Rpcl Nit Technical Specification

TECHNICAL SPECIFICATION

COAL HANDLING PLANT and MILL REJECT HANDLING SYSTEM

(PART-A)

FOR

2x800MW YERMARAS THERMAL POWER STATION PROJECT

OF

RAICHUR POWER CORPORATION LIMITED

PREPARED BY:

Evonik Energy Services India Pvt. Ltd.

(A wholly owned subsidiary of Evonik Energy Services GmbH, Germany) A-29 & 30, Sector-16 Noida 201301, India

MARCH 2011

2X800 MW YERMARAS TPS PROJECT

Doc. No.: E072-03-CHP-O-02 REV. NO.: R3 PAGE 2 OF 506

PART A

COAL HANDLING PLANT SPECIFICATIONS (COAL HANDLING PLANT & MILL REJECT

HANDLING SYSTEM)

R3 10-03-2011 Final Issue S.K.A J.K.K K.B R2 10-02-2011 Revised Issue S.K.A J.K.K. K.B. R1 08-12-2010 Revised Issue S.K.A J.K.K. K.B. R0 03-08-2010 Draft Issue S.K.A J.K.K. K.B. Rev Date Description Prepared By Checked Approved By



TABLE OF CONTENTS

SECTIONS PAGE 1.0 SYSTEM DESCRIPTION ................................................................... 6

1.1 MECHANICAL ................................................................................. 71.1.1 General ........................................................................................ 71.1.2 Coal Unloading System ................................................................ 81.1.3 Coal Crushing System .................................................................. 81.1.4 Coal Bunkering System .............................................................. 101.1.5 Coal Stacking and reclaiming System ......................................... 101.1.6 Coal blending system ................................................................ 121.1.7 Manual unloading system .......................................................... 121.1.8 Coal area Drainage system ......................................................... 13

1.2 ELECTRICAL .................................................................................. 131.3 CONTROL AND INSTRUMENTATION ............................................. 14

2.0 SCOPE OF WORK ......................................................................... 152.1 MECHANICAL ............................................................................... 162.2 ELECTRICAL .................................................................................. 232.3 CONTROL AND INSTRUMENTATION ............................................. 302.4 CIVIL ............................................................................................ 32

3.0 TERMINAL POINTS AND EXCLUSIONS ........................................... 374.0 TECHNICAL REQUIREMENTS OF COAL HANDLING PLANT .............. 40

4.1 MECHANICAL ............................................................................... 414.1.1 Rated and design capacity ......................................................... 414.1.2 Standards/Codes ....................................................................... 424.1.3 Specification of Equipment ........................................................ 43

4.2 ELECTRICAL .................................................................................. 864.2.1 Power Transformer .................................................................... 864.2.2 LT Distribution Type Transformer ............................................ 1004.2.3 HT Switchgear ......................................................................... 1054.2.4 LT Switchgear .......................................................................... 1354.2.5 HT & LT Power and Control Cables ........................................... 1494.2.6 Instrumentation cables ............................................................ 1624.2.7 DC System ............................................................................... 1654.2.8 HT Motor ................................................................................. 1754.2.9 LT Motor .................................................................................. 1804.2.10 HT&LT Bus Duct ....................................................................... 1864.2.11 Neutral Grounding ................................................................... 1944.2.12 Illumination system ................................................................. 196



4.2.13 Installation / Erection .............................................................. 2164.2.14 Earthing ................................................................................... 2424.2.15 Control Panels & Cabinets and Miscellaneous Electrical Equipment

2504.3 CONTROL AND INSTRUMENTATION ........................................... 253

4.3.1 General Requirements .............................................................. 2544.3.2 Design Criteria ........................................................................ 2554.3.3 Control and Instrumentation Items .......................................... 2574.3.4 Programmable Logic Controller (PLC) ....................................... 2604.3.5 Field Instruments ..................................................................... 2694.3.6 Drive Control Philosophy ......................................................... 2744.3.7 Instrumentation Cables, Wiring & Terminals ............................. 2764.3.8 Instrumentation Interconnection Philosophy ............................ 2764.3.9 Junction Box (JB) ...................................................................... 2764.3.10 Installation / Erection .............................................................. 277

4.4 CIVIL .......................................................................................... 2794.4.1 General .................................................................................... 2794.4.2 Specific Requirements for various components of Coal Handling

Plant ........................................................................................ 2854.4.3 Field Quality Plan ..................................................................... 3063.1.1 IS Codes & References ............................................................. 3074.4.4 Deliverables ............................................................................. 308

5.0 OPERATION & CONTROL PHILOSOPHY ........................................3096.0 SPARES LIST ...............................................................................316

6.1 MECHANICAL ............................................................................. 3176.2 ELECTRICAL ................................................................................ 3216.3 CONTROL AND INSTRUMENTATION ........................................... 326

7.0 DRAWINGS AND DOCUMENTS TO BE FURNISHED BY BIDDER .......3297.1 DATA TO BE FURNISHED WITH THE BID ...................................... 3307.2 DATA TO BE FURNISHED AFTER AWARD OF CONTRACT ............. 331

8.0 PERFORMANCE & AVAILIABILITY .................................................3398.1 SYSTEM PERFORMANCE REQUIREMENTS ..................................... 3408.2 ILLUMINATION LEVELS ................................................................ 3428.3 EARTHING RESISTANCE .............................................................. 3428.4 DUST CONTROL SYSTEM ............................................................ 3428.5 ENDURANCE TEST ...................................................................... 342

9.0 LAYOUT & MAINTAINANCE REQUIREMENT ..................................34310.0 VENDOR LIST .............................................................................345



11.0 DATA SHEETS ............................................................................347DATA SHEETS-A: SPECIFIC DATA SHEET................................................ 348

Mechanical .......................................................................................... 348Electrical ............................................................................................. 371Control and Instrumentation ............................................................... 394

DATA SHEET-B: DATA TO BE FILLED BY THE BIDDER ............................. 408Mechanical .......................................................................................... 408Electrical ............................................................................................. 424Control and Instrumentation ............................................................... 493

12.0 LIST OF DRAWINGS ENCLOSED ...................................................501LIST OF DRAWINGS ENCLOSED .............................................................. 502

13.0 ANNEXURES ...............................................................................503ANNEXURE-1: MECHANICAL-COAL ANALYSIS REPORT .......................... 504ANNEXURE-2: SUMMERY OF SCOPE ...................................................... 506



1.0 SYSTEM DESCRIPTION



SYSTEM DESCRIPTION 1.1 MECHANICAL 1.1.1 General 1.1.1.1 The propose 2 X 800 MW TPS is receiving coal from mines which has

calorific value ranging from 4000 5100 Kcal/Kg. It is also proposed to use imported Indonesian coal with calorific value of 6000 Kcal/Kg and high volatile and moisture content. The Indian coal and the imported coal shall be blended with maximum 70:30 % ratio. Thus the coal handling plant is required to operate with different type and combination of coal depending upon the availability of both Indian and imported coal. The boiler has been designed with worst Indian coal with calorific value of 4100 Kcal/Kg.

1.1.1.2 The daily coal consumption of 2 X 800 MW Yermaras TPP works out to

16500 - 19000 MT of coal based on the type of coal being used in the plant like blended coal or the indigenous coal.

1.1.1.3 Coal in size of (-) 300mm for the proposed 2 X 800 MW power plant is

envisaged to brought to Site by Railway in all types of Box-N type wagons as per latest RDSO G-33 norms. All transporting facilities including wagons and locomotives to transport the coal from the mine to the plant will be provided by Railways.

1.1.1.4 In order to handle the large quantity of coal required for the plant at

90% PLF five to six rakes are required to be handled daily. In order to handle unloading of six (6) nos. rake per day and avoid demurrage for holding the wagons it is proposed to install Five (5) nos. wagon tipplers with three available for actual operation and other one under maintenance and the other as the standby. The availability of three wagon tippler at any time would facilitate unloading of three rakes simultaneously with in the allotted time of unloading of wagons. The arrangement of wagon tippler is designed in cluster of three and two wagon tipplers so that the normally one stream of conveyor from two wagon tippler would be operated at full capacity.

1.1.1.5 Coal handling plant has been designed for operation of 14 hours.

However CHP shall be capable to operate for 24 hours. Two streams of conveyors considered from Conveyor BCN-1A/B/C/D/E to bunker bay



except stack yard conveyors. Out of two stream conveyors one stream will be working and other stream will be standby. However coal handling plant shall be designed for simultaneous and continuous operation of all the conveyors. Single stream conveyor will be provided for each stacker-cum Reclaimer,

The capacities of conveyors from Wagon tippler to bunker including yard conveyor are, Designed 2200 TPH and Rated 2000 TPH. Except manually unloaded coal conveyor BCN-23A/B, which has a capacity of Designed- 600 TPH and Rated- 500 TPH. Coal Stock yard shall be designed for about 30 days storage of coal requirement of both units. Maximum consumption of coal will be considered 800 Ton/hr for both the units. (Minimum capacity shall be 6.0 lacks tons.) The scope of work shall be as per coal flow diagram drawing No. E072-03-CHP-M-03-01 and Coal handling plot plan drawing No. E072-03-CHP-O-03-02.

1.1.2 Coal Unloading System 1.1.2.1 Below each wagon tippler, hopper shall be provided. Each hopper at

the bottom will be provided with rack and pinion gate for isolation of hoppers. Below the each wagon tippler hoppers apron feeder and dribble feeder shall be provided. Apron feeder and dribble feeder will feed coal to conveyor BCN-1A from Wagon tippler-1, BCN-1B from Wagon tippler-3, BCN-1C from Wagon tippler-5, BCN-1D from Wagon tippler-2, BCN-1E from Wagon tippler-4. In wagon tippler hoppers, grizzlies shall be provided at ground level. Wagon tippler shed floor level will be equal to rail top level.

1.1.3 Coal Crushing System 1.1.3.1 Path -1- Coal of (-) 150 mm is received (Raw/washed coal): The

raw/washed coal from wagon tippler WT-1, WT-3 and WT-5 will be fed to conveyor BCN-1A, BCN-1B and 1C respectively and further shall be transferred either to conveyor BCN-2A or BCN-2B at junction tower JT-15. Coal from Conveyor BCN-2A/B shall be transferred to either



conveyor BCN-4A/B through secondary crusher house. The conveyor BCN-2A will feed two Nos. of secondary crushers and the conveyor BCN 2B will feed two Nos. of secondary crushers each of Designed capacity - 1250TPH, Rated capacity - 1000 TPH, out of four crushers two crushers will be working and other two will be stand-by. However it shall be possible to operate all the four crushers simultaneously so that coal from two crushers of stream-A can be fed to bunkers and coal from Stream-B can be stacked.

1.1.3.2 Path-2- Coal of (-)25 mm is received (Washed coal or imported coal): The washed/imported coal from wagon tippler WT-1, WT-3 and WT-5 will be fed to conveyor BCN-1A, BCN-1B and 1C respectively and further shall be transferred to conveyor BCN-3, at junction tower JT-15, in turn the same will be fed to conveyor BCN-5A/B at junction tower JT-14 without crushing.

1.1.3.3 Path-3- Coal of (-)300 mm is received (Raw coal): The raw coal from wagon tippler WT-2 and WT-4 will be fed to conveyor BCN-1D and 1E respectively and further shall be transferred either to conveyor BCN-2C or 2D at junction tower JT-19, which in turn feed to conveyors BCN-4C/D at primary crusher house, PCH. In primary crusher house there are four Nos. of primary crushers of rotary breaker type which shall reduce the size of coal from (-) 300 mm to (-) 150 mm. Output of primary crushers shall be feed to conveyor BCN-4C/D for further transportation of coal to secondary crusher house SCH-1.The capacity of each rotary breaker are of Designed capacity - 1250TPH, Rated capacity - 1000 TPH, out of four primary crushers, two crushers will be working and other two will be stand-by. However it shall be possible to operate all the four crushers simultaneously.

1.1.3.4 In secondary crusher house there are four Nos. of secondary crushers

of ring granulator type which shall reduce the size of coal from (-) 150 mm to (-) 20 mm. Vibrating screens shall be provided above crushers to screen out the coal of size (-) 20 mm. Coal above 20 mm size from Screens will feed to secondary Crushers Output of secondary crushers shall be feed to conveyor BCN-5A/B or 10A/B for further transportation of coal. However it shall be possible to operate all the four crushers simultaneously so that coal from two crushers of



stream-A can be fed to bunkers and coal from Stream-B can be stacked.

1.1.4 Coal Bunkering System 1.1.4.1 Path-1: The crushed coal from secondary crusher at SCH-2 shall be

fed to Junction towers JT-14, JT-6, JT-5, JT-4, JT-3, JT-2 and JT-1 through conveyors BCN 4A/B, 5A/B, 16A/B, 17A/B, 18A/b, 19A/B, 20A/B, 21A/B and 22A/B respectively for direct bunkering.

1.1.4.2 Path-2: The imported/washed coal from conveyor either BCN-1A, BCN- 1B or BCN-1C will be fed to conveyors BCN -3, at Junction tower JT-15 (bypassing primary and secondary crushers). The bypassed coal through conveyors BCN -3, 5A/B, 16A/B, 17A/B, 18A/b, 19A/B, 20A/B, 21A/B and 22A/B respectively for direct bunkering.

1.1.4.3 Path-3:The crushed coal from primary crusher (PCH) and secondary crusher at SCH-1 shall be fed to Junction towers JT-14, JT-6, JT-5, JT-4, JT-3, JT-2 and JT-1 through conveyors BCN 5A/B, 16A/B, 17A/B, 18A/B, 19A/B, 20A/B, 21A/B and 22A/B respectively for direct bunkering.

1.1.5 Coal Stacking and reclaiming System 1.1.5.1 For stacking and reclaiming of coal Three (03) nos. stacker cum

reclaimer will be provided each of stacking capacity 2200 TPH (Designed)/2000 TPH (Rated) and reclaiming capacity 2200 TPH (Designed) /2000 TPH (Rated). In stack area six numbers (2 for imported coal and 4 for Indian coal) coal pile shall be provided to store crushed coal in stock pile area. Stockpile shall be capable to store 30 days coal requirement of the plant. The height of each stock pile shall be 8.75 meters. Boom length of each stacker cum reclaimer shall be 36 meters. Minimum capacity of coal stackyard shall be 6.0 lakh MT

1.1.5.2 Path-1: The coal from Secondary crusher house SCH-2 shall be feed to either conveyor BCN- 10A/B. coal from conveyor BCN-10A/B shall be transferred to Junction towers JT-11, JT-12 and JT-13 through conveyors BCN-6, BCN-7 and BCN-8 for stacking of coal in six nos of



stack piles for stacking Indian/imported coal pile through stacker cum reclaimer SCR-1, SCR-2 and SCR-3 respectively.

1.1.5.3 The reclaimed coal through yard conveyors BCN-6, BCN-7 and BCN-8 will feed coal to conveyor BCN 11A/B at junction towers JT-8, JT-9 and JT-10. The reclaimed and blended coal received on to conveyor BCN-11A/B will be fed to conveyor BCN-15A/B at junction tower JT-7 and onward transfer to junction towers JT-6, JT-5, JT-4, JT-3, JT-2 and JT-1 through conveyors BCN 11A/B, 15A/B, 16A/B, 17A/B, 18A/B, 19A/B, 20A/B, 21A/B and 22A/B respectively for bunkering.

1.1.5.4 Path-2: The imported/washed coal from conveyor either BCN-1A, BCN- 1B or BCN-1C will feed bypass conveyors BCN -3(bypassing primary and secondary crushers), which in turn feed conveyor BCN-10A/B at Junction towers JT-11, JT-12 and JT-13 through conveyor BCN-6, BCN-7 and BCN-8 for stacking of coal in six nos of stack piles for stacking Indian/imported coal pile through stacker cum reclaimer SCR-1, SCR-2 and SCR-3 respectively.

1.1.5.5 The reclaimed coal through yard conveyors BCN-6, BCN-7 and BCN-8 will feed coal to conveyor BCN 11A/B at junction towers JT-8, JT-9 and JT-10. The reclaimed and blended coal received on to conveyor BCN-11A/B will be fed to conveyor BCN-15A/B at junction tower JT-7 and onward transfer to junction towers JT-6, JT-5, JT-4, JT-3, JT-2 and JT-1 through conveyors BCN 11A/B, 15A/B, 16A/B, 17A/B, 18A/b, 19A/B, 20A/B, 21A/B and 22A/B respectively for bunkering.

1.1.5.6 Path-3 - The coal from Secondary crusher house SCH-1 shall feed to either conveyor BCN-5A/B. coal from conveyor BCN-9A/B shall be transferred to Junction towers JT-16, JT-17and JT-18, through conveyors BCN-6, BCN-7 and BCN-8 for stacking of coal in six nos. of stack piles for stacking Indian/imported coal pile through stacker cum reclaimer SCR-1, SCR-2 and SCR-3 respectively.

1.1.5.7 The reclaimed coal through yard conveyors BCN-6, BCN-7 and BCN-8 will feed coal to conveyor BCN 11A/B at junction towers JT-8, JT-9 and JT-10. The reclaimed and blended coal received on to conveyor BCN-11A/B will be fed to conveyor BCN-15A/B at junction tower JT-7 and onward transfer to junction towers JT-6, JT-5, JT-4, JT-3, JT-2 and



JT-1 through conveyors BCN 11A/B, 15A/B, 16A/B, 17A/B, 18A/b, 19A/B, 20A/B, 21A/B and 22A/B respectively for bunkering.

1.1.6 Coal blending system 1.1.6.1 The stacker cum reclaimer shall be used for blending of coal for

feeding to the boiler bunker during normal operation when rakes are not available. Any of the stacker cum reclaimer (SCR) shall be able to reclaim the indigenous coal from the dedicated indigenous coal stock pile for the purpose of blended coal, the indigenous coal and the imported coal can be blended in any ratio from 90:10 up to 70:30.

1.1.6.2 The indigenous coal shall be reclaimed through one SCR and other SCR would reclaim the imported coal. On the common conveyor mixture of the two coals shall be blended through three transfer tower (JT-8, JT-9and JT-10) to provide reasonably good mixture for feeding to raw coal bunker.

1.1.6.3 In case any of the SCR is out of service the blending can be achieved through one SCR reclaiming indigenous coal while the imported coal shall be reclaimed through manual reclaiming hoppers.

1.1.6.4 Blending can also be done on crusher by unloading one rake each for both Indian and imported coal simultaneously. Feed rate of coal will be adjusted by adjusting the feed rate of the feeder below wagon tippler hopper during direct bunkering of coal. During bunkering of coal from stock pile feed rate for blending of coal will be controlled from reclaiming by adjusting the reclaiming capacity of the stacker reclaimer.

1.1.7 Manual unloading system A manual unloading hopper shall be provided for unloading of coal from sick wagon. Double stream conveyor BCN-23A/B (1W+1S) of 600 TPH (Designed) /500 TPH (Rated) capacity shall be provided for transportation of coal from manual unloading hopper to primary crusher. Rack and pinion gates shall be provided below manual unloading hopper for isolation of hoppers.



1.1.8 Coal area Drainage system Around the coal stock yard, ground drains shall be constructed to take all the effluents/leach water from coal stockyard. This water along with water from other coal handling areas shall be led to decantation tanks (02 nos.) where all the coarse particles will settle down. The decanted water with finer particles will be collected in coal pile run off pond (2 nos.). Clear water from runoff pond will be collected in a RCC collection tank where it will be pumped to CMB/ETP. Two (02) Nos. pumps (1W+1S) shall be provided. Capacity of each decantation pond shall be 25000 M3. Capacity of collection tank shall be 35000 M3 and capacity of each pump shall be 300 M3/hr. Suitable drains shall be provided in entire coal handling plant area. These drains shall be connected to decantation tank. 1.2 ELECTRICAL The Electrical system is designed to operate both streams of CHP simultaneously & continuously. The Electrical system is also capable to feed the power when all wagon tipplers, all primary and secondary crushers and all stacker Reclaimers are under operation. One 11 kV switchgear is envisaged for the CHP operation. Power is fed from 11 kV station switchgear (under BHEL scope), to this switchgear. From the 11 kV switchgear, the power is fed to all CHP loads through 11 / 3.6 kV transformer, 11 /0.433 kV transformers and to the motors having capacity of more than or equal to 1500 kW. The number of the transformers, switchgears and their ratings is to be decided by the contractor based on the geographical location of the loads and will be finalized during detailed engineering. For the stacker reclaimers, the required number of feeders derived from 3.3 kV switchgear located in CHP Switchgear room. The 3.3 kV power supply is further distributed in SR through LT transformer for its auxiliary loads. Power Supply to Mill reject system shall be sourced from the nearby LT MCC of either Coal Handling or Ash Handling systems.



For the motors up to 160 kW, the power is fed through 415 V switchgear, >160 kW and less than 1500 kW motors, the power is fed through 3.3 kV switchgear. All local push button stations for HT drives are provided with only Emergency stop PB, all LT drives are provided with Start / Stop PB to enable Starting / Stopping of all equipment locally for maintenance purposes. A separate DC system is envisaged for the CHP area for breakers, DC lighting, etc., Separate lighting transformers are provided for illumination purposes. A decorative type 3 x 36 W CFL fitting is envisaged for the CHP control rooms and switchgears. The illumination level and type of fittings are described in the specification. AC drive (VFD) and DC drive (like for Apron feeders) is provided as per the system requirement. The peripheral earthing for the CHP is made to reduce the earth resistance less than 0.5 ohm. The required treated pit and test pit is as per IS 3043. For electronic equipment earthing is to be done as per IEEE 1100 and separate earth pit is to be provided. 1.3 CONTROL AND INSTRUMENTATION I&C system will consist of all local instruments Viz. Pressure Gauge, Temperature Gauge, limit switch, Pull cord switch, Belt Sway switch, Electronic Zero speed / Under speed switch, Bunker level switch/ indicator, other field sensors, Local panel & push button station, CHP control room equipment, as required erection hardware & interconnecting cables required for the control & monitoring of the entire Coal handling Plant along with control of Wagon Tippler & Stacker-Reclaimer as turnkey basis. A PLC based control system shall be provided for operation, control, interlocking, tripping of the entire coal handling plant and all associated equipment whenever required under specified abnormal conditions.

All 3.3 KV drives shall be provided with fluid coupling temperature/ bearing Temperatures measurement & shall be measured with Duplex RTD. Redundant Temperature Measurement sensor shall be provided for all bearing temperature measurement. Stator winding temperature measurement element shall be duplex type and all temperature measuring points shall be connected to PLC. Winding temperature high alarm will be generated in the PLC system. 3.3 KV



drives shall also be provided with vibration monitoring devices and shall be connected with PLC.

2.0 SCOPE OF WORK



SCOPE OF WORK The scope of supply and work for Coal Handling System under the specification covers the design, engineering, manufacture, supply, assembly and testing at manufacturers works, inspection, packing, forwarding, delivery FOR site and handling with storage at site (i.e. taking delivery of materials from carriers, transportation to site), fabrication (as needed), construction, erection, commissioning, trial run, PG testing including painting protection of all items as specified hereinafter but without excluding any other necessary components, which are not mentioned herein but are required for the completeness and; efficient, easy and reliable operation of the system. The supplier will provide the equipment including all necessary features, components, accessories, electrical and C&I accessories and appurtenances for efficient and reliable erection operation and maintenance whether mentioned in this specification or not. The equipment will consist of the following main components (however, not limited to the items listed). All necessary tools and tackles required for the maintenance of the proposed system shall also be supplied along with mandatory spares. 2.1 MECHANICAL The scope of coal handling plant shall be deemed to include all such items which although are not specifically mentioned in this section but are needed to make the system complete in all respect for safe reliable, efficient and trouble free operation but not limited to followings: 2.1.1 Five (05) Nos. wagon tipplers along with integral weighing system.

Wagon tippler shall be consisting of rails, tippling platform, cradle arms, cradle arm bearing, Side stop with pads, top stop with pads, driving motors, Girth gear and pinion drive, balance weight, limit switches for top and bottom stops, shafts, bearings, supporting steel, walkways, platforms and all other associated equipment to make a complete unit.

2.1.2 Five (05) Nos. Side arm chargers with power supply system, support,

Rack and Pinion, Hydraulic arrangement, electricals, buffer stop etc; one no. for each wagon tippler.



2.1.3 One (01) No. RCC Hopper for each wagon tippler. 2.1.4 One (01) No. rack and pinion gate for each wagon tippler hopper. 2.1.5 Five nos. (05) Wagon tippler gratings of mesh size 300mm X 300mm

for wagon tippler hoppers; One no. for each hopper. 2.1.6 One (01) No. Apron feeder for each wagon tippler hopper with drive

and accessories. 2.1.7 One (01) No. Dribble feeder for each wagon tippler hopper with drive

and accessories. 2.1.8 Rail above the tippler Hopper. 2.1.9 Belt conveyors: Each conveyor will be complete with drive equipment including motor,

Gear Box, Fast speed coupling, Slow speed coupling, Carrying idlers, self aligning carrying idlers, Return idlers, self aligning return idlers impact idlers, head pulley, snub pulley, tail pulley, pull cord, belt sway and zero speed switches, chute jam switches, deck plate for complete length of conveyors, gravity take-up system, internal and external scrappers stringers with short support, all over ground conveyors will be provided with conveyor galleries.

2.1.10 All Chute works for transfer of Coal with SS liner of SS 409M on

wearing surface with all sides welded and provided with countersunk bolt of hexagonal head (Allen key removable). The size of the liner shall be maximum 500X500 mm.

2.1.11 Junction towers from Wagon tippler to bunker bay. 2.1.12 Flap gates with SS liner of 409M complete with electrically operated

actuators as shown in flow scheme. 2.1.13 Four (04) Nos. Rotary breaker (Primary crushers) with drive equipment

including motor.



2.1.14 Four (04) Nos. Ring granulator (Secondary crushers) with drive equipment including motors in Secondary Crusher house -1.

2.1.15 Four (04) Nos. Ring granulator (Secondary crushers) with drive

equipment including motors in Secondary Crusher house -2. 2.1.16 Four (04) Nos. Vibrating screens with drives and supporting structure;

one no. for each secondary crusher in Secondary crusher House -1. 2.1.17 Four (04) Nos. Vibrating screens with drives and supporting structure;

one no. for each secondary crusher in Secondary crusher House -2. 2.1.18 One (01) No. elevator in secondary crusher house-1. 2.1.19 One (01) No. elevator in secondary crusher house -2. 2.1.20 One (01) No. Elevator near third JT of Unit #1 (Bunker bay). 2.1.21 Three (03) Nos. Emergency reclaim hoppers. 2.1.22 One (01) No. Rack and pinion gates for each Emergency reclaim

hoppers 2.1.23 One (01) No. Vibrating feeder below each emergency reclaim hoppers

with drive and supporting structures 2.1.24 Three (03) Nos. Bucket wheel type traveling Stacker-cum-Reclaimer

complete with all electrical, controls and structural including boom conveyer, intermediate conveyer, bucket wheels, rails with rail fixing arrangement to operate in conjunction with yard conveyor.

2.1.25 Eight (08) Nos. Mobile trippers complete with all electrical, rails and

rail fixing arrangement to operate in conjunction with bunker feeding conveyors.

2.1.26 Four(04) Nos. fixed trippers on Conveyor BCN-17A/B and 18A/B; One

(01) No. for each conveyor.



2.1.27 Eight (08) Nos. fixed tripper on Conveyor 9A/B and 10A/B; Two (02) Nos. for each conveyor

2.1.28 Eight(08) Nos. Metal detectors, one at each conveyor BCN-2A, 2B, 2C,

2D, 4C, 4D,16A and 16Bcomplete with all accessories. 2.1.29 Eight (08) Nos. In-line magnetic separators, one at each conveyor

BCN- 2A, 2B, 2C, 2D, 4C, 4D,16A and 16Bcomplete with all accessories and supporting structures.

2.1.30 Nine (09) Nos. Electronic continuous belt weigher, one at each

Conveyor BCN-2A, 2B, 4C, 4D, 6, 7, 8 (near junction tower JT-8, JT-9 and JT-10), 16A and 16B complete with all accessories.

2.1.31 Three (03) Nos. Electronic continuous belt weigher, one at Yard

conveyor BCN-6, BCN -7 and BCN-8 of each stacker reclaimer near junction tower JT-11, JT-12 and JT-13 respectively.

2.1.32 Six (06) Nos. Coal sampling units, one at each conveyor BCN-2A, 2B,

4C, 4D, 16A and 16B 2.1.33 One (01) No. Manual unloading hopper for unloading sick wagons 2.1.34 One (01) No. rack and pinion gates below manual unloading hopper 2.1.35 One (01) No. vibrating feeders below manual unloading hopper 2.1.36 Dust suppression (DS) system and service water system

(1). Dust Suppression system (Dry fog type) completed with piping, valves, pumps, nozzles water tanks, supporting structures, other accessories as required for Wagon tippler area and all coal transfer points except Bunker bay and Crusher House. DS system shall consists of water pumps (1W + 1S), compressor (1W + 1S), enclosed hood, etc.

(2). There shall be two service water pumps (1W + 1S) which supply water to (a) local water storage tank of DS system of stock yard, transfer house, etc., (b) service water tap point for plant sealing, toilet, etc., each system DS shall be provided with (1W + 1S) pumps.



(3). Service water piping shall be provided all along the tunnels and galleries with tap off points at 30 m interval to enable cleaning of walkways / deck plates using flexible hose. (4). Service water piping with tap off points (with isolating valve and quick connecting coupling) shall be provided for each floor of junction towers, transfer house and crusher house. Two (2) points per floor in junction tower and transfer house and four (4) points per floor in crusher house. Flexible hose of 20 m long each shall be provided with storage box. (5). Each tap off point shall contain isolating valve with quick connecting coupling to enable fixing of hoses. (6). Each water spray header in DS system shall be provided with a solenoid valve to stop the water spray when the concerned plant and equipment of Coal handling system do not operate. Necessary load monitor shall be provided for all conveyors to detect presence of material on them. (7). Each DS system shall be operated from the local control panel and shall be interlocked with respective conveyor / equipment.

2.1.37 General requirements of Dust extraction (DE) system

(1). Dust extraction system in all Junction towers (at all coal transfer point) and crusher house. (2).Except for the requirements stipulated in the specification, all other design and construction features of DE system shall be generally in conformity with the recommendation of American Conference of Governmental Industrial Hygienists. The duct sizing and fan selection shall be based on balancing without blast gate criterion. (3). The bag filter material shall be fire proof, non woven type with antistatic property.



(4). The air to cloth ratio of the bag filter shall not exceed 2 m3/min/sqm. The bag filter cleaning system shall be reverse pulse jet air system. Necessary instrument air supply shall be provided. (5). Thickness of suction hood, dust collecting hopper and ducts shall be minimum 5 mm. Thickness of casing of centrifugal fan shall be minimum 5 mm. (6). Dust extraction system shall be provided for at all coal transfer points and also in the crusher house. The DE system shall have cyclone separator and / or bag filter. The outlet dust emission shall be max 50 mg/Nm3. (7). Bunker ventilation system will be provided for the bunkers to minimize the dust nuisance on the tripper floor and also to prevent fire hazards inside the bunkers due to volatile gases liberated by coal. The DE system shall have cyclone separator and bag filter. The outlet dust emission shall be max 50 mg/Nm3. The bunker ventilation shall be designed for handling minimum of 60,000 m3/hof volume of dusty air. (8). These shall be operated from the local control panels with monitoring in CHS and interlocked with operation of conveyor equipment. (9). DE system shall be designed for two stream operation. The tunnel ventilation system shall be designed based on a minimum of 12 air changes per hour. Adequate capacity of supply air fan and exhaust fan shall be provided.

2.1.38 Dust extraction system for coal bunkers of each units (Bunker

ventilation system). The bunker ventilation system should be designed for handling minimum of 60,000 m3/hr of volume of dusty air.

The outlet dust emission of DE system shall be maximum 50 mg/Nm3



2.1.39 Dust suppression system (Plain water type) completed with piping, valves, pumps, nozzles water tanks, supporting structures, other accessories as required for all stock pile areas

2.1.40 One (01) No. Dust sweeping hopper covered with removable

chequered plate for conveyor galleries at each trestle location 2.1.41 Two (02) Nos. Dust sweeping hopper covered with removable

chequered plate at each floor of each junction tower and each crusher house.

2.1.42 Mechanical Ventilation equipment for underground structures, MCC

room, bunker floor. Pressure ventilation shall be provided for all switchgear rooms.

2.1.43 Two Nos. (1 W+1 S) Sump pumps with piping and valves at each pent

house, Emergency Reclaim hopper, Manual unloading hopper and wagon tippler hopper areas and connected tunnels. The sump pump shall be suitable to handle coal slurry and impeller shall be of non clogging type.

2.1.44 Hydraulic press type belt-vulcanizing machine complete with all

accessories and consumables for a period of minimum three years operation.

2.1.45 Five (05) Nos Bulldozer along with Dozer shed with repair bay for

reclaiming coal from stock piles. 2.1.46 Four (04) Nos. locomotives along with all accessories and loco shed

with repair bay. 2.1.47 Coal pile runoff pond near stock pile area. 2.1.48 Air conditioning of main CHP control room wagon tippler control and

operator cabin of SCR complete with all accessories 2.1.49 Material handling facilities including associated electrical and support

structures shall be provided for handling all the equipment during



maintenance/repair/replacement at all working floors of all TPs, Crusher house, Bunker bay, loco shed, underground building and wherever required. Electric hoist with traveling trolley will be provided when capacity is 2.0T or more. Capacity less than 2.0 T, manually operated chain pulley block with traveling trolley will be provided. All hoists will be able to lift material from ground to place of use.

One (01) No. each 40 ton capacity EOT crane shall be provided in each

wagon tippler shed. One (01)No. electric hoist each of capacity 15 ton shall be provided in

primary crusher house, secondary crusher house-1 and secondary crusher house-2.

2.1.50 Painting of all equipment and technological structures. 2.1.51 All equipment open to outdoor application shall be provided with

suitable weather and corrosion proof enclosure. 2.1.52 Plummer block shall be of Cast steel with Aluminum labyrinth seal. 2.2 ELECTRICAL The scope of Contractor shall include Engineering design, manufacture, inspection, supply including transportation to site, transit insurance, storage at site, transportation from place of storage to erection site, erection, testing and commissioning and handing over in fully operable condition satisfactory to Owner of all electrical equipment required for the coal Handling System for 2X800 MW Yeramaras Thermal Power Project, besides obtaining all statutory clearances such as clearance from chief Electrical inspector to Government including furnishing of all Drawings, data etc. to the satisfaction of the statutory authorities shall be in the scope of the Bidder. The entire cost including all necessary fees, incurred for obtaining such approval / clearances, shall be borne by the contractor. The bidder shall design the Electrical system suitable to operate both streams of CHP simultaneously & continuously. Electrical system should also be designed in such a way that the transformers, switch gears, bus duct, etc., are adequately rated considering simultaneous operation of all wagon tipplers, primary & secondary crushers, coal conveyers etc. continuously.



Power & Service Transformers 2 nos. 11/3.6 kV Power Transformer for all HT loads of CHP and required No. of 11/0.433 kV transformers for feeding all the auxiliary loads of Wagon tipplers and crusher area LT loads and 2 nos. 11/0.433 kV transformers for feeding all the auxiliary loads of Bunker area and required number of transformers as per system requirement for SR area. The transformers shall be complete with all fittings and accessories. The quantity shall depend on the geographical location of loads and shall be chosen such that the transformers are 100% redundantand shall be rated to take care of the entire load on the respective switchgear considering the outage of the other transformer. The fire wall is to be provided as per CBIP / Indian Electricity rules. Neutral earthing equipment The adequate value of neutral grounding resistor is to be selected to restrict the phase to earth fault current for 3.3 kV system to 300 A. The resistor is to with stand the fault current for a period of 10 seconds. HT Switchgear (11 & 3.3 kV): Fully draw out type 11 kV& 3.3 kV Switchgears with two incomers (2x100%) & a bus coupler scheme complete with Vacuum Circuit breakers, busbars, Instrument transformers, relays, meters, transducers, line PT, Bus PT, terminal blocks & accessories for feeding all the loads of the Coal Handling System package shall be included in the scope of work. All HT feeders shall have vacuum circuit breaker. The bidder has to submit the electrical system arrangement in entire CHP area including SR to the Owner / Consultant for his approval. Any change made by the Owner / Consultant is final. LT Switchgear (415 V): Fully draw out type 415 V switchgear with 2x100% incomers & bus coupler scheme complete with Air Circuit breaker, bus bar, Instrumentation transformers, line PT, relays, meters, terminal blocks & accessories as required for the Coal Handling System. The SR LT MCC is based on the system requirement however it generally as per LT switchgear specs mentioned elsewhere in the specs. For apron feeder of WT and long travel of stacker reclaimer, the bidder can offer VFD/Variable Speed drives. In case of apron feeder the drive panels may be located in Wagon tippler control room, which can be discussed & finalized during detailed Engineering. It shall be the responsibility of the CHP vendor to finalize and propose the quantity and locations of the LV Switchgear required to feed the auxiliary systems connected with the Coal Handling System. In general a



dedicated LV switchgear shall be considered for each area / yard (covered as part of the CHP) that are having a significant number of electrical consumers to warrant a separate switchgear. The quantity and location of the switchgear proposed by the Vendor will be subjected to review and approval by the Owner / Consultant. Segregated / Non-Segregated Bus Duct one lot of Segregated Phase Bus Duct between 11 kV / 3.6 kV transformer secondary to 3.3 kV switchgear, Non segregated phase Bus Duct between 415 V Service Transformer to service switchgear with required bends, supporting structures with related civil work. Control Panel / JB/ PB - Control panels for auxiliaries like Hoist electrics, trolley lines and power supply arrangement, Electrics for ventilation, air-conditioning, JB's as required for all systems pertaining to CHP, Local start/stop PB for all motors and forward / reverse / off PB for all valve/Flap Gate/Sector Gate actuators (as applicable), as well as PBs and JBs required to meet requirements shall be provided. All outdoor JBs shall be of FRP / die cast aluminum make with canopy, IP-65 degree of protection. Local push button stations will be with IP-65 with canopy for outdoor use and IP-54 for indoor applications. Cable & Cable Carrier System shall consist of but not limited to the following: a) One lot of MV/LV Power, control, Instrumentation, trailing cable and any

other special cables required for proper operation, monitoring and control of the CHP system. Sizing of the cable is to be designed as mentioned in the specification.

b) Cable raceway system consisting of cable racks, cable trays, Cable rack / tray supporting structures, support members / channels for cable trays, cable tray covers, cable trenches, Duct Banks, conduits, pipe sleeves, hume pipes, associated foundation and civil works, cable tray accessories, etc., as required.

c) Cable laying and cable termination including all necessary accessories like cable termination kits, cable jointing kits, glands, lugs, tools for termination, ferrules, identification tags etc.,

d) Necessary fire protection systems like fire barriers, fire breaks, fire stops, and fire proof sealing for wall/floor openings(after laying of all cables) and fire protective coating systems etc., as necessary.

All the above items and any other item required for completing the Cable carrier system shall be provided for the entire Coal Handling System.



220V DC System: complete with Batteries, Chargers, Battery racks, Battery MCBs, Distribution Board, associated flexible and power cables as required for supplying all the DC loads and DC lighting system of the Coal Handling System package. As a minimum requirement, 1x100% 220 V batteries of suitable capacity with 2x100% float cum boost chargers and DC distribution board shall be provided for catering to the requirements of Coal Handling System. The sizing of the battery and charger is to be designed as per the specification.

Primary and Secondary Earthing and Lightning protection system: For the entire Coal Handling System area, buildings, etc., complete with buried peripheral earthing and earth electrodes or earth pits for the entire area shall be provided in this package. This shall include earthing conductors buried in soil, earthing conductors embedded in concrete inside the buildings, equipment earth conductors, treated earth pits, earth rods, all above ground earth conductors to which all the electrical equipment & metallic structures are connected to have earth continuity for safety reasons. The primary earthing shall be interconnected with the main grid at minimum four points. The system is to be designed in such a way that the earth resistance is less than 0.5 ohm when it is isolated from the main earth grid. Lightning protection complete with vertical air termination rods, horizontal roof conductors, down comers, test links and pipe electrodes shall be provided for all structures for which the safety norms dictate requirement as per relevant standards. Coal handling system earth mat shall be connected to the owners main earth gird at minimum four places. Illumination: Indoor, outdoor, road and yard lighting, power and welding receptacle system for entire Coal handling system Package areas shall be provided as part of this contract. This shall include, but not be limited to, lighting transformers, normal Lighting DBs, AC / DC lighting panels, towers, poles, lighting fixtures, lamps, Power sockets, welding receptacles etc for the entire coal handling system covering all the buildings, outdoor areas, yard lighting, in its scope as per the requirement. Lighting circuits will be protected by MCB/ELCB as required. At



MLDB, two (2) nos. adequate capacity of uncabled feeders are to be given to GCW bidder for his further usage. The major areas to be illuminated under the scope of this package are

o Conveyor and underground tunnel conveyor o CHP all control rooms o HT /LT switchgear o Crusher area o Transfer tower/Junction Towers o Transformer area o Roads under CHP. o The required uncabled lighting feeder will be given to General civil

works bidder for his usage and the same will be discussed during detailed Engg.

o Coal yard o Stacker reclaimer o Wagon tippler o Marshalling yard o Loco shed o Dozer shed

The areas listed are however indicative only for the purpose of guidance to the bidder and is subjected to change during detail engineering after finalization of plant layouts. The minimum lux level shall be as per highest value mentioned in the IS 3646 / as mentioned in the specs whichever higher is to be maintained. The necessary software shall be used to determine the number of fittings required in a particular area and desired lux level. Equipment painting and its thickness is to as per relevant standard. Special tools and tackles as required for installation, operation and maintenance of electrical equipment shall be supplied. Essential and Start-up spares for all equipment shall be included in the scope. Bidder shall furnish a comprehensive list of the same.



Control room alarms/indications/SER points: Remote Control, monitoring, alarm and indication for the electrical system such as switchgears, transformers, DC system etc shall be from PLC / DCS system provided in the CHP control room. All Control, Digital & Analog signals as required shall be included and shall be subject to approval by owner during detail design stage. All necessary communication protocol shall be taken care by bidder. Control, monitoring, measurement and annunciation of complete electrical system shall be possible from CHP main control room PLC / DCS through HMIs. Control of all 11 kV, 3.3 kV and 415V breakers i.e. incomer, Bus coupler, outgoing breakers of all switchboards shall be possible from PLC / DCS and the same shall be linked with plant DCS located in the main control room. Remote position, service position, breaker healthy i.e. trip circuit healthy, spring charged, reset position of trip relay, other permissives interlocks, etc., shall be considered as input to PLC / DCS system. The current and voltage measurements for each bus and line shall be available on PLC / DCS. The operation, indications and fault alarms for the motors of the auxiliaries shall be displayed. Any other electrical equipment which are not specifically listed above but are required to make the CHP complete in all respects as per specification shall be included in the scope of work. The scope shall also include preparation and submission of all required drawings for Owners approval not limited to: i) Main One Line Diagram for CHP clearly highlighting the scope of work

considered by the vendor. ii) Detailed Single Line Diagram for 11 kV, 3.3 kV and 415 V, DC and UPS

system. iii) Protection and metering One Line Diagram clearly indicating the

detailed protection and instrumentation provided by the vendor. iv) Layout drawings - Electrical equipment layout drawings including

General Arrangement layouts for all CHP areas / buildings / equipment, Cable tray and trench layout drawings, lighting layout drawings, Earthing & Lightning Protection layout drawings including



earthing details etc., as required by Owner with all supporting calculations and documentation.

v) Scheme drawings for all Switchgear / MCC /Motor modules/Control Panels.

vi) Block Logic Diagrams for 11, 3.3 kV & 415 V systems. vii) Vendor drawings for all equipments covered in the scope. viii) Relay Setting calculations, relay co-ordination studies, largest motor

starting study and recommended relay settings. ix) Foundation drawings with supporting calculations. x) The scope shall include submission of all required design calculations for

the following: (a) Transformer sizing calculations for arriving at the MVA rating,

Selection of transformer impedances and tap ranges vis--vis Voltage drops, Voltage dips and fault levels etc.

(b) MV & LV Switch board sizing o Bus Ducts Calculation for Span and Supporting Arrangement, and

busbar and enclosure sizing. Heat loss and temperature rise calculations for conductor and enclosure

o CT & VT Sizing calculations o Cable Sizing All Power Cables. o Voltage Dip Calculations. o 220 V DC Battery & Battery Charger Sizing o Earthing Conductor and below and above ground earthing sizing. o Lightning Protection System Design o Lighting System Design and lux level calculations using well

known software like Calculux or Dialux. o Short Circuit Calculation for the entire coal handling system. o Relay Setting and Relay Co-ordination graphs for the Coal

Handling System plant The contractor shall include all the required schedules including the following in the scope:

Drawing control schedule Cable Schedules For all Power, Control and Instrumentation Cables. Interconnection cable Schedule for all cables supplied and installed by

contractor. Relay setting schedules Procurement schedule etc



Data Sheets for all equipments included in the scope shall be submitted for review & approval by Owner. MQP & Field Quality Plan (FQP) are to be submitted for Owners approval. 2.3 CONTROL AND INSTRUMENTATION 2.3.1 The operation and control of entire coal handling plant including

Wagon unloading, conveyer, tippler, stacker-reclaimer etc. shall be performed from its own dedicated PLC located in CHP & respective control room in a completely integrated manner. This shall include following as minimum: a) Redundant processor, redundant communication controller,

redundant power supply modules, redundant bus at all level, I/O cards, operator work station and engineering work station with dedicated keyboard and 24 TFT monitor, printers and time synchronisation facility with plant GPS master clock ( time format shall be as per GPS master clock requirement).

b) Three nos. 24 TFT operator work station, one no. 24 TFT operator work station cum engineering work station, Two nos. industrial grade 52 thin bezel LCD display unit, one no. A4 size (B/W), one no. A3 colour medium speed laser and one no. high speed (180 columns) dot matrix printer shall be provided in CHP control room. For more details regarding number of HMI, Printers, LCD display units and others bidder shall refer CHP PLC configuration diagram E072-03-CHP-1-03-08-R1.

c) Solid state annunciation system/PLC based system with hardwired annunciation windows.

d) Emergency Trip push button for HT drives & for all Electrical power breakers mounted on auxiliary console/ panel.

e) Bidder shall provide necessary modular control desk and standard make furniture for installation of operator station / engineering station in the control room shall be subject to approval by Owner.

f) Bidirectional Redundant TCP/IP fast Ethernet connectivity/ redundant serial MODBUS RTU interface with plant DCS for monitoring including cable, both side required hardware/software are under bidder scope. Bidder shall also co-ordinate with Main Plant DCS supplier for achieving suitable interface between Coal Handling Plant PLC and Main Plant DCS.



g) Few hardwired signals exchange between CHP PLC and Main Plant DCS provision has to be made.

h) Local control panels for Belt weigher, ILMS, Dust suppression, Dust extraction, ventilation system, etc. shall be provided.

2.3.2 One no. 24 TFT operator work station and one no. 24 TFT operator

work station cum engineering work station and one no. A4 size (B/W printer shall be provided for each stacker cum reclaimer control room. Bidirectional communication shall be provided between stacker cum reclaimer PLC and CHP control System. For more details regarding number of HMI, Printers, LCD display units and others bidder shall refer CHP PLC configuration diagram E072-03-CHP-1-03-08-R1.

2.3.3 One no. 24 TFT operator work station and one no. 24 TFT operator work station cum engineering work station and one no. A3 colour medium speed laser and one no. high speed (180 columns) dot matrix printer shall be provided for each wagon tippler control room. Bidirectional communication shall be provided between wagon tippler PLC and CHP control System. For more details regarding number of HMI, Printers, LCD display units and others bidder shall refer CHP PLC configuration diagram E072-03-CHP-1-03-08-R1.

2.3.4 All junction boxes, local push button stations, all Interconnected cabling between sensors to JB/ Panel, Panel to I/O card, card to PLC system operator station, Instrumentation/ special cables/ RTD cables/ pre-fabricated cable/ earthing cable, cable glands, Lugs, ferrules, cable trays, conduits, instrument racks, impulse/ air supply pipes/ tubes, erection hardware, instrument isolation valves, instrument fittings (double compression type) and other accessories are within battery limits.

2.3.5 All field instruments/ sensors/ switches/ belt protection switches, final control elements with actuators as per finalised P&IDs, schemes, operation and control philosophy and logics approved during detailed engineering stage within the coal handling plant package.

2.3.6 Vibration monitoring system for HT drives as recommended by package vendor and same shall be located in the CHP control room and interfaces with CHP PLC. The vibration monitoring system shall



include the Vibration Probes (Proximity/ Thrust/ Velocity/ Accelerometer), Special Cables, Sensors/ Signal Conditioners, Pre-Amplifiers (if required), minimum IP-55 Junction Boxes, Signal Conditioners, Pre-Amplifiers, Vibration Monitors, etc.

2.3.7 Coal Bunker Level measurement instrument shall be provided by BTG

supplier, all necessary required cable (laying and termination) up to CHP control room, instrument installation hardware, installation of instrument, etc. of coal bunker level instrument are under CHP Package supplier scope.

2.3.8 PLC I/O cards and relays for control and monitoring of all instruments, drive and equipment are to be housed in air-conditioner environment (room/enclosure).

2.3.9 Licensed software required for complete PLC operation as well as for interface of CHP PLC with plant DCS.

2.3.10 Redundant UPS power supply requirements & conversions to required

voltage levels and further distribution of entire coal handling plant shall be in the scope of bidder.

2.3.11 Any other item not covered herein but essential for successful

installation and commissioning of the coal handling plant and integrity of the system shall be included by the Bidder.

2.3.12 All necessary Vendor/Drawing/documents shall be subject to approval

from Owner. 2.4 CIVIL The works to be performed under this specification include execution of complete civil, architectural and structural works for foundations for equipment, buildings, facilities, substructures, superstructures including structural steel fabrication and erection and infrastructure works for the entire coal handling system. The works shall generally comprise (but not limited to) carrying out detail engineering, design computations, preparation of detail construction drawings & design reports and getting the same approved by owner/ consultant including all necessary survey, tests, studies, investigations including geotechnical investigation work as may be required for design, construction or



erection up to the specified terminal points mentioned elsewhere, including supply of all materials, consumables, tools & plants and labour etc as per approved drawings and these specification for the following: Site clearance, leveling and grading to achieve FGL as per requirement: for

complete coal handling plant area. Coal Crushing and screening system Includes crushers and screens. Main CHP control room and MCC Room Wagon tippler control room and MCC Room Wagon Tippler shed and allied works Wagon Tippler (WT) & side arm charger- 5 nos. Conveyor tunnels from tipplers Conveyor tunnels from Manual Reclaim hoppers Transfer Towers (TT) Nos. as per mechanical specification. Transfer House (TH) Nos. as per mechanical specification. Stacker Reclaimer foundations Coal stack yard Manual Reclaim Hopper (MRH) Bulldozer Shed. Pent House Nos. as per mechanical specification. Dust suppression system as per mechanical specifications Dust extraction system as per mechanical specifications Works related to transformers and other electrical facilities for CHP area (As

per Electrical specification & scope) Foundations and Support columns (as and where required ) for Belt

Conveyors/Gallaries etc. All main roads in CHP area and approach roads connecting all facilities in the

Coal Handling package to the nearest main roads of BTG area, including drains, culverts and bridges, diversion / training of existing nalas wherever required.

Civil works required for illumination of the facilities in the Coal Handling package and connecting approach roads.

Any other structure / building necessary for completion of coal handling plant.

Water Tanks and pump houses for Dust Suppression System Tunnel Ventilation System Emergency Reclaim Hopper/Mill reject Handling system; Quantity as per

Mechanical Specification No of stacks/stacker reclaimer as per Mechanical specification



Garland Drains, Decantation tanks, Coal pile run off pond, Coal sampling room and Office Complex for O & M staff for CHP

About 15 nos. of toilet blocks along with adequate size of soak pit / septic tanks and water tanks and connections are to be provided in the coal handling area. The location and size of the toilets blocks to be decided during detail engineering.

The work to be performed under this specification shall include all incidental items not mentioned or specified but reasonably implied or necessary for the completion and proper functioning of the plant, all in strict accordance with the specifications including revisions and amendments thereto as may be required during the execution of work. This specification covers the methodology to be followed for design and construction of all civil, structural and architectural works for the complete Coal handling system. Description of various items of work and nature of work involved under this specification are given hereinafter. The items, though not specifically mentioned, but are needed to make the system complete shall be treated as though included and the same shall also be furnished and erected / constructed unless otherwise specifically mentioned as excluded. The bidder should also note the following details, pertaining to the scope of civil works under this specification: i) The civil works to be performed shall cover providing all labour,

materials, construction equipment, tools and plant, scaffolding, supplies, transportation, all incidental items necessary for successful completion of the work. The work shall involve earthwork in excavation including controlled blasting and very deep underground excavation, extensive de-watering, shoring and strutting, sheet piling, back filling around completed structures and plinth protection, area paving, disposal of surplus excavated materials, concreting including reinforcement and form work, brick work, fabrication and erection of structural / miscellaneous steel works, inserts, architectural items & finishes such as plastering, painting, flooring, doors, windows & ventilators, glass and glazing, rolling shutters etc., permanently colour coated profiled steel sheeting, anchor bolts, R. C.C. trenches with covers, laying and testing of



water pipes, sanitation, water supply, drainage, damp proofing, water proofing and other ancillary items.

ii) The work shall be carried out both below and above ground level and

shall include basements, equipment foundations including vibration isolation systems, grounding, slabs, beams, columns, footings, rafts, walls, steel frames, brick walls, stairs, trenches, pits, access roads, culverts, conveyer galleries, trestles, penthouses, wagon tippler hoppers, emergency reclaim hoppers, underground tunnels, crusher house, transfer towers, buildings for switchgear and control room, finishes, complete architectural aspects, drainage, sanitation, water supply (from terminal points to various buildings, conveyor galleries) and all other civil, structural and architectural works associated with the complete Coal Handling Plant.

iii) All buildings shall be complete with all electrical, civil, structural,

architectural works, cable trenches, fire safety walls, foundation, earth mat, fencing, earthing for transformers. All cables, duct banks, trenches, cable trestles shall be complete with associated civil/ structural work and necessary civil foundations. Buildings to be provided shall include the following:

a) Underground/partially underground transfer points (RCC

construction) b) Overground transfer points and Crusher House (steel construction) c) Electrical & control buildings (RCC construction) listed below:

Main switchgear and central control room building near crusher house

Wagon tippler/ emergency reclaim hopper switchgear and control building near wagon tippler complex

Office complex for O&M staff and storage rooms near main control room.

iv) Scope shall also include supply and laying earthing mat all around the

periphery of buildings, structures, and outdoor equipment, as per the approved drawings.

v) The analysis, design and detailed drawing for the structures like wagon

tipplers tunnels etc. coming below the railway track shall be got



approved from the concerned railway authority before taking up construction.

vi) Arranging construction water from underground sources, storage in

underground/ over ground tanks and taking the water to construction site through pipelines by pumping or by road tankers etc., including all necessary accessories, tools & tackles etc.

vii) Access roads to all buildings/facilities of CHP including construction and

maintenance of temporary access roads for approach to the building/facilities for construction/erection activities.

The scope shall also include setting up by the Contractor of a complete testing laboratory in the field to carry out all relevant tests required for the Civil and structural works as detailed elsewhere in the specification.



3.0 TERMINAL POINTS AND EXCLUSIONS



TERMINAL POINTS AND EXCLUSIONS 3.1 Terminal Points 3.1.1 Mechanical Tripper conveyor along with its rail at Bunker floors. Potable and service water at one point 5 meter away from Secondary crusher

house -1. CMB/ETP for coal yard drainage piping. 3.1.2 Electrical Two nos uncabled breaker terminals of 11 kV Station switch board (under

BHEL scope). Four points of Main earth grid for below ground earthing. Two uncabled feeders at MLDB for GCW bidders scope 3.1.3 Control & Instrumentation Few hardware signals of CHP for linking with Main Plant DCS: All Cables (including laying and termination) up to Main Plant DCS Marshalling Cabinet. SOE - Points for CHP: All Cables (including laying and termination) up to Main PlantDCS Marshalling Cabinet. Interfacing Cable for CHP PLC with Main Plant DCS: All required software/hardware, cable (including laying and termination) up to Main Plant DCS system. 3.1.4 Civil Roads: All approach roads interconnecting all facilities under CHP package and their connections to the Main plant roads at suitable locations. (As per enclosed drawing).



Sewerage line: Upto existing connection chamber/ manhole nearest to the toilets. However, if no chamber / manhole exists, the bidder shall provide the same with proper connections. Drains: All garland drains/ local drains for effective drainage of rain water at all facilities and roads under CHP package and their connections to the Main storm water drainage network at suitable locations. 3.2 Exclusions 3.2.1 Mechanical Service water pipe line beyond the terminal point Potable water pipe line beyond the terminal point Bunker house including bunker floor Marshalling yard on either side of the wagon tippler rail 3.2.2 Control & Instrumentation Coal bunker level instrument: BTG supplier scope.

3.2.3 Civil Roads: Main plant roads except approach roads interconnecting all facilities under CHP package and their connections to the Main plant roads at suitable locations.

Sewerage line: Beyond connection chamber/ manhole near the toilet. Drains: Storm water drains beyond CHP battery limit.



4.0 TECHNICAL REQUIREMENTS OF COAL HANDLING PLANT



TECHNICAL REQUIREMENTS 4.1 MECHANICAL 4.1.1 Rated and design capacity Conveyor system Design and Rated Capacity of each conveyor

The capacities of conveyors from Wagon tippler to bunker including yard conveyors are, Designed 2200 TPH and Rated 2000 TPH. Except manually unloaded coal conveyor BCN-23A/B, which has a capacity of Designed-600 TPH and Rated- 500 TPH.

Primary Crusher Rated capacity of each Crusher 1000 TPH Designed capacity of each crusher 1250 TPH

Input coal size (-) 300 mm size of crusher output (-) 150mm Vibrating Screens Rated capacity of each screen 1000 TPH Designed capacity of each screen 1250 TPH Size of coal screened (-) 20mm Secondary Crushers (Ring granulators) Rated capacity {considering 100% feed coal above 20 mm size}

1000 TPH

Designed capacity {considering 100% feed coal above 20 mm size}

1250 TPH

Input coal size (-) 150 mm Guaranteed size of crusher output 98% down to (-) 20 mm Traveling Trippers (Mobile)Capacity (Rated/Design) 2000/2200 TPHStacker cum Reclaimer Rated/Guaranteed capacity of yard conveyor

2000/2200 TPH

Design Capacity (considering specified % bucket fill)



(i) Stacking 2200 TPH(Designed)/2000 TPH(Rated)

(ii) Peak Reclaiming (for bucket sizing) 2200 TPH(Designed)/2000 TPH(Rated)

Height of stock pile to be formed 8.75 Meters Boom length (Minimum) 36 meters Lump size to be handled (-) 20 mm

All other equipment under the scope of work of the contract shall be suitable to the system capacities parameters as specified above. 4.1.2 Standards/Codes The design, manufacture, inspection and testing of all equipment/system shall comply with all the currently applicable statutes, regulations and safety codes in the locality where the equipment is to be installed. All equipment/system shall conform to the latest edition of the following standards and codes. Other internationally acceptable standards/codes, which ensure equal or higher performance than those specified, shall also be accepted. Nothing in this specification shall be construed to relieve the contractor of the required statutory responsibility. In case of any conflict in the standard and this specification, the decision of the RPCL shall be final and binding. All construction, installation, workmanship, design & equipment shall conform to following or equivalent standards or codes, in so far as they apply: IS: 7155: Codes of Practice for Conveyor Safety. IS: 1891 (Part-I) : General Purpose BeltingIS: 8598: Idlers and Idler Sets for Belt Conveyors IS: 4009 (Part-II) : Conical Head Grease NipplesIS: 8531: Pulleys for Belt Conveyors.IS: 2062: Structural Steel (Standard Quality)IS: 4682: Codes of Practice for Lining of Vessels and Equipment

for Chemical Processes.IS: 11592: Code of practice for selection and design of Belt

Conveyors.CAN / CASA - M422 Canadian standard association.



Conveyor Equipment Manufacturers Association (CEMA) All other national / international codes and standards. 4.1.3 Specification of Equipment 4.1.3.1 Wagon Tippler Wagon tippler shall be as per RDSO latest G-33 (Revision-1) norms. The wagon tippler provided shall be hydraulically operated type. The wagon clamping arrangement shall necessarily be hydraulic type. The wagon tippler shall be suitable for continuous duty, designed to unload all standard broad gauge wagons of Indian Railways. It shall be capable of taking at a time one all Box N type open Wagons for weighing and unloading at a rate not less than as specified in data sheet. The wagon tippler shall be equipped with inline Electronic weighing. The tippler shall consist of tippling platform, cradle arms, cradle arm bearing, Side stop with pads, top stop with pads, driving motors, gear and pinion drive, balance weight, limit switches for top and bottom stops, shafts, bearings, supporting steel, walkways, platforms and all other associated equipment to make a complete unit. During each cycle of operation, the tippler shall be capable of holding, complete unloading and replacing the standard railway wagon to its original position. The wagon tippler shall be designed for outdoor installation and shall be of heavy duty construction rigidly reinforced throughout and suitable for continuous duty. The operation of the wagon tippler shall be through hydraulic motor without gear box & coupling & directly coupled to driven shaft and completely automatic such that one operator can control all the operations from a single control panel. However, one more labourer shall be required to uncouple loaded wagon from the rake during operation of wagon tippler. The location of the control room shall be such that the operator can have a clear view of the tippler operation as well as the railway facilities. The tippler design shall be co-ordinated with that of the unloading hopper and it shall be arranged to provide convenient access to any part of the tippler and the hopper from any point above or below ground, as may be required during operation and/or in-operative periods.



The design of civil and structural work for the wagon tippler complex shall be as per relevant IS codes. The design of equipment as well as civil and structural work of tippler shall conform to the requirements of latest Indian Railways Research, Designs and Standards Organization (RDSO) G-33 regulation of local railways authorities and all other statutory norms with regard to the nature of loading, impact factor and allowable stresses etc. It shall be the sole responsibility of the Bidder to ensure that each & every component of the wagon tippler is adequate in rigidity, strength of heavy duty construction and of first class quality to guarantee against failure or major repair, assuming proper maintenance and usage. The tippler table shall be designed to allow passage of the standard main Indian Railways diesel locomotive over the table. The wagon tippler shall be capable of adjustments of clamps automatically i.e. without physically changing attachments to cater different type of wagons. The tippler shall be driven by suitable separate hydraulic systems for operation of tippler drive hydraulic motors and hydraulic clamp cylinders. The individual hydraulic power packs to be located away from tippler shall be provided inside a room at the ground floor of WT control room. The wagon tippler drive shall comprise of independent hydraulic motors each mounted directly on the shaft of drive pinion meshing with cast steel racks bolted to the periphery of the one end section of wagon tippler. All hydraulic motors shall be provided with disc brakes to hold the tippler at any position during rotation. All working parts requiring lubrication shall be of sealed construction so that dust, dirt and other foreign matter do not come in contact with wearing surface. The tippler shall be designed to have a proper tippling angle to discharge all the contents of the wagon from it. The top stop structure shall be designed to hold the partially uploaded wagon at the maximum tipping position for specified length of time, without any damage or distortion. Limit switches shall be provided to cut off power supply at the end of travel. Back up limit switches shall also be provided. Provisions shall be made for alignment of tippler platform by inching operation in case it does not align properly with outside rail. All rack and pinions, unless otherwise specified in the Data Sheet shall be of steel. Gear teeth shall be of 200 involute stub form, and shall be



machine cut from solid blank. Provision shall be made for adequate lubrication of the gear drives. All gears shall be totally enclosed and housed in fabricated steel housing. This shall be fitted with bolted type machined inspection covers. Dip sticks or indicators shall be provided for indicating the oil level. Bidder shall give guarantee for the noise less and distortion-less operation of the gears when handling the specified full load. A reliable braking arrangement shall be provided to hold the tippler table at the maximum tipping position for a specified length of time or at any intermediate position on failure of power supply. The brake shall be located such as to ensure a positive braking action, actuated by remote operation. The torque capacity shall be equal to the normal operating torque of the driving motor. A weather proof cover shall be provided for each complete brake mechanism. The brake shall be heavy duty type, electrically released, spring set, friction shoe type and shall apply when the power supply is cut off. All auxiliary equipment for the brake shall be supplied by Bidder. The brake shall be fail safe type and it shall perform satisfactorily even in the event of power failure. Rack & Pinion arrangement shall have ample strength to drive cradle with full wagon. The material of construction shall be of a high grade steel to suite the specific operating condition. Factor of safety to be considered as per code to withstand the operation. Colour signal shall be provided at the inhaul side of tippler table for the guidance of loco operator. All shafting shall be proportioned for stiffness as well as strength. Shafts 76 mm (3) in diameter and more shall be fabricated from steel forgings or hot rolled steel rounds with a minimum carbon content of 0.3%. Shafts smaller than 76mm may be made from cold finished steel, or hot rolled steel. Shafts turned to provide changes of section shall have a minimum 6 mm fillet radius wherever such changes occur. All shaft couplings shall be gear type flexible and an approved product of a reputed manufacturer of equipment of this nature and shall develop full strength of the shafting which it connects and shall be pressed and keyed to the shafting. Rigid plate guards shall be provided for all couplings.



All antifriction bearings shall be of approved make, shall have a minimum life expectancy of 30,000 working hours and may be ball / roller type. Bearing housing shall be split and designed to exclude dirt and prevent leakage of oil or grease. Bidder shall furnish necessary electricals, control desk, safety interlocks for controlling the operation of the wagon tippler from control desk. It should be possible to control the operation of the wagon tippler by a single push button. Operation of this switch shall rotate loaded wagon, hold it at the maximum tipping position for the specified length of time and lower the empty wagon to the original position. Separate push buttons for tilting and repositioning of tippler table shall also be provided by the Bidder. Suitable interlocks shall include but not being limited to the following: Signal light: It shall not be possible to operate the tippler when the Wagon placing is taking place. Suitable interlocks shall be provided so that tippler operates only if the wagon is centrally located on the tippler table. Limit Switches shall be provided to stop the travel of the tippler table at the predetermined extreme positions. In addition, back-up over-travel limit switches shall be provided for the tippler discharge position. Besides above, any other limit switches required for the safe operation of wagon tippler shall be provided. Ballast, necessary for proper balancing of the tippler, shall be provided so as to have minimum power requirement. Any concrete work required for it shall be provided by the Bidder. The complete design of the wagon tippler and accessories shall meet the approval of RDSO and obtaining the necessary approval from RDSO / Zonal railways statutory authority for wagon tippler and its layout is included in the scope of Bidder, under this specification. However necessary application only as an Owner shall be given by the Owner to the bidder as and



when required, for obtaining above approval. All the statutory fees/charges for obtaining such approval shall be borne by bidder. 4.1.3.2 Side Arm Charger The side arm charger shall be used for wagon positioning at the wagon tippler for unloading of materials, It shall be used for pushing / pulling a rake of 60 wagons of 110MT gross weight each and locating wagons one by one on tippler platform. The tractive effort shall not be less than 30 Tons. The train shall be brought by locomotive either heading or pushing and stopped with the leading wagon within range of the side arm charger. The charger shall be driven to the leading wagon, its arm shall be lowered and it shall be coupled to the first wagon of the train. The train shall be hauled forward by the charger until the front of the second wagon is about 2 meters away from the tippler. The charger shall stop and the first wagon shall be uncoupled from the train. The charger shall then propel the leading wagon to the tippler, automatically uncouple and shall run clear of the tippler. Its arm shall be raised and it shall travel back to the train and the tippler shall rotate. On reaching near the standing train, the charger arm shall be lowered and shall be coupled to the train ready for repeating the cycles. In the next cycle the train shall be drawn up by the wagon length and the previously tippled wagon on the tippler table shall be pushed on the outhaul side. The charger shall be used under manual control to eject the last wagon from the tippler, if the next wagon is not already in position. The supply includes side arm charger with power supply system, support, Rack and Pinion, electricals, buffer stop etc The side arm charger shall be mounted alongside the main rail track and shall run on its rail track parallel to the main track. It shall have a suitable stroke from point just over one wagon length ahead of tippler to a point just beyond the tippler on the outgoing side. The rail envisaged for SAC shall be standard rail section. It shall be fitted with an arm pivoted at right angles to the track capable of being raised and lowered and carrying at its outer end an automatic coupler to couple the train.



The charger frame shall consist of a single fabrication from rolled sections and plate on which every other item shall be directly mounted to form a robust compact unit. The charger shall run on four steel wheels mounted on spherical r

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Rpcl Nit Technical Specification