventilation system. simply supported. Screw type air compressor air cooled oil Flooded. A Standard IS2062.A . 9. Air Receiver shall be as per IS: 2825 6. gr. Compressor capacity shall be 1. 3. Instrument quality air considered for bag filter pulsing. Location Considered for Dust Extraction System: 1. Chimney: 1. Noise level shall be 85 d BA from 1 m distance. Motor speed shall be 2900 rpm. For Bunker floor ventilation system 1. Instrument quality air calculation will be done on the basis of 3. Fan Capacity calculated 10% more than the Calculated Volume of DE system. Capacity of compressed air shall be approximately 140 cfm. For Compressed air: 1. 4.5 Kg/cm2. 3. For bunker Floor ventilation system volume calculation 8 air change /hr considered. A Is-2062gr. Bunker floor length considered 60mtr.0 mtr from nearest house. 10% margin considered on calculated volume for selection of fan volume. 2. Fan shall be SISW type Centrifugal fan with backward curved blades. 8. Chimney/Stack shall be supported from nearest building.25 times of the required compressed air flow capacity. The height of Stack shall be +3. Screen House : Capacity of Bag Filter: 45000 m3/Hr 2.A 5 mm Thk Standard Standard Standard Standard IS:2062 gr.1.A 5 mm Thk Is-20620 gr. gr.4 Nm3/m2 of bag Area. Tertiary Crusher House : Capacity of Bag filter : 22500 m3/Hr Major Equipment involved in the DE system 1 Filter bags 2 Cages 3 Centrifugal fan (backward curved) 4 3 PH-motor for centrifugal fan 5 Inlet damper for centrifugal fan 6 Suction hoods 7 Manual & motorised damper 8 Sequential controller 9 Solenoid operated pulse valve 10 DP switch 11 Pressure switch 12 Rotary Air lock valve 29 | P a g e Polyester Homopolymer Bags. 5. Pressure 8. 2. 5. Noise level shall be 85 dBA from 1 mtr distance. 4. cable vaults to eliminate stagnant contaminated air & produce a continuous flow of fresh air inside the tunnel. The air quantity for mechanical ventilation system shall be estimated either based on the equipment heat load or adequate air change. 30 | P a g e .15 Thk mm 15 Screw conveyor IS:2062 gr. Ventilation System: Description for Mechanical (Tunnel) Ventilation System: Push-pull type mechanical ventilation system shall be provided in the underground portion of building & conveyor tunnels.A As per IS: 2825.A 3.A 5 Thk 15 Plenum IS:2062 gr.A 5 mm Thk 14 Bag filter hopper IS:2062 gr. The system consists of a fresh supply air arrangement (push type) & a exhaust air arrangement (pull type) to maintain a healthy atmosphere inside the tunnel. cable tunnel. Supply air is distributed inside the tunnel by supply air duct.A 16 Ducting & bends IS:2062 gr. oil flooded ) Standard 19 Air dryer (refrigerated type) Standard 20 Air receiver IS:2062 gr. Centrifugal fan is considered for supply of fresh air inside the system. Axial type fan is considered for extraction of contaminated or polluted air from the system.A 5 THIK MM 18 Air compressor (screw type. air cooled.13 Bag filter housing IS:2062 gr. Polluted or contaminated air is sucked from the underground building by exhaust air grill placed at regular interval in the exhaust air duct.A 5 THIK MM 17 Stack IS:2062 gr. At regular interval supply air grill with VCD shall be provided in the supply air duct to distribute the supply air inside the underground building. whichever is higher. a. v) Velocity in branch duct shall be 6-8 m/s vi) Ducting : GI sheet ducting (IS:655:2008 & IS:277) vii) Grills: GI sheet construction with volume control dampers and double directional louvers. No. 4 pole INLET DAMPER AT CENTRIFUGAL FAN INLET SUPPLY AIR DUCT (RECTANGULAR TYPE) EXHAUST AIR GRILL (RECTANGULAR TYPE) DUCT SUPPORT FOR SUPPLY & EXHAUST SUPPLY AIR GRILL WITH VCD EXHAUST AIR GRILL (FIXED TYPE) RAIN PROTECTION COWL WITH BIRD SCREEN FOR EXHAUST FAN FIRE DAMPER(FUSIBLE LINK TYPE) 31 | P a g e MOC IS: 2062 Gr. Spacing of Grills: 5m (max) vii) Duct support shall be as per IS: 655:2008 c. efficiency 90% down to 10 micron. A HDPE. Exhaust air system: i) Underground area: No of air changes considered 7 /hr. Supply air system: i) Underground area: No of air changes considered 15 /hr. HDPE filter shall be 3Ply having efficiency 90% down to 10 micron. AC motors For Exhaust Fan. 610x610x50. 1 2 3 4 5 6 7 8 9 10 11 12 13 Equipments Centrifugal Type Supply Air Fan Axial Type Exhaust air Fan Panel Type Air Filter at Inlet of Supply Fan 3 Ph. iii) Velocity through grill shall be 3-4 m/s iv) Fan shall be Centrifugal type. A IS: 2062 Gr. Standard Standard GI GI GI IS:2062 GI GI GI GI . ii) Velocity Maintained in the supply air duct & fan outlet shall not exceed 12 m/s. iii) Velocity maintained in the exhaust air duct shall not exceed 6-8 m/s iv) The Velocity of air sucked in the exhaust air grill shall be 3-4 m/s v) Ducting : GI sheet ducting (IS:655 & IS:277) vi) Grills: GI sheet construction with volume control dampers and double directional louvers.Design Considerations: Mechanical Ventilation System: a.4 pole 3 Ph. AC motors For Supply Fan . 3 PLY . ii) Axial type fan for exhaust of contaminated air. backward curved vanes for supply of fresh air.25 m/s. Face velocity considered in the HDPE panel filter shall be 2-2. Major Equipments involved in Mechanical Ventilation system: Sr. Spacing of Grills: 5m (max) viii) Duct support shall be as per IS: 655:2008 b. As the air pressure inside the room is more than atmospheric pressure there shall be rise in temperature inside the room limited to 2-3 deg c above outside air temperature. This Fan draw the air from the atmosphere though panel filter. Fire damper fusible link type shall be provided at the inlet of the room to prevent fire hazard inside the room. Gravity damper shall be used to make the room pressurized. Fan volume is decided by air change method or heat load calculation Method whichever is higher. Tube axial type fan is used to supply the air through air duct & supply grill.Pressurized Ventilation System at MCC / Switchgear room & Exhaust Ventilation system in Battery Room Introduction: Pressurized ventilation system shall be provided in the MCC room to make the room pressurized & prevent the in rushed dusty air to entre inside the room. Velocity in the duct shall be max. the air pressure above atmosphere shall be maintained inside the room. Thus as the name implies. Panel type air filter is used at the inlet of fan to prevent dust to deliver inside the room. This gravity damper shall open when the pressure inside the room exceed the value of 2-3 mmwg above atmospheric pressure.25 m/s Codes & Standard: CODE IS-655:2008 IS-3588: 1987 IS-277-2003 UL-555 : : : : DESCRIPTION METAL AIR DUCT (GI) SPECIFICATION OF ELECTRICAL AXIAL FLOW FAN GALVANISED STEEL SHEETS FIRE DAMPER Major Equipment Involved in the System: EQUIPMENTS MOC INLET FILTER CENTRIFUGAL FAN MOTOR FOR FAN BIFURCATED TYPE TUBE AXIAL FAN AIR DUCT SUPPLY AIR GRILL WITH VCD RAIN TROTECTION COWL/BIRD SCREEN FIRE DAMPER PROPELLER FAN 32 | P a g e : : : : : HDPE TYPE IS: 2062 STANDARD IS-2062/AL CAST GI : GI : GI : AL DIE CAST/MS . Rise in temperature inside the room is 2-3 deg c. For Battery room exhaust ventilation is used to extract the contaminated air.10 m/s Velocity of air at supply grill shall be 3-4 m/s Velocity of air at gravity louver shall be 5 m/s Filter face velocity shall be 2-2. General Consideration for Dry Pressurized Ventilation : i) ii) iii) iv) v) vi) vii) viii) No of air change considered for supply of fan shall be 15/hr. Gravity type wall mounted damper is provided to exhaust the excess amount of air from the mcc room. Air Conditioner. No 1 2 3 4 5 Indian standard (IS) IS:3588 IS:2312 IS:4894 IS 1391 (PART 2) : 1992 IS: 8148:1976 Title Specification for electrical axial flow fans Propeller type ac ventilation fans Centrifugal fans Split air conditioners Package air conditioner Air conditioning location: 33 | P a g e . 1 2 3 4 5 6 7 8 Equipments MOC Package Air Conditioner Hi Wall Mounted Spilt Air Conditioner Horizontal Split Casing Pump Cooling Tower (Induced Draft type) Duct & its supporting structure Fire Damper Insulation for Duct Standard Standard Standard FRP Type GI/MS(As per IS:655:2008) GI Resin bonded glass Wool (24 Kg/m3. No. to maintain a uniform temperature & relative humidity within the air conditioned areas. computer room.) Cladding 30G GI sheet 5 Mtr of the supply air duct. Office room . Occupancy considered 4 Nos Lighting load considered 1 Watt/ft2 of room area. solar heat load. Design Considerations: Indoor condition considered 23±2 °C & 55±5 % Fresh Air Intake: Minimum 1. heat gain into the room adequate number of air changes etc. material : Fiber Glass Wool of Density 48 Kg/m3 Acoustic Insulation Codes & standards: Sr.5 air change per hour. Major equipments involved in the system: Sl. Non Ductable Hi wall mounted split Type air conditioner is considered. 50Thk.Ventilation Location: Dry Pressurized Ventilation: i) HT MCC Room ii) LT MCC Room Exhaust Ventilation: i) Battery Room Air Conditioning System for PLC/CONTROL ROOM: Introduction: Air Conditioning system shall be considered for PLC cum control room. It is designed considering equipment heat load.Package type water cooled. Rev-0. Purchaser‟s 11 kV Gantry will be considered as the Take Over Point (TOP).433 kV transformers with associated LT switchboard to feed power supply to various LT loads of the plant will be included in scope of work. LA &11 kV(E) XLPE cables and thereby to 11 kV indoor switch board to be established for feeding entire Beneficiation Plant loads over 11/3. All HT motor load will be feed from client 3. As per the above document a detail Overall SLD has been generated and attached for reference.i) ii) PLC/ Control Room: Package Air Conditioner Office Room: Hi Wall Mounted Split Air Conditioner 3) ELECTRICAL Power distribution: CHP power distribution has been considered as per basic Overall power distribution diagram Drg.3/0.3KV transformer& 11KV/0.3 kV cable from HT motors to 3. The Power from TOP will be drawn over 11KV Isolator (G.3kV HV substation/HV MCC and 11/0.3 kV transformers and associated 3.433V transformer as per single line diagram.O. No. 11 kV/3.CET RN 3812 EE1 00001. laying and termination (at both ends) of 11kV cable from the11 kV Switchboard at MRSS to 11/3. 11/3. 11/0.3KV switch gear up to motor which are mentioned in attached single line diagram. The scope of work will commence from tapping 11 kV power from TOP and feeding to 11 kV Switch board at MRSS.433kV LT substations will be included in the scope. HT load will be feed from 11KV switch board to 11KV/3. 34 | P a g e . Similarly supply.D).3 kV switch board will be under the scope. Purchaser will establish 11kV gantry structure to terminate two 11 kV feeders of „Panther‟ ACSR overhead conductor over LA & string insulators.3 kV HT substation with 2 nos. Supply. laying and termination (at both ends) of 11kV cable from the 11kV Gantry Structure (TOP) up-to 11 kV Switchboard at MRSS shall be in the scope of work. Adequate number of Load Centre Substations (LCSS) each comprising of 2 nos. One no.415kV power distribution system. Power at 11 kV will be made available by the Purchaser at take over point within 100 metres from MRSS proposed to be installed by BTL. Supply. laying and termination (at both ends) of 3.3 kV switch board will be provided in the MRSS to cater to the motor loads having ratings above 160 kW. three-phase outdoor. doc.3KA/3 sec.6MVA ONAN.3 kA for 3s switch board consisting of two (2) incoming VCBs. 3.5MVA. All motor feeders (10 no) will be provided with LA & R-C snubber circuit. 1 Set Al the above item will be considered as per specification CET/26/RN/3812/TS/CC/01/R=1 which short description are as follows. off-circuit gang operated vertically mounted. 11 kV Circuit Breaker control Panel.26. 36KA/3sec.3kV equipment at MRSS & HT s/s 11/0.0 MVA. O/G VCB will operate on ABT based system. 1. The two (2) I/C VCBs & B/C VCB. one (1) bus coupler VCB and outgoing VCB feeders each provided with imploding type LA. Dyn11 power transformer with all fittings and accessories.3 kV.Following switch gears are considered for HT load distribution: Sl. 26. Dyn11 transformer of suitable rating for auxiliary power supply and dedicated lighting load of the complete plant 1 Set 1 Set 1 No 4 Nos. The enclosure protection class of the switchgear will be IP4X. 11/0. 2 Nos. 110V DC plante type lead acid battery of adequate capacity along with battery charger and 110V DCDB for 11 kV & 3. outgoing and bus-sectionalizing circuits as required. Station Class complete with surge arrestor and insulating base.433kV. No 11 kV Switchboard: The switchgear distribution boards will generally comprise horizontally operated. triplepole. ONAN. Dyn11 lighting transformer with all fittings and accessories. along with bus and cable earthing VCB. 1 2 3 4 5 6 7 8 9 10 11 12 ITEM DESCRIPTION 11 kV. 1 No.1600A draw out type HT MCC for various HT motors. Dyn11 transformer of suitable rating for auxiliary power supply and dedicated lighting load of the complete plant 11/0.433 kV. 2 Unit No 11kV LA. 2 Nos. 2MVA ONAN.26. 35 | P a g e . 11/3.3 kV neutral grounding resistor and transformer neutral isolator panel. 4 Nos.3KA/3 sec. 11 kV switch board will operate on Automatic Bus Transfer (ABT) based system. comprising relay & metering cubicle for the above. ONAN. floor mounted heavy duty circuit-breakers for incoming. 1250A.45 kV. Class-1 Trifurcating cable box for terminating 11KV HT cables 2 Set 2 No 11 kV. 1. 3. 1. single break type isolator with manual earth switch on outgoing side Qty.433 kV. 75/85KV peak Min Clearance in air (mm) Phase to Phase: 229 Phase to earth: 178 36 | P a g e . Circuit breakers and motor feeders will be provided with trip-neutral-close (TNC) spring return control switch in HV MCC and the same will be mounted on its low voltage compartment. 11KV HT isolator: Description of Isolating Panel. The bus bars will be made of electrolytic grade copper & Raychem sleeved and run throughout the length of the distribution board.3kV HT MCC will have two (2) incomers and one (1) bus coupler breaker (VCB) with protective relay. Non-magnetic removable bottom base plate will be provided in each chamber for cable entry. master trip relay and auxiliary relays will be provided as a standard feature of breaker control.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. Automatic safety shutters will be provided over the isolating contacts in the stationary portion and will be so designed that the busbar compartment is completely segregated from the breaker/PT compartment for all positions of the circuit breaker/PT. Each outgoing motor feeder will basically comprise HRC fuse and high voltage vacuum contactor mounted on a draw-out unit for isolation.Pole Mounted Off load isolator with Earth switch Standard followed in design. Incoming and bus coupler circuit-breakers will be provided with CT operated numerical relay having non-directional inverse definite minimum time lag (IDMTL) over current and earth fault protection along with instantaneous over current element along with time delay relay. The switchboard will be natural cooled. HT Motor Control Centre (HT MCC) for 3. “Test” and “Isolated” positions of the circuit breakers will be achieved with the front door closed. Vacuum contactor will be „mechanically held‟ (latched) type.5mm for load bearing members. floor mounting type indoor.2/50ms Impulse withstand voltage: 28/32KVrms. Minimum degree of enclosure protection for the HV MCC will be IP4X. dust and vermin-proof.3kV switchboard. Each cubicle will have lockable doors for the VCB compartment & metering compartment. ABT scheme will be adopted for HT MCC as indicated in the 3.The cubicle will be CRCA sheet steel of 2 mm for non-load bearing members and 2. manufacture and Testing. trip circuit supervision relay. The cubicles will be totally sheet steel enclosed.3 kV Motors: 3. The HT MCCs will be provided with copper busbars. Anti-pumping relay. The cast resin insulated Line & Bus PTs will be mounted on independent draw out type carriages in separate panels. “Service”. Neutral earthing Arrangement: A full capacity neutral terminal will be brought outside the tank and provided with a bushing CT with dual ratio 1000-500/5A. 300 sq mm Cu PVC cable to earth stations as specified. Main characteristics are: Transformer type: Oil filled Cooling class: ONAN Winding vector group: Dyn11 Installation: Outdoor Primary off-load tap changer: ±5% @2. of poles: Three Rated continuous current: 1250A Installation: Outdoor. 11/0.g.433 kV distribution transformer. 1/C.5% with steps of 2. by 1. ±7. 630 sq mm Al. 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. Type of Support insulators: Porcelain No.3 kV Sub-station Power Transformer: Basic requirements are given in General Design Features of Power Transformer. PVC or 1/C. The neutral point after CT connection will be bifurcated. 15 VA. ii) Pressure relief valve iii) Buchholz relay Basic features of the transformers: i) Primary voltage.5% by step 37 | P a g e .1 kV. Rated short time withstand current: 25KA/3sec Finish Hot dip galvanized Approx. additionally remote signaling for winding & oil temperature.433 kV Distribution Transformer: The 415V load centre substations will be fed from 11/0. Distribution transformers will be selected from sizes 1600 kVA/2000 kVA. 11 kV ii) Secondary voltage. However.45 kV iii) Rated power output will be furnished by the EPC vendor iv) Type of cooling. isolator weight: 250Kg. One of the leads after bifurcation will be connected to a suitable terminal for solid earthing via two (2) knife switches. ONAN v) Tapping.5% off load Transformer will be installed outdoor suitably designed along with all safety features (e. 5P20 for standby earth fault protection. The other lead will be taken inside LV box through a bushing and provided with a suitable terminal for neutral connection Neutral earthing isolator. HVWS-if required). 3. pole mounted type 11/3. Required rating bus duct will be considered from transformer secondary to PCC incomer & PCC outgoing to MCC Incomer . MCCs . 11KV/433V. load. DS MCC . In this regards one dedicated PCC will be considered for supplying LT load to Conveying system MCC.The transformers will be designed. If transformers are not in the vicinity of HT switch gear.433KV Transformer & PCC 2 2000A. For isolation of load centre transformers. & Aux. 1600KVA transformer for WT system & fire fighting system. the other healthy transformer is not loaded beyond 80%. constructed and tested in accordance with the applicable sections of the latest revision of relevant Indian Standard (IS). The boost charger will be rated to charge the battery from fully discharged condition to charged condition within 8 hours. No. VCB with protection along with LPT will be provided. Single front. Each set will have redundant battery charger circuit but batteries will be common. 11KV/433V 2000KVA transformer for conveying& others auxiliary system. ITEM DESCRIPTION 1 4000A LT Bus duct for ELB-1 between 11/. PDB as per SLD. Nos. Stand-by and spare feeders will not be considered in transformer sizing. Indian Electricity Acts & Codes equivalent IEC standards. The float cum booster charger will be rated to cater to the trickle changing current of batteries as well as the boost charging (2 rate) of a fully discharged battery and continuous load on DC bus including 20% margin. 2 nos. Following switchgears are considered for LT load distribution: Sl. Single front. Motor Control Centres (MCC) with two incomers & one bus-coupler 7 MCC for DS SYSTEM MCCs Conventional. LT load distribution: LT load will be supplied from 2 nos. The transformer capacity will be designed such that in the case of outage of one transformer. Non-draw-out type. DC distribution boards 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. LT Bus duct for WT PCC 3 3200A LT Bus duct for MCC Conveying system 4 PCC for ELB-1 5 PCC for WT 6 MCC for Coal Handling Part Conv. 2 Unit Nos. Non-draw-out type. No. 2 2 1 1 1 Nos. No 1 No .Sub-station power transformers will be sized based on consumed loads in operation. load breaks isolators along with LPT panel will be considered. Each charger will operate on float-cum-boost mode.Conventional. Motor Control Centres (MCC) with two incomers & one bus-coupler 38 | P a g e Qty. 7kW. The power distribution boards (PDBs) are generally intended for distribution of power to various consumers in the plant area and will be suitable for 415V. 8 9 10 ITEM DESCRIPTION MCC-5 FIRE FIGHTING MCCs Conventional. 1 Unit No 1 1 No. power supply feeders to repair shop. The switchboard will be a sheet steel-clad low-voltage distribution board with door interlocking facility. selfsupporting. non draw-out type. Local/remote selector switch will be provided in the PCC/MCC. maintenance cranes. MCCB will be used as power isolating cum short circuit protection device for all outgoing feeders. 4 wire. floor mounted. Qty. Sheet steel thickness will generally be 2 mm& non load bearing member 1. floor mounted. The distribution boards will be of cubicle type having incoming & outgoing drawout ACB/MCCB units. S/C & E/F protection. type construction. Non-draw-out type. single front. self-supporting. The low-voltage switchgear will be PCC& Motor Control Centres of totally enclosed. doc. housing draw out Air Circuit Breakers and MCCBs with O/C. laboratory. 39 | P a g e . having one incomer will be provided for loads like welding sockets. modular construction. Generally MCCB will be provided for motor and power feeders in 415V MCC. Power distribution boards: Single front. sheet steel enclosed. Cubicle type power distribution boards will be totally enclosed. dust & vermin proof in 2 mm thick sheet steel construction. Single front. 50Hz. compartmentalized nondraw out type 415V motor control centre will be adopted. utility aux load etc. Ammeter and selector switch along with current transformer will be considered for incomer. Set Al the above item will be considered as per specification CET/26/RN/3812/TS/CC/01/R=1 which short description are as follows.Sl.6 mm. MPCB will be provided for power feeder rated up-to 10A and motor feeders rated up-to 3. Degree of Protection will be IP-54. The cubicle will be floor mounting type and will be dust and vermin proof generally conforming to IP-54 with multitier compartmental arrangement. The bus bars will be of aluminium and will have continuous current rating same as that of the incoming ACB/MCCB and will be suitable to withstand without damage the effect of maximum short circuit current of 50 kA RMS for one (1) second. hoists. admin building. 3-phase. No LT SWITCHGEAR (PCC/MCC): Industrial. compartmentalized. Motor Control Centres (MCC) with two incomers & one bus-coupler PDB for coal handling area VFD for apron feeder. The bus bars as well as the incoming circuit breaker/outgoing MCCB will be capable of withstanding a through fault current of 50 kA for 1 second. will be detected. Material for the bus bar will be aluminium. Power supply (Line . Expansion type joints will be provided in the bus-duct sections to take care of variation in lengths due to variation in temperature. Suitable programming and debugging unit will be provided. The PWM inverter will have fully digital microprocessor based regulation and control system with suitable interfaces for instruments and signals. 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 speed range to maintain constant motor torque. A continuous aluminium earth bus will be provided throughout the length of the bus-duct. U/V) Drive faults (Fuse blown. cooling fan stop. alarms. All faults. Flexible terminal connectors will be provided for termination at transformer and switchgear ends. selfdiagnostic and operator interface. The microprocessor will carry out all the functions required from unit including triggering protection. The bus-duct enclosure will be provided with earthing terminals at both ends for connection to the station earthing system.Bus-ducts will be provided with complete supporting structures. Busbars inside the enclosure will be supported on insulators of required voltage grade. load side contactor/isolator and current limiting choke where required. instant O/C. The VVVF will comprise incoming fuse unit. three–phase diode bridge. Seal-off wall bushings will be provided where the bus. overload) Motor faults 40 | P a g e . First fault annunciation will be provided. non–segregated bus duct with 3 mm thick aluminium alloy enclosure will be provided up to 15 meter length for connection between the transformer secondary and the 415 V switch board. as well as diagnostic messages will be available in plain text on the operator panel of the cubicle. inverter unit. dry type line reactor. The degree of protection for enclosure will be IP–54. Sections of bus-ducts installed outdoors will be supported from ground while indoor sections will be supported from ceiling and/or wall. Display of faults. The number and spacings of insulators will be so selected that the bus bars will be capable of withstanding the dynamic forces set up under rated through fault conditions.415 V Bus ducts: Three phase and neutral.duct enters a building from its outdoor run. not limited to the following. annunciated and protective measures will be initiated accordingly. Matching flanges will be provided at both ends of the bus-duct run. device over temperature. O/V.O/C. Suitable adapter chamber will be provided for terminating the bus-duct on to switchgear. as required. speed/voltage relationship abnormal. phase loss. over speed. One I/C will be fed from dedicated transformer designed based on lighting load and the 2nd I/C will be fed from nearest 415V LCSS switch board. CPU abnormal. sync. Conveyor Gallery. Crusher House. LCSS. brake abnormal. compartmentalized nondraw out type 415V MLDB will be adopted. Lighting Load: Normal/AC lighting Load Lighting load will be feed from 11/0. earth fault in motor circuit) Others (Control power abnormal.(Motor overheating. floor mounted. requisite number of outgoing miniature circuit-breakers and adequately rated aluminium bus bars. Secondary Crusher House. Main Lighting Distribution Boards (MLDB) with two incomers and bus coupler with IP54 enclosure for Power supply to various LDB: The LDBs will be provided with incoming MCCB (I) and outgoing DP miniature circuitbreakers (MCB). stall detection. Transfer point. control rooms. MRSS. For other area 10% will be considered (Including Entry. speed detection abnormal. The bus bars as well as the incoming circuit breaker/outgoing MCCB will be capable of withstanding a through fault current of 50kA for 1 second. 30% emergency lighting will be considered for Sub-station Buildings only. Surge Hopper House. earth fault. Tertiary. The MLDB will be provided with two (2) I/C which will be electrically and mechanically castle key interlocked to avoid any parallel operation. Emergency /DC Lighting Load Battery based emergency lighting system (for evacuation purpose) for all electrical rooms. Exit point & staircase. cellars etc which should switch on instantly in case of Power failure. Other features will be as per Low voltage switchgear. control cubicle overtemperature) Welding Load: Welding power will be feed from above PDB to welding receptacle 100A receptacle has been considered for the following area at 50 mtr interval. Bunker Floor. sheet steel enclosed. Screen House. MCPP. WT-MCC. self-supporting. power abnormal. 415V MLDB: Industrial. basements. cooling fan stop. 41 | P a g e .433KV transformer to MLDB & MLDB to LDB panel at various location and LDB to lighting fixture.The sub-lighting distribution board will generally comprise incoming MCCB (I). All the motors will be provided with two earth connections. higher cross sections as required will be used. The boards will have welded back and sides and gasketed hinged door at the front with door handle and suitable locking devices.stranded Almunium conductor with extruded XLPE insulated.G. wall mounted. HT & LT Motor for conveyor drive: The Electric motors has been considered Squirrel Cage induction type in horizontal foot mounted design. XLPE insulated.T Power cables: LV Power Cable has been considered 1100 V grade. stranded copper conductor having 7 strands. extruded FRLS PVC. minimum 2. strip / wire armoured having over all Extruded PVC sheathing (Type-ST-1) with oxygen index not less than 29. PVC insulated. Minimum conductor cross section of power cables shall be 4 Sq.5 sq. stranded aluminium conductor. sheet steel cubicle design.mm cables will be used. Operating knobs of outgoing MCBs will be accessible only after opening the front door of the cubicle. For boards with incoming MCCB (I) the access to the operating handle will be from the front of the cubicle without opening the front door. Motor has been considered as per technical specification doc. temperature rise limited to class-B limit over an ambient temperature of 50deg .galvanized single round steel wire/strip armoured and with outer sheath made of FRLS PVC compound of type ST-2. each phase having screening by a semi conducting material . inner FRLS PVC sheathed of type ST-1.6KV (UE) grade . Protective insulated cover plate will be provided inside the cubicle to shroud all the live parts with only the operating knobs of the MCBs protruding outside the cover plate. galvanized steel wire armoured and outer sheath made of FRLS PVC compound of type ST-1.The motors will be provided with a terminal block on the side which can be rotated through 360deg in steps of 90deg.mm. The ratings of all motors will be as per the drive list furnished with mech. HT power cable has been considered from purchaser‟s switch gear room to proposed CHS MCC room (Near WT-3). Control cables: Control cables have been considered 1100V grade. inner sheathed of type ST2.T Power cables: The H.5 sq.I. In situations where accuracy of measurement or voltage drop in control circuit. Adequate space will be provided within the board to facilitate termination of incoming and outgoing cables. All the motors will be provided with Class –F insulation.0 H. L. totally enclosed dust-proof. No CET/26/RN/3812/TS/CC/01/R=1& S&TMCPL/DB-ELE-001. single/multi-core. warrant. For all the CT & PT cables.The boards will be of industrial. totally enclosed fan cooled with IP-55 degree of protection. with Extruded PVC inner sheath . The cables used for DC system will be of single core type. minimum 1.mm cross section. Instrumentation cables: 42 | P a g e . The boards will be factory wired and assembled.T power cables will be 6. multicore. clause no-5. with over all annealed tinned copper braiding on all the pairs with over all PVC sheathing as per relevant I. Stop push button will be pressed to lock and turn to release type mushroom-headed push button.All signal cables will be twisted pair copper conductor of 1. „Local selected‟ indication lamp will be provided on the LCS. The cables will be in 2 Pair/ 3Pair/ 5 /8P /12 Pair configuration as per the system requirement & detail engineering. Switch Sockets for Repair network: 415 V. Gallery Type 70W HPSV 70W HPSV 70W HPSV DC Light GLS) Transfer Points & 150W HPSV Houses Staircase for all 70W HPSV buildings Switchgear room/LTSS 2X40W FTL 2X40W FTL Control room 2X40W FTL Battery room 2X40W FTL Transformer Room 2X40W FTL 43 | P a g e (100W . 1 2 3 4 5 Location Normal Lighting Emergency Lighting Conv.S. Lighting Fixtures & Lamps: Lighting Fixture has been considered in all the area within BTL battery limit after considering suitable lux level as per industrial sta ndard with necessary fitting are as follows: Sl No. Local control stations will be normal type. Local control stations will be provided with start/stop push button. Terminal blocks will be mounted on DIN rail. Local pushbutton Station & Junction box: Local control station (wall mounted/pedestal mounted) will be provided for proper control and operation of all equipment supplied by the Contractor. The local control stations will be located near the respective equipment. Control junction box will be made of Thermoplastic polycarbonate with IP-65 degree of protection.0mm2 with PVC insulation for each core with semiconductor Mylar taping over each Pair. 4 pin switch sockets have been envisaged at suitable locations for the purpose of welding. 100A. 20% spare terminals will be considered for each control box. Degree of enclosure protection will be IP: 65. Required size conduit has been considered for field instrument looping and termination purpose.rails. Cabling.433 Transformer.rail tracks & other non-current carrying metal parts Earth Pit for lightning Down-Comer Electronic Earth Pit VVVF/DCDB/UPS/PLC 44 | P a g e Earth conductor ground level 40mm dia MS Rod 75X10 mm GS flat above 40X6 mm GS flat 65X8 mm GS flat 50X6 mm GS flat 40X6 mm GS flat 25X6 mm GS flat 16 Sqmm stranded Wire 50 Sq mm stranded 6 Sq mm stranded 50X6 mm GS flat 25X6 mm GS flat 25X6 mm GS flat 25X6 mm GS flat 1CX25 Sqmm Cu. High mast has been considered for ground hopper stock pile& reject stock pile area for yard lighting. Earthing and Lighting Protection: Cabling has been considered for the above cable including laying by different size cable tray. Wire . clause no-5.structures.cable trays & busduct enclosures Crane. Location Normal Lighting Emergency Lighting HT Switchgear room 2X40W FTL /MRSS Switchyard & all 250W HPSV outdoor areas 6 7 In addition with above road lighting will be considered for material handling area up to 1200 meter by 10 meter lighting pole with fixture at 30 meter interval to achieve required lux level. separate cable tray has been considered for Power cable.Sl No. termination has been considered as per specification. No CET/26/RN/3812/TS/CC/01/R=1 & S&TMCPL/DB-ELE-001.0 Earthing material has been considered in various areas in CHP system are as follows: Sl No. Cable laying. 2MVA LT Motors (160-200KW) LT Motors (110KW to 132KW) LT Motors (15KW to 90KW) LT Motors (3.3KV Switchgear/415V Switchgear/11/3.45 KV Trafo 11KV Switchgear 11/0.7KW to 11KW) Control panels & Control desk PB Station/JB Columns. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Equipment Earth Pit Main earth grid 3. 6 nos. control cable & instrument cable. Earthing & Lightning protection system has been considered as per specification doc. cast aluminium box with indirect acting mechanism such that the belt does not come in direct contact with the switch element. cast aluminium box. The same will be provided with 2 NO + 2 NC auxiliary contact of 10 A rating at 110V. has been considered as per equipment standard application and specification which details can be given during detail engineering stage. The pull cord switches will have 2 NO + 2 NC contacts each rated 10 A at 110 V and will be complete with parallel running pull wire and associated accessories. Heavy-duty proximity type positioning switches. hoist. The degree of protection for enclosure of pull cord switches will be IP65. with sensing distance to suit the application. The switch will be supplied with special cable between sensor and the electronic unit. The degree of protection for enclosure will be IP65. Pull Chord Switch: Pull cord switch will be provided in conveyor gallery @ 25minterval along walkway on both sides.Electrics for Equipment Wagon tippler & side arm charger. 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 of protection class conforming to IP55. The electronic unit will have provision to receive auxiliary power at 110V AC and generate potential free 1 NO + 1 NC contact each rated for 10A at 110 Volt. elevator. The degree of protection for enclosure will be IP:65. All electrics for Wagon tippler & side arm charger. Belt sway switches will be industrial. The pull cord switches will be industrial. heavy-duty types. Limit Switch: Heavy-duty type limit switches will be provided for automatic reversal of shuttle conveyor as well as stoppage during over travel. tripper etc. The switches will have 2 NO + 2 NC auxiliary contacts each rated for 10A at 110 V AC. housed in a dust and vermin proof cast iron. will be provided for automatic positioning of the carriage of reversible 45 | P a g e . Belt Sway Switch: Belt sway switches will be provided along conveyor @ 50 m interval on both sides with a minimum of 1-pair for each conveyor. hoist. elevator. The proximity switch shall be suitably designed to sense with a gap up to 20 mm. tripper etc. The switches will be operable in both directions with automatic locking arrangement in the operated position and will be manually reset type. enclosed in a dust and vermin proof cast iron. The electronic unit will have provision to adjust time delay for contact actuation as well as dropping of relay to avoid nuisance tripping. heavy duty type. Chute jamming switch: Chute jamming indication will be needed for automatic stoppage of upstream/downstream conveyors through tilt switch which will be located at the exit side of the chute. The design consideration is as follows: Probe materials :SS with PTFE or Ceramic as per requirement No. The mercury switch will get tilted regardless of the direction of tilt and the NO contact of the switch will close. When there is no material flow from the chute. Level Measurement System Radar type continuous level measuring system will be provided at the top of bins & silos. 5 A. The switches will be 3 wire type with leakage current below 10 mA and suitable for signal exchange with PLC system. The probe will contain an inner active section and an outer shield section. The tilt switch will be actuated when material flow on conveyor is normal to tilt the probe of the tilt switch 15 degrees or more from its vertical position. ultrasonic/ microwave operated switch inside the chute may be adopted. the NO contact will open and will generate a signal to PLC system to trip the conveyor. There will be provision for adjustable time delay to prevent stoppage of conveyors in case of momentary tilting of the probe. The probe will be adequately protected against mechanical damage. detector. The system will comprise of probe & electronics unit.shuttle conveyor. Enclosure : As per IPSS : 2-07-001-87 Belt Weighing System Microprocessor based system for Belt Weigher system will provide mA signal output for the coal feed to be connected to DCS of CHP. Temperature transmitter The said transmitter will be considered for each HT motor bearing and winding RTD application as per specification Individual JB will be considered for transmitter housing of each HT motor as per RTD & BTD application.: 0-70 oC Power supply : 230V. of points : As per requirement Range : As required Output : 4-20 mA DC with 600 ohms load Alarm output : Potential free contact for High. where specified in TS. Green (normal) and Red (alarm) indicating lamps will be provided on the front panel of the control unit. The control unit will be suitable for outdoor installation with degree of protection IP 54. 2 NC contacts will be made available for interlocking/alarm. 50Hz AC Mounting : Flanged connection at top of Covers/side walls.110 V AC. 2 NO. Low level Operating temp. Alternatively. 46 | P a g e . thus indicating „chute jammed‟ condition. The electronics unit will consist of oscillator. The signal will be transmit up to DCS (employer scope) by the help of respective PLC &RIO panel. etc. signals for remote indication and overload alarm will be given in the belt scale. This transmitter is a dual channel one and the output could be fed in to the CHP DCS. which provides a continuous display. Operator stations (OS). i) ii) iii) Automation system for Pre & Post Material Handling facilities Automation system for Wagon Tippler house Integration among automation system of Material Handling facilities. Boom conveyor of SCR to record quantity coal available in stockpile and also reclaiming rate. Necessary hardware will be considered for bringing all signals from different areas to PLC system. The belt scales will be of electronic microprocessor type. The output from the Two Sensors would be fed in to the Dual Channel Monitor. Weigh scales will be of multi-idler type. Each PLC system will be complete with necessary application software. 47 | P a g e . Control of sampler. Each PLC system will have redundancy with respect to CPU. communication sub system. primary & secondary instruments and field devices. system cabinet. Suitable device for testing the accuracy by test weights will be provided. Main Coal Processing Plant. peripherals etc. The belt scale is considered as load cell type and of continuous operating. Provisions for local and remote measurement of instantaneous through put. input/output subsystem. On conveyors to record the quantity of coal received in the plant and quantity of coal conveyed. Vibration Monitoring System for each Crusher: Vibrating monitoring system is considered for the ring granulator type Crushers to sense and for indication of vibration of the equipment and transmission of the sensed signal to the Control room for indication of alarm and tripping in case of any abnormality of the equipment. power supply & communication modules with hot standby feature. Engineering stations. local signalling of load limits of conveyors will be provided. We have also considered a buffer output using handheld portable data collector for further analysis of the data. Automation system for each area will be achieved through dedicated PLC system housed in respective control room along with Human Machine interface (HMI). process monitoring & supervision. We have considered simple Vibration Monitoring System for total 2 Nos. data acquisition. system software & communication Software. of Crusher (both its Driving End & Non Driving End location and in Horizontal & Vertical location). historical trending and logging. Alarm-Alert Relay and 4-20 mA Output. Automation System Level-1 Automation System: The proposed instrumentation & automation system will comprise of PLC systems (PLC). Individual control panel will be considered for each system. for execution of sequential operation & logic control. PID. totalling. Wagon Tippler system. The purchaser will provide two feeders of 440V AC 3 phase. static by-pass line should have selector switch for manual by pass of the UPS& SCVS system in case of maintenance of UPS. It will consist of one number EPABX system with 4x64 line capacity and line cards for 192 extensions including power supply equipment along with rechargeable Battery bank. The system will be complete with standard telephones 48 nos and necessary telephone cable network for the subscribers within the plant office building & control room buildings.All control loops will also be achieved in the PLC system. 48 | P a g e . Sequential controller. voice communication system. Plant telephone system: The Automatic telephone exchange and allied equipment along with the required cabling network are intended for providing internal communication inside the plant as well as for external communication beyond the plant. Fire Detection & Alarm system. PA system & CCTV system.Pulse valve All the instrument associated with DE & DS system will be considered as per said specification & requirement. Necessary IO hook up provision has been kept inside the control panel. The UPS will be designed such that it is loaded up to 60% of the capacity. Further. 1. The output of the UPS will be suitable for 230 V AC. operator console and Main Distribution Frame (MDF). 3. PLC system will be considered as per said specification & requirement. Instrument for DE & DS system Following instrument will be considered for DE & DS system for various locations as per scope which detail will be submitted along with P & ID diagram during the time of detail engineering.UPS distribution board will be provided with 20% spare feeders. 4 wire input supply. Signal will be transmitted from respective control panel up to PLC/ RIO panel. Pressure switch.5% respectively or better. The Bidder will generate two feeders of 440V. Metal Detector /Magnetic separator The above equipment has been considered as per flow diagram with specification which E & I part control panel has been considered. 50 Hz with voltage and frequency variation limited to +1% and +0. The UPS will be provided with servo controlled voltage stabilizer (SCVS) in the by-pass line with static switch. Necessary potential free contact will be provided for alarm and status contacts to be hook up to respective automation system. The UPS will be installed in A/C environment in or near the Control Rooms. . UPS with Battery Backup: UPS system (minimum 2x10 KVA) in parallel redundant mode & single phase 220 V ac with neutral grounded output and sealed maintenance free battery will be provided catering the need of Instrumentation &Automation system. EPABX. 2. 4 wire AC input along with manual changeover scheme for input supply to UPS. DPMCB with suitable rating will be provided at each of the feeders including the spare ones.UPS failure will be displayed in the Operator station of PLC. Displacer type level 3. PLC. 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. The monitors shall be housed in the main control room.5 per specification doc.no 3. of wall/desk mounted subscriber stations with required no.6. clause. System will be considered as per specification doc.The above system will be considered as CET/26/RN/3812/TS/CC/01/R=1. control cable and mains cable with cabling accessories. No VHF voice communication system: The VHF communication system will be used to provide instantaneous audio communication facility among control rooms & plant personnel.no 3. of horn / cone type loudspeaker and other accessories as per requirement. The facility for recording the events as historical events with time limit of storage will be provided in the system. junction boxes. clause. clause. 49 | P a g e . 2) Required quantities of armoured signal cable. System will be considered as per specification doc. No T/26/RN/3812/TS/CC/01/R=1. This system will assist in monitoring various areas on a continuous basis from a central location and for taking timely action in the event of any dysfunction.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.no 3. 3) Any other accessory or equipment as required for the proper functioning of the above mentioned loudspeaker communication system. No CET/26/RN/3812/TS/CC/01/R=1.6. Main Features of CCTV system will be as follows: Remote control facility Recording of events Motorized pan & tilt head (as required) Centralized viewing The CCTV system will consist of cameras to view the respective area along with monitors for viewing independent areas.8 Loudspeaker communication system: Two Channel Open Line Page Party type Loudspeaker Communication system (PA) for establishing reliable and quick communication amongst various sections of the manufacturing complex comprising of the following: 1) Thirty (30) nos.6. PDBs as per requirement. 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. The height of skirt shall be minimum 400 mm for 800 mm BW. . In case of multiple feeding. Skirt board top cover shall be 3. Short posts shall be made of ISMC 150 for Conveyors above 1000 mm Belt Width & ISMC 125 for conveyors upto 1000 mm Belt Width. liners of full height shall be provided and beyond feed zone. Modular segmented type skirt sealing system for effective sealing against spillage and dust shall be provided. In feed zone. Head and Tail pulley frame & Guide column for Vertical gravity take-up. liner height shall be 200 mm. Skirt shall be made of 10 mm thick plate . MS deck plate of 3.1 TECHNOLOGICAL STRUCTURES S NO. Short post. the length of the skirt shall be minimum 4000 mm.15 mm thk MS cover.4) STRUCTURAL WORK: 4. Description QTY. 450 mm for 1000 mm and 1200 mm BW and 500 mm for more than 1200 mm BW.15 mm thick shall be provided at every feed point up to 3 m beyond the skirt length of all the conveyors. 1 Stringer. Length of skirt board for single discharge. 6 m long deck plate from the centre line of head pulley shall also be provided at the head end of all conveyors. length of the skirt shall be continuous covering all feed points. Lot 2 Deck plate Lot 3 Skirt Board Lot 50 | P a g e Location Stringer will be made of ISMC 150 for Conveyors above 1000 mm Belt Width & ISMC 125 for conveyors up to 1000 mm Belt Width. Liners shall be provided at three (3) sides of chute plates for inclined chute at all four (4) sides for vertical chutes. For conveyors of length more than 250m. The cross over/under-passages shall be spaced not more than every 180 m. Location All the chute body shall be minimum 10 mm thick MS plate. 1. The conveyor belt with hood cover shall be located on top of the supporting structural gallery girder. Under-passages may also be provided in lieu of cross over. Emergency escapes via staircases of width 750mm. All clean coal chutes shall be lined with SS-304 liner. The size & shape of liner shall be provided for easy handling and shall not exceed 20 kg/hour 4. Cross Over 51 | P a g e . wherever required.2 Building /Normal Structures S NO.S NO. Height of single piece of chute shall not more than 2 meters Impact zone of all chutes shall be lined with 60 mm thick rubber liner and sliding areas with 30 mm thick ultra high molecular weight polymer. Description QTY. cross-over shall be provided over the conveyors at the location of emergency escapes. Conveyor hood shall be made of minimum 5 mm thick MS plate. 2. shall be provided from near the locations of cross-overs / under-passages. Description Gallery QTY. Conveyor Discharge Chutes & Liners 4 Lot Hinged type inspection doors minimum of 500 x 500 mm and poke doors of 300 x 300 mm shall be provided. Lot Location Conveyor Galleries shall be of open type welded latticed steel construction with belt hood. galvanised colour coated roof. 1000 mm walkway at centre and 600mm on either side shall be provided. ladders & handrails etc as per technological requirements. access stairs. crane maintenance walkway/ platforms. side & gable end sheeting. Air compressor shed. The walkways shall be of 6mm thick MS chequered plate. 5. 3. Tertiary crusher house. ladders & handrails etc as per technological requirements. ladders. Flocculent dosing shed. c) Main coal preparation plant (Washery unit ) with EOT crane. Suitable toe guard shall be provided on the conveyor side of the walkway for protection in all the conveyor galleries. 4. Junction houses. 3. Description QTY. b) Wagon tippler shed with EOT crane. They shall be spaced at 20 m c/c and supported on RCC foundations. Screening house. For double conveyors in the gallery /tunnel. 2. crane supporting structures. galvanised colour coated roof. side & gable end sheeting. Trestles supporting overhead and over ground conveyor galleries shall be either 4-legged or 2-legged and of structural steel conforming to IS:2062. Walkway for galleries Lot 5. 52 | P a g e . The other major structural work shall be as follows: a) Structures for following unit with galvanised colour coated roof & side sheeting with working platforms. 6. working platforms. Pent house. 8. Trestles Lot 4. 7. The clear width of walkway in conveyor gallery / tunnels shall be 1000mm on one side and 600mm on the other side for single conveyors. Walkway width Lot Location Conveyor supporting trestles and towers shall be of steel construction and arranged with due care for stability of the gallery to be achieved by providing adequate bracing system.S NO. crane supporting structures. access stairs. Ground feeding hopper shed. handling facilities & handrails etc 1. working platforms. Primary & secondary crusher house. crane maintenance walkway/ platforms. access stairs. as per technological requirements. f) Trestles & bridges for utility pipe lines & cables routing with working platforms. e) Plant feed silo (surge hopper) supporting structures with handling facilities. penthouses. electrical substation. including RCC works for tunnels (minimum height 3. Floatation Reagent Storage building.d) Shed with handling facilities over new RCC silos. with grating platforms over silos. minimum width 4. walkway. Canteen-cumtoilet building. d) Administrative Building Civil works including RCC framed structure with brick cladding for Administrative building. access stairs. RCC foundations and grouting of structural supports etc. apron feeders. underground hopper and for underground conveyor system Civil works for RCC famed control building for the wagon tippler. b) Conveyor System and Junction Houses Civil works for underground conveyor system. handrail & handling facilities as per requirement. Classifying Screen House. Flocculent Dosing building and other such buildings along with the foundations for equipments. working platforms & maintenance platform. surge hoppers. ground feeders. 5. ladders & handrails etc as per technical technological requirements. RCC foundations for structural trestles supporting conveyors etc. RCC foundations for MCPP building. 53 | P a g e . including RCC foundations for overhead shed. MCC building. side & gable end sheeting. RCC foundations and flooring for the junction houses c) Technological Buildings Civil works including RCC framed structure with brick cladding for Magnetite Storage building. ladder. laboratory building and other such buildings along with equipment foundations. shall be covered with Galvanized colour coated sheets on roof. access stair. ladder. galvanised colour coated roof. handling facilities & handrail etc. Structural silos. hoppers.5m. junction houses etc. including RCC trenches etc. Air compressor shed. stair. Tertiary Crusher. vibro-feeders. ladder & handrails etc. The building shall consist of rooms for executives and for in-charge with attached toilets. h) All the buildings. Middling and reject stock piles. sides & gable end. Crusher House. Civil Work The major civil works involved are as follows: a) Wagon Tippler Civil works for Wagon Tippler. There shall be one conference room and a pantry.5m). Store cum Workshop building. Transformer building. g) Access stair. water tanks. 7. with RCC columns. Necessary sewer lines. drinking water lines all fittings and fixtures.6m height of concertina coil. plinth beams. This excludes the control room area of the Main Washery which shall also be housed in the the same Administrative building. Boundary wall shall have a height of 2. septic tank & soaking pits. The building shall have one common toilet block (for gents and ladies separately) in each floor. The scope also includes distribution network of pipelines to various points for drinking and sanitation purposes. k) Roads.5m wide WBM roads all around the premises and to approach all the buildings and facilities. hoppers foundations and supporting structures. l) Civil work for RCC garland drains of 1. This drainage shall be part of the new drainage system catering to the entire developed area and same shall be connected to the sedimentation pond. h) Water Tanks and Pump houses RCC water tanks for raw water and fresh water RCC framed pump houses with brick cladding for Raw water and Fresh water i) Sedimentation Ponds Civil works including concrete floor and walls in brickwork for the sedimentation ponds. RCC underground reservoirs and pumps for lifting of water from underground reservoir shall be provided. j) Drinking & Sanitation water Construction of RCC water sump and RCC overhead water tank of adequate dimensions as per technological and functional requirement. tie beams and brick-work. Landscaping in front of the building. pedestals and other supporting structures. e) Thickeners RCC foundations columns. The total floor area shall not be less than 500 Sqm.6m including 0. Civil works for RCC culverts Civil work for RCC framed Boundary wall. 54 | P a g e . The requirement of roads indicated here is tentative and may changeas per the technological and functional requirement. f) Weigh-bridges Civil works for Weigh-bridges Civil works for RCC famed control room for weigh-bridges g) Silos RCC works in silos. Culverts and Boundary Wall Civil works in bituminous. Civil works for Parking shed for cars.5m and sufficient depth to carry storm water (considering volumetrically 2m depth through out) and connection with the sedimentation pond. scooters and cycle. Transformer foundations along with rails.m) Miscellaneous RCC flooring for the buildings. Civil works for electrical substations. process and system requirement. as per technological. process and system requirement. shops and finishes shall be as per technological. Hydraulic rooms. oil pits. computer room. process and system requirement. PLC rooms. RCC Scale pit. control rooms. as per technological. AC & ventilation rooms cable trenches/tunnels etc and all units. scale tunnel including pump houses with handling facilities etc. 55 | P a g e . electrical and MCC rooms.
Report "DESIGN BASIS OF COKING COAL BENEFICIATION PLANT.pdf"