Professional Documents
Culture Documents
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BASIS OF OFFER
The desired 1.8 MTPA Coking Coal Beneficiation System shall be as per Tender drawing
Nos.
Tender Drawings:
1
Layout Drawing
S&T/003
Surface Plan
3
4
5
B.
4. Belting:
4.1
Top cover
6 mm for N/N
4.2
Bottom Cover
3 mm for N/N
4.3
Cover grade
M-24
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4.4
Running tension
4.5
Type of belt
4.6
No. of Plies
5.2
Return Idlers Single Roll Flat Return Idler for Conveyor of Belt Width
less than 1000 mm and Two Roll V return idlers with 10 0 troughing angle
for Conveyors of Belt Width 1000 mm and above.
5.3
Return / SARI:
Impact:
5.4 Tube material & thickness ERW tube, 4.5 mm (Min) thickness.
5.5 Bearing Seize Resistant /Single row deep groove ball bearing
5.6 Bearing Life 40,000 hrs B-10 life.
5.7 Bearing dia.
Carrying / SACI :
30 mm.
Impact
30 mm.
Return / SARI
25 mm.
1.0 m
Return
3.0 m
15.0 m
30.0 m
Impact Idler
300 mm
(Min. 5 Nos. impact idlers shall be
provided at each feed point)
Transition Idlers
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5.11 Two (2) Nos. Self Cleaning Type Rubber Disc Return Idlers Shall be provided
at Discharge pulley.
5.12 Eight (8) Nos. Machined Idlers shall be provided for Belt Scale Location
5.13 Four (4) Nos. Non-Magnetic Idlers shall be provided at Tramp Iron Separator
5.14 One (1) No. Inverted V-Return Idler shall be provided at Tail and Head end.
6. Pulleys (Face width as per IS: 8531 1986, Reaffirmed in 1993)
6.1
Drive Pulley
6.2
Pulley lagging:
Drive Pulley
Non-drive Pulley
6.3 All pulleys shall be connected to the shaft through key arrangement
6.4 Pulley shaft deflection at hub shall be maximum 5 minutes.
6.5 Pulley Shaft material shall be Class- IV, IS-1875, up to 150 mm and
40Cr1MO28, IS-1570 above
6.6 Pulley Shell Material shall be MS conforming to IS: 2062.
6.7 Pulley Hub Material shall be Cast Steel Gr. II, IS-1030
6.8 Pulley Diaphragm Material shall be MS conforming to IS: 2062.
6.9 Bearing Type: Double row self aligning spherical roller bearings
6.10
6.11
Plummer Blocks The pulley shaft shall be supported on heavy duty; split type
Plummer blocks of 4 bolts construction.
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8.1 The gearbox mechanical rating shall be 1.5 times of consumed power at pulley shaft
or1.25 times of motor power, whichever is higher.
8.2 For Motor Power Rating up to 15 kW Worm Gear Box shall be provided.
8.3 For conveyor having motor kW above 15 kW, the type of gearboxes shall be helical
type. If required due to space constraint Bevel Helical Gearboxes shall also be used.
8.4 All Inclined conveyors shall be provided with roller type holdback integral with
gearbox.
8.5 Housing of the gearbox shall be made of Cast iron housing of FG 260 as per IS: 210.
9
CONVEYORS STRUCTURAL
12 Take up
12.1. Conveyors of length up to 30 m shall be provided with screw type take-ups and
conveyors of length above 40 m shall be provided with automatic take-ups
preferably vertical gravity take-up, wherever possible.
12.2. Conveyor of length between 30 m and 40 m, screw type take-up may be
considered if vertical gravity take-up is not possible to be provided.
12.3. Conveyors counter weight shall be made of 60% cast concrete block & balance in
cast iron block in steel box. Where RCC block counter weight cannot be
accommodated due to space problem, cast iron counter weight will be provided.
Weight of single piece of counterweight will not be more than 25 Kg.
13.
Skirt Board Length of skirt board For single discharge, the length of the skirt
shall be minimum 4000 mm. In case of multiple feeding system, length of the skirt
shall be continuous covering all feed points. Skirt board top cover shall be 3.15
mm thk MS cover. The height of skirt shall be minimum 400 mm for 800 mm belt
width, 450 mm for 1000 mm and 1200 mm belt widths and 500 mm for more than
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1200 mm belt width. Modular segmented type skirt board sealing system for
effective sealing against spillage and dust shall be provided. Steel liner MN STEEL
(IS:276 GRADE-1) of 10 mm thick shall be provided in the skirt which shall be
fixed by csk bolt. In feed zone, liners of full height shall be provided and beyond
feed zone, liner height shall be 200 mm. Skirt shall be made of 10 mm thick plate.
14.
Belt Scrapers Primary external scraper shall be poly urethane blade and
secondary external scraper shall be sprung blade type (Tungsten tipped) at
discharge pulley shall be provided. For reversible conveyors the same shall be
provided at both the ends. One no. V-plough type internal scraper shall be
provided for each conveyor. Diagonal plough type scraper shall be provided for the
reversible type conveyor/feeder at both head and tail ends.
15.
Deck Plate 3.15 mm thick Sheets shall be provided throughout the length of
Conveyor. MS deck plate of 3.15 mm thick shall be provided at every feed point up
to 3 m beyond the skirt length of all the conveyors. 6 m long deck plate from the
centre line of head pulley shall also be provided at the head end of all conveyors.
16.
Conveyors stringer size: ISMC 150 for Conveyors above 1000 mm Belt Width &
ISMC 125 for conveyors upto 1000 mm Belt Width.
17.
Short support size: ISMC 150 for Conveyors above 1000 mm Belt Width & ISMC
125 for conveyors upto 1000 mm Belt Width.
18.
Chutes:
18.1
Chute
18.2
Liners
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Valley Angle
Bin/ Bunker
Bin Bunker Details
Sl. No.
1.
2.
Items
Type/MOC
Coal
Raw coal silos
Concrete silos
Concrete hopper
3.
4.
Structural
Concrete hopper
Items
Liner Specification
20 mm thick Hardox 450
20 mm thick Hardox 450
3.
4.
5.
6.
7.
8.
9.
Media pipelines
1.
2.
10.
11.
Launders
Return pipelines & coal
water slurry line
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20 mm thick UHMWPE
10 thick Mn Steel (IS:276 Part-I)
45kg/m rail
45kg/m rail
1 meter bottom vertical portion &
all Conical portion 20mm thick.
Hardox-450
1 meter bottom vertical portion &
all Conical portion 20mm thick.
Hardox-450
Cast basalt having shell thickness 8
mm with surface coating of epoxy.
Ceramic tiles (> 90% alumina)
HDPE (based on the suitability)
19.
Pull Cord Switch. Pull cord switch of lock-out type shall be provided at a
regular interval of 25 m along each conveyor and on both sides for manual
tripping of drive motor under emergency. Minimum distance of switch shall be 5 m
from the head & tail end of conveyor.
20.
Belt Sway Switch Belt sway switch shall be provided at both sides and at 50 m
interval along conveyor length to automatically stop the conveyor in case of
excessive sway of the belt. Minimum distance of switch shall be 10 m from the
head & tail end of conveyor.
21.
Zero Speed Switch One for each conveyor at non drive pulley. Belt slip/zero
speed switch shall be provided at the tail end along the belt conveyor to
automatically stop the equipment in case of excessive slip of belt or snapping of
the belt.
Chute Blockage Switches Chute plug switch shall be provided for chutes and
22.
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SCOPE OF WORK/SUPPLY
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Conv.
No.
Qty.
(Nos)
Belt
width
(mm)
Approx
Conv. Length
Along length
per conveyor
(m)
Belt Speed
(m/s)
Capacity
R/D
(TPH)
Remarks
Rail Wagon
Unloading
Circuit
BC-1
1800
40.00
2.50
1500/1800
2.
BC-2
1800
155.00
2.50
1500/1800
BC-3
1200
201.00
2.00
500/600
4.
BC-3A
1200
21.00
2.00
500/600
5.
BC-4
1600
45.00
2.90
1500/1800
6.
BC-4A
1600
105.00
2.90
1500/1800
7.
TC-1
1800
77.00
2.90
1500/1800
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Truck
Dump
Hopper
Circuit
Raw Coal
Silo
Feeding
S.
No.
Conv.
No.
Qty.
(Nos)
Belt
width
(mm)
Approx
Conv. Length
Along length
per conveyor
(m)
Belt Speed
(m/s)
Capacity
R/D
(TPH)
8.
BC-5
1000
55.00
2.00
500/600
BC-6
1000
106.00
2.00
500/600
10
BC-7
1000
11.00
2.00
300/360
11
BC-7A
1000
78.00
2.00
300/360
12
BC-8
1000
74.00
2.00
300/360
13
BC-9
1000
90.00
2.00
500/600
14
BC-10
1000
73.00
1.80
300/360
15
BC-11
800
45.00
2.00
200/240
Remarks
Tertiary
Crushing
Circuit &
feed to
main
process
plant
through
Surge
Hopper
Clean Coal
16
BC-12
800
186.00
2.00
200/240
17
BC-13
800
77.00
2.00
200/240
18
BC-14
800
58.00
2.00
200/240
19
BC-15
800
130.00
2.00
200/240
20
BC-16
800
60.00
2.00
200/240
Rejects
21
BC-17
1600
168.00
3.20
1800/2160
Middling/
Rejects
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Middling
S.
No.
Conv.
No.
Qty.
(Nos)
Belt
width
(mm)
Approx
Conv. Length
Along length
per conveyor
(m)
Belt Speed
(m/s)
Capacity
R/D
(TPH)
22
BC-18
1600
168.00
3.20
1800/2160
BC-19
1600
154.00
3.20
1800/2160
BC-20
1600
38.00
3.20
1800/2160
23
24
Remarks
Wagon
Loading
Circuit
BC-316
1600
3.20
1800/2160
BC-319
1600
3.20
1800/2160
Note:
Existing
Conveyors
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450on scale A). Technological structure viz. Stringers, short post, head
frame, tail frame, skirt board, conveyor discharge chute.
Skirt board for all Conveyors as specified in Basis of Design.
B.
CRITICAL EQUIPMENT:
S.
No.
1.
Equipments
Specifications
Wagon Tippler
i) Quantity
1 (One) No.
25 tips/ Hr
iii) Type
Rota side
iv) Drive
i) Quantity
1 (One) No.
ii) Location
At inhaul of WT
2.
3.
Apron Feeder
i)
Quantity
1 (One) No.
ii)
Capacity (Rated)
1500 TPH
iii)
Material Handled
iv)
Discharge
BC-1
4.
Lump Breaker
1 (One) No.
Hydraulic
6 (Six) Nos.
500 tph
i) Type
ii) Quantity
iii) Drive
5.
Vibrating Feeders
a) Pre MCCP Building
i) Quantity
ii) Type
iii) Capacity
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S.
Equipments
No.
iv) Location
Specifications
4 (Four) Nos.
iii) Capacity
1000 tph
iv) Location
Sizer
1 (One) No.
1500 tph
v) Output Size
(-) 200 mm
vi) Receives
BC-2
Secondary Sizer
Sizer
1 (One) No.
1500 tph
(-) 200 mm
v) Output Size
(-) 50 mm
vi) Receives
Primary Sizer
BC-4
1 (One) No.
Impact Crusher
iii) Capacity
300 tph
(-) 50 mm
v) Output Size
(-) 13 mm
vi) Receives
6.
Primary Sizer
i) Type
ii) Quantity
vii) Discharges
7.
Secondary Sizer
i) Type
ii) Quantity
vii) Discharges
8.
Tertiary Crusher
i) Quantity
ii) Type
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S.
Equipments
No.
vii) Discharges
Specifications
i) Quantity
1 (One) No.
ii) Capacity
500 tph
iii) Aperture
13 mm
iv) Receives
BC-6
vi) Discharges
i) Quantity
1 (One) No.
ii) Capacity
300 tph
iii) Aperture
13 mm
iv) Receives
BC-8
vi) Discharges
i) Quantity
1 (One) No.
ii) Capacity
1500 tph
1800 mm
iv) Location
At conveyor TC-1
2 (Two) Nos.
iii) Capacity
15 t & 20 t
iv) Location
v) Span
6 (Six) Nos.
9.
Classifying Screens
a) Classifying Screen 1
b) Clasiifying Screen 2
10.
11.
Travelling Tripper
EOT Crane
i) Quantity
ii) Type
12.
i) Quantity
ii) Type
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S.
Equipments
No.
iii) Location
13.
Specifications
Below Raw Coal Silos & Surge
Hopper
1 (One) No.
Flap Gate
i) Quantity
ii) Type
iii) Location
14.
Rod Gate
i) Quantity
ii) Type
5 (five) Nos.
Manual
i) Quantity
1 No.
ii) Capacity
300 tph
4 Nos.
iii) Location
15.
16.
Auto Sampler
i) Quantity
ii) Type
iii) Location
17.
1 (One) Nos.
Banana Type
iii) Capacity
300 tph
iv) Aperture
1 mm
v) Dimension
3m x 6.1 m (Approx)
vi) Receives
Over product
Through Product
ii) Type
vii) Discharges
b)
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Sl.
Equipments
No.
i) Quantity
Specifications
1 (One) Nos.
Banana Type
iii) Capacity
200 tph
iv) Aperture
1 mm
v) Dimension
vi) Receives
HM Cyclone Overflow
Over product
Through Product
To dilute sump
ii) Type
vii) Discharges
c)
i) Quantity
1 (One) Nos.
Banana Type
iii) Capacity
200 tph
iv) Aperture
1 mm
v) Dimension
vi) Receives
HM Cyclone Underflow
Over product
Through Product
To dilute sump
1 (One) Nos.
Banana Type
iii) Capacity
150 tph
iv) Aperture
1 mm
v) Dimension
vi) Receives
Over product
To middlings centrifuge
Through Product
To dilute sump
Banana Type
ii) Type
vii) Discharges
vii) Discharges
e. Reject DR Screen
i) Quantity
ii) Type
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Sl.
Equipments
No.
iii) Capacity
Specifications
150 tph
iv) Aperture
1 mm
v) Dimension
vi) Receives
To reject conveyor
To dilute sump
1 (One) No.
iii) Capacity
iv) Feed Size
210 tph
(-) 13 mm
v) Receives
Overflow
Underflow
vii) Discharges
Over product
Through Product
18.
vi) Discharges
b) Secondary HM Cyclone
i) Quantity
1 (One) No.
iii) Capacity
160 tph
(-) 13 mm
v) Receives
Overflow
Underflow
ii) Type
vi) Discharges
19.
Classifying Cyclone
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1 (One) Set
S.
Equipments
No.
ii) Capacity (R/D)
Specifications
350 mm
iv) Classification at
0.25 mm
v) Receives
Overflow
Underflow
2 (Sets) No.
30tph/35 tph
350 mm
vi) Classification at
0.25 mm
v) Receives
TBS Overflow
Overflow
Underflow
vi) Discharges
vi) Discharges
20.
Magnetite Separator
1 No. each
long
b) Magnetic Separator for Fresh Magnetite Charging
i) Quantity
ii) Type
iii) Size
21.
1 (One) No.
1 (One) No.
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S.
Equipments
No.
ii) Capacity
Specifications
150 tph
0.35 mm
iv) Receives
Over Product
Through Product
i) Quantity
1 (One) No.
ii) Capacity
150 tph
0.35 mm
iv) Receives
Over Product
To Middlings conveyor
Through Product
i) Quantity
1 (One) No.
ii) Capacity
20 tph
iii) Diameter
20 m
iv) Receives
Overflow
Underflow
V) Discharges
b) Middlings Centrifuge
v) Discharges
22.
v) Discharges
23.
i) Quantity
1 (One) No
iii) Capacity
30 tph
iv) Receives
Cake
Filtrate
To thickener
ii) Type
v) Discharges
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S.
No.
24.
Equipments
Specifications
i) Quantity
1 (One) No
ii) Capacity
60 tph
(-) 1 to 0.25 mm
iv) Receives
Overflow
Underflow
i) Quantity
1 (One) No.
ii) Capacity
40 tph
< 0.25 mm
Minimum 10 minute
v) Receives
Clean Coal
Tailings
To thickener
v) Discharges
25.
vi) Discharges
26.
i) Quantity
2 (Two) Nos.
ii) Capacity
40 tph
0.35 mm
1 (One) No.
Coil Type
On Conveyor BC-6
i) Quantity
1 (One) No.
ii) Capacity
1000 gauss
Metal Detector
i) Quantity
ii) Type
iii) Location
28.
Magnetic Separators
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S.
Equipments
No.
iii) Location
Specifications
On Discharge of BC-2
2 (Two) No.
ii) Capacity
1000 gauss
iii) Location
7 (Seven) Nos.
29.
Belt Scales
i) Quantity
ii) Type
iii) Capacity variation
iv) Locations
i) Quantity
Lot
ii) Type
30.
NOTE: Hoist Schedule for the Various Location in CHP is furnished below and the
hoist required for the other areas can be referred in the detail list of equipment.
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MANUAL
HOIST
QTY.
1
1
1
1
2T
2T
1
1
2T
1
2
1
1
1
2T
TP-4
TP-5
RAW COAL SILOS
15T
8T
3T
3T
5T
SCREEN HOUSE
12T
2T
2T
2T
2T
2T
2T
1
1
1
5
1
1
12T
3T
8T
3T
3T
1
1
2
1
1
2T
2T
1
2
3T
3T
1
1
3T
3T
1
1
18
2T
2T
3T
2T
2T
1
1
1
1
1
22
LOCATION
WAGON TIPPLER HOUSE
TP-1
TP-2
TP-3
PRIMARY & SECONDARY
CRUSHER HOUSE
TERTIARY CRUSHER
HOUSE
SURGE HOPPER HOUSE
MCPP
TP-6
TP-7(EXISTING)
TP-8
TP-9
TP-10
TP-11
TOTAL
ELECTRIC
HOIST
QTY.
5T
3T
3T
3T
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2. UTILITIES
We have considered the following dust suppression systems at Wagon Tippler and the
adjacent Junction Houses prior to the MCPP as per plant layout:
1. DFDS-1 (Dry Fog Dust Suppression System) for all Dust Generation Points of
WAGON TIPPLER AREA, Primary & Secondary Crusher House, Reclaim Hopper
Area, and all Transfer Towers before Coal Washery.
2. DFDS-2 (Dry Fog Dust Suppression System) for all Dust Generation Points of all
transfer Towers after Coal Washery and Wagon Loading Station.
The intermediate Transfer Towers between Coal Washery and Middling Stockpile
& Reject Stockpile will not in consideration of DFDS System.
Operation Logic For Dry Fog Type Dust Suppression System:
Consideration for DFDS System
Minimum 4 nos. DFDS Nozzle will be provided at each dust generation point.
2 nos. water pumps (1W + 1S) have been considered for each system.
2 nos. oil injected air cooled screw compressor (1W + 1S) has been considered for
each system.
The dry fog dust suppression system will consists of Vertical Centrifugal Pump
with Drive Motor (2 Pole), Air Compressor with Drive Motor, MCC, Local Control
Panel, Flow Activation Station, Pressure Regulating Unit, Nozzles, Nozzle
Headers, UBESS, Level Switch, Pressure Gauge, Pressure Switch, Differential
Pressure Switch, Gate Valves, Globe Valves, Check Valves, Ball Valves, Pressure
Relief Valves, Solenoid Valves, Air Release Valves, Drain (Ball) Valves & Duplex
Filter.
There are 2 water pumps (1W + 1S) for Dry Fog Dust Suppression System (DFDS)
will suck water from the RCC Water Storage Tank dedicated for DFDS System
and supply water to the Dry Fog Nozzles through Flow Activation Stations and
Pressure Regulating Units at different Transfer Points.
There are 2Screw Compressors (1W + 1S) for Dry Fog Dust Suppression System
(DFDS) will deliver compressed air to a Air Receiver from which air will supply to
the Dry Fog Nozzles through Flow Activation Stations and Pressure Regulating
Units at different Transfer Points.
Pump House shall have a MCC for the operation of Drive Motors of Pumps and
Compressors.
The operation of above Pumps of DFDSS shall be interlocked with the Low Level
Switch of the respective Storage Tank, so that the Pumps for the entire Dust
Suppression System will run only when the water level at the respective Tank is
adequate. If the water level somehow falls and reaches the Low Low Level , the
water Pumps will trip automatically via signal of Low Low Level of Level Switch
in order to prevent dry running of the Pumps. Therefore care must be taken so
24 | P a g e
that water level in the respective Storage Tank does not go below the Low Low
level of the Level Switch to prevent automatic tripping of the Pumps.
There are two re-circulation by-pass lines with one having Pressure Relief Valve,
with an isolation Gate Valve and one having manually operated Globe Valve at
the common outlet line of Water Pumps of DFDS System for the purpose of recirculation of the water back to the RCC Water Tank when the respective Dust
Suppression System application points are not in operation.
Under Belt Electronic Speed Switches (UBESS) shall be used for selected
conveyors to get input signals of conveyors running on load. These signals shall
be interlocked with the operation of Solenoid Valves of Flow Activation Stations to
actuate the application points automatically only the conveyors will be moving
with load.
The Flow Activation Stations have provision for both manual and automatic
operation. In manual operation, the system becomes operational with selector
switch. In auto mode, the fogging operation starts on receiving a signal either
from a Respective UBESS or Flap gate limit switches installed at a strategic
location in the material Conveyor line or Potential Free Contact from the drive
motor of equipment as per requirements.
Each application point is provided with two numbers of spray bar assembly (One
for Water and other for Air) with Air Atomized Nozzles. FAS can be provided for a
single Application Point or more than one Application Points. FAS can be
connected to one or more PRU. A PRU is used to regulate the air and water
pressure for a group of headers.
The pressure switch in the respective building ensures the FAS that the solenoid
valves in the air and water lines are switched ON only when there is adequate air
pressure in the system. Each application point shall have a set of spray bar of air
and water. The nozzles shall be fixed at the discharge hoods/suction hoods and
shall be connected by flexible tubing with the headers. Each PRU shall have air
and water pressure regulators to ensure that the medium at the required
pressure is flowing through the nozzles.
Water level adequate signal from pre adjusted Low Level set point of Level Switch.
Any one of the water pump out of two water pumps (1W + 1S) is selected.
Overload Relay (In pump starter panel) is not in tripped condition.
For Pump-1 & Pump-2 operation separate electrical interlock will be provided in
the MCC.
When pump-1 is in operation then Pump-2 will not in operation& vice versa.
If any fault arises in the operation of Pump-1 then Pump-2 will start
automatically and vice versa.
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For the selection and operation of Compressor -1 & 2 the same logic will be
followed as followed by selection & operation of Pump-1 & Pump-2.
And, the water Pumps can be started from MCC (Pump Starter Panel) under following
conditions.
Remote mode selected.
Local mode selected.
Start / Stop push button is pressed manually.
In local mode, the system can only be started on receiving local start permissive
command from control room. For the same, Local permissive indication lamp
shall be provided on the local panel.
Following signal should be generated once for any one of the two pumps running.
Pressure healthy signal from Pressure Switch at the common delivery line of
pumps.
Logic for Tripping of Pumps:
The water pumps shall trip while running, under any one of the following conditions,
Water level touches the low- low level (preset) set point of level switch at the
Water Tank.
Signals from the Pressure switch at the common delivery line are not healthy.
General Considerations:
Incoming Power Supply up to DS MCC incomer at Pump House will be provided
by Client.
All pipe will be ERW Carbon Steel as per IS:1239 (Part-1), Gr.- Heavy for Water
Pipe Lines and Medium for Compressed Air Line.
Pipes <& = 50 NB will be GI & Screwed ends.
Pipes >& = 65 NB will be Bevel Ends.
All valves up to 32 NB will be of F.C.S and Screwed Female Ends.
Valves of size 40 NB & above will be of Cast Iron with SS Internals and with
Flange Ends.
Duplex Filter will be placed in the common Suction Lineforboth DFDS System.
All Pumps & Compressors for DFDS-1 & 2 will be located in Raw Water Pump
House.
Water Tap Points for DWS, DFDSS 1&2 and Fire Hydrant System will be
provided by client at a distance of 50 meter from RCC Water Tank which is
located within 15 meter from Raw Water Pump House.
Fire Fighting system:
1. Water Source
The new built production and fire-fighting water tank and pump house will
provide water production and fire-fighting uses.
2. Water Consumption
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27 | P a g e
dislodging the dust particles held on the outer surface of the bags. By this mechanism,
the dust collected is released from the bags and falls into the hopper. From this hopper
it is discharged through suitable device i.e. Rotary valve, screw conveyor.
Since only fraction of the total filter area of the bag filter is cleaned at any given time,
continuous flow through the bag filter at rated capacities is assured.
The Volume calculation of the system is done with the reference of ACGIH norms.
Calculation Basis for Dust extraction system:
1. Design of bag filter is done as per ACGIH norms.
2. ON line cleaning bag filter Considered.
3. Velocity of air inside the duct: 18-22 M/Sec.
4. Intake velocity of air through hood: 1.5 -2 M/Sec.
5. Emission Level shall be max. 10 mg/Nm3 at Outlet of stack.
6. Bag filter material shall be 550 GSM with homopolymer bags.
7. Bag filter cleaning arrangement shall be pulse jet compressed air system.
8. Bag filter shall be designed for outdoor installation.
9. Air to Cloth Ratio Considered 1.05 m3/min/m2
10. Max. Operating temperature considered 120 Deg C Considered for polyester
homopolymer bags.
11. Pressure drop considered 150mmwg.
12. Operation of DE system shall be started/ stopped from the local control panels
and interlocked with conveyor drives.
13. Instrument grade compressed air pressure 6 -7 kg/cm2 for pulse cleaning of bag
filter will be provided from compressor house with air Receiver.
14. Dust content at inlet and outlet of each bag filter will be minimum 10 gm/Nm3.
15. The height of Stack shall be +3.0 mtr from nearest house.
Volume Calculation as per ACGIH Norms:
For Belt Conveyors:
1. Air quantity to be extracted is 2800 m3/hr. per meter of belt width for belt
speed more than 1.0 M/Sec. Additional exhaust at the back of chute of the
loading conveyor of following
Capacity shall be provided wherever shown and possible as per layout for
more than 3 ft. Fall:
i)
Belt width 300 mm to 900 mm
: 1190 m3/hr.
ii)
Belt width above 900 mm
: 1700 m3/hr.
2. Belt width 1000 mm considered. Belt Speed 2 m/s
For screen:
Air quantity to be extracted is 915 m3/hr. per sq. meter of top cover area. Screen
(CS-1), size considered
14.4 m2 & Screen (SC-2), size considered 8.64 m2
For Crusher:
Air quantity to be extracted is 3600 m3/hr. per sq. meter of inlet opening. Inlet
opening considered
2.7X 0.8 M x M
For Fan
28 | P a g e
1. Fan Capacity calculated 10% more than the Calculated Volume of DE system.
2. Noise level shall be 85 d BA from 1 m distance.
3. Fan shall be SISW type Centrifugal fan with backward curved blades, simply
supported.
4. Fan RPM shall be max 1000 rpm Direct Coupled/Belt Driven.
5. 10% margin considered on calculated volume for selection of fan volume.
Chimney:
1. The height of Stack shall be +3.0 mtr from nearest house.
2. Chimney/Stack shall be supported from nearest building.
For Bunker floor ventilation system
1. For bunker Floor ventilation system volume calculation 8 air change /hr
considered.
2. Bunker floor length considered 60mtr.
3. Axial Flow fan is considered for bunker floor ventilation system.
For Compressed air:
1. Instrument quality air considered for bag filter pulsing.
2. Instrument quality air calculation will be done on the basis of 3.4 Nm3/m2 of bag
Area.
3. Compressor capacity shall be 1.25 times of the required compressed air flow
capacity.
4. Dryer is also considered to get instrument quality air.
5. Air Receiver shall be as per IS: 2825
6. Screw type air compressor air cooled oil Flooded.
7. Motor speed shall be 2900 rpm.
8. Noise level shall be 85 dBA from 1 mtr distance.
9. Capacity of compressed air shall be approximately 140 cfm, Pressure 8.5
Kg/cm2.
Location Considered for Dust Extraction System:
1. Screen House : Capacity of Bag Filter: 45000 m3/Hr
2. Tertiary Crusher House : Capacity of Bag filter : 22500 m3/Hr
Major Equipment involved in the DE system
1
Filter bags
2
Cages
3
Centrifugal fan (backward curved)
4
3 PH-motor for centrifugal fan
5
Inlet damper for centrifugal fan
6
Suction hoods
7
Manual & motorised damper
8
Sequential controller
9
Solenoid operated pulse valve
10
DP switch
11
Pressure switch
12
Rotary Air lock valve
29 | P a g e
13
IS:2062 gr.A
5 mm Thk
14
IS:2062 gr.A
5 Thk
15
Plenum
IS:2062 gr.A
3.15
Thk
mm
15
Screw conveyor
IS:2062 gr.A
16
IS:2062 gr.A
5
THIK
MM
17
Stack
IS:2062 gr.A
5
THIK
MM
18
Air compressor
(screw type, air cooled, oil flooded )
Standard
19
Standard
20
Air receiver
IS:2062 gr.A
As per IS:
2825,
Ventilation System:
Description for Mechanical (Tunnel) Ventilation System:
Push-pull type mechanical ventilation system shall be provided in the underground
portion of building & conveyor tunnels, cable tunnel, cable vaults to eliminate stagnant
contaminated air & produce a continuous flow of fresh air inside the tunnel. The air
quantity for mechanical ventilation system shall be estimated either based on the
equipment heat load or adequate air change, whichever is higher. The system consists
of a fresh supply air arrangement (push type) & a exhaust air arrangement (pull type) to
maintain a healthy atmosphere inside the tunnel. Centrifugal fan is considered for
supply of fresh air inside the system. Axial type fan is considered for extraction of
contaminated or polluted air from the system. Supply air is distributed inside the tunnel
by supply air duct. At regular interval supply air grill with VCD shall be provided in the
supply air duct to distribute the supply air inside the underground building. Polluted or
contaminated air is sucked from the underground building by exhaust air grill placed at
regular interval in the exhaust air duct.
30 | P a g e
Design Considerations:
Mechanical Ventilation System:
a. Supply air system:
i)
Underground area: No of air changes considered 15 /hr.
ii)
Velocity Maintained in the supply air duct & fan outlet shall not exceed 12
m/s.
iii)
Velocity through grill shall be 3-4 m/s
iv)
Fan shall be Centrifugal type, backward curved vanes for supply of fresh air.
a. Face velocity considered in the HDPE panel filter shall be 2-2.25 m/s.
HDPE filter shall be 3Ply having efficiency 90% down to 10 micron.
v)
Velocity in branch duct shall be 6-8 m/s
vi)
Ducting : GI sheet ducting (IS:655:2008 & IS:277)
vii)
Grills: GI sheet construction with volume control dampers and double
directional louvers. Spacing of
Grills: 5m (max)
viii)
Duct support shall be as per IS: 655:2008
b. Exhaust air system:
i)
Underground area: No of air changes considered 7 /hr.
ii)
Axial type fan for exhaust of contaminated air.
iii)
Velocity maintained in the exhaust air duct shall not exceed 6-8 m/s
iv)
The Velocity of air sucked in the exhaust air grill shall be 3-4 m/s
v)
Ducting : GI sheet ducting (IS:655 & IS:277)
vi)
Grills: GI sheet construction with volume control dampers and double
directional louvers. Spacing of
Grills: 5m (max)
vii)
Duct support shall be as per IS: 655:2008
c. Major Equipments involved in Mechanical Ventilation system:
Sr. No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Equipments
Centrifugal Type Supply Air Fan
Axial Type Exhaust air Fan
Panel Type Air Filter at Inlet of Supply Fan
3 Ph, AC motors For Supply Fan ,4 pole
3 Ph, AC motors For Exhaust Fan, 4 pole
INLET DAMPER AT CENTRIFUGAL FAN INLET
SUPPLY AIR DUCT (RECTANGULAR TYPE)
EXHAUST AIR GRILL (RECTANGULAR TYPE)
DUCT SUPPORT FOR SUPPLY & EXHAUST
SUPPLY AIR GRILL WITH VCD
EXHAUST AIR GRILL (FIXED TYPE)
RAIN PROTECTION COWL WITH BIRD
SCREEN FOR EXHAUST FAN
FIRE DAMPER(FUSIBLE LINK TYPE)
31 | P a g e
MOC
IS: 2062 Gr. A
IS: 2062 Gr. A
HDPE, 3 PLY , 610x610x50,
efficiency 90% down to 10
micron.
Standard
Standard
GI
GI
GI
IS:2062
GI
GI
GI
GI
:
:
:
:
DESCRIPTION
METAL AIR DUCT (GI)
SPECIFICATION OF ELECTRICAL AXIAL FLOW FAN
GALVANISED STEEL SHEETS
FIRE DAMPER
MOC
INLET FILTER
CENTRIFUGAL FAN
MOTOR FOR FAN
BIFURCATED TYPE TUBE AXIAL FAN
AIR DUCT SUPPLY AIR
GRILL WITH VCD
RAIN TROTECTION COWL/BIRD SCREEN
FIRE DAMPER
PROPELLER FAN
32 | P a g e
:
:
:
:
:
HDPE TYPE
IS: 2062
STANDARD
IS-2062/AL CAST
GI
: GI
: GI
: AL DIE CAST/MS
Ventilation Location:
Dry Pressurized Ventilation:
i)
HT MCC Room
ii)
LT MCC Room
Exhaust Ventilation:
i)
Battery Room
Air Conditioning System for PLC/CONTROL ROOM:
Introduction:
Air Conditioning system shall be considered for PLC cum control room, computer room,
Office room . It is designed considering equipment heat load, solar heat load, heat gain
into the room adequate number of air changes etc. to maintain a uniform temperature &
relative humidity within the air conditioned areas.
Air Conditioner- Package type water cooled, Non Ductable Hi wall mounted split Type
air conditioner is considered.
Design Considerations:
Indoor condition considered 232 C & 555 %
Fresh Air Intake: Minimum 1.5 air change per hour.
Occupancy considered 4 Nos
Lighting load considered 1 Watt/ft2 of room area.
Major equipments involved in the system:
Sl.
No.
1
2
3
4
5
6
7
8
Equipments
MOC
Standard
Standard
Standard
FRP Type
GI/MS(As per IS:655:2008)
GI
Resin bonded glass Wool (24
Kg/m3, 50Thk.) Cladding
30G GI sheet
5 Mtr of the supply air duct,
material : Fiber Glass Wool of
Density 48 Kg/m3
Acoustic Insulation
Title
Specification for electrical axial flow fans
Propeller type ac ventilation fans
Centrifugal fans
Split air conditioners
Package air conditioner
33 | P a g e
i)
ii)
3) ELECTRICAL
Power distribution:
CHP power distribution has been considered as per basic Overall power distribution
diagram Drg. No- CET RN 3812 EE1 00001, Rev-0.
As per the above document a detail Overall SLD has been generated and attached for
reference.
Power at 11 kV will be made available by the Purchaser at take over point within 100
metres from MRSS proposed to be installed by BTL. Purchaser will establish 11kV
gantry structure to terminate two 11 kV feeders of Panther ACSR overhead conductor
over LA & string insulators. Purchasers 11 kV Gantry will be considered as the Take
Over Point (TOP).
The scope of work will commence from tapping 11 kV power from TOP and feeding to
11 kV Switch board at MRSS. The Power from TOP will be drawn over 11KV Isolator
(G.O.D), LA &11 kV(E) XLPE cables and thereby to 11 kV indoor switch board to be
established for feeding entire Beneficiation Plant loads over 11/3.3/0.415kV power
distribution system.
One no. 11 kV/3.3 kV HT substation with 2 nos. 11/3.3 kV transformers and
associated 3.3 kV switch board will be provided in the MRSS to cater to the motor
loads having ratings above 160 kW. Adequate number of Load Centre Substations
(LCSS) each comprising of 2 nos. 11/0.433 kV transformers with associated LT
switchboard to feed power supply to various LT loads of the plant will be included in
scope of work. Supply, laying and termination (at both ends) of 11kV cable from the
11kV Gantry Structure (TOP) up-to 11 kV Switchboard at MRSS shall be in the scope
of work. Similarly supply, laying and termination (at both ends) of 11kV cable from
the11 kV Switchboard at MRSS to 11/3.3kV HV substation/HV MCC and 11/0.433kV
LT substations will be included in the scope.
Supply, laying and termination (at both ends) of 3.3 kV cable from HT motors to 3.3 kV
switch board will be under the scope.
HT load will be feed from 11KV switch board to 11KV/3.3KV transformer&
11KV/0.433V transformer as per single line diagram. All HT motor load will be feed
from client 3.3KV switch gear up to motor which are mentioned in attached single line
diagram.
34 | P a g e
2
3
4
5
6
7
8
9
10
11
12
ITEM DESCRIPTION
11 kV, 1250A,26.3KA/3 sec, three-phase outdoor, triplepole, off-circuit gang operated vertically mounted, single
break type isolator with manual earth switch on
outgoing side
Qty.
2
Unit
No
Set
No
Set
Set
No
Nos.
Nos.
Nos.
No.
Nos.
Set
doc.
No
11 kV Switchboard:
The switchgear distribution boards will generally comprise horizontally operated, floor
mounted heavy duty circuit-breakers for incoming, outgoing and bus-sectionalizing
circuits as required. The enclosure protection class of the switchgear will be IP4X.
35 | P a g e
The cubicle will be CRCA sheet steel of 2 mm for non-load bearing members and 2.5mm
for load bearing members.
The cast resin insulated Line & Bus PTs will be mounted on independent draw out type
carriages in separate panels.
Each cubicle will have lockable doors for the VCB compartment & metering
compartment. The switchboard will be natural cooled.
Non-magnetic removable bottom base plate will be provided in each chamber for cable
entry.
The bus bars will be made of electrolytic grade copper & Raychem sleeved and run
throughout the length of the distribution board.
Service, Test and Isolated positions of the circuit breakers will be achieved with the
front door closed.
Automatic safety shutters will be provided over the isolating contacts in the stationary
portion and will be so designed that the busbar compartment is completely segregated
from the breaker/PT compartment for all positions of the circuit breaker/PT.
HT Motor Control Centre (HT MCC) for 3.3 kV Motors:
3.3kV HT MCC will have two (2) incomers and one (1) bus coupler breaker (VCB) with
protective relay. The cubicles will be totally sheet steel enclosed, dust and vermin-proof,
floor mounting type indoor. Incoming and bus coupler circuit-breakers will be provided
with CT operated numerical relay having non-directional inverse definite minimum time
lag (IDMTL) over current and earth fault protection along with instantaneous over
current element along with time delay relay. Anti-pumping relay, trip circuit supervision
relay, master trip relay and auxiliary relays will be provided as a standard feature of
breaker control. ABT scheme will be adopted for HT MCC as indicated in the 3.3kV
switchboard.
Each outgoing motor feeder will basically comprise HRC fuse and high voltage vacuum
contactor mounted on a draw-out unit for isolation. Vacuum contactor will be
mechanically held (latched) type.
Circuit breakers and motor feeders will be provided with trip-neutral-close (TNC) spring
return control switch in HV MCC and the same will be mounted on its low voltage
compartment.
Minimum degree of enclosure protection for the HV MCC will be IP4X.
The HT MCCs will be provided with copper busbars.
11KV HT isolator:
Description of Isolating Panel- Pole Mounted Off load isolator with Earth switch
Standard followed in design, manufacture and Testing- IEC 60129/IS 9921
Type Designation: DFT
Rated current:
1250A
Supply Voltage and Frequency: 11KV50Hz
Rated operation/Insulation voltage:
12KV Insulation level
One minute power frequency withstand voltage:
1.2/50ms
Impulse withstand voltage:
28/32KVrms,75/85KV peak
Min Clearance in air (mm)
Phase to Phase: 229
Phase to earth: 178
36 | P a g e
37 | P a g e
38 | P a g e
Qty.
2
Unit
Nos.
2
2
1
1
1
Nos.
Nos.
No.
No.
No
No
Sl.
8
9
10
ITEM DESCRIPTION
MCC-5 FIRE FIGHTING
MCCs Conventional, Non-draw-out type, Single
front, Motor Control Centres (MCC) with two
incomers & one bus-coupler
PDB for coal handling area
VFD for apron feeder.
Qty.
1
Unit
No
1
1
No.
Set
doc.
No
LT SWITCHGEAR (PCC/MCC):
Industrial, floor mounted, self-supporting, sheet steel enclosed, compartmentalized nondraw out type 415V motor control centre will be adopted. The bus bars as well as the
incoming circuit breaker/outgoing MCCB will be capable of withstanding a through
fault current of 50 kA for 1 second. Sheet steel thickness will generally be 2 mm& non
load bearing member 1.6 mm. Generally MCCB will be provided for motor and power
feeders in 415V MCC. MPCB will be provided for power feeder rated up-to 10A and
motor feeders rated up-to 3.7kW. Ammeter and selector switch along with current
transformer will be considered for incomer.
The low-voltage switchgear will be PCC& Motor Control Centres of totally enclosed, selfsupporting, floor mounted, compartmentalized, single front, type construction. The
switchboard will be a sheet steel-clad low-voltage distribution board with door
interlocking facility. Local/remote selector switch will be provided in the PCC/MCC.
Power distribution boards:
Single front, non draw-out type, modular construction, having one incomer will be
provided for loads like welding sockets, maintenance cranes, hoists, power supply
feeders to repair shop, laboratory, admin building, utility aux load etc.
MCCB will be used as power isolating cum short circuit protection device for all
outgoing feeders.
The power distribution boards (PDBs) are generally intended for distribution of power to
various consumers in the plant area and will be suitable for 415V, 3-phase, 4 wire,
50Hz. The distribution boards will be of cubicle type having incoming & outgoing drawout ACB/MCCB units.
Degree of Protection will be IP-54.
Cubicle type power distribution boards will be totally enclosed, dust & vermin proof in 2
mm thick sheet steel construction, housing draw out Air Circuit Breakers and MCCBs
with O/C, S/C & E/F protection. The cubicle will be floor mounting type and will be
dust and vermin proof generally conforming to IP-54 with multitier compartmental
arrangement.
The bus bars will be of aluminium and will have continuous current rating same as that
of the incoming ACB/MCCB and will be suitable to withstand without damage the effect
of maximum short circuit current of 50 kA RMS for one (1) second.
39 | P a g e
Power supply
(Line - O/C, O/V, U/V)
Drive faults
(Fuse blown, cooling fan stop, device over temperature, instant O/C, overload)
Motor faults
40 | P a g e
(Motor overheating, phase loss, over speed, cooling fan stop, earth fault, brake
abnormal, stall detection, earth fault in motor circuit)
Others
(Control power abnormal, sync. power abnormal, CPU abnormal, speed detection
abnormal, speed/voltage relationship abnormal, control cubicle overtemperature)
Welding Load:
Welding power will be feed from above PDB to welding receptacle 100A receptacle has
been considered for the following area at 50 mtr interval.
MRSS, LCSS, MCPP, Transfer point, Secondary Crusher House, Tertiary, Crusher
House, Screen House, Bunker Floor, Surge Hopper House, WT-MCC, Conveyor Gallery.
Lighting Load:
Normal/AC lighting Load
Lighting load will be feed from 11/0.433KV transformer to MLDB & MLDB to LDB panel
at various location and LDB to lighting fixture.
Emergency /DC Lighting Load
Battery based emergency lighting system (for evacuation purpose) for all electrical
rooms, control rooms, basements, cellars etc which should switch on instantly in case
of Power failure. 30% emergency lighting will be considered for Sub-station Buildings
only. For other area 10% will be considered (Including Entry, Exit point & staircase.
415V MLDB:
Industrial, floor mounted, self-supporting, sheet steel enclosed, compartmentalized nondraw out type 415V MLDB will be adopted. The bus bars as well as the incoming circuit
breaker/outgoing MCCB will be capable of withstanding a through fault current of 50kA
for 1 second.
The MLDB will be provided with two (2) I/C which will be electrically and mechanically
castle key interlocked to avoid any parallel operation. One I/C will be fed from dedicated
transformer designed based on lighting load and the 2nd I/C will be fed from nearest
415V LCSS switch board. Other features will be as per Low voltage switchgear. Main
Lighting Distribution Boards (MLDB) with two incomers and bus coupler with IP54
enclosure for Power supply to various
LDB:
The LDBs will be provided with incoming MCCB (I) and outgoing DP miniature circuitbreakers (MCB).The sub-lighting distribution board will generally comprise incoming
MCCB (I), requisite number of outgoing miniature circuit-breakers and adequately rated
aluminium bus bars.
41 | P a g e
The boards will be of industrial, totally enclosed dust-proof, wall mounted, sheet steel
cubicle design.
The boards will have welded back and sides and gasketed hinged door at the front with
door handle and suitable locking devices. For boards with incoming MCCB (I) the access
to the operating handle will be from the front of the cubicle without opening the front
door. Operating knobs of outgoing MCBs will be accessible only after opening the front
door of the cubicle. Protective insulated cover plate will be provided inside the cubicle to
shroud all the live parts with only the operating knobs of the MCBs protruding outside
the cover plate. Adequate space will be provided within the board to facilitate
termination of incoming and outgoing cables. The boards will be factory wired and
assembled.
HT & LT Motor for conveyor drive:
The Electric motors has been considered Squirrel Cage induction type in horizontal foot
mounted design, totally enclosed fan cooled with IP-55 degree of protection. All the
motors will be provided with Class F insulation, temperature rise limited to class-B
limit over an ambient temperature of 50deg .The motors will be provided with a terminal
block on the side which can be rotated through 360deg in steps of 90deg. All the motors
will be provided with two earth connections. The ratings of all motors will be as per the
drive list furnished with mech. Motor has been considered as per technical specification
doc. No CET/26/RN/3812/TS/CC/01/R=1& S&TMCPL/DB-ELE-001, clause no-5.0
H.T Power cables:
The H.T power cables will be 6.6KV (UE) grade ,stranded Almunium conductor with
extruded XLPE insulated, each phase having screening by a semi conducting material ,
with Extruded PVC inner sheath ,G.I. strip / wire armoured having over all Extruded
PVC sheathing (Type-ST-1) with oxygen index not less than 29. HT power cable has
been considered from purchasers switch gear room to proposed CHS MCC room (Near
WT-3).
L.T Power cables:
LV Power Cable has been considered 1100 V grade, single/multi-core, stranded
aluminium conductor, XLPE insulated, extruded FRLS PVC, inner sheathed of type ST2,galvanized single round steel wire/strip armoured and with outer sheath made of
FRLS PVC compound of type ST-2. The cables used for DC system will be of single core
type. Minimum conductor cross section of power cables shall be 4 Sq.mm.
Control cables:
Control cables have been considered 1100V grade, multicore, minimum 1.5 sq.mm
cross section, stranded copper conductor having 7 strands, PVC insulated, inner FRLS
PVC sheathed of type ST-1, galvanized steel wire armoured and outer sheath made of
FRLS PVC compound of type ST-1. In situations where accuracy of measurement or
voltage drop in control circuit, warrant, higher cross sections as required will be used.
For all the CT & PT cables, minimum 2.5 sq.mm cables will be used.
Instrumentation cables:
42 | P a g e
All signal cables will be twisted pair copper conductor of 1.0mm2 with PVC insulation
for each core with semiconductor Mylar taping over each Pair, with over all annealed
tinned copper braiding on all the pairs with over all PVC sheathing as per relevant I.S.
The cables will be in 2 Pair/ 3Pair/ 5 /8P /12 Pair configuration as per the system
requirement & detail engineering.
Local pushbutton Station & Junction box:
Local control station (wall mounted/pedestal mounted) will be provided for proper
control and operation of all equipment supplied by the Contractor. The local control
stations will be located near the respective equipment.
Local control stations will be normal type. Degree of enclosure protection will be IP: 65.
Local control stations will be provided with start/stop push button. Stop push button
will be pressed to lock and turn to release type mushroom-headed push button. Local
selected indication lamp will be provided on the LCS.
Control junction box will be made of Thermoplastic polycarbonate with IP-65 degree of
protection.
Terminal blocks will be mounted on DIN rail. 20% spare terminals will be considered for
each control box.
Switch Sockets for Repair network:
415 V, 100A, 4 pin switch sockets have been envisaged at suitable
locations for the purpose of welding.
Lighting Fixtures & Lamps:
Lighting Fixture has been considered in all the area within BTL battery
limit after considering suitable lux level as per industrial sta ndard with
necessary fitting are as follows:
Sl
No.
1
4
5
Location
Normal Lighting
Emergency
Lighting
Conv. Gallery
Type
70W HPSV
70W HPSV
70W HPSV
DC Light
GLS)
Transfer
Points
&
150W HPSV
Houses
Staircase
for
all
70W HPSV
buildings
Switchgear room/LTSS 2X40W FTL
2X40W FTL
Control room
2X40W FTL
Battery room
2X40W FTL
Transformer Room
2X40W FTL
43 | P a g e
(100W
Sl
No.
Location
Normal Lighting
Emergency
Lighting
HT Switchgear room
2X40W FTL
/MRSS
Switchyard
&
all
250W HPSV
outdoor areas
6
7
In addition with above road lighting will be considered for material handling area up to
1200 meter by 10 meter lighting pole with fixture at 30 meter interval to achieve
required lux level.
6 nos. High mast has been considered for ground hopper stock pile& reject stock pile
area for yard lighting.
Cabling, Earthing and Lighting Protection:
Cabling has been considered for the above cable including laying by different size cable
tray, separate cable tray has been considered for Power cable, control cable &
instrument cable. Required size conduit has been considered for field instrument
looping and termination purpose. Cable laying, termination has been considered as per
specification.
Earthing & Lightning protection system has been considered as per specification doc.
No CET/26/RN/3812/TS/CC/01/R=1 & S&TMCPL/DB-ELE-001, clause no-5.0
Earthing material has been considered in various areas in CHP system are as follows:
Sl
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Equipment
Earth Pit
Main earth grid
3.3KV
Switchgear/415V
Switchgear/11/3.45 KV Trafo
11KV Switchgear
11/0.433 Transformer, 2MVA
LT Motors (160-200KW)
LT Motors (110KW to 132KW)
LT Motors (15KW to 90KW)
LT Motors (3.7KW to 11KW)
Control panels & Control
desk
PB Station/JB
Columns,structures,cable
trays & busduct enclosures
Crane,rails,rail tracks & other
non-current carrying metal
parts
Earth Pit for lightning
Down-Comer
Electronic Earth Pit
VVVF/DCDB/UPS/PLC
44 | P a g e
Earth
conductor
ground level
40mm dia MS Rod
75X10 mm GS flat
above
40X6 mm GS flat
65X8 mm GS flat
50X6 mm GS flat
40X6 mm GS flat
25X6 mm GS flat
16 Sqmm stranded Wire
50 Sq mm stranded
6 Sq mm stranded
50X6 mm GS flat
25X6 mm GS flat
25X6 mm GS flat
25X6 mm GS flat
1CX25 Sqmm Cu. Wire
Electrics for Equipment Wagon tippler & side arm charger, hoist, elevator, tripper
etc.
All electrics for Wagon tippler & side arm charger, hoist, elevator, tripper etc. has been
considered as per equipment standard application and specification which details can
be given during detail engineering stage.
Instruments:
Safety Switches (ZSS/PCS/BSS):
Zero Speed Switch:
Each conveyor will be provided with industrial duty non-contact type
proximity type zero speed switch along with its electronic controller of
protection class conforming to IP55. The electronic unit will have
provision to receive auxiliary power at 110V AC and generate potential
free 1 NO + 1 NC contact each rated for 10A at 110 Volt. The electronic
unit will have provision to adjust time delay for contact actuation as well
as dropping of relay to avoid nuisance tripping. The switch will be
supplied with special cable between sensor and the electronic unit. The
proximity switch shall be suitably designed to sense with a gap up to 20
mm.
Pull Chord Switch:
Pull cord switch will be provided in conveyor gallery @ 25minterval along walkway on
both sides. The pull cord switches will be industrial, heavy-duty types, enclosed in a
dust and vermin proof cast iron, cast aluminium box. The switches will be operable in
both directions with automatic locking arrangement in the operated position and will be
manually reset type. The pull cord switches will have 2 NO + 2 NC contacts each rated
10 A at 110 V and will be complete with parallel running pull wire and associated
accessories. The degree of protection for enclosure of pull cord switches will be IP65.
Belt Sway Switch:
Belt sway switches will be provided along conveyor @ 50 m interval on both sides with a
minimum of 1-pair for each conveyor. Belt sway switches will be industrial, heavy duty
type, housed in a dust and vermin proof cast iron, cast aluminium box with indirect
acting mechanism such that the belt does not come in direct contact with the switch
element. The switches will have 2 NO + 2 NC auxiliary contacts each rated for 10A at
110 V AC. The degree of protection for enclosure will be IP65.
Limit Switch:
Heavy-duty type limit switches will be provided for automatic reversal of shuttle
conveyor as well as stoppage during over travel. The same will be provided with 2 NO +
2 NC auxiliary contact of 10 A rating at 110V. The degree of protection for enclosure will
be IP:65. Heavy-duty proximity type positioning switches, with sensing distance to suit
the application, will be provided for automatic positioning of the carriage of reversible
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shuttle conveyor. The switches will be 3 wire type with leakage current below 10 mA and
suitable for signal exchange with PLC system.
Chute jamming switch:
Chute
jamming
indication will be needed
for automatic stoppage
of
upstream/downstream conveyors through tilt switch which will be located at the exit
side of the chute. The tilt switch will be actuated when material flow on conveyor is
normal to tilt the probe of the tilt switch 15 degrees or more from its vertical position.
The mercury switch will get tilted regardless of the direction of tilt and the NO contact of
the switch will close. When there is no material flow from the chute, thus indicating
chute jammed condition, the NO contact will open and will generate a signal to PLC
system to trip the conveyor. The probe will be adequately protected against mechanical
damage. The control unit will be suitable for outdoor installation with degree of
protection IP 54. Green (normal) and Red (alarm) indicating lamps will be provided on
the front panel of the control unit. There will be provision for adjustable time delay to
prevent stoppage of conveyors in case of momentary tilting of the probe.110 V AC, 5 A, 2
NO, 2 NC contacts will be made available for interlocking/alarm. Alternatively,
ultrasonic/ microwave operated switch inside the chute may be adopted, where
specified in TS.
Temperature transmitter
The said transmitter will be considered for each HT motor bearing and winding RTD
application as per specification
Individual JB will be considered for transmitter housing of each HT motor as per RTD &
BTD application. The signal will be transmit up to DCS (employer scope) by the help of
respective PLC &RIO panel.
Level Measurement System
Radar type continuous level measuring system will be provided at the top of bins &
silos. The system will comprise of probe & electronics unit. The probe will contain an
inner active section and an outer shield section. The electronics unit will consist of
oscillator, detector, etc. The design consideration is as follows:
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On conveyors to record the quantity of coal received in the plant and quantity of
coal conveyed.
Boom conveyor of SCR to record quantity coal available in stockpile and also
reclaiming rate.
The belt scale is considered as load cell type and of continuous operating. Provisions for
local and remote measurement of instantaneous through put, totalling, local signalling
of load limits of conveyors will be provided. Control of sampler, signals for remote
indication and overload alarm will be given in the belt scale. Suitable device for testing
the accuracy by test weights will be provided. The belt scales will be of electronic
microprocessor type. Weigh scales will be of multi-idler type.
Vibration Monitoring System for each Crusher:
Vibrating monitoring system is considered for the ring granulator type Crushers to
sense and for indication of vibration of the equipment and transmission of the sensed
signal to the Control room for indication of alarm and tripping in case of any
abnormality of the equipment.
We have considered simple Vibration Monitoring System for total 2 Nos. of Crusher
(both its Driving End & Non Driving End location and in Horizontal & Vertical location).
The output from the Two Sensors would be fed in to the Dual Channel Monitor, which
provides a continuous display, Alarm-Alert Relay and 4-20 mA Output. This transmitter
is a dual channel one and the output could be fed in to the CHP DCS. We have also
considered a buffer output using handheld portable data collector for further analysis of
the data.
Individual control panel will be considered for each system.
Automation System
Level-1 Automation System:
The proposed instrumentation & automation system will comprise of PLC systems (PLC),
primary & secondary instruments and field devices.
i)
ii)
iii)
Automation system for each area will be achieved through dedicated PLC system housed
in respective control room along with Human Machine interface (HMI), Operator stations
(OS), Engineering stations, system cabinet, input/output subsystem, communication
sub system, peripherals etc. for execution of sequential operation & logic control, PID,
process monitoring & supervision, data acquisition, historical trending and logging.
Each PLC system will be complete with necessary application software, system software
& communication Software. Each PLC system will have redundancy with respect to
CPU, power supply & communication modules with hot standby feature. Necessary
hardware will be considered for bringing all signals from different areas to PLC system.
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All control loops will also be achieved in the PLC system. PLC system will be considered
as per said specification & requirement.
UPS with Battery Backup:
UPS system (minimum 2x10 KVA) in parallel redundant mode & single phase 220 V ac
with neutral grounded output and sealed maintenance free battery will be provided
catering the need of Instrumentation &Automation system, PLC, Fire Detection & Alarm
system, voice communication system, EPABX, PA system & CCTV system. The UPS will
be installed in A/C environment in or near the Control Rooms. The purchaser will
provide two feeders of 440V AC 3 phase, 4 wire input supply. The UPS will be designed
such that it is loaded up to 60% of the capacity. The Bidder will generate two feeders of
440V, 4 wire AC input along with manual changeover scheme for input supply to
UPS.UPS failure will be displayed in the Operator station of PLC.
The UPS will be provided with servo controlled voltage stabilizer (SCVS) in the by-pass
line with static switch. Further, static by-pass line should have selector switch for
manual by pass of the UPS& SCVS system in case of maintenance of UPS. The output of
the UPS will be suitable for 230 V AC, 50 Hz with voltage and frequency variation
limited to +1% and +0.5% respectively or better. Necessary potential free contact will be
provided for alarm and status contacts to be hook up to respective automation
system.UPS distribution board will be provided with 20% spare feeders. DPMCB with
suitable rating will be provided at each of the feeders including the spare ones.
.
Metal Detector /Magnetic separator
The above equipment has been considered as per flow diagram with specification which
E & I part control panel has been considered. Necessary IO hook up provision has been
kept inside the control panel. Signal will be transmitted from respective control panel up
to PLC/ RIO panel.
Instrument for DE & DS system
Following instrument will be considered for DE & DS system for various locations as per
scope which detail will be submitted along with P & ID diagram during the time of detail
engineering.
1. Pressure switch, 2. Displacer type level 3. Sequential controller, 3.Pulse valve
All the instrument associated with DE & DS system will be considered as per said
specification & requirement.
Plant telephone system:
The Automatic telephone exchange and allied equipment along with the required cabling
network are intended for providing internal communication inside the plant as well as
for external communication beyond the plant. It will consist of one number EPABX
system with 4x64 line capacity and line cards for 192 extensions including power
supply equipment along with rechargeable Battery bank, operator console and Main
Distribution Frame (MDF). The system will be complete with standard telephones 48 nos
and necessary telephone cable network for the subscribers within the plant office
building & control room buildings. The exchange will be equipped with required
hardware and software to interface with the Loudspeaker Intercommunication system
(LSIS)/ Public Address (PA) system of the respective shop.
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The
above
system will
be
considered
as
CET/26/RN/3812/TS/CC/01/R=1, clause- no 3.6.5
per
specification
doc.
No
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4) STRUCTURAL WORK:
4.1 TECHNOLOGICAL STRUCTURES
S
NO.
Description
QTY.
Lot
Deck plate
Lot
Skirt Board
Lot
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Location
Stringer will be made of ISMC 150 for
Conveyors above 1000 mm Belt Width
& ISMC 125 for conveyors up to 1000
mm Belt Width.
Short posts shall be made of ISMC
150 for Conveyors above 1000 mm
Belt Width & ISMC 125 for conveyors
upto 1000 mm Belt Width.
MS deck plate of 3.15 mm thick shall
be provided at every feed point up to 3
m beyond the skirt length of all the
conveyors. 6 m long deck plate from
the centre line of head pulley shall
also be provided at the head end of all
conveyors.
Length of skirt board for single
discharge, the length of the skirt shall
be minimum 4000 mm. In case of
multiple feeding, length of the skirt
shall be continuous covering all feed
points. Skirt board top cover shall be
3.15 mm thk MS cover. The height of
skirt shall be minimum 400 mm for
800 mm BW, 450 mm for 1000 mm
and 1200 mm BW and 500 mm for
more than 1200 mm BW. Modular
segmented type skirt sealing system
for effective sealing against spillage
and dust shall be provided. Steel liner
MN STEEL (IS:276 GRADE-1) of 10
mm thick shall be provided in the
skirt which shall be fixed by csk bolt.
In feed zone, liners of full height shall
be provided and beyond feed zone,
liner height shall be 200 mm. Skirt
shall be made of 10 mm thick plate .
S
NO.
Description
QTY.
Location
All the chute body shall be minimum
10 mm thick MS plate. Conveyor hood
shall be made of minimum 5 mm thick
MS plate.
Lot
Hinged
type
inspection
doors
minimum of 500 x 500 mm and poke
doors of 300 x 300 mm shall be
provided, wherever required.
Height of single piece of chute shall
not more than 2 meters
Impact zone of all chutes shall be
lined with 60 mm thick rubber liner
and sliding areas with 30 mm thick
ultra high molecular weight polymer.
All clean coal chutes shall be lined
with SS-304 liner. Liners shall be
provided at three (3) sides of chute
plates for inclined chute at all four (4)
sides for vertical chutes.
The size & shape of liner shall be
provided for easy handling and shall
not exceed 20 kg/hour
4.2
S
NO.
1.
2.
Description
Gallery
QTY.
Lot
Location
Conveyor Galleries shall be of open
type welded latticed steel construction
with belt hood. The conveyor belt with
hood cover shall be located on top of
the supporting structural gallery
girder.
For conveyors of length more than
250m, cross-over shall be provided
over the conveyors at the location of
emergency escapes. Under-passages
may also be provided in lieu of cross
over. The cross over/under-passages
shall be spaced not more than every
180 m. Emergency escapes via
staircases of width 750mm, shall be
provided from near the locations of
cross-overs / under-passages.
Cross Over
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S
NO.
Description
QTY.
3.
Trestles
Lot
4.
Lot
5.
Walkway width
Lot
Location
Conveyor supporting trestles and
towers shall be of steel construction
and arranged with due care for
stability of the gallery to be achieved
by providing adequate bracing system.
Trestles supporting overhead and over
ground conveyor galleries shall be
either 4-legged or 2-legged and of
structural steel conforming to IS:2062.
They shall be spaced at 20 m c/c and
supported on RCC foundations.
The walkways shall be of 6mm thick
MS chequered plate. Suitable toe
guard shall be provided on the
conveyor side of the walkway for
protection in all the conveyor galleries.
The clear width of walkway in
conveyor gallery / tunnels shall be
1000mm on one side and 600mm on
the other side for single conveyors. For
double conveyors in the gallery
/tunnel, 1000 mm walkway at centre
and 600mm on either side shall be
provided.
a) Structures for following unit with galvanised colour coated roof & side sheeting
with working platforms, access stairs, ladders, handling facilities & handrails etc
1.
2.
3.
4.
5.
6.
7.
8.
Junction houses.
Ground feeding hopper shed.
Pent house.
Primary & secondary crusher house.
Tertiary crusher house.
Screening house.
Air compressor shed.
Flocculent dosing shed.
b) Wagon tippler shed with EOT crane, working platforms, crane supporting
structures, crane maintenance walkway/ platforms, galvanised colour coated
roof, side & gable end sheeting, access stairs, ladders & handrails etc as per
technological requirements.
c) Main coal preparation plant (Washery unit ) with EOT crane, working platforms,
crane supporting structures, crane maintenance walkway/ platforms, galvanised
colour coated roof, side & gable end sheeting, access stairs, ladders & handrails
etc as per technological requirements.
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d) Shed with handling facilities over new RCC silos, with grating platforms over
silos, working platforms & maintenance platform, galvanised colour coated
roof, side & gable end sheeting, access stairs, ladders & handrails etc as per
technical technological requirements.
e) Plant feed silo (surge hopper) supporting structures with handling facilities,
walkway, stair, ladder & handrails etc.
f) Trestles & bridges for utility pipe lines & cables routing with working
platforms, access stair, ladder, handling facilities & handrail etc. as per
technological requirements.
g) Access stair, ladder, handrail & handling facilities as per requirement.
h) All the buildings, junction houses etc. shall be covered with Galvanized colour
coated sheets on roof, sides & gable end.
5. Civil Work
The major civil works involved are as follows:
a) Wagon Tippler
Civil works for Wagon Tippler, including RCC foundations for overhead shed,
underground hopper and for underground conveyor system
Civil works for RCC famed control building for the wagon tippler, including RCC
trenches etc.
b) Conveyor System and Junction Houses
Civil works for underground conveyor system, including RCC works for tunnels
(minimum height 3.5m, minimum width 4.5m), penthouses, hoppers, apron
feeders, ground feeders, vibro-feeders, surge hoppers, Structural silos, Middling
and reject stock piles, RCC foundations and grouting of structural supports etc.
RCC foundations for structural trestles supporting conveyors etc.
RCC foundations and flooring for the junction houses
c) Technological Buildings
Civil works including RCC framed structure with brick cladding for Magnetite
Storage building, MCC building, Store cum Workshop building, Canteen-cumtoilet building, electrical substation, Floatation Reagent Storage building,
Transformer building, laboratory building and other such buildings along with
equipment foundations.
RCC foundations for MCPP building, Crusher House, Classifying Screen House,
Tertiary Crusher, Air compressor shed, Flocculent Dosing building and other
such buildings along with the foundations for equipments.
d) Administrative Building
Civil works including RCC framed structure with brick cladding for
Administrative building. The building shall consist of rooms for executives and for
in-charge with attached toilets. There shall be one conference room and a pantry.
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The building shall have one common toilet block (for gents and ladies separately)
in each floor. Necessary sewer lines, septic tank & soaking pits, drinking water
lines all fittings and fixtures, water tanks, RCC underground reservoirs and
pumps for lifting of water from underground reservoir shall be provided. The total
floor area shall not be less than 500 Sqm. This excludes the control room area of
the Main Washery which shall also be housed in the the same Administrative
building.
Civil works for Parking shed for cars, scooters and cycle.
Landscaping in front of the building.
e) Thickeners
RCC foundations columns, pedestals and other supporting structures.
f) Weigh-bridges
Civil works for Weigh-bridges
Civil works for RCC famed control room for weigh-bridges
g) Silos
RCC works in silos, hoppers foundations and supporting structures.
h) Water Tanks and Pump houses
RCC water tanks for raw water and fresh water
RCC framed pump houses with brick cladding for Raw water and Fresh water
i) Sedimentation Ponds
Civil works including concrete floor and walls in brickwork for the sedimentation
ponds.
j) Drinking & Sanitation water
Construction of RCC water sump and RCC overhead water tank of adequate
dimensions as per technological and functional requirement. The scope also
includes distribution network of pipelines to various points for drinking and
sanitation purposes.
k) Roads, Culverts and Boundary Wall
Civil works in bituminous, 7.5m wide WBM roads all around the premises and to
approach all the buildings and facilities. The requirement of roads indicated here
is tentative and may changeas per the technological and functional requirement.
Civil works for RCC culverts
Civil work for RCC framed Boundary wall, with RCC columns, plinth beams, tie
beams and brick-work. Boundary wall shall have a height of 2.6m including 0.6m
height of concertina coil.
l)
Civil work for RCC garland drains of 1.5m and sufficient depth to carry storm water
(considering volumetrically 2m depth through out) and connection with the
sedimentation pond. This drainage shall be part of the new drainage system catering
to the entire developed area and same shall be connected to the sedimentation pond.
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m) Miscellaneous
RCC flooring for the buildings, shops and finishes shall be as per technological,
process and system requirement.
Civil works for electrical substations, Transformer foundations along with rails,
oil pits, control rooms, PLC rooms, computer room, Hydraulic rooms, electrical
and MCC rooms, AC & ventilation rooms cable trenches/tunnels etc and all
units, as per technological, process and system requirement.
RCC Scale pit, scale tunnel including pump houses with handling facilities etc.
as per technological, process and system requirement.
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