1.0.

0 Specification of Coal Handling Plant Filed under: thermal power plant Tags: chp, COAL HANDLING PLANT, specification o f coal handling plant shivajichoudhury @ 5:40 am 1.0.0 Intent of Specification This specification is intended to cover the following ac tivities and services in respect of all the equipments of Coal Handling Plant fo r 2500 MW units. 1.1.0 Scheme of Coal Handling System

1.1.1 Coal shall be transported to the plant in bottom discharge wagon rakes and shall be unloaded in under ground R.C.C. Track hopper. 1.1.2 Six (6) number paddle (Rotary plough) feeders, each of 800 T/Hr rated capacity shall be installed at the bottom of the Track hopper to sco op the coal from track hopper and feed coal on to the underground conveyors 1A/1 B. There shall be three paddle feeders on each conveyor of which two shall work simultaneously and one shall remain stand by. 1.1.3 Two (2) nos. In-Line Magnetic separators to remove tramp i ron pieces shall be mounted on the discharge end of conveyors 3A/3B. The rated c apacity of each conveyor in coal handling plant shall be1600 TPH. 1.1.4 Conveyor 1A/1B will discharge coal on conveyor 2A/2B in tr ansfer point TP-1. Conveyor 2A/2B will carry coal to Primary Crusher House for crushing coal from 300mm to (-) 150mm. In the Primary crusher House each of the conveyor 2A and 2B shall transfer coal to separate sets of two Crushers through feeders, such that coal flow may be properly distributed to the crushers in serv ice. There shall be Four (4) numbers rotary breakers each of 800 TPH capacity wi th two (2) normally working and two as standby. Provision shall be made such tha t all the four crushers may run when both streams are required to operate. 1.1.5 Two (2) nos. belt weigh scales shall be provided on conv. 1A/1B for weighing the coal received in the track hopper. 1.1.6 Conveyor 3A/3B will convey coal to Secondary Crusher house which shall have four (4) Crushers each of 800 TPH capacity. Coal from each inc oming conveyor 3A/3B to crushers will pass through a set of two nos. dedicated v ibrating roller screens so that maintenance of equipment, hopper, chutes in eith er stream does not affect the operation of other stream. 1.1.7 Each roller screen shall be of 800 TPH capacity. The four (4) Crushers, each of 800 MTPH capacity, shall crush the coal to (-) 20 mm size. Input coal above 20 mm size shall be fed to the crushers. Both, the screened co al below 20 mm size and crushed coal shall be discharged either onto conveyor 4A /4B or to stacking yard Conveyor No. 8. From conveyor 4A/4B, normally the crushe d coal will be fed on Conveyor 5A/5B for onward transmission to Conveyor 6A/6B t hrough the transfer point2 (TP-2), TP-3 and TP-4. In TP-2 and TP-3, provision s hall be kept for feeding the coal to one future conveyor for second future Stack er-cum-Reclaimer and Conveyor for extension stage if required. 1.1.8 Stacker-cum-Reclaimer is envisaged for stock-yard having r eversible conveyor 8 as yard conveyor. The feeding of coal from conv. 8 on boom conveyor of SR shall take place during stacking mode. Yard conv. 8 shall dischar ge coal on conv. 9A/9B at TP-6 while on reclaim mode. 1.1.9 At TP-5, conveyor 6A/6B will discharge coal onto conveyor 7A/7B. Two (2) nos. In-line magnetic separators (ILMS) shall be provided over th e discharge end of conveyor 6A/6B for extraction of tramp magnetic pieces.

1.1.10 Two (2) nos. belt scales shall be provided on conveyor 6A/6 B for weighing the coal received from stock yard. 1.1.11 rs 7A/7B at TP-5. Conveyor 6A/6B shall discharge coal onto bunker bay conveyo

1.1.12 One (1) no. Travelling Tripper mounted on each of the conve yors 7A/7B shall feed coal into Raw coal bunkers of the boiler units. 1.1.13 One (1) no. stacker cum reclaimer (S/R) machine of 1600 TP H rated capacity shall be provided on yard conveyor 8. The S/R machine shall ope rate on rails for stacking/reclaiming the coal in the stock yard area. During re claiming the coal shall be conveyed to the yard conveyor 8 by reclaiming operati on of S/R machine and shall be fed to conveyor 9A/9B at TP-6. During stacking mo de of operation of the machine, coal from crusher house shall be fed to yard con veyor 8. One belt scale shall be provided on Yard Conveyor. 1.1.14 Two nos. coal sampling units shall be installed one each a t crusher house and TP-4 to sample the coal of (-) 150 mm size and (-) 20 mm siz e respectively. 1.1.15 In the event of direct flow through 1A/!B, 2A/2B, 3A/3B, 4A /4B is not resorted, then the coal will be reclaimed from coal heap with the hel p of S/R and chain of conveyor No. 8, 9A/9B and 10A/10B and will be transfer cru shed coal to conveyor 6A/6B at TP-4 1.1.16 In the case of S/R being out of order and crushed coal is r equired to be reclaimed, six emergency underground reclamation hoppers shall be provided on conveyor No. 9A/9B. The coal from crushed coal heaps shall be dozed into these hoppers with the help of Bull-Dozer. 1.3.0 System Design Basis 1.4.0 Spare Parts 1.6.0 Equipment Specification 1.8.0 Testing and Inspection 1.2.0 Scope of Work Filed under: thermal power plant Tags: chp, specification of coal handling plant shivajichoudhury @ 5:38 am 1.2.0 Scope of Work The work shall include but not limited to the following: 1.2.1 Mechanical Equipment

1.2.1.1 Six (6) Nos. Paddle feeders, complete with all electricals, rails, supporting structures, end stops, cable reeling drums, trailing cables a nd necessary accessories. 1.2.1.2 Complete Belt Conveying Systems including Conveyor Nos. 1A/ 1B, 2A/2B, 3A/3B, 4A/4B, 5A/5B, 6A/6B, 7A/7B, 8, 9A/9B and 10A/10B complete with conveyor supporting structures, short supports, stringers, deck plate, seal pla te etc. drive motors, drive units, pulleys, idlers, gravity take ups, take up st ructure upto ground level, internal and external belt wipers, pull chord switche s, belt sway and zero speed switches, electro-hydraulic thruster brakes, all ele ctricals etc. including all civil, structural and architectural works for convey or gallery, gallery supporting trestles and their associated foundations. 1.2.1.3 Tripper floor belt conveyors 7A/7B in the bunker building c omplete with conveyor supporting structures, short supports, stringers, deck pla te, seal plate etc. drive motors, drive units, pulleys, idlers, gravity take ups

with guides upto ground level excluding the take-up structure, internal and ext ernal belt wipers, pullchord switches, belt sway and zero speed switches, electr o-hydraulic thruster brakes etc. and all electricals etc. 1.2.1.4 Yard conveyor 8 complete with conveyor supporting structure s, short supports, stringers, deck plates, etc., drive motors, drive units, pull eys, idlers, take-ups, take-up structure, internal and external belt wipers, pul l chord switches, belt sway and zero speed switches, electro hydraulic thruster brakes, all electricals, etc. including all civil, structural and architectural works and their associated foundations. 1.2.1.5 Four (4) Nos. Vibrating feeders in Primary Crusher House co mplete with drives, all mechanical, electrical and accessories. Four Nos. Rotary Breakers complete with drives, all mechanical, electrical including civil and s tructural works. 1.2.1.6 Two (2) numbers crusher house (one primary crusher house an d one secondary crusher house) complete with all civil, structural, architectura l and electrical works etc accommodating four nos. crushers and associated vibra ting grizzly feeders, gates etc., goods cum passenger lift, conveyors, chute wor k alongwith actuator operated flap gates, hoists and other equipment such as coa l sampling unit, dust suppression & ventilation system etc. as specified elsewhe re. 1.2.1.7 Four (4) nos. roller Screens (in secondary crusher house) c omplete with drives, all mechanical, electricals and accessories. 1.2.1.8 Four (4) nos. crushers complete with drives, all mechanical , electricals including civil & structural works, vibration isolation system wit h springs & viscous dampers, vibration monitoring system etc. 1.2.1.9 Four (4) sets of Gates each comprising of one rod gate and one actuator operated rack & pinion gate at inlet to each of the above vibrating roller screens complete with drives, all mechanical, electrical, structural wo rks etc. 1.2.1.10 Transfer point TP1 alongwith under ground tunnel and pent h ouse PH-I, TP-6 alongwith underground tunnel and pent house PH and drive house fo r yard conveyor 8 complete with all civil, structural, architectural and elect rical works including chutes, monorails, hoists/chain pulley blocks, hoist ma intenance platforms, RCC/steel floors, external staircases, hand rails etc. Al l transfer points shall have separate debris disposal chute right up to the grou nd floor. 1.2.1.11 All mechanical, electrical equipment to be housed in Transfe r points TP-1, TP-2, TP-3, TP-4, T.P-5, T.P-6, T.P-7, drive house of yard conve yor and pent houses including chutes, maintenance / operating platforms, Monorai ls, electric hoists etc. 1.2.1.12 One (1) no. stacker cum reclaimer machine having rated capac ity of 1600 TPH/ 1600 TPH complete with all equipment and conveyors, structural, electricals, cable reeling drums, all trailing cables and accessories, rails, r ail foundations, fixing and grouting of rails and other associated civil & stru ctural works to operate in conjunction with yard conveyor 8. 1.2.1.13 Complete chute work along with chute block switches and actu ator operated flap gates between various conveyors and equipment at all transfer points and crusher house. 1.2.1.14 Three (3) Nos. passenger cum goods elevators with drives, al

l mechanical, civil, structural & associated foundation works, accessories and e lectricals to serve various floors of the Primary and secondary Crusher House (C H) and TP-5 1.2.1.15 Two (2) Nos. motorized Travelling Trippers, One (1) each on conveyor 7A/7B. Trippers shall be complete with all mechanical, electrical equip ment, rails, rail supporting structure (any structural stools, if required), cab les with cable reeling drum, all trailing cables, brakes, rail clamp etc. Grid/ grating over the bunker slot on tripper floor is to be provided by the bidder. The drive chain equipment for conveyor 7A/7B therefore s hall first be placed at the end of unit no. 1 bunkers for commissioning of unit no. 1 and shall be later shifted at the end of the bunker bay at the time of com missioning of unit no. 2. Bidders scope of work shall include shifting of the dr ive chain equipment for conveyors 7A/7B for unit no.2 commissioning including it s associated civil and electrical works and making good the bunker floor after s hifting of the drive chain equipment to its ultimate location for unit no. 2 com missioning. 1.2.1.16 Adequate number of ventilation for ventilating the track hopper, TP-1, underground portion of conveyor 1A/1B, under ground portion of TP-6 and un der ground portion of conv. 9A/9B and bunker bay (housing tripper conveyors) com plete with all mechanical, electrical, civil and structural works. 1.2.1.17 Pressurised Ventilation system for all HT Switchgear room, M CC rooms and S&T room complete with all mechanical, electricals, accessories, ci vil and structural works. 1.2.1.18 Air conditioning of Main CHP control room; operators cabin & MCC room on Stacker/Reclaimer complete with all electricals, civil & structural works etc. 1.2.1.19 Minimum nine (9) Nos. sump pumps six (6) nos. in track hoppe r and three (3) nos. sump pumps each in underground tunnel and Transfer point of Conveyor no. 9A/9B complete with motors, local control panel, level switches, i ndividual discharge piping with fittings and valves to nearest plant drain as sp ecified and as indicated elsewhere. 1.2.1.20 Two (2) Nos. coal sampling units, one for (-) 300 mm size co al complete with all accessories and electricals, supporting structures, approac h/ maintenance platforms in unit, in crusher house and one for (-) 20 mm size co al in TP-4 complete with all accessories and electricals, supporting structures, approach/ maintenance platforms. 1.2.1.21 One (1) No. belt vulcanising machines of adequate size compl ete with all mechanical, electricals, accessories and consumables. 1.2.1.22 Four (4) Nos. Inline Magnetic Separators, complete with reje ct chutes, reject bins, and all mechanical, supporting arrangement, electricals, civil, structural works and accessories. 1.2.1.23 Four (4) Nos. Electronic Belt weighers complete with all mec hanical, supporting arrangement, electricals, and accessories. 1.2.1.24 Complete dust suppression system for control of fugitive dus t in track hopper, paddle feeder, transfer points, crusher house, coal stock yar d complete with pump houses, water tanks, pumps, drives, piping, valves etc. 1.2.1.25 Belt Sealing arrangement in Bunker bays to operate in conjun ction with tripper for control of dust coming out of R.C. Bunkers.

1.2.1.26 Suitable monorails and electrically operated hoist blocks as well as hand operated chain pulley blocks for servicing/ installation / easy re placement of drive machinery, different types of pulleys for all conveyors, GTU and other equipment from ground level to all locations. Electric hoist provided at bunker (Tripper) floor and all transfer houses/crusher house shall also be ab le to lift one belt drum (including wooden/ Steel drum) safely. 1.2.2 Electricals

Two nos. 11 kV feeders and two nos. 3.3 kV supply feeders shall be provided from 11 kV & 3.3 kV station board for feeding entire CHP. The scope of work shall include, but not limited to the following: 1.2.2.1 3.3 KV CHP Switchgears to feed HT drives including Stacker Reclaimer and auxiliary transformers. 1.2.2.2 Auxiliary Transformers :

a) Two (2) nos. 11/3.45 kV, ONAN, out door transformers for 3.3 K V CHP Switchgear. b) 3.3 / 0.433 KV, ONAN, out door transformers for each of the CHP MCC-I, II, III. c) machine One (1) no. 3.3/0.433 KV, Dry type indoor Transformer for S/R

1.2.2.3 Three (3) nos. of 415 V CHP MCCs to feed LT loads of entire coal handling plant. These three CHP MCCs are proposed to be located as follows : a) b) c) 1.2.2.4 MCC-II in the MCC room near Track hopper area. MCC-I in the switchgear room at CHP control room building near Secondary Crusher House. MCC-III in the MCC room near Transfer Tower. One (1) no. of 415 V Stacker/Reclaimer MCC.

1.2.2.5 3.3 KV segregated phase bus ducts from 11/3.45 KV transform er to 3.3 KV CHP switchgear alongwith bends, terminations, supports etc. 1.2.2.6 Control desk and Programmable logic controllers (PLCs) :

a) Main control desk with CRT/keyboard and large video screen, PL C panels, remote I/O racks etc. for the control of the entire coal handling plan t. b) PLC system with control desk and I/O racks etc. for Stacker/ Re claimer machine. 1.2.2.7 AC distribution boards as required.

1.2.2.8 Six (6) nos. DC distribution boards (2 Nos. each at the loc ation of MCC-I, II, III. 1.2.2.9 Local push button stations for all drives.

1.2.2.10 Internal and external illumination system for the complete C HP & coal stock yard, including track hoppers, TPs/ conveyors in bunker area etc . 1.2.2.11 3.3 KV and 1.1 KV grade FRLS, XLPE/ PVC, AI/Cu, Armoured pow er, control, trailing and special cables for the complete system a) between equipment supplied under this specification. Purchasers e

b) between equipment supplied under this specification and quipments.

1.2.2.12 Cable trenches / trestles including trays and supporting arr angement etc., required for the cables including laying & termination / jointing etc. 1.2.2.13 equipment and buildings. 1.2.2.14 1.2.2.15 tes. Earthing and lightning protection system for all Close circuit TV system. Grouting of bolt holes and underside of base pla

1.2.2.16 One (1) No. Main CHP control building located adjacent to th e secondary Crusher House to house Main Control Desk, PLC panels for the coal ha ndling plant on the first floor and 3.3 KV CHP switchgear, 415V CHP MCCs DCDB, lighting panels etc. on the ground floor. Associated auxiliary outdoor transfor mers shall be located suitably adjacent to the building. 1.2.2.17 Two (2) no. MCC rooms each to be located near T.P-1 and T.P -5. Each MCC room shall have 415V CHP MCC-1 and CHP-MCC-II respectively, lightin g distribution boards, DCDB, I/O panel etc. Associated auxiliary outdoor transfo rmers shall be located suitably adjacent to the building. 1.2.2.18 One (1) no. S&T (signalling & telecommunication) building to be located at exit of track hopper. 1.2.2.19 All MCC room buildings shall be complete with all electrical , civil, structural, architectural works, cable trenches, fire safety walls, fou ndation / fencing / earthing for transformers etc. 1.2.2.20 civil & structural works. 1.2.3.0 All cable/duct tanks/trenches/trestles including

Control & Instrumentation Operation and Control Philosophy The coal handling system shall be controlled from the fo

llowing control points. 1.2.3.1 Coal Handling Plant Main Control Room

Overall, operation of the following equipment of Coal Handling Plant shall be co ntrolled from the main CHP control room.

a) Conveyors, feeders, flap gates, R & P gates, crushers, Vibrating Roll er Screens. b) c) d) . e) f) ion). g) h) i) j) ns). 1.2.3.2 Local Control Panels Local control stations for following equipments shall be provided a) b) c) d) e) button f) g) h) Paddle feeders along with its dust suppression system Mobile trippers over bunkers Coal Sampling units Belt Weighers Electric hoist wall mounted control box with pendent push controls. In line magnetic separators Sump Pump Suspended Magnet Coal Sampling Systems (ON/OFF control with indication). Belt weigher (ON/OFF control with indication) Stacker Reclaimer (ON/OFF status with stop facilities). Mobile trippers over bunkers (tripper position indicatio Vibration Monitoring System In line Magnetic separators (ON/OFF control with indicat Paddle feeders (running status with stop facilities). Complete Dust Suppression system & service water system. Ventilation system (group/individual control as required)

All the above local control panels shall be accessible and located near their re spective equipment and shall be complete with all the required controls, interlo cks, annunciations etc. Further, necessary controls, indications and annunciations for all the above equipment shall also be provided at main CHP Control Room as described under relevant clause. 1.2.3.3 Stacker / Reclaimer Control Room

The entire control & operation of Stacker Reclaimer machine shall be from the op erators cabin on the machine itself. 1.2.3.4 In addition to the remote control of various equipments, loc al stop push button stations shall be provided for all equipment. Track hopper to the reclaim conveyor shall be controlled from the paddle feeder

itself based on instructions from main control room. 1) The following equipment will not come under interlock of the onveyor scheme. 2) Belt sway switch not operated c

3) Under speed switch closed at 90% speed of the conveyor within d esigned accelerating time. 4) 5) 6) . Motor protection not tripped Local stop PB reset

Chute Block switch not operated. Two such switches shall be provided 7) End of travel limit switches reset. Annunciation System:

1.2.3.5

The mimic panel cum Control desk shall be provided with adequate number of facia type annunciation windows operating through PLC for audio-visual fault annuncia tion purposes. Wherever group annunciation is provided, alarm status of individu al equipment shall be provided on CRT. Comments (1) 1.3.0 System Design Basis Filed under: thermal power plant Tags: chp shivajichoudhury @ 5:34 am 1.3.0 System Design Basis The mechanical and structural / civil system shall be designed for 1600 TPH rate d capacity and round the clock operation with both the streams operating simulta neously. i) low. red. The Coal delivered to the power station shall be of size 300 mm & be Occasionally 1-2% coal of 400 mm lump size may also be encounte

ii) HGI of the Coal shall be between 44 to 65. Normally moisture content in coal will vary between 12% to 15%. However for design purposes, moist ure content of 20% shall be considered. iii) Due to open cast method of mining involved, the coal may conta in shale and sand stone as high as 20%. Also occasionally metal pieces like bro ken shovel teeth, brake shoe, wires etc., may also come alongwith coal from open cast mine. iv) The coal as received shall contain varying percentage of fines. C oal with such fines may tend to form adhesive lumps, particularly during monsoon when surface moisture is at its maximum value. The sizing and selection of the vital equipment viz. crushers, vibrating roller screens, paddle feeders etc. covered under the system shall be based on the abov e characteristic of coal and operating conditions. Bidder shall ensure that equi pment/ system efficiency shall not be effected particularly during monsoon when surface moisture is at its maximum value. For the purpose of volumetric computation, the bulk density of the coal shall be taken as 800 kg/m3. Therefore for calculation of belt conveyor capacity, for th

eir drives & drive motors kW requirement, and sizing (volume calculations) of ch ute, hoppers etc. the above bulk density shall be considered. For all other purp ose viz. for stresses/ load on structures, torque calculations of paddle wheel o f paddle feeder, bucket wheel of stacker / Reclaimer, sizing of actuators for fl ap gates, R&P gates, calculations of plugged chute/ hopper loads etc. the bulk d ensity of the coal shall be taken as 1100 kg/m3. All mechanical, and structural / civil system design shall consider simultaneous running of both the streams, starting of one stream with the other stream in st andstill condition as well as starting of one stream with the other stream in op eration. 1.3.1 System Requirement

1. Coal Consumption per 500 MW unit 390 TPH 2. Coal consumption for 2500 MW units 780 TPH 3. Daily Coal consumption for 2500 MW units 18720 T 4. No. of streams provided for the Coal Handling Plant Two (2) (1 operating + 1 standby) 5. Since plant is to be operated generally on design coal, hence capacity o f each coal stream considering 2 no. shift daily 7 hrs. per shift 18720 27 = 1337 T 6. Capacity of each coal stream chosen considering 120% margin over worst c oal requirement 1604 T 7. Hence capacity of each coal stream 1600 T The CHP facility shall have two (2) coal streams; one (1) operating + one (1) st andby having guarantee capacity of each stream as 1600 TPH. CHP shall be operated normally for two shifts per day (single stream operation b asis) to meet the daily coal requirement of the two (2) units. However, all co mponents of CHP facility shall be designed for continuous duty of 24 hours/day. The CHP shall be designed & installed such that any one stream can be operated a nd if required both the streams can be operated simultaneously. Comments (1) 1.4.0 Spare Parts Filed under: thermal power plant Tags: chp shivajichoudhury @ 5:32 am 1.4.0 Spare Parts 1.4.1 General

The Contractor shall indicate and include in his scope of supply all the necessa ry mandatory spares, start-up commissioning spares and recommended spares in the relevant schedules. The variation in quantity of spares based on unit rates (ra tes as quoted for mandatory spares and rates as mutually agreed for recommended spares), if desired by the Purchaser shall be acceptable to the contractor. The Purchaser reserves the right to buy any or all mandatory and recommended spa res. The contractor shall identify service expectancy period for all items of sp ares, under normal operating conditions before order placement. The Contractor shall also indicate the unit wise population of each item and the service expectancy period for the spare parts (both mandatory and recommended) under normal operating conditions before order placement is necessary.

All spares supplied under this contract shall be strictly interchangeable with t he parts for which they are intended for replacements. The spares shall be treat ed and packed for long storage under the climatic conditions prevailing at the s ite, e.g. small items shall be packed in sealed transparent plastic bags with di ssector packs as necessary. Each spare part shall be clearly marked or labeled on the outside of the packing with the description. When more than one spare part is packed in single case, a general description of contents shall be on the outside of such case and a deta iled list enclosed. All cases, containers and other packages must be suitably ma rked and numbered for the purposes of identification. Purchase specification & addresses of Procurement sources of all mandatory spare s & recommended spares shall be furnished. Details of all types of bearings in t he plant shall also be furnished. 1.4.1 Mandatory Spare Parts

The list of mandatory spares, which are considered essential by the Purchaser, i s indicated in enclosed Annexure- . The Purchaser reserves the right to buy any or all mandatory spares. The Bidder shall include all the mandatory spares in h is proposal. The Bidder shall furnish in the relevant schedule of Bid proposal s heets, the itemwise and total price for these spares mentioned in the above Anne xure. Further whenever the spares are indicated in percentage and numerical figu res, arrived is in fraction, the same be converted to the next whole number. In line with the requirements in ITB, the prices for mandatory spares indicated separately shall be used for bid evaluation purposes. All mandatory spares shall be delivered at site at least two months before scheduled date of trial operati on of the system. However, spares shall not be dispatched before dispatch of cor responding main equipment. 1.4.2 Recommended Spares

In addition to the spares mentioned above, the contractor shall also provide a l ist of recommended spares with unit and total prices for 3 years of normal opera tion of the system for spares of Indian origin and 5-years for spares for non-In dian origin in relevant schedule of Bid Proposal Sheets. The list shall take int o consideration the mandatory spares specified in Annexureand should be in dependent of the list of the mandatory spares. The Purchaser reserves the right to buy any or all recommended spares. Prices of recommended spares will not be used for the evaluation of Bids. The pr ices of these spares will remain valid upto 12 months after the placement of ord er for main equipment package. The Purchaser reserves the right to buy any or a ll recommended spares. Further, the prices of recommended spares wherever common with the mandatory spares shall be the same as those of mandatory spares. Price s of recommended spares not listed as mandatory spares shall be reviewed by Purc haser and shall be mutually agreed with the contractor. However, the contractor shall be liable to provide necessary justification for the quoted prices for the spares desired by the Purchaser. 1.4.3 Start-up Commissioning Spares

Start-up commissioning spares are those spares which may be required during the start-up and commissioning of the equipment / system. All spares used until the plant is handed over to the Purchaser shall come under this category. The contra ctor shall provide for an adequate stock of such start-up commissioning spares t o be brought by him to the site for plant erection and commissioning. They must be available at site before the equipment are energised and the unused spares, i

f any, should be removed from there only after the issue of taking over certific ate. All start up spares, which remain unused at that time, shall remain the pro perty of the Contractor. The list of commissioning spares to be brought by the C ontractor to ensure smooth commissioning of the plant shall be subject to Purcha sers approval. The Contractor shall submit a complete list of all such start-up c ommissioning spares. The cost of above spares, if any, and that consumed before the handing over of the plant shall be deemed to have been included in the lumps um proposal price of the package and the Contractor shall have no claim on this account to the Purchaser. All cases, containers, other packages are liable to be opened for such examinati on, as may be considered necessary by the Project manager. In case contractor is not able to submit report of type test(s) conducted in las t five years, or in case type test report(s) are not found to be meeting the spe cification/relevant standard requirements, then all such tests shall be conducte d under this contract by the Contractor free of cost to Purchaser, and reports s hall be submitted for approval. Even if the Bidder is furnishing valid test report as indicated above, Purchaser may get some type test conducted under this contract as specified in subsequent chapters for which Bidder shall include in his total equipment price the cost o f carrying out all such type tests. The charges for each of these type tests sha ll be given separately in the relevant schedule of bidding documents for the pri ce adjustment purpose, in case waiver of any test at a later date. All acceptance and routine tests as per relevant standard and specification shal l be carried out. Charges for these shall be deemed to be included in the bid pr ice. Comments (1) 1.5.0 Testing Filed under: Uncategorized Tags: chp shivajichoudhury @ 5:30 am 1.5.0 Testing Tests at Site After erection at site, the complete system/ equipment will be operated at site to show satisfactory performance as required by the applicable clauses of the sp ecification. Further, all piping shall be hydraulic-tested at site. The contractor shall furnish the quality procedures to be adopted for assuring q uality from the receipt of material at site, during storage, erection, pre-commi ssioning to final trial run and commissioning of the complete system/ equipment. Leave a Comment 1.6.0 Equipment Specification Filed under: Uncategorized Tags: chp shivajichoudhury @ 5:28 am 1.6.0 Equipment Specification 1.6.1 Paddle Feeder

Travelling paddle feeders of self-contained, self-propelled design shall be furn ished and erected to scoop out coal from the hopper and each feeder shall be cap able of travelling back and forth along the entire length of the hopper and tran sfer the coal from the hopper uniformly onto the conveyors below. Each paddle fe eder shall have capacity to scoop out coal at the guaranteed capacity in both fo rward and reverse motions with no indication of wheel slipping (water tank full) . Each paddle feeder shall be designed for guaranteed capacity while handling en tire range of lump sizes.

It shall operate on the principle of positive discharge and shall not depend on friction or moisture content. The Paddle wheel shall be driven by a stepless hydraulic drive. Carriage travel shall be achieved through electric motor gearbox (2 speed) and flexible coupling or through hydraulic drive. Minimum number of starts/min. for chain drive equip ments shall be 15 starts/min. (with minimum 10 consecutive starts) All equipments shall be designed to withstand any rate of acceleration imparted b y drives or any strain resulting from a sudden change in load. Further, the desi gn of paddle feeder carriage should be such that it does not run off from its ra ils due to sudden change in load or other reasons. The Bidder shall include in his proposal necessary electricals for paddle feeder and carriage such as motorised cable reeling drum with trailing cables, cable t rays for resting the trailing cables, and end limit switches for protection agai nst over travel of the feeder carriage. The cable reeling drum and trailing cabl e of each feeder shall be suitable for the entire length of the hopper. Mechanic al track stops shall also be provided. Dust suppression equipment for paddle fee der shall also be provided. For designing the paddle wheel as well as travel drive, Bidder shall consider th e hopper fully loaded with coal on either side of the paddle wheel to the maximu m capacity. The hydraulic system normal average working pressure shall be selec ted considering the above loading condition. Further hydraulic system shall be d esigned to stall / trip beyond a certain pressure above the normal average worki ng pressure. The minimum margin between the normal working pressure and the stal l / trip pressure shall be 50%. Feeder carriage drive shall be suitably designed so that the forward & reverse m ovement of carriage can be achieved without stopping the scooping operation. Tan k filled with water in DS trolley shall also be considered for travel drive. Rail having section of 90 lb/yard structure shall be designed considering two-wh eel support and accounting no frictional force from the other two wheels and con sidering hydraulic motor stall condition. The hydraulic motor shall be selected based on 110% of actual power requirement motor output shaft at specified guaranteed capacity. The capacity of paddle adju stment shall be 0 to 100% of the guaranteed value. Bidders design of paddle feeder should not incorporate a separate loading table ( impact cradle) below the paddle feeders. However, the height of fall of coal bet ween paddle wheel and conveyor belt shall be kept minimum. Further, the length o f the skirt board shall adequately extended on both sides of the paddle wheel so that there is no spillage of coal on to the paddle feeders trolley. Minimum 500 mm extension shall be considered for this purpose. Hydraulic components shall b e provided with dust proof cover for protection against spillage of coal/ dust. Complete telephone communication system shall be provided between each paddle fe eder and main CHP control room. The paddle feeders shall run on rails mounted on the supporting structures of as sociated conveyors. Both paddle feeder and carriage drives shall be mounted on t he feeder carriage. The paddle feeder wheel shall comprise of suitable numbers of vanes with cutting edges. The vanes shall be of high strength steel construction with removable ti scral or equivalent liner plates. Vanes shall be easily removable individually.

The feeder carriage shall be of steel construction and of robust design. Skirt p lates shall be provided integral with the equipment for collecting the material drawn by the paddle feeder from the track hopper and discharging on to the conve yor belt. Feeder skirts of paddle feeders shall be extended at least by 500 mm o n either side of the paddle wheel to avoid spillage of coal. Necessary baffle/re tainer plates for suitably guiding the flow of coal from track hopper to the rec laim conveyor being fed by paddle feeders shall be provided. Hand railing shall be provided on the top deck of feeder carriage together with an access ladder. The feeder carriage shall be provided with suitable number of double flange whee ls of steel construction, complete with sealed bearing unit. The drive mechanism shall be suitable for continuous reversible motion of the carriage. Start/stop switches shall be provided at the local control panel for the operation of paddl e wheel and feeder carriage. The carriage shall automatically reverse its motion , when two paddle feeders operating on the same track come within a predetermine d distance. Suitable anti-collision device (infrared and mechanically operated l imit switch type) shall be provided. Provision shall be made to trip the track hopper conveyor from respective paddle feeder and provision shall be made for tr ipping of paddle feeder from CHP main control room. Suitable indication of paddle wheel rpm shall be provided on the paddle feeder c ontrol panel and flow rate indicator of belt weigh scale shall also be duplicate d on control panel of paddle feeder. Suitable rail cleaners shall be provided at the leading as well as trailing side of the feeder carriage for both tracks. Suitable cable trays minimum 300 mm above floor shall be provided along the trav el of paddle feeder for supporting and guiding the trailing cables. In order to save flexible cables from damage due to tension/over-tension protection switches shall be provided. Spacing of carrying idlers in the loading zone of paddle feeders shall be 600mm. Various equipment of Paddle Feeder assembly shall be easily accessible. It shal l be possible to replace electrical, mechanical and hydraulic components of padd le feeder when in position. Various drive equipment and hydraulic/other componen ts shall be so arranged that coal spillage from track hopper month does not accu mulate near/over them. 1.6.2 In-Line Magnetic Separator and Suspended Magnet

Inline Magnetic Separators shall be provided for continuous and automatic extrac tion and discharge of tramp magnetic pieces from coal being discharged from conv eyors as specified. The sets shall be complete in all respects with drives, magn ets, inline belts, hoppers, chutes, tramp-iron boxes and all electrical ancillar ies like control panels etc. Suspended Magnetic Separator shall be provided for picking up tramp magnetic pieces from moving coal over Conveyor. Magnetic core material shall be pure annealed iron or equivalent high permeabili ty magnetic material. The coil shall be of aluminum wire with class H insulation, to limit the absolute temperature of the winding to 140 deg. centigrade. The IL MS shall be oil cooled. The Force Index i.e. the product of flux density in gauss and rate of change of fl ux density w.r.t. distance, at the bottom of falling material trajectory shall b e 100,000 (gauss x gauss/inch) minimum in hot condition for mounting height of 4 00 mm. However, the strength of the magnet shall not be less than 1000 gauss in hot running condition at 400 mm distance. The minimum strength of the magnet sh all be 1000 gauss at the specified mounting height through out the burden width.

Mounting height of 400 mm shall be taken between top of conveyor belt or bottom of falling material trajectory and the surface of magnetic separator belt. Char acteristic curve of magnet with the value of flux density varying between 50 mm to face of conveyor belt shall be provided. The cross section of magnet shall b e suitably designed to provide sufficient area for magnetising the coil effectiv ely covering full cross section of the discharge material. The magnetic separat or shall be located such that it picks-up tramp iron from coal trajectory after it has been discharged from head pulley. The tramp magnetic pieces picked up by the magnetic separator shall be discharge d suitably to ensure that it falls into the tramp iron chute, which shall be pro vided upto ground level. All conveyors with magnetic separator at head end shall have non-magnetic SS pulleys & shafts. The motor and the gear reduction unit for driving the in-line belt shall be adeq uately sized with minimum 20% margin to avoid any over loading during operation. Suitable zero speed switch shall be provided. The belt gnet and on. The ll be of shall be designed to withstand high temperature at the bottom of the ma any serious damage due to the impact of the sharp edges of the tramp ir belt shall be provided with rubber cleats spaced suitably. The belt sha fire resistant grade.

The magnetic separator units shall be supported by suitable structural member fr om the top by taking support from the operating floor beams with turn buckle arr angement to facilitate the necessary adjustments during operation. Further, manu al cross travel arrangement shall be provided to move the magnetic separator awa y to facilitate maintenance of the conveyor discharge pulley. ON/OFF control push buttons with indicating lamps shall be provided at the local station. Both local and remote manual control shall be possible. The materials of chutes and hoppers associated with magnetic separators above the drive floor shall be SS-304 in the magnetic zone. Other chutes shall be of 1 mtr. sq. dimens ion and shall be made of MS. chutes shall have poking doors at all floors to cle ar jammed material. Suitable arrangements shall be provided in the magnet for keeping the coil of th e magnet dry from atmospheric condensation when the magnetic separator is not in use. Following items of tramp iron are expected to be handled by the system: 2.2.0 Tramp Iron Items (i) MS cube of 20 mm size (ii) Brake shoe of Railway Wagon (Cast Iron 15 Kg.) (iii) MS plate of 250 x 250 x 100 mm size. (iv) Shovel Teeth and spikes. Material Carbon Steel Size Typical (v) MS round bar of 50 Kg with L/D ratio not exceeding 5. Coal Sampling Unit Coal Sampling Unit shall be complete with necessary samp lers, crushers, flap valves, chutes, hoppers, belt feeders and sample collectors

etc. to give samples from any of the two streams running at guaranteed capacity . Coal sampling unit shall be automatic & provided at place specified elsewhere. The coal sampling units suitable to give Samples conforming to ASTM-D-2234 shall b e selected by the Bidder for taking samples from any of the two streams running at guaranteed capacity. The different Equipment selected for coal sampling unit shall be such that there shall be no loss of fines and moisture from the samples . The capacity, make and model of all equipments of coal sampling unit shall be subject to approval of Project Manager. The normal input feed size shall be considered as (-) 250 mm for coal sampling u nit before coal crushers (Ring granulators). However occasionally (-) 400 mm lum ps may also arrive. Coal lump size after crusher (as fired coal) shall be (-) 20 mm. However occasionally (-) 50 mm lumps may also arrive in as fired coal. Primary samplers (separate for each conveyor) shall be rugged, able to withstand severe shock loads and operate trouble free. Belt feeders shall be provided for entire sampling path upto sample collector. T he feeders shall meter the flow accurately, produce a non-plugging condition and resist sticky and wet coal. For rejects path also, belt feeders shall be preferred. Screw conveyors for the same shall be accepted only where space constraints do not permit distribution o f coal rejects to receiving conveyors below. Suitable sample crushers shall be provided for reducing the main input feed coal to 95% minus 8 mesh size and 100% minus 4 mesh size. Single stage crushing shal l be provided. There should be no re-circulation of fines in the crushers. Lot size shall be equivalent coal quantity handled in 8 hours operation assuming a verage conveyor loading at 75% of rated conveyor capacity. However sampling syst em shall also be suitable for taking one gross sample for each lot of 3500 Te coal (approx. equal to one rake load). Belt feeders shall be positively self cleaning and have dust tight construction. It shall be provided with flanged belt, rubber lagged head pulleys and inspecti on doors. No chain/belt drives shall be accepted. The crushers base should be built of reinforced concrete and be sufficiently larg e in mass. The primary / secondary samplers shall be of dust tight construction and self co ntained type. The sample chutes shall have minimum valley angle of 60 degrees to horizontal an d shall be of stainless steel plates. The welding of chutes shall be done extern ally only. The inside surface of the material near welds shall be smooth. Radiu s at corners not less than 1 shall be provided in chutework. All solid connected members shall be by means of bolting flanges with atleast 6 mm thick standard gr ade neoprene gasket material between the metal flanges. No control gates to regu late the flow of material shall be incorporated in the chute work. The materials rejected from samplers shall be returned to main conveyor stream. Minimum 4 nos. sample collecting bins shall be provided. The bins shall be prov ided with air tight connection.

1.6.3

Roller Screens

The Roller Screens shall be of mechanical type. The roller screens shall be capable to segregate the (-) 20 mm size of coal alon gwith coal dust, any muck & muddy coal (which is likely to be encountered during rainy season) etc. The segregated material shall be directly fed onto the corr esponding belt conveyors/feeders through separate hoppers/chutes provided under each grizzly feeder. The width of vibrating roller screen shall match to feed the material uniformly over the entire length of crusher rotor without any defl ectors in the feeding chute. Inclination of the grizzly pan shall not exceed 10 deg. from horizontal. The equipment shall be designed in such a manner that choking does not occur dur ing operation, particularly during rainy season when the coal gets sticky. The deck of vibrating roller screens shall have continuous solid deck section in the impact zone under direct coal fall and remaining deck shall be fitted with grizzly bars. The solid deck section shall be provided with replaceable tiscral or eqvt. liner plate of adequate thickness. The grizzly bars shall be wear resi stant. The bars shall be rigidly fixed with main frame along with the length of grizzly deck. The vibrating roller screens shall be mounted on the floor with the help of heli cal springs made of alloy steel. No rubber/synthetic material for the support s hall be acceptable. Vibrator bearings shall be grease lubricated, double spherical roller type suita ble for vibrating equipment. The bearings shall be sized for minimum 8,000 hour s of operation. Bearing calculations shall be furnished during detail engineeri ng for Owners approval. Suitable sealing arrangement shall be provided between the vibrating structure a nd chute work to avoid dust nuisance in the surrounding area. Proper arrangement to avoid dust ingress into lubricant of eccentric shafts shal l be provided. In case of V- belt drive to avoid loosening of sheave mounted on eccentric shaf t, suitable arrangement like taper bush or coupling shall be provided.

1.6.4

Crusher and Vibration Monitoring System

The Crushers of 800 T/H shall be provided. The crusher shall be of ring granulat or type such that the crushing action is accompanied by the minimum of attrition . Uniform crushing impact shall be assured. The Crusher shall be suitable to handle coal with size of (-) 250 mm (occasionally 1-2% coal shall be 400mm siz e.) 98% output of the crusher shall be down to (-) 20 mm. Maximum crushing ratio of surface m. Accordingly, mum with minimum efficiency shall be of obtained, i.e., thermo dynamically, the energy produced to the kinetic energy expended should be maximu the number of central discs along the rotor shaft shall be maxi spacing in between.

The crusher shall be capable of delivering the normal rated output even when han dling damp sticky coal having maximum moisture content. No clogging or building up of material on the crushing element shall develop. The material for major co

mponents of crusher shall not be inferior to the quality and standards as mentio ned below: Ring Hammers Manganese steel to IS 276 Gr. III. Rotor Shaft ASTM A668, Class E Suspension bars ASTM-A322, Grade AISI 4140 Cage bars/cage screens and side screen plates Manganese Steel (IS:276) Rotor Discs ASTM-A108, AISI 1045 Breaker plate Manganese steel IS-276 Gr. III Liners (a) Material Material composition shall be as that of breaker plate a bove (b) Thickness 20 mm minimum. VIBRATION MONITORING SYSTEM FOR COAL CRUSHER Vibration monitoring system should be offered for crushers as indicative below : Sl.No. Equipment Type No. *locations per Equipt. 1. 2 ring * Vibration shall be measured at each location in Horizontal as well as vertical direction. 1.6.5 Belt Conveyors System Coal Crusher Radial 4 No. of

Design of belt conveyor system shall be suitable for coal parameters specified e lsewhere. Slopes of conveyors, wherever applicable, shall not exceed 15 deg. depending on the lump size, and other governing factors. The guaranteed capacity of all conveyors shall be the rated capacity. All conveyors (except boom conveyor of S/R) shall be designed for 110% of rated capacity. The boom conveyor of S/R shall be designed for 125% of rated capacity. Design capacity of the conveyor system shall be considered for the selection of belt width, belt speed and the continuous motor rating at 50oC. The drive chain equipments for various belt conveyor systems shall consist of dri ve motors, fluid couplings, gear reduction units, low speed flexible couplings a nd pulleys. Conveyors and belt feeders shall be provided with electro hydraulic thrustor bra kes to adjust the coasting time of conveyors such that there will not be any bui

ld up of material in the chutes. Further conveyor shall come to halt as early as possible. Belt conveyor system shall be designed as per the latest edition of Belt Conveyor s for Bulk Materials published by Conveyor Equipment Manufacturers Association or e quivalent International Standard. 1.6.5.1 Construction Requirement Belting The belting shall be of either synthetic fabric such as Nylon/Nylon, Polyester/P olyamide etc. with rubber covers of adequate flexibility to give a troughing ang le of 35 deg. For all the conveyors the number of plies, cover thickness, factor of safety etc. shall be as per the recommendation of belt manufacturer, but not inferior to the followings: Belting Type bric of Nylon / Nylon, Polyester / Polyamide, etc. Cover Grade (Conforming to Canadian standard association CAN/ CSA M-422- M87 Grade C. Synthetic Fa

Fire resistant

Cover Thickness (without -ve tolerances). (a) ) (b) Bottom 2.0 mm (min. Minimum 4 Face 5.0 mm (min.

No. of plies Drive Arrangement i) Snub drive ngs upto 160 kW and for motor ratings above 320 kW. ii) Dual tandem drive not covered above. Factor of Safety Normal Working tension allowable at design capacity 10 (Minimum)

For motor rati

For motor ratings

Less than 80% of max. working tension

Carrying idlers shall be provided with three equal rolls with troughing angle of 35 deg. and 2 deg. forward tilt (except in case of reversible conveyors). In no case, shall the diameter of the idler roll be less than 152 mm for both ca

rrying side and return side. Roller used in idlers shall be made from ERW steel tube. Wall thickness shall b e minimum 4.0 mm without any negative tolerance. The rollers shall be mounted on EN-8 or equivalent material spindles by means of heavy duty ball bearings, pref erably seize resistant type (SKF/Equivalent), of 30 mm size for carrying idlers and 20 mm size for return idlers. The bearings shall be adequately sealed and lu bricated for life. The rolls shall be supported from fabricated steel brackets. Fixing arrangement of rollers with brackets shall be drop-in type. For adjusting the alignment of the idlers, slotted holes shall be provided in idler supportin g base plates. Direction of belt travel shall be clearly marked on the brackets of carrying idlers. Idler rollers shall be waterproof, dust proof and weather proof against a high v elocity water jet. All idlers shall be provided with minimum tripple labyrinth dust seal. Impact idlers used at the loading and transfer point shall be so designed as to avoid direct loading impact, belt damage and excessive punishment to the carrier . The material used in construction of this type of idlers shall be of resilient type. The return idlers for all conveyors shall be single roll type. For conveyors lo nger than 400m, two roll return idlers with 10 deg. troughing angle shall be pro vided. The self-aligning idlers shall be direct acting type, complete with actuating ro llers fitted with the ball bearings and mounted inclined towards the belt. The idler frame shall be suitably cradled about a vertical pivot, supported in beari ng over a fixed plate. Adequate sealing arrangement shall be provided to preven t contamination of the lubricant by dirt and moisture. Transition type troughing idlers shall be used adjacent to all pulleys to permit proper support of the loaded belt near the pulleys without excessive stretch of the belt edges. The transition idlers shall be provided with preferably adjusta ble concentrator (end) rolls and long center rolls to suit the troughed belt con tour between the last regular troughing idler and the adjacent pulleys. The tran sition length and the number of the transition idlers shall be selected dependin g upon the tensions, type and size of belt, number of plies and other necessary governing factors. All the conveyors shall be provided with one self cleaning type rubber disc retu rn idler located near the head pulley for cleaning the return belt. Proper arrangement shall be provided in the brackets of all types of idlers for preventing the rollers from coming out of the brackets during normal / abnormal conditions. 1.6.5.2 Belt Cleaners External Belt Cleaner Spring loaded scraper type cleaner with modular segmented and replaceable polyur ethane scrapers blades complete with main cleaner, pre-cleaner along with access ories and necessary fines chutes shall be furnished for all belt conveyors, trip per head pulley and belt feeders at discharge pulleys. The modular units shall b e easily replaceable. The scraper assembly shall be easily maintainable from out side without any interference with the chute arrangement and assembly.

Internal Belt Cleaner V-plough type belt cleaner made of mild steel flats and hard rubber strips with automatic wear adjustment and necessary accessories shall be furnished for clean ing internal surface of the conveyor belt. 1.6.5.3 Belt Take-up Arrangement

Automatic take-up of gravity type shall be generally provided with necessary tak e-up arrangements complete with bend pulleys, take-up pulley, with its supportin g / sliding assembly, wire ropes for suspending the separate take up weight slid ing assembly close to the ground, counter weights and other accessories. Suitabl e guards, marked up scale attached to the frame to monitor belt stretch and acce ss/maintenance platforms with handrails all around etc. shall be provided. Adeq uate access from conveyor gallery/transfer house/ground etc., as the case may be shall be provided to inspect, repair and maintain the gravity take-up arrangeme nt. Suitable arrangements shall be provided for clearing accumulated coal from v arious platforms to ground level. Guides of take up pulley/counter weights shall be sufficiently strong so that they do not bend during belt snapping. The prime consideration should be to locate the automatic take-ups at a place wh ere these will work best, in relation to the drive, to keep belt tension at a mi nimum. Other considerations such as available space, maintenance considerations and the economics of the location should also be taken into account while desig ning. Take up shall not be located over buildings.. Height of take-up guide st ructure shall be sufficient to allow the take-up weight movement up and down for all operating conditions of conveyor and to allow minimum two (2) vulcanising l engths margin in the belt or percentage of conveyor length (2.5% for synthetic b elting) whichever is larger. Suitable guides shall be provided both for take up pulley and take up weight. Hoists with monorails for holding take-up pulley and weight in case of belt chan ging, vulcanising etc. shall be provided. 2 M safety fencing along with suitabl e gate and locking arrangement shall be provided around gravity take-up at the b ase level / ground level. Irrespective of take-up location, the travel zone of take-up weight shall start from a suitable height above ground. Suitable buffer arrangement shall be provided to arrest the fall of take-up pull ey in order to avoid damage of the pulley assembly in case of belt snapping. Si milar buffer arrangement shall be provided for take-up weight also in case of ta ke-up weight travel zone terminating above a building floor. Suitable sandpits shall be provided at ground below the take-up weights. In case of double stream conveyors, a partition of 3mm steel plate shall be prov ided between the two take-up pulleys along entire travel zone of take-up pulleys . Intermediate platforms shall be provided in the take-up zone for maintenance o f take up pulleys / counter weight. Take-up weight shall consist of multi-blocks and not of single block to facilita te adjustment in weight if required during operation. Weight of the blocks shal l be in descending order and single heaviest piece shall be suitable for easy ha ndling. 1.6.5.4 Hold Back Devices

Suitable hold back devices for preventing running back of the conveyor belt in c ase of conveyor being stopped in loaded conditions due to power failure or durin g normal operational delays shall be provided to give positive protection. The

hold back shall instantaneously engage without shock and be capable of protectin g equipment and personnel. It shall be released instantly when power resumes or t he delay is removed. The holdback devices shall be integral with gearbox. 1.6.5.5 Pulleys

Pulleys shall be provided as required for various conveyors. In determination of pulley diameter, no account shall be taken of the pulley lagging. The nominal diameter and face width of the pulleys shall be as stated in IS:8531. The snub pulleys on each conveyor shall be located to provide a belt wrap on the drive pulleys of not less than 220 deg. wrap is envisaged for single snub drive only. All drive pulley surfaces shall be hot lagged with vulcanised natural rubber lag ging grooved in diamond pattern. All non-drive pulleys shall be vulcanised natural rubber lagged (hot) with plain lagging. The rubber to be used for lagging of pulleys shall confirm to following specific ations The rubber lagging of pulleys and method of lagging and testing the same shall conform to IS:4682. Pulleys General (for all types of Pulleys) (i) (ii) (iii) s deflection of shaft at the hubs (iv) Pulley shaft diameter Margin of minimum 20% shall be considered on maximum tension for arriving at the shaft dia. Drive Pulleys (1) (2) th vulcanised natural rubber (3) thick grooved in diamond mm deep (4) (5) nominal diameter Minimum angle of wrap 220 degrees Maximum Out of 0.5% of Lagging thickness pattern with grooves 6 mm wide x 6 12 mm Minimum shell thickness 16 mm Lagging Hot lagged wi Minimum shell thickness Minimum end disc thickness Maximum allowable 16 mm 24 mm 5 minute

roundness Other pulleys (1) (2) d natural rubber (3) Lagging thickness Rubber for lagging (1) Type r blended with styrene butadiene rubber. (2) eter (Shore A) (3) (4) 2 (5) DIN 53516 (6) (7) Specific Gravity Adhesion Strength Bearings for Pulleys (1) eavy duty roller type (2) lit Type (3) abyrinth seals. (4) gement with conical Lubrication head shape nipples. Pulley Material IS:226 / IS : 2062. The pulleys shall be made from mild steel conforming to IS:2062 (Tested Quality) . However for conveyors with in line magnetic separators, at head end the pulley s and the shaft shall be of non-magnetic stainless steel. All the pulleys shall be keyed to forged steel shafts of EN-8 or equivalent mate rial of adequate proportion running in heavy duty roller bearings with proper gr Mild steel conforming Greasing arran Sealing Dust tight with double l Casing Horizontal Sp Type H 1.4 to 1.5 10 kg/cm (minimum) Abrasion loss 250 mm3 as per Hardness Elongation Strength Natural rubbe 12 mm thick plain Minimum shell thickness 16 mm Lagging Hot lagged with vulcanise

55 to 65 durom Over 300% 160-200 kg/cm

easing arrangement. The plummer blocks for pulleys shall be of horizontally spl it type construction with minimum (4) nos. bolts holding the two split halves an d with min (4) nos. foundation bolts. The plummer blocks shall be dust tight wi th double labyrinth seals. Conical head shape nipples conforming to IS:4009, sui table drain plug and eye bolt shall be provided. Side covers of plummer blocks s hall be heavy duty metallic sheets. No plastic components shall be used. Pulleys shall be mounted on machined & ground surfaces. Suitable guards shall b e provided for all tail pulleys and bend pulleys for safety of operating personn el. Suitable stiffening arrangements shall be provided in all pulleys. For selectio n of pulley shaft dia of all the pulleys, a margin of atleast 20% shall be consi dered on the maximum tension. Selection of pulley diameter, shell thickness, st iffening and shaft diameter shall be subject to approval of Project Manager duri ng detailed engineering. Pulleys of same diameter shall be completely interchangeable in totality and com ponent wise. To have interchangeability of same diameter pulleys procured under separate contracts for a station, the bearing center distance of pulleys shall b e subject to approval of the Owner. The adjustments required shall be done by th e Contractor at no extra cost to the Owner. 1.6.5.6 a) Belt Protection Equipment Pull chord Switch

Pull chord type (manually reset type) emergency stop switches shall be located o n both sides of belt conveyors along the walkways for the entire length of conve yors for emergency stopping of conveyor at spacing of 30 Meters. The enclosure s hall be of cast aluminum with degree of protection IP-65. It shall have a separa te terminal box with a separate hinged cover which shall be totally sealed from main box containing actuating mechanism / limit switch etc. Local pull chord act uation shall be provided by means of mechanical flap. Each switch shall have two NO and two NC contacts, which shall be wired out to the terminal block. The ter minal block shall have facilities of cable looping. The Contact rating of the sw itches shall be rated for atleast 5 Amps, breaking at 240 VAC at 0.3 p.f. laggin g. Adequate length of rope and all accessories shall be furnished. b) Belt Sway Switches

Belt sway switches of self resetting type shall be furnished one pair at 50 mete r intervals to limit belt sway to permissible extent. The enclosure shall be of cast aluminum having degree of protection of IP-65. It shall have a separate te rminal box with a separate hinged cover totally sealed from the main box contain ing actuating mechanism/ limit switch etc. Each switch shall have two NO and two NC contacts one for alarm and one for trip, which shall be wired upto terminal block. The terminal block shall have facilities for cable looping. The contacts of the switches shall be rated for at least 5 Amps. breaking at 240 VAC at 0.3 p .f. lagging. c) Zero Speed Switch

Zero speed switch shall be non-contact (proximity) type electronic switch. Mount ing arrangement/ location shall be such that operation, effective sensing distan ce, sensitivity etc. shall not be effected by accumulation of dust on rotating p art or surface of probe. Adequate mechanical protection by means of non-metallic shields shall be provided on top of the switch to prevent any damage due to fal ling coal / metallic pieces etc. In built initial start up delay and nuisance, t ripping delay through timers shall be provided. Each switch shall have two NO an

d two NC contacts wired out to the terminal blocks. The contact of the switches shall be rated for atleast 5 Amps. breaking at 240 VAC at 0.3 p.f. lagging. The monitoring unit shall have cast aluminum body having IP-65 degree of protection. A separate terminal box with a separate cover, which shall be totally sealed fr om main box, shall be provided. Terminal blocks shall be suitable for terminatin g 1.5 mm sq. standard copper cable. d) Under belt switch

These switches shall be installed under the belt for detecting the presence of m aterial on the belt whose contacts shall in turn be used for operating solenoid valves of dust suppression system elaborated elsewhere. The switch and its opera ting arrangement shall be suitable for working in dusty areas. The minimum degre e of protection of switch shall be IP-62. The switch shall be capable of detecti ng three events simultaneously as follows : i) ii) iii) Belt loaded Belt running at more than preset speed. Preset initial start delay. e) Chute Blockage Switches

One no. chute blockage switch of proven type (subject to approval of the Employe r) shall be provided at a suitable height on each leg of the conveyors chute nea rest to the skirt boards. Chute blockage switch shall trip the feeding conveyor in case of Chute blockage and protect the feeding conveyor equipment. The switch and its operating arrangement shall be suitable for working in dusty areas. The minimum degree of protection of switch shall be IP-62. Local indica tion of chute blockage switch actuation shall also be provided. Location of chu te block switch shall be such that washing/cleaning of chute by pipe / rod does not affect it. 1.6.5.7 Drive Equipment

Rating of all drive motors of conveyors shall not be less than 120% of the power required at drive motor output shaft at specified design capacity. Suitable Drive Chain Equipments like electric motors, gea rboxes (where applicable), fluid couplings (where applicable), flexible coupling s and other accessories shall be provided for all the belt conveyor systems, pad dle feeders, vibrating grizzly feeders, vibrating feeders (if applicable), crush ers, mobile trippers, various pumps of dust suppression system, fans for ventila tion system, monorail electrical hoists and other equipments specified in this sp ecifications. Various requirements as spelt out in the Technical Specifications for individual equipments shall be taken into consideration while designing the associated drive chain equipments. Gear Boxes Gear Boxes shall be of sealed type and mounted on machined or ground surfaces. The gearboxes shall be designed for 24 hours continuous duty. For thermal and mechanical rating of the gearbox the data sheet shall be referred to. Gearboxes with cooling coils are not acceptable. The gears used shall be helical conforming to IS:3681 (latest revision) or worm reduction units or spiral bevel speed reduction units conforming to suitable Ind

ian Standards. The dimensions of the shaft end shall conform to IS:3688 or its latest revision. Above 40 kW drive rating, all gearboxes shall be helical or be vel helical type only. Recommended oil grade shall be compatible with gear internals like material of b earing, cages. Further, all gearboxes shall have suitable breather plugs. Couplings Flexible Couplings Approved type of couplings shall be used for power transmission depending upon d uty requirements. The design of the coupling shall be such that it can take sho ck and misalignment without sacrificing its efficiency. Flexible couplings shal l be provided on low speed side of gearbox for all conveyors. Flexible couplings shall be geared type. Fluid Couplings Fluid couplings shall be provided in all the drive machinery for belt conveyor s ystems and coal crushers if the actual power requirement at motor output shaft i s more than 30 kW. The fluid coupling for LT motors shall be of traction type. Cooling water coils for traction type fluid coupling shall not be accepted. Sc oop tube type fluid coupling shall be provided for conveyors with HT motors and coal crushers. Suitable electrically operated actuators shall be provided for s coop tube operation from local as well as remote. Suitable provision for altern ate manual operation shall also be kept. If required by the equipment designer, separate pump with motor shall be provided for circulating the fluid coupling o il through oil cooler. Independent arrangement for forced cooling water supply using 2X100% capacity pumps to oil cooler shall be provided by bidder. Suitable interlock using flow switches shall be provided in both oil as well as water li nes to trip the drive motor in the event of flow in either lines falling below/ acceptable levels. Suitable pressure indicators and flow indicators shall be pr ovided in the cooling water lines along with all relevant valves, strainers and accessories. Necessary interlock shall also be provided so that the HT motor ca nnot be started from remote / local unless position of scoop tube permits no loa d start of the motor. Tripping of downstream equipment while the system is under normal operation shall result in scoop tube re-positioning to permit no load ru n of the concerned HT motor. 1.6.5.8 Conveyor Galleries

All overground and overhead conveyors shall be located in suitably enclosed brid ge structure. Structural steel bridges of adequate width and depth (3000 mm cle ar head room for under ground and 2700mm for overground) shall be provided compl ete with conveyor bottom deck plates, seal plates, walkways of chequered plates with anti-skid arrangement(s) hand rails (on both sides of each conveyor belt ex cept where equipment like paddle feeders, stacker/ reclaimers, trippers etc. tra verse over conveyor), conveyor supports etc. The conveyor bridge shall have permanently colour coated steel sheeting covers o n roof and both sides, properly screwed or locked to steel structure as required . Adequate provision of windows shall be kept. A continuous slot opening of 50 0 mm shall be provided on both sides just below the roof sheeting. The floors of outdoor conveyor galleries shall be designed and constructed as fo llows: All conveyors shall be provided with 12 G steel seal plates throughout the lengt h of the conveyor gallery in such a way that complete gallery bottom surface are

a y d l

forms a single water proof floor. It is envisaged to clean the conveyor galler with water periodically. All the water / coal slurry shall be suitably guide to down comers (min 300 mm dia) provided at every trestle. Each downcomer shal lead the coal slurry into a 2 m3 brick wall tank at ground level having 2 Nos. decanting taps at suitable elevations. Decanted water shall be led to the neare st storm water drain of the Owner. Necessary arrangement shall be provided to a void choking of downcomers by bigger coal lumps and for cleaning of choked downc omers. The conveyors shall be provided with continuous steel decking plate of minimum 3 mm thickness. Structures and floors shall be so designed as to provide suitable space for rout ing of 200 NB fire fighting pipe with water, and conduits. Power and control cab les shall be routed outside conveyor gallery. Steel trestles to support the conveyor bridge shall rest upon concrete foundatio ns to be provided by the Contractor. Complete trestle structures shall also be supplied by the Contractor. Suitable approach/access platforms with handrailings shall be provided to approach the conveyor gallery (like in case of fire) throu gh monkey ladders on the trestles. Suitable wire mesh doors on steel frame const ruction lockable from outside only shall be provided in the conveyor galleries a t these locations. All monkey ladders shall have cage for safety of personnel us ing them. The width of conveyor galleries shall be decided by the Bidders depending on the equipments size and the walkway width as specified. Provision shall be kept with platforms and ladders for crossing over the conveyo rs at approximately every 100m intervals of route length and min. one per convey or. Further provision shall also be kept with platforms and ladders for atleast two (2) crossings over the track hopper. Walkways shall be kept as follows: Walkways (a) Construction Chequered plate with antisk id arrangement. Chequered plate steps shall be provided where conveyor slope exceeds 10 degrees. (Totally sealed so that no water falls down while washing.) (b) allowed) width (c) Side walkway 800 mm clear (no infringement allowed) width (for single conveyors, the width of side walkwa ys shall be 800 mm on one side and 1100 mm on the other). (no infringement allow ed) Side Windows (a) ered to center) (b) (c) Size Window material fashion) 1.5 m x 1.5 m Refer Civil Section Spacing (Center 25.0 m on each side (in stagg Central walkway 1100 mm clear (no infringement

1.6.6

Stone Picking

Manual Stone Picking arrangement at a suitable location in the conveyor gallery before the primary crusher house shall be provided complete with platforms, over head lighting, hand railings, suitable seating & holding arrangement for manual pickers and disposal chutes to ground level etc. Four (4) nos. manual pickers ( two on each side) shall be positioned for each belt. Each manual picker shall c over 3 m long belt stretch adjacent to each other. The picked up stone lumps (u pto 600 mm size) shall be collected over the conveyor gallery walkway level from where these stones can be pushed into the hopper/chute upto disposal trolley at the ground level. 1.6.7 Belt Vulcanizing Machine

Belt Vulcanizing Equipment shall be suitable for hot vulcanizing of belt splice and shall be of easy-to-handle type. Equipment should be suitable for vulcanizing of entire splice width in single se tting. Equipment should be capable of applying uniform pressure over the splice by pneu matic or hydraulic means. Heating element should be preferably of flexible type. 1.6.8 CHUTES AND HOPPERS

Chutes & Hoppers, flap gates and rack & pinion gates sha ll be furnished alongwith all necessary accessories, electricals etc. shall be p rovided to ensure proper flow/storage/bifurcation of coal as per system requirem ents. The minimum valley angle of chutes shall be 60 degrees from horizontal. The actu al valley angle and chute design shall be finalised after carrying out coal flow ability studies at worst conditions. Transfer chutes shall be adequately sized and sloped to ensure smooth flow of co al without any accumulation anywhere. Complete chute work above the drive floor for conveyors provided with In-line bel t magnetic separators shall be of 10 mm thick SS 304 in the zone of magnetic fie ld. Direct impact of material on conveyor belt shall be avoided by providing an incl ined surface at 60 degrees valley angle at the feeding point to guide the materi al in the direction of belt travel. Further, chute construction below flap gate shaft shall be such that there will not be any accumulation of coal dust betwee n chute and flap gate in that zone. Hoppers and Chutes shall be made of minimum 10 mm thick TISCRAL/MS or equivalent with adequate stiffeners. Long chutes guiding flow from considerable height sh all be provided with impact plates wherever change in direction of flow takes pl ace. Hinged inspection doors (generously sized) of leak proof construction shall be provided for access/ maintenance purpose, at approachable heights, of the ch utes. All chutes should have one inspection door at every floor and for the ones in between the floors, suitable access ladder and platform etc. shall be provid ed. Maximum distance between two inspection doors in a chute shall be 2 mtrs. Fo r sealing at inspection doors labyrinth type arrangement (with rubber inserted i n grooves) to be provided. In addition to mounting bolts, swiveling eccentric ha

ndle(s) to tighten the door further against rubber shall also be provided. Bottom side of the chutes on which the coal slides shall be welded to the side p lates to form a trough. Bottom sides along with its adjacent sides shall be flan ged and made from TISCRAL or equivalent material of 10 mm thickness. The non s triking surface i.e. the covers of the trough shall be of 10 mm thick mild steel and bolted to the flange provided on the trough. Inside welding shall be provid ed in the corners for permanent sealing. Further, the chute boxes not more than 1.5 m in length shall be joined through bolted flange connection to form the chu te legs. Bolted flange joints shall be of dust tight construction and necessary sealing m aterial shall be provided in all the flange connections for adequate sealing. Complete chute work in the region of flap gates shall be fabricated from TISCRAL or equivalent. In case of vertical chute (valley angle more than 80 degree) com plete chute, work shall be of 10 mm thick TISCRAL or equivalent material. While finalising the chute work inside the building, arrangement for shifting and repl acing chute legs, proper handling arrangement/wall openings, trolleys, hoists sh all also be provided. Hoods over the conveyor head pulleys shall be made of suitably stiffened minimum 4 mm M.S. Plates and shall be provided with hinged and gasketed inspection door s with suitable access to them. Further, rubber seal shall also be provided at the very inlet of head chute to minimise dust nuisance. Minimum size of chute sh all be kept as 2/3rd of belt width or 1000X1200 mm which ever is higher. 1.6.9 Skirt Boards

Skirt board shall ensure centralised loading of conveyor belt to avoid coal spil lage. Suitable Skirt Plates of minimum 3.0 meters length shall be provided at each feeding point of conveyor. The width of the Skirt Boards shall be two-third the conveyor belt width. In the belts before Crusher House where coal of appreciab le lump size (250 mm) is being conveyed, the gap between the bottom of the skirt board and the belt shall be made to increase uniformly in the direction of belt travel. The height of the skirt boards shall be sufficient to contain the mater ial volume as it is loaded on the belt and shall not be less than 750 mm. The sk irt plates shall be fitted with modular segmented and replaceable rubber skirtin g pads having facility of adjusting the pressure on the belt conveyor and shall have provision of on line removal for the purpose of easy maintenance. Such segm ented rubber pads with its holding down adjustment arrangements shall be of prov en design. The edges of segmented pads shall be installed at an angle for provid ing a better seal. All care shall be taken while designing, to combine good sea ling with minimum belt wear. 1.6.10 Flap Gates

The motor operated two position flap gates shall be provided in transfer chutes as specified and shall be complete with electrically operated actuators. The gat es shall be of robust construction and suitable for trouble free operation. The face of the flap gate shall be mode out of 10 mm thick TISCRAL or equivalent mat erial. The equipment shall be capable of being operated for at least 15 switchings per hour at rated load and thrust and shall be suitable for 10 Nos. consecutive swit chings at rated load and thrust. The equipment shall be shop tested to prove th is requirement. The motor rating for the actuator shall be so selected as to provide sufficient thrust for operation of the flop gates against the moving weight of coal and/or

flap gate. The flap gate travel shall be in the range of 60 deg. to 70 deg. The motor shall be completely dust tight. Lever arm shall be provided between actuator and flap gate shaft for obtaining r equired thrust. The actuators shall be capable of preventing any over travel. Suitable travel d ependent limit switches controlling the travel of the flop gates on either direc tion shall be furnished. These shall be placed internal to the drive unit and s hall be completely dust-proof. The limit switches shall be capable of adjustment s to vary the total length of travel of the gates. Suitable thrust dependent limit switches shall be provided in the actuator, whic h shall trip off the actuator motor in case of excessive thrust due to jamming o f the gates during its travel in either direction. The same shall also be integ ral to the drive unit and shall be dust proof. Provision for alternative manual operation shall also be made using declutchable handwheel. The diameter of handwheel shall be selected considering convenient f orce to be applied by a single operator. However, minimum diameter of hand wheel shall be 500 mm. Limit switch for safety of person operating the hand wheel sha ll be provided. All the two way chutes, one way of which is leading towards the future conveyor, shall be provided with blind flange and flap gate with a provision to mount an actuator in future. All the actuators in the plant should be selected based on heaviest loading, but the rating shall not be less than 2500 kg with a lever arm of 1.0 m in any case . Suitable stiffening arrangement shall be provided between the two faces of the g ate plate. At the end of the travel the total length of edge of the flap gate s hall rest on a suitable projected surface from chute to prevent leakage of coal dust through the available clearance between chute and flap gate. Maximum feasible counterweights shall be provided for better utilisation of syst em. Suitable self aligned double row ball bearings in dust tight housing shall carry the gate shaft. Suitable provision for regreasing shall be provided. For standardisation purposes, only one standard type of actuator for flap gates shall be provided. The standard type actuator shall be selected for maximum thru st as calculated for various locations. Flap gate actuator as a whole and indivi dual component wise shall be completely interchangeable for all locations. The material of shaft shall be EN-8 or equivalent. The diameter of the shaft sha ll be suitable for motor stalled condition and associated twisting. Approach/maintenance platforms complete with the chequered plate floor, hand rai ls, ladders etc. shall be provided for all flap gates. Shaft & flap gate shall be tightly fitted to each other. On both faces of flap gate main plate, 10mm thick TISCRAL liner plate or equival ent material shall be provided. Comments (1) 6.CHP EQUIPMENTS-2 Filed under: Uncategorized Tags: chp shivajichoudhury @ 5:13 am

1.6.10

Flap Gates

The motor operated two position flap gates shall be provided in transfer chutes as specified and shall be complete with electrically operated actuators. The gat es shall be of robust construction and suitable for trouble free operation. The face of the flap gate shall be mode out of 10 mm thick TISCRAL or equivalent mat erial. The equipment shall be capable of being operated for at least 15 switchings per hour at rated load and thrust and shall be suitable for 10 Nos. consecutive swit chings at rated load and thrust. The equipment shall be shop tested to prove th is requirement. The motor rating for the actuator shall be so selected as to provide sufficient thrust for operation of the flop gates against the moving weight of coal and/or flap gate. The flap gate travel shall be in the range of 60 deg. to 70 deg. The motor shall be completely dust tight. Lever arm shall be provided between actuator and flap gate shaft for obtaining r equired thrust. The actuators shall be capable of preventing any over travel. Suitable travel d ependent limit switches controlling the travel of the flop gates on either direc tion shall be furnished. These shall be placed internal to the drive unit and s hall be completely dust-proof. The limit switches shall be capable of adjustment s to vary the total length of travel of the gates. Suitable thrust dependent limit switches shall be provided in the actuator, whic h shall trip off the actuator motor in case of excessive thrust due to jamming o f the gates during its travel in either direction. The same shall also be integ ral to the drive unit and shall be dust proof. Provision for alternative manual operation shall also be made using declutchable handwheel. The diameter of handwheel shall be selected considering convenient f orce to be applied by a single operator. However, minimum diameter of hand wheel shall be 500 mm. Limit switch for safety of person operating the hand wheel sha ll be provided. All the two way chutes, one way of which is leading towards the future conveyor, shall be provided with blind flange and flap gate with a provision to mount an actuator in future. All the actuators in the plant should be selected based on heaviest loading, but the rating shall not be less than 2500 kg with a lever arm of 1.0 m in any case . Suitable stiffening arrangement shall be provided between the two faces of the g ate plate. At the end of the travel the total length of edge of the flap gate s hall rest on a suitable projected surface from chute to prevent leakage of coal dust through the available clearance between chute and flap gate. Maximum feasible counterweights shall be provided for better utilisation of syst em. Suitable self aligned double row ball bearings in dust tight housing shall carry the gate shaft. Suitable provision for regreasing shall be provided. For standardisation purposes, only one standard type of actuator for flap gates shall be provided. The standard type actuator shall be selected for maximum thru st as calculated for various locations. Flap gate actuator as a whole and indivi

dual component wise shall be completely interchangeable for all locations. The material of shaft shall be EN-8 or equivalent. The diameter of the shaft sha ll be suitable for motor stalled condition and associated twisting. Approach/maintenance platforms complete with the chequered plate floor, hand rai ls, ladders etc. shall be provided for all flap gates. Shaft & flap gate shall be tightly fitted to each other. On both faces of flap gate main plate, 10mm thick TISCRAL liner plate or equival ent material shall be provided. 1.6.11 Rack & Pinion Gates

Rotary actuator operated rack and pinion gates shall be provided at various loca tions as specified. The gate shall be mounted such that coal load does not act v ertically on gate. Suitable manually operated rod gates shall be provided over rack and pinion gate s for their easy operation and maintenance. The rack and pinion gate shall be guided properly and suitable rollers with bear ings sealed for life and dust proof shall be provided. The rack and pinion gates shall be of mild steel construction with liner plate o f 10 mm thick tiscral or equivalent material. The gates shall be operated by mea ns of double rack and pinion. The material for rack & pinion wheel shall be cas t steel and shaft shall be EN.-8. Provision for alternative manual operation of motorised rack and pinion gates sh all also be made. Limit switch for safety of person operating the hand wheel sha ll be provided. Manual effort required to operate the rack and pinion gate shall not exceed 25 k g. Maximum time for closing/opening shall be 25 sec. Approach/maintenance platforms complete with chequered plate floor, hand railing s, ladder etc. shall be provided for all gates. 1.6.12 TRAVELLING TRIPPER AND BUNKER SEALING ARRANGEMENT

Mobile Trippers on bunker conveyors along with belt seal ing arrangement shall be furnished and erected complete with rails, including ne cessary supporting structures, approach/ maintenance platforms with ladders and hand railings, trailing cables, all electricals including machine mounted local control panel & control panel on one end of Bunker, location of which shall be d ecided during detail engineering. Complete Bunker Sealing arrangement shall be provided over the bunkers to preven t dust emission into tripper bay. 1.6.12.1 Travelling Tripper

The Travelling tripper on bunker conveyors shall be motor driven type. It shall consist of structures, supports, walkways, rails, belt scrapper with adjustable rubber strip, rubber lagged head and bend pulleys complete with shaft bearings, chutes, stops, limit switches, brakes etc. The tripper shall have provision fo r dropping coal both sides of conveyor into the bunker and back to the conveyor for the purpose of skipping intermediate bunkers. The rating of tripper travel

motor shall be adequate to move the tripper smoothly either in same or opposite direction to belt direction under fully loaded conditions. Adhesive weight requi rement and tractive effort calculations shall be subject to approval of Project Manager. Coefficient of adhesion shall be considered as maximum 0.15. Minimum t wo drive axles shall be provided for tripper travel. Arrangement shall be provid ed at the starting point of the tripper to avoid folding of belt. In case of tripper running at a speed more than its rated speed due to chute jam ming or other reason, conveyor shall trip and annunciation shall appear. Supply of adequate length of rails to cover the runway length for the motor driv en tripper shall be included. The supporting structures for the rails with nece ssary end stops shall also be supplied under this specification. Suitable belt hold down guide pulley shall be provided over the concave curve of belt over tri pper. The Bidder shall include in his proposal necessary electricals for traveling tri ppers such as motorised cable reeling drum with trailing cables, cable trays for resting the trailing cables and end limit switches for protection against over travel of the tripper. The cable reeling drum and trailing cable of each tripper shall be suitable for the entire length of the bunker bay. Mechanical track st ops shall also be provided. The cables shall have copper conductors, proper insu lating material and braided armouring in accordance with IS:691. Complete Tele phone Communication system between Travelling tripper and CHP control room is in Bidder scope. The travelling trippers shall be provided with fail safe A.C. thrustor operated brake of totally enclosed type which shall engage as soon as tripper travel mot or stops. A.C. thrustor operated rail clamps with hand operation facility from e ither side of the tripper shall also be provided. The specifications of brakes a nd clamps are as discussed elsewhere. For selection and specification of drive motor, gearboxes and all other equipmen t associated with tripper relevant clauses of this specification shall be referr ed to. All drive equipment shall be selected based on 115% of actual power requirement at specified guaranteed capacity. Further complete drive equipment shall be suit able for minimum 60 starts/hours. Monorail & electric hoist shall be provided for lifting conveyor drum to bunker floors. Monorail all along the bunker conveyor to facilitate maintenance of trip per shall be provided. 1.6.12.2 Bunker sealing arrangement

The sealing belt shall be of suitable grade (minimum 2 plies) with 5 mm x 5 mm c overs (fire resistant) in line with other conveyor belting. The belt shall rest on 20mm MS round bars spaced at 150 mm provided over the bunker slot (minimum 1 100 mm) on tripper floor for tripper conveyor. Needed guide rollers, bearings, brackets, safety guards etc. shall be provided by the Contractor. The bunker se aling arrangement shall keep the bunkers sealed and prevent dust emission into t ripper room. The width of the bunker seal belt shall be at least 100 mm more th an the bunker slot opening. Separate openings shall be provided on the bunker fl oor of each bunker to measure level of coal in the bunker. Hinged dust sealed do or / flaps shall be provided on these openings. Suitable grating to be provided in between bunkers in the tripper travel zone. T ripper floor is by Purchaser. Openings on the tripper floor for level measuremen t will be provided by Purchaser. Opening size will be informed to successful bid

der during the detail engineering stage. Suitable dust cover shall be provided over tripper head pulley. Serrated rubber seal shall be provided at open side to prevent dust nuisance. Suitable dust tig ht access doors shall be provided. Counter-weighted type belt cleaner shall be p rovided below the tripper head pulley for cleaning the carrying side of the belt . The tripper shall run on rails (90 lbs/yard) with double flanged wheels. Rails for tripper travel shall be mounted on supporting structure of respective convey ors. Suitable system for monitoring position of tripper shall be provided. In additi on, travel end limit switches and end stops shall also be provided. Suitable access platform of chequered plate with ladders, handrailing and walkwa ys on both sides shall be provided for access/maintenance of equipment on trippe r. In addition, crossover platform shall be provided with tripper so that opera tor can cross the belt through the same. Suitable rail cleaners shall be provided on leading and trailing edge of tripper for either track. 3mm deck plate continuous shall be provided below carrying idlers on the tripper s. For specification of flap gates/actuator on trippers relevant clauses of this sp ecification shall be referred to. Walkway of 800 mm wide shall be provided on both side of the tripper Provision shall be kept for automatic tripping of bunker bay conveyor in the eve nt of travelling tripper getting dragged (i.e. travel speed in excess of rated s peed). 1.6.13 Belt Scale

Belt weigh scale for measurement of coal flow rate and q uantity shall be provided at specified locations. System shall be complete with flow rate indicator, totaliser, control panel etc. The weigh scale shall be automatic and electronic type. It should be designed fo r continuous automatic weighing, metering and printing of coal flow. Each belt weigh scale shall comprise of a belt weigh scale platform with minimum 4 nos. weighing idlers. It shall have unitised construction for ease of install ation and shall be fully floating type (without pivot points). Minimum 4 nos. se aled load cells of precision strain gauge type shall be applied in tension to su pport the weighbridge. The load cells shall have 100% overload protection and sh all be structurally safe upto to 250% of rated belt scale capacity. Belt scale shall be electronic microprocessor based with its program stored in n on-volatile memory. It shall be provided with self diagnostic features for trouble shooting of the e ntire belt scale system. Fully automatic zero and span calibration facility shall be provided.

The electronic systems offered by the Bidder shall include all signal conditioni ng, power amplifiers and printed circuits etc. The printed circuits shall be enc apsulated against dust and moisture. Belt scale shall be provided with flow rate, total quantity etc. Remote flow rat e indicators shall also be provided on paddle feeders. The flow rate indicator shall have minimum 4 digits. The flow totalizer should h ave 8 digits display scale with reset facility. Complete belt scale system shall be suitable for 70C ambient temperature and 100% relative humidity. It shall be suitable for out door installation in a dusty a rea. The electronic circuit enclosure, sensors housing shall be dust and watert ight, explosion proof conforming to NEMA and NEC (National Electronic Code). The electronic printed circuits shall be encapsulated with epoxy or other suitable material for protection against dust and moisture. Minimum three years battery back up power failure protection shall be provided. Belt scale shall be designed for a range of 20% to 120% of rated capacity with a n accuracy of atleast (+) 0.25 percent throughout its range. Belt scale provided in Stacker Reclaimer Boom Conveyor shall have an accuracy (in the horizontal po sition of Boom) of (+) 1 percent for the range of 20% to 120% of boom conveyor c apacity. Local panel for belt scale shall be of FRP material. 1.6.14 Travelling Stacker cum Reclaimer

Travelling Stacker cum Reclaimer operating in conjunction with reversible yard c onveyor shall be provided as specified. Stacker-cum-Reclaimer shall be capable o f both stacking and reclaiming complete with adequate length of rail track, cant ilever boom conveyor, intermediate conveyor, support carriage with vibrating fee ders (if required), boom hoist, reclaimer bucket wheel, control panel, operators cabin, electrical power distribution system, motorised cable reeling drum, adeq uate length of trailing cables etc. The design capacity of the yard conveyor shall not be less than 110% of the rate d (guaranteed) capacity. For bucket size calculations and boom conveyor capacity , a peak reclaim capacity of 125% of rated capacity shall be considered. The dr ive train of yard conveyor consisting of motor, scoop type fluid coupling, gear box etc. shall be provided at both ends of the yard conveyor. Both the drive tr ain at each end of the yard conveyor shall run simultaneously in one direction a nd reversed depending upon stacking or reclaiming operation of the machine. The continuous motor rating at 50C Ambient of the drive motors to be provided on eac h side of the yard conveyor shall be 120% of the actual power requirement at mot or output shaft. The actual requirement at motor output shaft of both the motor s at each end shall be calculated based on 75% of the total load demand at desig n capacity. Stacker/Reclaimer shall be capable of operating at high wind velocities upto 65 km/hr. It shall also be able to withstand maximum wind velocity as indicated in C riteria for Wind Resistant Design of Structures & Equipment placed in the documen t on civil aspect, when it is not operating. An anemometer shall be provided whi ch shall indicate the wind velocity in the control cabin. Electro-hydraulic thruster operated rail clamp shall be provided for holding the stacker-cum-reclaimer. Suitable arrangement shall be provided for keeping the s tacker-reclaimer in fixed stable position when the weather is stormy.

Stacker-cum-reclaimer shall operate on rail track of 52 kg/mtr. running for adeq uate length to cover the entire coal stockyard. The ratio of boom length (as spe cified) to the rail track gauge shall not exceed 5. Top of rail level shall be m aintained at 1.0 m above the ground level, i.e., coal pile base level unless spe cified otherwise. Suitable number of rail scrappers shall be provided. The machine shall be mounted on traverse carriage provided with driven and non-d rive wheels of cast or forged steel and double flange design. The track wheels shall be combined in pairs in the track wheel bogies. The wheels shall rotate on self-aligning roller bearings. Between the motor and the gearing, electro-hydra ulic thrustor brake shall be provided. The reclaimer shall be traversed by manual control at any desired speed within i ts speed range. During stacking/reclaiming operation, the equipment travel shall be limited to its travel zone and shall automatically stop when the machine rea ches the extreme ends of such travel zone. The lower works of the under-carriage of the machine shall be designed to transm it load on the wheel sets of the travel carriage in such a manner that the equip ment is stable during normal operating condition as well as during hazardous wea ther condition with maximum permissible variation in center distance of rails an d rail top levels. The rail mounting for under-carriage shall be four legged sy stem with hydraulic/mechanical equalising arrangement to make it three point sus pension system for the best stability during operation. The traverse carriage an d the under-carriage shall be interconnected in a manner, which will permit unif orm distribution of overloads even if the rails are not level. The upper frame of the machine shall be designed in such a manner that minimum n umber of angular movement points affects the luffing operation. In addition, th e variation of moment/torque on slew bearing shall be minimum. The ring bearing s shall be dimensioned in such a way that all forces can be safely transmitted t o the structures of the wheels. The roller bearing slewing ring shall be sealed against penetration of water and dust. Angular movement points (hinge points) namely between equalising beam and base f rame, luff pivots and hydraulic cylinder hinge points shall be provided with mai ntenance free bearings requiring no periodic lubrication during entire life span of bearings. Minimum life span of self lubricating type bearings shall be 25 y ears with average 10 hrs. daily operation. The luffing motion shall be through hydraulic pumps and cylinders. In case of m ore than one cylinder being used for boom luffing operation, necessary provision s shall be provided such that the differential oil pressure between two cylinder s are always maintained within permissible limits, during luffing operation and as well as when the boom is fixed at any position. In case of any undue increas e in differential pressure, the hydraulic circuit shall trip and suitable alarm indication shall be provided before tripping. The hydraulic system of luffing s hall be such that in case of failure of hydraulic system due to leakage or any o ther reason the boom could be held in position. The boom shall revolve by at least 210 about the center of the receiving hopper a nd discharge/reclaim material on/from both sides of track anywhere within specif ied radius of the boom. The boom conveyor shall be of adequate design capacity to match with the rate of peak reclaiming by the bucket wheel. Boom conveyor with 41 m length shall be provided with a Belt Weighing Scale with

weighing accuracy (in the horizontal position of the boom) of 1% for a range o f 20% to 120% of boom conveyor capacity. The belt scale shall provide only flow rate indication in the Operators Cabin on the Stacker/Reclaimer. The bucket wheel assembly shall consist of 8 numbers of buckets of cell-less des ign and stationary annular chute. The bucket shall be of suitable shape and des ign, which will enable to empty out the material fully from the bucket, and to p revent spilling of the scooped material during transfer to boom conveyor. The b uckets shall be readily removable. Bucket size shall be selected for peak reclaim capacity based on maximum 80% deg ree of fill with respect to water fill capacity of the bucket. Further, not mor e than 50% of annular ring volume shall be considered as effective volume. Rate of bucket discharges shall not exceed 55 per minute. The bucket wheel drive shall be complete with electric motor, reduction gear uni t moving in oil bath and suitable coupling between motor and the gear unit. Buck et wheel drive system, structural members, mast, hydraulic system etc shall be d esigned considering completely wet coal with max. surface moisture. Adequate saf ety devices shall be provided to prevent overloading of the bucket wheel drive, particularly when wheel will get stuck-up in the stockpile. In such an event, th e power supply of the drive shall get automatically cut-off. Suitable electro hy draulic thrustor brake shall be provided to avoid backward movement of the bucke t wheel after the power supply is cut-off and during maintenance work. The boom conveyor with bucket wheel assembly, the mast and counter weight mounte d on the upper structure shall rotate on the bearing ring. The drive mechanism shall consist of the gear rim and drive unit shall comprise of motor, safety cou pling, gearbox and pinion. Protective devices against overloads shall also be p rovided. The slew speed shall be variable. Boom conveyor shall be provided with self-training arrangement of latest design to avoid belt sway in the boom conve yor. One tripper shall be furnished for stacker-cum-reclaimer unit for working in con junction with the yard conveyor. The tripper & intermediate conveyor shall be co mplete with supporting structure, walkways, platforms, railing, belt scrapper, h ead pulleys, bend pulleys, hold-down pulley, chute and support with adequate num ber of wheels in bogie construction travelling on the same rails as those of the stacker-cum-reclaimer. The intermediate conveyor will be skewed longitudinally to enable to receive mat erial (during stacking) from tripper conveyor. The intermediate conveyor shall be of adequate capacity to match with the design capacity of stacking which shal l be 110% of rated capacity of stacking. For other details, the relevant clause s of belt conveyor system of this specification shall be referred to. The interm ediate conveyor shall be completed with supporting structure, walkway, railings, platforms, belt scrappers, head pulley, tail pulley and necessary chute work. Group-wise lubrication system shall be provided combining different zones of lub rication points under different groups depending upon location and number of lub rication points. Each group lubrication unit shall be independently functional through separate pump (motorised), grease container, valves, metering devices, p ipes and other accessories etc. Preferably, the grease entry into various lubric ation points shall be vertically downwards. The grease container shall have adeq uate capacity for supply of lubricants to all points and grease quantity for the points to be greased shall be adjustable. Further, all the lubrication points s hall be easily accessible. The stacker-reclaimer shall receive power through trailing cables. Separate moto rised cable reeling drums for power and control cable shall be provided with arr

angements for winding and rewinding of the cables. The trailing cables shall ru n in a cable tray. Further, the trailing cable arrangement shall be such that t he cables run in-between the track rails. Cushion shall be provided in the cable reeling drums for about 30 m extra cabling length. Complete telephone communication system between stacker-cum-reclaimer operators c abin and main coal handling plant control room shall be provided. Limit switches shall be provided to prevent traverse movement, slew and hoisting etc. beyond the respective safe extremities. Interlocking shall also be provid ed for S/R rail clamps and travel motors. Travel drive equipment and slew drive equipment shall be suitable for 150 starts /hr. with continuous reversals. Hydraulic control shall be provided for : (a) (b) (c) c equalising) Hoisting/luffing Operator cabin level adjustment Equalising arrangement for travel carriage (in case of hydrauli

Axial piston pumps shall be provided for pressurising hydraulic control fluid. All drive equipments shall be selected based on 120% of actual power requirement at specified design capacity. In addition to the requirements elaborated above, the structural design of the s tacker-reclaimer shall be supplemented by following standards:ISO 5049/1 : Mobile Continuous Bulk Handling Equipment.

FEM : Federation Europeanne De La Manutention Section-I Rules for Design of Hoisting Appliances. Suitable RCC platform to be provided at one end of travel of the stacker-cum-rec laimer to rest the head end of the boom while either under maintenance or out of operation. The under-carriage shall be fabricated of steel plates and section. The wheel mounting arrangement shall be such that the wheels can be dismantled e asily from their supports. 800 M wide walkways with hand railings shall be provided on both sides of boom c onveyor. The upper structure shall consist of rigid box type steel plate construction on which the super-structure supporting mast, boom with bucket wheel and counterwei ght boom with ballast are erected. The upper works shall be mounted on under-ca rriage by means of large diameter ring bearing of double roll roller type. The boom shall be fabricated from rolled steel plates and sections and shall be of luffing type. The counterweight boom with ballast, which balances the boom conveyor, shall be mounted on the upper structure and shall be suitably dimensioned. The counterwe

ight boom shall be fabricated with rolled steel plates and sections. Suitable b oxes shall be provided for placing the counter weights. The stacker-reclaimer shall be provided with one enclosed dust proof & air condi tioned operators cabin and so located as to enable the operator to get clear visi on of both sides of the track and the field of operation. The cabin shall be sui table for operation in monsoon and tropical conditions and the inside ambient te mperature shall be maintained at 27C. The cabin shall be provided with toughened glasses with wipers and the arrangement shall be such that glasses can be cleane d from outside without any scaffolding. Cabin door shall be provided with hydrau lic door closures. The cabin shall be kept in horizontal position through hydrau lic cylinders irrespective of the angle of inclination of the boom conveyor. All controls for operation of all parts of the stacker-reclaim unit shall be provid ed in the cabin within easy reach of the operator. Lights and fan for operators c abin and adequate number of floodlights for all necessary illumination for worki ng at night shall also be provided. Electrical/MCC room shall be fabricated of sheet steel with suitable floor matti ng. The room shall be dust tight and air conditioned. Fireproof insulation shal l be provided under the roof of MCC room. Further, the door shall be provided w ith hydraulic door closer. Adequate number of impact idlers shall be provided integral with stacker-cum-rec laimer at the region where the bottom conveyor feeds material through transfer c hutes onto the yard conveyor for the protection of the yard conveyor. Suitable arrangement shall be provided at the starting point (belt take off poin t) of the tripper to avoid folding of belt while the tripper is in tension. Brakes shall be provided for decelerating driven equipme nt/conveyor as per requirement. Rail clamps shall be provided for various mobile machines travelling on rails as specified for those machines. The necessary Electro Hydraulic Thrustor (AC) brakes, totally enclosed and fail safe, shall be provided as required for various equipments. Braking torque shall be adjustable from 0 to 100% of rated braking torque. The brake shall be actuat ed by compression springs. The spring shall apply braking force directly to the shoe without using lever arm linkages. Rail Clamp shall be designed for holding the machine stationary. Rating of the r ail clamp shall be subject to the approval of Engineer. Rail Clamp shall be actuated by compression springs, the spring shall apply the clamping force directly on the Rail clamp mechanism without using lever arm link ages once power supply is cut-off. The force transmission mechanism from spring to rail clamp faces shall be very simple with minimum linkages. The electro hydraulic thrustor shall be fitted with the brake. Limit switches sh all be provided for brake applied/released positions. The windings shall be pro 10% at 50 Hz 5% and combined v vided with class-B insulation suitable for 415V ariation of 10%. Brake lining shall be asbestos with inter woven brass wires ca pable of withstanding 200C temperature. The lining shall be fixed to the shoe by counter sunk screws. Electro Hydraulic thrustor shall be fitted directly above spring without any int ermediate linkage mechanism.

Rail clamp shall be provided between the two travel wheels. Further, limit switc hes shall be provided for Rail clamp ENGAGED and DISENGAGED signals. Minimum clearance between the Rail clamp face and rail surface shall be 50mm. H owever, this clearance may not be uniform for both the faces of Rail clamp throu ghout the length of rails. Rail clamp shall operate satisfactorily under this c ondition without the need for any adjustments. Complete Rail Clamp mechanism shall be manufactured from forged steel. 1.6.15 Monorails and Hoists arrangements shall be provided for all maintenance area within the building and building upto ground level for further shall provide monorails and hoist bloc

Suitable handling equipments to transfer the equipment to /or to transfer the equipment outside the transportation. For this purpose Bidder ks with cross travel facility.

For the Hoists with more than 3.0 tonne lifting capacity or more than 10.0 M lif t, motor operated hoist blocks for both long travel and lift shall be provided. Other hoist blocks shall be of hand operated type for both travel and lift. How ever, all monorails coming out of the building shall be provided with electric h oist blocks, irrespective of load and lift. Adequate length of Cantilever shall be provided in monorails to lower the equipment to ground level clearing the bui lding sidewalls. The center line of monorail shall not deviate by more than 500 mm from the cente r of gravity of any equipment that is to be lifted. Bidder shall take clear not e of the fact that the number and monorail hoisting systems shall also be decide d considering the movement of the equipment being lifted over/by the side of oth er equipments without removing the later. The necessary levels of floors in vari ous buildings shall be decided considering the above requirement. Monorails shall be extended outside the building to handle the equipment to grou nd level. Suitable machinery well/ hatch and removable handrailing/ grating shal l be provided on various floors of buildings, as necessary. Electrically operated monogirder type hoists shall consist of following major co mponents. (a) Electrically operated trolley complete with drive motor (Trolle y travel speed maximum 15 m/min.). (b) Hoist cable, hoisting block and hooks complete with drive motor (Hoisting speed maximum 6m/min.). (c) avel. (d) (e) (f) Limit switch to prevent overhoisting, over lowering and over tr Festoon arrangement of feeding power to trolley assembly. Erection hardware. Pendent control station suspended from hoist.

The hoist shall be designed and constructed in accordance with the latest revisi on of IS:3938 and shall be suitable for duty class 2. Trolley movement and hoisting shall be effected by using two separate motors. H

owever the motors shall be suitable for 150 starts per hour at 40% CDF. Trolley shall be designed to accommodate a wide range of I beams and shall be ca pable of travelling on straight as well as curved monorails with the design bein g such to maintain uniform distribution of pressure on the flanges. Motor operated geared trolley shall have two (2) pairs of wheels, one pair of wh ich shall be driven through motor. Wire rope shall be of pre-formed type, hemp cored, regular lay 6/37 construction with a breaking strength of 160-175 kgf/mm2. Reverse bend of ropes is not acce ptable. Minimum number of falls of rope shall be four (4). All gears and pinions shall be of hardened and tempered steel with machine cut t eeth in metric modules. Surface hardening of steel is not acceptable. All running shafts and wheels shall be fitted with roller bearings with a rated life not less than 20 years based on equivalent running time as per IS:3938. An electromechanical brake shall provide restraining torque. Brake lining shall be of asbestos. Cast iron parts, wherever used, shall be of minimum grad e 30, IS:210. All hand operated chain pulley blocks shall be designed to IS:3832, the operatin g hand chain shall conform to IS:2429(1) grade 30 pitched and polished and the l oad chain to IS:3109 grade 40. The chain pulley block shall be suitable for dut y class 2. Hooks shall be of high tensile steel and heat treated as per Clause 7 .1 (b) IS:3815. All hoists/chain pulley blocks shall be selected to have minimum headroom and sh all be selected to lift heaviest piece of equipment. Further, it shall be possi ble to handle any equipment without disturbing other equipment. The hand chain wheels shall be of cast steel, the wheels shall be with flanges a nd designed to ensure effective operation of hand chain. Further, suitable local brake shall be provided as per IS:3832 to arrest and sustain loads in all worki ng positions. The velocity rates, effort on chain required to raise the safe working load and travel and speed shall be within the limit specified in IS:3832. Proof load tes t shall be carried out as per IS:3832. The hoist mechanism shall consist of a grooved rope drum driven by electric moto r through gears. Each end of the rope shall be anchored to the drum in such a wa y as the anchorage is readily available for maintenance. Each rope shall have no t more than two (2) full turns of the drum when the hook is at its lowest positi on and one (1) spare groove when the hook is at its highest position. The leadi ng rope taken by the drum should not slope sideways when slack and it should not be caught between the gear wheel. Rope drum, gear box, block etc. should be fabricated out of weldable quality ste el. Trolley wheels shall be of single flange type in the taper treads. The wheels s hall be mounted on antifriction bearings and shall be easily removable for repai r/replacement. The load hook shall be swiveling type forged circular shank section and shall co

nfirm to IS:3815. All gears and bearings shall be lubricated by grease. All lubricating points sh all be grouped together in easily accessible position. The bottom block shall be of enclosed type and shall have guard against rope jam ming in normal use. It shall have standard forged swivel shank hook fitted on a ntifriction thrust bearing. Lock to prevent hook from rotation and locking arra ngement to prevent accidental unlocking shall be provided. Pulley of the bottom block shall be provided with antifriction bearings. All parts requiring replacement/inspection/lubrication shall be accessible witho ut need for dismantling of other parts/structures. All components of hoists of identical capacity and duty shall be interchangeable . Hoists shall have permanent inscription on each side readily recognizable from f loor level stating safe working load. Pendant shall be provided with up/down/forward/reverse travel push buttons and i ndicating lamps. Its power supply shall be limited to 24V AC. The control panel shall be wall mounted type & easily approachable from the floo r by a standing man. For Inspection / maintenance of hoist components a fixed platform with ladder sh all be provided for each hoist. 1.6.16 Dust Control System

The dust control system is required for control of fugitive dust emissions from dust generation points such as transfer points, feeders, crushers etc. Dust cont rol is achieved by dust suppression system. Bidder shall provide adequately sized fool proof dust control systems the perfor mance of which should be guaranteed by the Bidder. 1.6.16.1 Dust Suppression System

Dust Suppression system complete with water supply system, valves, piping, spra y heads, pumps, drive motors with canopy, couplings with enclosure electricals, including supporting structures, approach/maintenance platforms, handling for eq uipment, civil & structural works, necessary accessories shall be provided at al l places. At specified locations dust suppression system shall be provided which comprises spray equipment discharging water in a fine mist, to capture air borne dust par ticles and direct them into the main coal flow, agglomerate dust in the main co al flow and prevent release of dust particles from the main coal flow. Water shall be drawn from the water storage tank by 2100% electric motor driven p umps, and delivered through a pipe network system to spray heads at the dust sup pression zones. Solenoid valves shall be provided for open/close control of sol ution line to each spray head. Each spray head shall consist of minimum 4 nos. nozzles. Spray heads shall be provided at coal loading, discharge and at skirt board zone. Pressure at inlet to spray head shall not be less than 3.5 Kg/cm (g). Trolley mounted pumping arrangement shall be provided for supplying water to the

mobile paddle feeders. In this arrangement, tank, supply pump(s) and spray noz zle header shall be mounted on paddle feeder trolley. The tank on P/F trolley sh all be filled through flexible hose tapings on a ring header, which will remain, flooded through a connection to on ground storage tank. This storage tank shal l have make up connection from the common dust suppression system. Each spray head shall have a provision for installing a pressure gauge whenever required. Further, pressure gauges shall be provided at least at two locations. At specified locations dust suppression system shall be provided which comprises spray nozzles discharging plain water in a fine spray to capture air borne dust particles and direct them into the main coal flow. Water shall be discharged v ia a pipe work system through spray heads at the dust suppression zones. 1.6.16.2 Track Hopper Dust Suppression System

Water shall be drawn from the water storage tank by electric motor driven pumps and discharged via a pipe work system through spray heads. The dust suppression system shall consist of headers with spray nozzles routed along the entire leng th of track hopper on each side. Each nozzle header shall be provided with adeq uate number of spray nozzles spaced at 1000 mm interval in zig zag way. Further, at the track hopper the water spray shall be of fogging type with a minimum pre ssure of 2.5 kg/cm2(g) at spray nozzle inlet. 1.6.16.3 Coal Yard Dust Suppression System

Water shall be drawn from the water storage tank by electric motor driven pumps and discharged via a pipe work system through spray heads. Spray heads shall co mprise of swiveling type spray units spaced at an interval of approximately 30 m eters around each coal pile. Manually operated globe valve shall be provided to control water supply to each spray unit. One no. pump shall be provided for ea ch individual stock pile with common header. Pressure at inlet to spray unit sh all not be less than 4.5 kg/cm2(g). 1.6.17 Sump Pumps

Sump pumps alongwith level switches & piping upto nearest Purchasers drain (max u pto 50.0 mtrs. from outside the building) shall be provided at all locations whe rever natural drainage is not possible. Further sump pumps alongwith drain pits shall be provided at other locations also, if required, during detailed enginee ring stage. The capacity of each pump shall not be less than 50 M3/hr. Minimum 10% margin o n capacity and 20% margin on computed head shall be considered for selection of pumps. Size of the sump pit shall not be less than 2.0 meters x 2.0 meters x 2.5 meters . One no. of settling pit shall also be provided before sump pit so that water without heavy coal particles goes into sump pump pit. High and low level switch es shall be provided in the sump pump pit. 2100% sump pumps alongwith level switches and piping up to nearest Owners drain (m ax. up to 50.0 meters from outside the building) shall be provided at all locati ons wherever natural drainage is not possible. Sump pumps along with drain pits shall be provided at other locations also, if required, during detailed engineer ing stage. 1.6.18 Service Water System

Service water distribution system complete with water supply system, valves, qui

ck couplings, hose pipes with nozzle, piping, pumps, drive motors with canopy, c ouplings with enclosure, electricals, including supporting structures, handling for equipments, civil and structural works and necessary accessories shall be pro vided throughout the coal handling plant area in Bidders scope. 1.6.18.1 Pipings, Fittings, Valves and Specialities

The material to be supplied for completing the pipe work shall inclu de but not be limited to Straight piping, bends, tees, elbows, branches, lateral s, crosses, reducing unions, couplings, caps, blank flanges, saddles etc. necess ary for making reliable piping system. Gaskets, ring joints, jointing material etc. as required. Instrument tapping connections, stubs. Gate, globe and check valves to start/stop, regulate and to prevent back flow. Duplex Strainers

Anchors, hangers and supports as required including secondary steel embedments etc. Bolts, nuts, fasteners as required for interconnection piping, valve s and fittings as well as for terminal points. ecessary. 1.6.18.2 Underground pipe protection for all underground pipe work. Painting, anti-corrosive coatings etc. inside and outside pipes as n Welding electrodes and welding rods. Service Water System

Service water connections are to be provided in conveyor galleries and tunnels a t 50 meter intervals. Adequate number of these connections shall be provided in all transfer houses with minimum one no. at each floor and with minimum two (2) nos. at each floor in crusher house. Each connection shall be provided with on e (1) no. 32 NB globe valve and quick coupling. One (1) No. Hose pipe with nozz le shall be provided in each building. Service water distribution system shall be designed considering the water scheme and water requirement. 1.6.18.3 Water Supply Pumps Water supply pumps shall be provided as required. The pumps shall be complete with drive motors, base plate and other accessories. The constructional features of the pump shall be as follows: (a) Pump casing may be axially or radially split. The casing shall be of robust construction. Casing drain and vent connections shall be provided. (b) Impeller shall be made in one piece and securely keyed to the sh aft. Locking device shall be provided to prevent its loosening during all condi tions of operation.

(c) Wearing rings shall be of renewable type. Opposed wearing surf ace shall be of hardened material and shall have a hardness difference of at lea st 50 BHN. (d) Replaceable shaft sleeves shall be provided to protect the shaft where it passes through bearings and stuffing boxes. The end of the shaft slee ve assembly shall extend through the packing gland. Shaft sleeve shall be secur ely locked or keyed to the shaft to prevent loosening or rotation. Shaft and sh aft sleeves shall be machined and assembled for concentric rotation. (e) The design of the shaft shall take into consideration the criti cal speed, which shall be at least 20% away from operating speed. (f) Pump bearings shall be of antifriction type. Bearings shall be readily accessible without disturbing the alignment of pump. (g) Packed stuffing boxes shall be of sufficient length to prevent leakage along the shaft and shall be complete with all packing and lantern rings required. (h) Pumps shall be furnished complete with flexible -coupling.

(i) Couplings guards made of expanded metal and bolted to the base plate shall be furnished. (j) The common base plate for pumps and motor shall be in one piec e and shall be made of fabricated steel. (k) Pump speed shall be less than 1500 rpm for pumps of capacity mor e than 10 m3/hr. The power, head and flow characteristics of each pump shall be suitable for para llel operation. The Power characteristics of the pumps shall be of non overload ing type. All rotating parts of the pumps shall be statically and dynamically balanced. Design duty point of pump shall match with the average value of maximum and mini mum flow rates of the pump in the stable operation zone. Materials of construction of pump components shall be as follo ws: CONSTRUCTION REQUIREMENTS Water Supply Pumps Casing Axial or radially split with drain & vent connection Impeller One piece, keyed to shaft along with locking device Shaft Critical speed atleast 20% away from operating speed Shaft sleeves at bearings & stuffing boxes. Bearings Antifriction type Wearing rings Renewable type Wearing surface Hardness 50 BHN difference between ring & surface hardness. Pump speed Below 1500 rpm for capacity more than 10 m3/hr. Head flow characteristics Suitable for parallel operation. Materials (a) Casing Cast Iron to IS:210, FG 260

(b) Impeller Bronze conforming to Gr.I of IS:318 (c) Impeller Wearing ring Bronze conforming to Gr.I of IS:318 (d) Casing Wearing ring Bronze conforming to Gr.I of IS:318 (e) Shaft Medium carbon steel (f) Shaft sleeve Stainless steel conforming to AISI-416 hardened. (g) Gland packing Impregnated teflon Metering Pumps Type Positive displacement diaphragm type Capacity Adjustable from 10 to 100% through stroke variation. Capacity control Manual with stroke positioner. Pressure relief system Integral with the pump Sump Pumps Type Wet pit type vertical shaft Duty Capacity to handle large solids or unscreened liquid. Materials (a) Casing and rotor housing Ni-Cast Iron (350 BHN) (b) Rotor Ni-Cast Iron (350 BHN) (c) Shaft Medium carbon steel (d) Gland Bronze (e) Wearing rings Stainless steel (f) Shaft enclosing tube Carbon steel Pipings & Fittings Joints (i) Pipe to pipe Pipe size < 50 NB Pipe size > 65 NB Socket welding/screwed Butt welding (ii) Pipe to valves Pipe size < 50 NB Pipe size > 65 NB Screwed Flanged Isolation of flow Plug / Gate / Sluice valves Regulation of flow Globe Valve Valves (i) Size > 65 NB Bolted bonnet outside screw rising type. (ii) Size < 50 NB Union bonnet with screwed ends for Globe valves & screwed ends for plug valves. Materials for Pipework (a) For sizes 200 NB and Larger ERW carbon steel pipes to API-5L-Gr.B mi nimum thick 6.35 mm or plate fabricated and welded pipes to IS:3589, Class-2. (b) For sizes 150 NB to 80 NB ERW carbon steel black pipes to IS:1239 (Part-Heavy class. (a) For sizes below 80 NB ERW carbon steel galvanised pipes to IS:1239 (Part-I) He avy class. Materials for Valves & Specialities (a) Cast Iron Valves (above 65 NB) (i) Body and bonnet Cast Iron to IS:210, Gr.FG-200 (ii) Disc for non- return Cast Iron to IS:210, Gr.FG-200 valves (iii) Seating surfaces and rings 13% chromium steel (iv) Hinge pin for non return valves Stainless steel type AISI-316 (v) Stem for gate and globe valves 13% chromium steel (vi) Back seat bush 13% chromium steel (b) Gun metal valves (65 NB & below and upto a working pressure of 10 kg/ cm2) (i) Body Gun metal to IS:318, Gr-2. (ii) Trim Gun metal to IS:318, Gr-2.

(c) (i) (ii) (d)

Duplex Strainer Body MS fabricated Strainer Stainless steel type element AISI-316 Pressure Gauge/Switch (to be provided with isolating valves)

(i) Dial size 150 mm (ii) Accuracy + 1% of range span (iii) Bourdon AISI 316 SS (iv) Block AISI 316 SS (v) Movement AISI 316 SS (vi) Case and Bezel Die cast Alum. Weather proof case stove enameled block with screwed type inner bezel of ABS plastic. (vii) No. of contacts 2 NO + 2 NC (viii) Type of contact Adjustable throughout the range. (ix) Degree of protection IP. 65 (e) Solenoid valve (to be provided with isolating valve) (i) Type 2/2 way Diaphragm type pilot operated (ii) Diaphragm molded synthetic rubber (iii) Body Forged brass / SS (iv) Pressure 0.5 to 20 kg/cm2 (v) Protection Class IP 65 (f) Flow Switch (to be provided with isolating valves) (i) Body Forged steel (ii) Extension Rod/wire SS-304 (iii) Sleeve and Sleeve pipe SS-304 (iv) Cover Die cast aluminum (v) Max. working pressure 10 kg/cm2 0.5% (vi) Repeatability (vii) No. of contacts 2 NO + 2 NC (viii) Type of contact Adjustable throughout the range. (ix) Protection class IP 65 (g) Level Switch (i) Type Displacer operated magnetic type (ii) Displacer SS 316 (iii) Wire rope SS 316 (iv) Spring Housing Spring and sleeve pipe SS 316 (v) Cover Cast Aluminum (vi) No. of Contacts 2 NO + 2 NC (vii) Type of Contact Adjustable throughout the range. (viii) Protection class IP 65 (h) Level gauges (i) Type Float type mechanical gauge with arrow scale (ii) Accuracy 1% of full scale range (iii) Material of construction (a) Float & Guide wire 316 SS (b) Elbows Suitable grade of SS (c) Housing Mild Steel (d) Cable fastener SS 304 (i) Nozzles (for Plain and Chemjet DS except Stockyard DS) (i) Type Fogging, non-clogging type (ii) Material Stainless Steel (iii) Nozzle housing To ensure protection of nozzle against damage. 1.6.19 Special Cleaning, Protection and Painting Piping & Fittings

Surfaces to be painted shall be thoroughly cleaned of loose mill scale, rust etc . by wire brushing. For overground exposed steel pipes, one shop and one site coat of red oxide zinc phosphate and two coats of synthetic enamel finishing paints unless specified o therwise shall be applied. A minimum of 120 microns Dry Film Thickness (DFT) af ter finished coat of paint shall be ensured. For steel buried pipeline, three (3) coats of heavy duty bitumastic paint shall be applied on the cleaned surface. Finally, it should be wrapped with minimum 3 mm thick bitumen impregnated tar felt. The lap joint of the felt shall be gene rally touched with heavy duty bituminous paint. 1.6.20 1.6.20.1 Ventilation Systems General

The specification is intended to cover design, engineering, manufacture, supply, erection, testing and commissioning of the complete Ventilation & A.C. systems as specified hereinafter for the smooth and trouble free operation of CHP. The Contractor shall refer to the other sections enclosed to appraise himself of the work and scope of supply of the other Contractors/Owners and shall coordina te his work with the work of other Contractors. 1.6.20.2 General Description

The air quantity for mechanical ventilation system shall be estimated based on e quipment and solar heat loads and the temperature rise inside the building. Nece ssary air filters shall be provided to supply only clean air into building. Exh aust air shall be discharged at a suitable height above building. Exhaust fans shall be provided for tripper floor. The pressurised ventilation system having adequate nos. of supply air fans with washable metallic pre filters, HDPE fine filters, and exhaust fans with self clo sing flaps, ducting along with 3 phase AC motor drives, electricals, supporting structures, access / maintenance platforms shall be provided in all MCC/switchge ar room areas of coal handling plant to be furnished under this specification. T he pressurized ventilation system shall be designed considering 15 air changes t o maintain these areas pressurised slightly above atmospheric pressure to preven t ingress of dust from outside. Air conditioning system shall be furnished for control room area of main control room, MCC room on S/R and operators cabin and PLC rooms for Coal sampling units. It shall be designed considering the equipment heat loads, solar heat loads, h eat gain into the room, adequate no. of air changes etc. to maintain a uniform t emperature and relative humidity within the air conditioned areas. Outside desi gn condition shall be as specified in Data Sheet of this section. PLC room havin g the PLC of coal sampling units near the CSU shall also be air-conditioned. The ventilation system generally consisting of adequate number of supply air fil ters, ducting along with 3 phase AC motor drives, electricals, supporting struct ures, approach/maintenance platforms, civil and structural works and necessary a ccessories shall be furnished for ventilating the track hopper, underground port ion of transfer points, underground conveyor tunnels and pent houses. Exhaust fa ns shall be provided for tripper floor. For design purpose the outdoor ambient temperature shall be taken as

50oC. The ventilation system generally consisting of adequate number of supply and exh aust fans, metallic pre filters, HDPE fine filters, ducting along with 3 phase A C motor drives, electricals, supporting structures, approach / maintenance platf orms, necessary shed, civil & structural works and necessary accessories shall b e furnished for all MCC/switchgear rooms. For design purpose the outdoor ambient temperature shall be taken as 50oC. 2100% capacity air conditioning packaged units (PAC) with roof mounted air cooled condensers shall be provided for control room area of main control room. One (1) no. window AC each for MCC room of S/R, operators cabin and PLC room for coal sampling unit shall also be provided. Supply and return air distribution ducting complete with insulation, of resin bo nded mineral wool equivalent of density at least 24 Kg/m and thermal conductivity of max. 0.49 mw/cmC conforming to IS:8183 including supporting structures, appro ach/maintenance platforms, civil and structural works and necessary accessories shall be provided. GENERAL Mech. Ventilation System To provide ventilation using fans for specified areas. No. of air changes per hour (a) For overground building Not less than 10 (b) For underground areas Not less than 15 Area (1) Track Hopper/ Under-ground tunnel/portion of transfer points and pent houses Centrifugal fans/Axial Fans (2) Tripper floor in bunker bay Axial fans and / or roof ventilators Pressurised ventilation system To provide clean air and to maintain the area pressurized to prevent ingress of dust No. of air changes per hour Not less than 15 Area MCC/Switchgear rooms and S&T room Air-conditioning system For main control room, MCC room on S/R and operators cabin & PLC room of coal sampling units. Temperature to be maintained 24 1 deg. C Humidity to be maintained 50 5% relative humidity Fresh Air intake More than 1.5 air changes per hour. Outside Ambient Conditions (i) Summer As per weather data given in project synopsis. (ii) Monsoon - Do (iii) Winter - Do DESIGN & CONSTRUCTION Roof Ventilators Capacity 10% more of actual requirement Head 20% more of actual requirement Speed (a) Impeller dia above 450 mm Max. 960 rpm (b) Impeller dia less than or equal to 450 mm Max. 1440 rpm (c) Critical speed 25% above operating speed. Axial Fans Capacity 10% more of actual requirement Head 20% more of actual requirement Speed (a) Impeller dia above 450 mm Max. 960 rpm (b) Impeller dia less than or equal to 450 mm Max. 1440 rpm

(c) Critical speed 25% above operating speed. Centrifugal Fans Capacity 10% more of actual requirement Head 20% more than actual requirement Speed Max. 1500 rpm Outdoor temperature 50 deg. C. Rating Continuous Packaged Air-Conditioning Unit Type Roof top mounting Service/application Continuous, round the clock. Capacity (i) TR Suitable (ii) CFM Suitable Type of compressor Multiple cylinder hermetic compressor. Condenser Air cooled type Fan Forward curved centrifugal fan Filter High efficiency filter Cooling Coil (a) Type Direct Expansion (b) Material Copper (c) Fins Aluminum mechanically bonded. Refrigerant Piping Copper Insulation for PAC parts Expanded polyethylene of density at least 15 kg/ m. Filters Metallic Filters (1) Max. air velocity 2m/sec. HDPE filters (1) Efficiency 90% down to 5 microns (2) Max. velocity 2.5 m/sec. (3) Testing As per BS 2831 / Sqv. High Efficiency Filter (1) Efficiency 99.9% down to 5 microns. (2) Pr. drop across 10 mm W.C. (3) Testing As per BS 2831 / Sqv. Insulation for A/C Ducting Resin Bonded Mineral wool as per IS:8183 Density 24 kg/m Thermal conductivity 0.49 mw/cm oC