BASIS OF DESIGN/OFFER

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BASIS OF DESIGN / OFFER COAL HANDLING SYSTEM

A.

BASIS OF OFFER

The desired 1.8 MTPA Coking Coal Beneficiation System shall be as per Tender drawing
Nos.
Tender Drawings:
1

CET RN 3812 GL0 00 001 REV R=0

Layout Drawing

S&T/003

Surface Plan

3
4
5

B.

CET RN 3812 CC1 00 001 REV

R=1
CET RN 3812 CC1 00 002 REV
R=0
CET RN 3812 CC1 00 003 REV
R=0

Process Flow Diagram

Equipment Flow Sheet
P&I Diagram

CET RN 3812 EE1 00 001 REV R=0

Overall Single Line Diagram

CET RN 3812 IN0 00 001 REV R=0

Automation System Configuration Diagram

BASIS OF DESIGN FOR PROPOSED CONVEYORS.

1. The conveyor power and tension will be calculated as per IS: 11592.
2. The drive motor rating of all conveyors will have a margin of 20% over Consumed
kW.
3. The bulk density of the material has been considered as:
Coal

0.8 t/m3 for volumetric calculation.

1.2 t/m3 for structural design.

4. Belting:
4.1

Top cover

6 mm for N/N

4.2

Bottom Cover

3 mm for N/N

4.3

Cover grade

M-24

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4.4

Running tension

< 80 % of allowable belt tension.

4.5

Type of belt

N-N or EP for all conveyors

4.6

No. of Plies

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

5.1

Troughing Angle of Carrying idler 45 0 for all conveyors

5.2

Return Idlers Single Roll Flat Return Idler for Conveyor of Belt Width
less than 1000 mm and Two Roll V return idlers with 10 0 troughing angle
for Conveyors of Belt Width 1000 mm and above.

5.3

Roll Dia (OD)

Carrying / SACI:

152.4 mm for all conveyors. (Outer Dia.)

Return / SARI:

139.7 mm for all conveyors. (Outer Dia.)

Impact:

190 mm for all conveyors (Outer Dia.)

5.4 Tube material & thickness ERW tube, 4.5 mm (Min) thickness.
5.5 Bearing Seize Resistant /Single row deep groove ball bearing
5.6 Bearing Life 40,000 hrs B-10 life.
5.7 Bearing dia.
Carrying / SACI :

30 mm.

Impact

30 mm.

Return / SARI

25 mm.

5.8 Lubrication Life Lubrication type.

5.9 Idler Spacing
Carrying (Troughing)

1.0 m

Return

3.0 m

Carrying training / SACI

15.0 m

Return training / SARI

30.0 m

Impact Idler

300 mm
(Min. 5 Nos. impact idlers shall be
provided at each feed point)

Transition Idlers

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

200, 350 each at Head end

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

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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

Pulley shell thickness:

12 mm (minimum) for all conveyors.

Non Drive pulley

10 mm (minimum) for all conveyors.

Drive Pulley
6.2

Pulley lagging:
Drive Pulley

Non-drive Pulley

12 mm thick natural rubber lagging (shore

hardness 35-4 5 on Scale A), herringbone
except Conveyors Nos. BC-1, BC-2, BC-17, BC18,BC-19, BC-20 which will be provided with 12
mm thick Ceramic Lagging.
10 mm thick plain natural rubber lagging for all
non-drive pulleys (shore hardness 35-45 on
scale A).

6.3 All pulleys shall be connected to the shaft through key arrangement
6.4 Pulley shaft deflection at hub shall be maximum 5 minutes.
6.5 Pulley Shaft material shall be Class- IV, IS-1875, up to 150 mm and
40Cr1MO28, IS-1570 above
6.6 Pulley Shell Material shall be MS conforming to IS: 2062.
6.7 Pulley Hub Material shall be Cast Steel Gr. II, IS-1030
6.8 Pulley Diaphragm Material shall be MS conforming to IS: 2062.
6.9 Bearing Type: Double row self aligning spherical roller bearings

6.10

Bearing Life: 40000 Hrs

6.11

Type of sealing: Double labyrinth with synthetic sealing.

Plummer Blocks The pulley shaft shall be supported on heavy duty; split type
Plummer blocks of 4 bolts construction.

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CONVEYOR DRIVE UNIT:

Reducers

8.1 The gearbox mechanical rating shall be 1.5 times of consumed power at pulley shaft
or1.25 times of motor power, whichever is higher.
8.2 For Motor Power Rating up to 15 kW Worm Gear Box shall be provided.
8.3 For conveyor having motor kW above 15 kW, the type of gearboxes shall be helical
type. If required due to space constraint Bevel Helical Gearboxes shall also be used.
8.4 All Inclined conveyors shall be provided with roller type holdback integral with
gearbox.
8.5 Housing of the gearbox shall be made of Cast iron housing of FG 260 as per IS: 210.
9

High Speed Coupling

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

9.2 Motor name plate rating above 37 kW to 200kW Traction Type Fluid Coupling.
9.3 Motor name plate rating above 200 kW (HT motor) Delayed fill chamber type fluid
coupling
10 Low Speed Coupling Gear coupling
11 Brakes Electro hydraulic thruster brakes shall be provided on conveyors where
reduction in coasting time is required.

CONVEYORS STRUCTURAL

12 Take up
12.1. Conveyors of length up to 30 m shall be provided with screw type take-ups and
conveyors of length above 40 m shall be provided with automatic take-ups
preferably vertical gravity take-up, wherever possible.
12.2. Conveyor of length between 30 m and 40 m, screw type take-up may be
considered if vertical gravity take-up is not possible to be provided.
12.3. Conveyors counter weight shall be made of 60% cast concrete block & balance in
cast iron block in steel box. Where RCC block counter weight cannot be
accommodated due to space problem, cast iron counter weight will be provided.
Weight of single piece of counterweight will not be more than 25 Kg.
13.

Skirt Board Length of skirt board For single discharge, the length of the skirt
shall be minimum 4000 mm. In case of multiple feeding system, length of the skirt
shall be continuous covering all feed points. Skirt board top cover shall be 3.15
mm thk MS cover. The height of skirt shall be minimum 400 mm for 800 mm belt
width, 450 mm for 1000 mm and 1200 mm belt widths and 500 mm for more than

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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

All the chute body shall be

minimum 10 mm thick MS plate.
Conveyor hood shall be made of
minimum 5 mm thick MS plate.
Hinged type inspection doors
minimum of 500 x 500 mm and
poke doors of 300 x 300 mm
shall be provided, wherever
required

18.2

Height of single piece of chute

shall not more than 2 meters
Impact zone of all chutes shall
be lined with 60 mm thick
rubber liner and sliding areas
with 30 mm thick ultra high
molecular weight polymer.

Liners

All clean coal chutes shall be

lined with SS-304 liner. Liners

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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.
18.3

Valley Angle

Valley angle of chute shall be

minimum 60 degree.

Bin/ Bunker
Bin Bunker Details
Sl. No.
1.
2.

Items

Type/MOC

Coal
Raw coal silos

Concrete silos
Concrete hopper

3.

Ground ROM receiving

hopper
Wagon tippler hopper

4.

Plant Surge hopper

Structural

Concrete hopper

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

Sl. No.

Items

Liner Specification
20 mm thick Hardox 450
20 mm thick Hardox 450

3.
4.
5.
6.
7.

Raw Coal handling chute

Clean/Middling/Reject Coal
lump size (-) 13mm Impact
zone
Sliding/non impact zone
Skirt
Wagon Tippler Hopper
Truck Dump Hopper
300T Hopper

8.

Raw Coal Silo

9.

Media pipelines

1.
2.

10.
11.

Launders
Return pipelines & coal
water slurry line

7|Page

20 mm thick UHMWPE
10 thick Mn Steel (IS:276 Part-I)
45kg/m rail
45kg/m rail
1 meter bottom vertical portion &
all Conical portion 20mm thick.
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)

CONVEYOR MOUNTED ELECTRICALS:

19.

Pull Cord Switch. Pull cord switch of lock-out type shall be provided at a
regular interval of 25 m along each conveyor and on both sides for manual
tripping of drive motor under emergency. Minimum distance of switch shall be 5 m
from the head & tail end of conveyor.

20.

Belt Sway Switch Belt sway switch shall be provided at both sides and at 50 m
interval along conveyor length to automatically stop the conveyor in case of
excessive sway of the belt. Minimum distance of switch shall be 10 m from the
head & tail end of conveyor.

21.

Zero Speed Switch One for each conveyor at non drive pulley. Belt slip/zero
speed switch shall be provided at the tail end along the belt conveyor to
automatically stop the equipment in case of excessive slip of belt or snapping of
the belt.
Chute Blockage Switches Chute plug switch shall be provided for chutes and

22.

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

8|Page

SCOPE OF WORK/SUPPLY

9|Page

SCOPE OF WORK / SUPPLY

Bengal Tools Ltd., Kolkata, India and Tangshan Guohua Technology Co. Ltd., Tangshan,
Hebei, China as consortium members jointly proposes to undertake design and
engineering, manufacture/procurement, painting, packing, supply, unloading, storage
and handling at site, construction, erection, testing, commissioning and demonstration
of performance guarantee of a coking coal beneficiation plant having capacity to treat
1.80 MTPA raw coal to produce clean coal, middling, tailings and reject as per scope of
supply on turnkey basis for M/s S&T Mining Company Pvt. Ltd. Kolkata, India at
Bhelatand, Dhanbad District of Jharkhand, India. The scope of supply shall consist of
the following equipment/ item:
1) MECHANICAL
A. BELT CONVEYORS:
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)

Remarks

Rail Wagon
Unloading
Circuit

New Belt Conveyors for proposed plant

1.

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

Belt Conveyors to be modified in the existing plant

1

BC-316

1600

3.20

1800/2160

BC-319

1600

3.20

1800/2160

Note:

Existing
Conveyors

The conveyors will consist of the following:

Troughing, Troughing training, Flat Return /two roll V-return Idler, Return
Training, Transition, Impact idlers, as required.
Drive, tail, take-up, bend and snub pulleys complete with Double Row
Spherical Roller bearings and Plummer blocks, as required.
Belting: Heavy Duty Nylon- Nylon/ EP belting
Drive unit consists of Motors (HT & LT), worm/ helical gearbox (with integral
holdback for inclined conveyors), high speed, low speed coupling and
coupling guard.
Screw/ Gravity type take-up with Counter weight as specified in Basis of
Design.
One sprung blade type (Tungsten tipped) and one one poly urethane blade
belt scrapers at discharge pulleys and one no. V-plough type (internal
scraper shall be provided for each conveyor.
12 mm thick natural rubber lagging (shore hardness 35-450 on Scale A),
herringbone type except for Conveyors Nos. BC-1, BC-2, BC-17, BC-18,BC19, BC-20 which will be provided with 12 mm thick Ceramic Lagging and 10
mm thick plain rubber lagging for non-drive pulleys (shore hardness 35-

12 | P a g e

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

VSD Drive for tippling of wagons

i) Quantity

1 (One) No.

ii) Location

At inhaul of WT

iii) Type of Traction

Drag Chain Arrangement

iv) Capacity to Pull

Capable of handling of gross load of

140t

ii) Capacity (Rated)

2.

Side Arm Charger

3.

Apron Feeder

i)

Quantity

1 (One) No.

ii)

Capacity (Rated)

1500 TPH

iii)

Material Handled

ROM (-) 600 mm

iv)

Discharge

BC-1

4.

Lump Breaker

Moil point hammer with swivel arm

1 (One) No.

Hydraulic

6 (Six) Nos.

Unbalanced Motor type

500 tph

i) Type
ii) Quantity
iii) Drive
5.

Vibrating Feeders
a) Pre MCCP Building
i) Quantity

ii) Type
iii) Capacity

13 | P a g e

S.
Equipments
No.
iv) Location

Specifications

1 No. below Raw Coal Receiving

Hopper and 5 Nos. below Raw Coal
Silos

4 (Four) Nos.

Unbalanced Motor type

iii) Capacity

1000 tph

iv) Location

Below Middlings & Rejects Hopper

Sizer

1 (One) No.

iii) Capacity (Rated)

1500 tph

iv) Input Feed Size

600 mm nominal top size

v) Output Size

(-) 200 mm

vi) Receives

BC-2

Secondary Sizer

Sizer

1 (One) No.

iii) Capacity (Rated)

1500 tph

iv) Input Feed Size

(-) 200 mm

v) Output Size

(-) 50 mm

vi) Receives

Primary Sizer

BC-4

1 (One) No.

Impact Crusher

iii) Capacity

300 tph

iv) Input Feed Size

(-) 50 mm

v) Output Size

(-) 13 mm

vi) Receives

Raw coal Classifying Screen Over

Product

b) Post MCPP Building

i) Quantity
ii) Type

6.

Primary Sizer
i) Type

ii) Quantity

vii) Discharges
7.

Secondary Sizer
i) Type

ii) Quantity

vii) Discharges
8.

Tertiary Crusher
i) Quantity

ii) Type

14 | P a g e

S.
Equipments
No.
vii) Discharges

Specifications

Classifying Screen 1 & 2

i) Quantity

1 (One) No.

ii) Capacity

500 tph

iii) Aperture

13 mm

iv) Receives

BC-6

vi) Discharges

Over product on tertiary crusher

and under product on BC-9

i) Quantity

1 (One) No.

ii) Capacity

300 tph

iii) Aperture

13 mm

iv) Receives

BC-8

vi) Discharges

Over product on BC-7 and under

product on BC-9

i) Quantity

1 (One) No.

ii) Capacity

1500 tph

iii) Belt Width

1800 mm

iv) Location

At conveyor TC-1

2 (Two) Nos.

Double Girder Type

iii) Capacity

15 t & 20 t

iv) Location

WT Complex & MCPP

v) Span

12.5 m at WT Complex & 20 m at

MCPP

6 (Six) Nos.

Electrical actuator type with

provision of manual operation

9.

Classifying Screens
a) Classifying Screen 1

b) Clasiifying Screen 2

10.

11.

Travelling Tripper

EOT Crane

i) Quantity
ii) Type

12.

Rack & Pinion Gate

i) Quantity
ii) Type

15 | P a g e

S.
Equipments
No.
iii) Location
13.

Specifications
Below Raw Coal Silos & Surge
Hopper

1 (One) No.

Electrical actuator type with

provision of manual operation
At tertiary Crusher House

Flap Gate

i) Quantity
ii) Type
iii) Location
14.

Rod Gate

i) Quantity

ii) Type

5 (five) Nos.

Manual

One Below WT Hopper & four

Middlings & Reject Hoppers

i) Quantity

1 No.

ii) Capacity

300 tph

4 Nos.

Automatic Coal Sampler

At Conv. BC-10, 11, 13 & 16

iii) Location
15.

16.

Belt Weigh Feeder

Auto Sampler

i) Quantity
ii) Type
iii) Location
17.

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

a) Raw Coal De-Sliming Screen

i) Quantity

1 (One) Nos.

Banana Type

iii) Capacity

300 tph

iv) Aperture

1 mm

v) Dimension

3m x 6.1 m (Approx)

vi) Receives

Plant Feed Conveyor

Over product

To primary HM Blending Tank

Through Product

To classifying cyclone sump

ii) Type

vii) Discharges

b)

Primary HM Media Cyclone Clean Coal D&R Screen

16 | P a g e

Sl.
Equipments
No.
i) Quantity

Specifications

1 (One) Nos.

Banana Type

iii) Capacity

200 tph

iv) Aperture

1 mm

v) Dimension

2.4 m x 6.1 m (Approx)

vi) Receives

HM Cyclone Overflow

Over product

To clean coal centrifuge

Through Product

To dilute sump

ii) Type

vii) Discharges

c)

Primary HM Cyclone Reject D&R Screen

i) Quantity

1 (One) Nos.

Banana Type

iii) Capacity

200 tph

iv) Aperture

1 mm

v) Dimension

2.4 m x 6.1 m (Approx)

vi) Receives

HM Cyclone Underflow

Over product

To secondary blending sump

Through Product

To dilute sump

1 (One) Nos.

Banana Type

iii) Capacity

150 tph

iv) Aperture

1 mm

v) Dimension

2.1 m x 6.1 m (Approx)

vi) Receives

Secondary HM Cyclone Overflow

Over product

To middlings centrifuge

Through Product

To dilute sump

1 (One) No. used for Drain & Rinse

Banana Type

ii) Type

vii) Discharges

d) Middlings D&R Screen

i) Quantity
ii) Type

vii) Discharges

e. Reject DR Screen
i) Quantity
ii) Type

17 | P a g e

Sl.
Equipments
No.
iii) Capacity

Specifications

150 tph

iv) Aperture

1 mm

v) Dimension

2.1 m x 6.1 m (Approx)

vi) Receives

Secondary HM Cyclone Underflow

To reject conveyor

To dilute sump

1 (One) No.

Scrolled evolute Type, 1000 mm dia

iii) Capacity
iv) Feed Size

210 tph
(-) 13 mm

v) Receives

Primary HM Cyclone feed pump

Overflow

Underflow

To primary HM Cyclone overflow

collecting tank
To primary HM Cyclone underflow
collecting tank

vii) Discharges
Over product
Through Product
18.

Heavy Media Cyclone

a) Primary Heavy Media Cyclone

i) Quantity
ii) Type

vi) Discharges

b) Secondary HM Cyclone
i) Quantity

1 (One) No.

Scrolled evolute Type, 850 mm dia

iii) Capacity

160 tph

iv) Feed Size

(-) 13 mm

v) Receives

Secondary HM Cyclone feed pump

Overflow

Underflow

To Secondary HM Cyclone overflow

collecting tank
To Secondary HM Cyclone
underflow collecting tank

ii) Type

vi) Discharges

19.

Classifying Cyclone

a) Raw Coal Classifying Cyclone Cluster

i) Quantity

18 | P a g e

1 (One) Set

S.
Equipments
No.
ii) Capacity (R/D)

Specifications

100 tph/ 120 tph

iii) Size dia

350 mm

iv) Classification at

0.25 mm

v) Receives

Classifying Cyclone Feed Pump

Overflow

To flotation feed pump

Underflow

To underflow collecting tank

2 (Sets) No.

30tph/35 tph

iii) Size dia

350 mm

vi) Classification at

0.25 mm

v) Receives

TBS Overflow

Overflow

To flotation feed pump

Underflow

To TBS Sieve Bend

vi) Discharges

b) TBS Product Cyclone

i) Quantity
ii) Capacity (R/D)

vi) Discharges

20.

Magnetite Separator

a) Primary & Secondary Magnetite Separator

i) Quantity
ii) Type

1 No. each

Counter Rotation Type, self level

controlled wet drum magnetic
separator
iii) Size
Drum Size 915 mm dia x3000

long
b) Magnetic Separator for Fresh Magnetite Charging
i) Quantity
ii) Type
iii) Size
21.

1 (One) No.

Counter Rotation Type, self level

controlled wet
Drum Size 915 mm dia

1 (One) No.

Coarse Coal Centrifuge

a) Clean Coal Centrifuge

i) Quantity

19 | P a g e

S.
Equipments
No.
ii) Capacity

Specifications

150 tph

iii) Basket Screen Aperture

0.35 mm

iv) Receives

Clean Coal Screen over product

Over Product

To clean coal conveyor

Through Product

To clean-up sump tank

i) Quantity

1 (One) No.

ii) Capacity

150 tph

iii) Basket Screen Aperture

0.35 mm

iv) Receives

Middlings D&R Screen Over Product

Over Product

To Middlings conveyor

Through Product

To clean up coal conveyor

i) Quantity

1 (One) No.

ii) Capacity

20 tph

iii) Diameter

20 m

iv) Receives

Tailings of flotation cells & pressure

filter effluent pump

Overflow

To clarified water tank

Underflow

To pressure filter feed sump

V) Discharges

b) Middlings Centrifuge

v) Discharges

22.

High Rate Thickener

v) Discharges

23.

Flotation Concentrate Filter Press

i) Quantity

1 (One) No

Steel Frame & Chamber Type

iii) Capacity

30 tph

iv) Receives

Pressure filter feed pump

Cake

To clean coal conveyor

Filtrate

To thickener

ii) Type

v) Discharges

20 | P a g e

S.
No.
24.

Equipments

Specifications

Teeter Bed separator/ Reflux Classifier

i) Quantity

1 (One) No

ii) Capacity

60 tph

iii) Feed Size

(-) 1 to 0.25 mm

iv) Receives

Classifying Cyclone underflow

Overflow

To TBS Product Sump

Underflow

To TBS Reject Sump

i) Quantity

1 (One) No.

ii) Capacity

40 tph

iii) Feed Size

< 0.25 mm

iv) Residence Time

Minimum 10 minute

v) Receives

Flotation Feed Pump

Clean Coal

To flotation concentration sump

Tailings

To thickener

v) Discharges

25.

Froth Flotation Cell

vi) Discharges

26.

High Frequency Screen for TBS Cleans & Rejects

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

iii) Screen Aperture

27.

Metal Detector

i) Quantity
ii) Type
iii) Location
28.

Magnetic Separators

a) In line Magnetic Separators

21 | P a g e

S.
Equipments
No.
iii) Location

Specifications

On Discharge of BC-2

b) Cross Belt Magnetic Separators

i) Quantity

2 (Two) No.

ii) Capacity

1000 gauss

iii) Location

On conveyors BC-6 & BC-8

7 (Seven) Nos.

Load Cell with microscopic

controller
10 % to 120%

29.

Belt Scales

i) Quantity
ii) Type
iii) Capacity variation

iv) Locations

Conveyors BC-2. 3,10,11,13,16 &

17

i) Quantity

Lot

ii) Type

Electric / Manual (As per requirement)

iii) Hoist Selection Basis

Manual Hoist ->

30.

Electric & Manual Hoists

To handle items up to 2000 kg.

Maximum Lift : up to 15 mtrs.
Electricl Hoist ->

To handle items beyond 2000 kg

Lift : More than 15 mtrs.

NOTE: Hoist Schedule for the Various Location in CHP is furnished below and the
hoist required for the other areas can be referred in the detail list of equipment.

22 | P a g e

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

23 | P a g e

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.

Operation Logic for Starting of Pumps (DFDSS & PWDSS)

The water Pumps can be started from MCC under following conditions.

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.

25 | P a g e

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

26 | P a g e

Municipal water consumption: the water consumption is 4.5m/d .

Fire-fighting water consumption: 38 L/S, the total water consumption for a fire
disaster will be 305 m.
The total quantity of makeup water for production is 0. 095 m 3/ton of raw coal
and 590 m/Day.
The recommended combined fire-fighting and process water tank is 1000
mhowever, a 1800 m3 water tank is used as the client requires in tender.
Fire fighting water consumption: outdoor fire fighting water: 25 l/s,
indoor fire fighting hydrant: 20 l/s, 3 hours duration for one fire disaster;
water curtain system: 16l/s, fire duration time: 3 hours; automatic water spray
system: 30 l/s, fire duration time: 1 hour.
Total 735m3 for one fire disaster
Water pressure:
1. Production water makeup: 25m
2. Municipal water line: 25m
3. Fire fighting water pipe line: at least 65m
Dust Extraction ventilation & Air Conditioning System
Dust Extraction System
Introduction:
Dust Extraction system is used to extract the air bone dust generated due to the
transfer & loading & unloading of materials, activities like screening etc. in the
Industries. This air borne dust makes the nuisance inside the plant premises. To
eliminate these hazards from the working area Dust extraction system is one of the
Solutions. Some of the equipments like Belt Conveyors
Screen, Crusher, Silo
Ventilation needs a aspiration system to provide the equipment to work according to
the its designed working capacity & to avoid dusting.
Working Principal of DE system:
In this system the dust generated in the equipment like Belt conveyor Transfer points,
Screen, Dust generated due to Height of fall is being collected through the suction hood,
Ducts, to the Bag filter .Air along with dust particles under suction or pressure enters
the lower portion i.e. hopper of the bag filter. The air travels through the filter bag,
which retains the dust particles on surface of the bag, and the clean air passes out
through bags and plenum to the outlet of Bag filter.
Dust collected on the outside of the filter bags causes an increase in the pressure
differential between dirty and clean airsides of the bag filter. To control the pressure
differential across the bag filter, a sequential timer actuates a series of normally closed
pulse valves at preset intervals causing them to open.
A momentary rush of high-pressure air (5-6 bar g) flows from the compressed air header
to the blow tube and is expelled from the blow tube through nozzles at a high velocity
(primary air flow). Air from each nozzle induces a secondary airflow the combined effect
of the primary and induced secondary air causes an instantaneous pressure rise on the
clean side of the filter bags, causing a reverse flow air through the filter bags, thus

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

Polyester Homopolymer Bags.

GI
IS2062, gr. A
Standard
IS2062, gr. A
Is-2062gr.A
5 mm Thk
Is-20620 gr.A
5 mm Thk
Standard
Standard
Standard
Standard
IS:2062 gr.A

13

Bag filter housing

IS:2062 gr.A

5 mm Thk

14

Bag filter hopper

IS:2062 gr.A

5 Thk

15

Plenum

IS:2062 gr.A

3.15
Thk

mm

15

Screw conveyor

IS:2062 gr.A

16

Ducting & bends

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

Air dryer (refrigerated type)

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

Pressurized Ventilation System at MCC / Switchgear room & Exhaust Ventilation

system in Battery Room
Introduction:
Pressurized ventilation system shall be provided in the MCC room to make the room
pressurized & prevent the in rushed dusty air to entre inside the room. Tube axial type
fan is used to supply the air through air duct & supply grill. This Fan draw the air from
the atmosphere though panel filter. Panel type air filter is used at the inlet of fan to
prevent dust to deliver inside the room. Gravity type wall mounted damper is provided
to exhaust the excess amount of air from the mcc room. This gravity damper shall open
when the pressure inside the room exceed the value of 2-3 mmwg above atmospheric
pressure. Thus as the name implies, the air pressure above atmosphere shall be
maintained inside the room. As the air pressure inside the room is more than
atmospheric pressure there shall be rise in temperature inside the room limited to 2-3
deg c above outside air temperature. Fire damper fusible link type shall be provided at
the inlet of the room to prevent fire hazard inside the room.
For Battery room exhaust ventilation is used to extract the contaminated air.
General Consideration for Dry Pressurized Ventilation :
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)

No of air change considered for supply of fan shall be 15/hr.

Rise in temperature inside the room is 2-3 deg c.
Gravity damper shall be used to make the room pressurized.
Fan volume is decided by air change method or heat load calculation Method
whichever is higher.
Velocity in the duct shall be max.10 m/s
Velocity of air at supply grill shall be 3-4 m/s
Velocity of air at gravity louver shall be 5 m/s
Filter face velocity shall be 2-2.25 m/s

Codes & Standard:

CODE
IS-655:2008
IS-3588: 1987
IS-277-2003
UL-555

:
:
:
:

DESCRIPTION
METAL AIR DUCT (GI)
SPECIFICATION OF ELECTRICAL AXIAL FLOW FAN
GALVANISED STEEL SHEETS
FIRE DAMPER

Major Equipment Involved in the System:

EQUIPMENTS

MOC

INLET FILTER
CENTRIFUGAL FAN
MOTOR FOR FAN
BIFURCATED TYPE TUBE AXIAL FAN
AIR DUCT SUPPLY AIR
GRILL WITH VCD
RAIN TROTECTION COWL/BIRD SCREEN
FIRE DAMPER
PROPELLER FAN

32 | P a g e

:
:
:
:
:

HDPE TYPE
IS: 2062
STANDARD
IS-2062/AL CAST
GI

: GI
: GI
: AL DIE CAST/MS

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

Package Air Conditioner

Hi Wall Mounted Spilt Air Conditioner
Horizontal Split Casing Pump
Cooling Tower (Induced Draft type)
Duct & its supporting structure
Fire Damper
Insulation for Duct

Standard
Standard
Standard
FRP Type
GI/MS(As per IS:655:2008)
GI
Resin bonded glass Wool (24
Kg/m3, 50Thk.) Cladding
30G GI sheet
5 Mtr of the supply air duct,
material : Fiber Glass Wool of
Density 48 Kg/m3

Acoustic Insulation

Codes & standards:

Sr. No
1
2
3
4
5

Indian standard (IS)

IS:3588
IS:2312
IS:4894
IS 1391 (PART 2) : 1992
IS: 8148:1976

Title
Specification for electrical axial flow fans
Propeller type ac ventilation fans
Centrifugal fans
Split air conditioners
Package air conditioner

Air conditioning location:

33 | P a g e

i)
ii)

PLC/ Control Room: Package Air Conditioner

Office Room: Hi Wall Mounted Split Air Conditioner

3) ELECTRICAL
Power distribution:
CHP power distribution has been considered as per basic Overall power distribution
diagram Drg. 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

Following switch gears are considered for HT load distribution:

Sl.
1

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

11kV LA,26.3KA/3 sec, Station Class complete with

surge arrestor and insulating base. Class-1
Trifurcating cable box for terminating 11KV HT cables

Set

No

11 kV, 26.3 kA for 3s switch board consisting of two (2)

incoming VCBs, one (1) bus coupler VCB and outgoing
VCB feeders each provided with imploding type LA, along
with bus and cable earthing VCB. 11 kV switch board
will operate on Automatic Bus Transfer (ABT) based
system.
11 kV Circuit Breaker control Panel, comprising relay &
metering cubicle for the above.
110V DC plante type lead acid battery of adequate
capacity along with battery charger and 110V DCDB for
11 kV & 3.3kV equipment at MRSS & HT s/s
11/0.433 kV, 2MVA ONAN, Dyn11 transformer of
suitable rating for auxiliary power supply and dedicated
lighting load of the complete plant
11/0.433 kV, 1.6MVA ONAN, Dyn11 transformer of
suitable rating for auxiliary power supply and dedicated
lighting load of the complete plant

Set

Set

No

Nos.

Nos.

11/3.45 kV, ONAN, 1.5MVA, Dyn11 power transformer

with all fittings and accessories.
11/0.433kV, ONAN, 1.0 MVA, Dyn11 lighting
transformer with all fittings and accessories.

Nos.

No.

3.3 kV neutral grounding resistor and transformer

neutral isolator panel.
3.3 kV, 36KA/3sec.1600A draw out type HT MCC for
various HT motors. The two (2) I/C VCBs & B/C VCB,
O/G VCB will operate on ABT based system. All motor
feeders (10 no) will be provided with LA & R-C snubber
circuit.

Nos.

Set

Al the above item will be considered as per specification

CET/26/RN/3812/TS/CC/01/R=1 which short description are as follows.

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

Rated short time withstand current: 25KA/3sec

Finish Hot dip galvanized Approx. isolator weight: 250Kg.
Type of Support insulators: Porcelain
No. of poles: Three
Rated continuous current: 1250A
Installation: Outdoor, pole mounted type

11/3.3 kV Sub-station Power Transformer:

Basic requirements are given in General Design Features of Power Transformer.
However, the power transformer and accessories will comply with the following:
Three-phase power transformer (Dyn11) will be supplied with:
Winding & oil temperature indicator with alarm/trip contact, additionally remote
signaling for winding & oil temperature.
ii) Pressure relief valve
iii) Buchholz relay
Basic features of the transformers:
i) Primary voltage. 11 kV
ii) Secondary voltage. 3.45 kV
iii) Rated power output will be furnished by the EPC vendor
iv) Type of cooling. ONAN
v) Tapping. 7.5% with steps of 2.5% off load
Transformer will be installed outdoor suitably designed along with all safety features
(e.g. HVWS-if required).
Neutral earthing Arrangement:
A full capacity neutral terminal will be brought outside the tank and provided with a
bushing CT with dual ratio 1000-500/5A, 15 VA, 5P20 for standby earth fault
protection. The neutral point after CT connection will be bifurcated. One of the leads
after bifurcation will be connected to a suitable terminal for solid earthing via two (2)
knife switches, by 1.1 kV, 1/C, 630 sq mm Al. PVC or 1/C, 300 sq mm Cu PVC cable to
earth stations as specified. The other lead will be taken inside LV box through a bushing
and provided with a suitable terminal for neutral connection
Neutral earthing isolator.
11/0.433 kV Distribution Transformer:
The 415V load centre substations will be fed from 11/0.433 kV distribution
transformer.
Distribution transformers will be selected from sizes 1600 kVA/2000 kVA. Main
characteristics are:
Transformer type: Oil filled
Cooling class: ONAN
Winding vector group: Dyn11
Installation: Outdoor
Primary off-load tap changer: 5% @2.5% by step

37 | P a g e

Sub-station power transformers will be sized based on consumed loads in operation.

Stand-by and spare feeders will not be considered in transformer sizing. The
transformer capacity will be designed such that in the case of outage of one transformer,
the other healthy transformer is not loaded beyond 80%.The transformers will be
designed, constructed and tested in accordance with the applicable sections of the latest
revision of relevant Indian Standard (IS), Indian Electricity Acts & Codes equivalent IEC
standards. For isolation of load centre transformers, load breaks isolators along with
LPT panel will be considered. If transformers are not in the vicinity of HT switch gear.
VCB with protection along with LPT will be provided.
110V DC Battery with charger& DCDB:
110V Plant type lead acid battery system will be provided for control and monitoring of
the 11 kV and 3.3 kV switchboards located in two different substations. Each set will
have redundant battery charger circuit but batteries will be common. Each charger will
operate on float-cum-boost mode. The float cum booster charger will be rated to cater to
the trickle changing current of batteries as well as the boost charging (2 rate) of a fully
discharged battery and continuous load on DC bus including 20% margin. The boost
charger will be rated to charge the battery from fully discharged condition to charged
condition within 8 hours. DC distribution boards will be provided.
LT load distribution:
LT load will be supplied from 2 nos. 11KV/433V, 1600KVA transformer for WT system &
fire fighting system, 2 nos. 11KV/433V 2000KVA transformer for conveying& others
auxiliary system.
In this regards one dedicated PCC will be considered for supplying LT load to Conveying
system MCC, DS MCC , PDB as per SLD. Required rating bus duct will be considered
from transformer secondary to PCC incomer & PCC outgoing to MCC Incomer .
Following switchgears are considered for LT load distribution:
Sl.
ITEM DESCRIPTION
1
4000A LT Bus duct for ELB-1 between 11/.433KV
Transformer & PCC
2
2000A, LT Bus duct for WT PCC
3
3200A LT Bus duct for MCC Conveying system
4
PCC for ELB-1
5
PCC for WT
6
MCC for Coal Handling Part Conv. & Aux. load.
MCCs - Conventional, Non-draw-out type, Single
front, Motor Control Centres (MCC) with two
incomers & one bus-coupler
7
MCC for DS SYSTEM
MCCs Conventional, Non-draw-out type, Single
front, Motor Control Centres (MCC) with two
incomers & one bus-coupler

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

Al the above item will be considered as per specification

CET/26/RN/3812/TS/CC/01/R=1 which short description are as follows.

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

415 V Bus ducts:

Three phase and neutral, nonsegregated bus duct with 3 mm thick aluminium alloy
enclosure will be provided up to 15 meter length for connection between the transformer
secondary and the 415 V switch board. Material for the bus bar will be aluminium. The
degree of protection for enclosure will be IP54.
Suitable adapter chamber will be provided for terminating the bus-duct on to
switchgear. Matching flanges will be provided at both ends of the bus-duct run. Flexible
terminal connectors will be provided for termination at transformer and switchgear
ends. Expansion type joints will be provided in the bus-duct sections to take care of
variation in lengths due to variation in temperature.
Busbars inside the enclosure will be supported on insulators of required voltage grade.
The number and spacings of insulators will be so selected that the bus bars will be
capable of withstanding the dynamic forces set up under rated through fault conditions.
The bus-duct enclosure will be provided with earthing terminals at both ends for
connection to the station earthing system. A continuous aluminium earth bus will be
provided throughout the length of the bus-duct.Bus-ducts will be provided with
complete supporting structures, as required. Sections of bus-ducts installed outdoors
will be supported from ground while indoor sections will be supported from ceiling
and/or wall.
Seal-off wall bushings will be provided where the bus- duct enters a building from its
outdoor run.
LT Variable Speed AC Drives for apron feeder:
The VVVF will be of pulse width modulation (PWM) type with open loop frequency
control to keep the ratio of voltage to frequency (V/f) constant throughout the speed
range to maintain constant motor torque.
The VVVF will comprise incoming fuse unit, dry type line reactor, threephase diode
bridge, inverter unit, load side contactor/isolator and current limiting choke where
required.
The PWM inverter will have fully digital microprocessor based regulation and control
system with suitable interfaces for instruments and signals. The microprocessor will
carry out all the functions required from unit including triggering protection, selfdiagnostic and operator interface. Suitable programming and debugging unit will be
provided. Display of faults, alarms, as well as diagnostic messages will be available in
plain text on the operator panel of the cubicle.
All faults, not limited to the following, will be detected, annunciated and protective
measures will be initiated accordingly. First fault annunciation will be provided.

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

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

Motor faults

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

45 | P a g e

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:

Probe materials :SS with PTFE or Ceramic as per requirement

No. of points : As per requirement
Range : As required
Output : 4-20 mA DC with 600 ohms load
Alarm output : Potential free contact for High, Low level
Operating temp.: 0-70 oC
Power supply : 230V, 50Hz AC
Mounting : Flanged connection at top of Covers/side walls.
Enclosure : As per IPSS : 2-07-001-87

Belt Weighing System

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

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 On conveyors to record the quantity of coal received in the plant and quantity 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 Pre & Post Material Handling facilities

Automation system for Wagon Tippler house
Integration among automation system of Material Handling facilities, Main
Coal Processing Plant, Wagon Tippler system.

Automation system for each area will be achieved through dedicated PLC system 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

VHF voice communication system:

The VHF communication system will be used to provide instantaneous audio
communication facility among control rooms & plant personnel. System will be
considered as per specification doc. No CET/26/RN/3812/TS/CC/01/R=1, clause- no
3.6.6
Closed circuit television (CCTV) system:
Supervision & monitoring system will be provided for process monitoring and
functioning of equipment from a central location by installing CCTV system. This system
will assist in monitoring various areas on a continuous basis from a central location and
for taking timely action in the event of any dysfunction.
Main Features of CCTV system will be as follows:
Remote control facility
Recording of events
Motorized pan & tilt head (as required)
Centralized viewing
The CCTV system will consist of cameras to view the respective area along with monitors
for viewing independent areas. The monitors shall be housed in the main control room.
The facility for recording the events as historical events with time limit of storage will be
provided in the system.
System will be considered as per specification doc. No T/26/RN/3812/TS/CC/01/R=1,
clause- no 3.6.8
Loudspeaker communication system:
Two Channel Open Line Page Party type Loudspeaker Communication system (PA) for
establishing reliable and quick communication amongst various sections of the
manufacturing complex comprising of the following:
1) Thirty (30) nos. of wall/desk mounted subscriber stations with required no. of horn /
cone type loudspeaker and other accessories as per requirement.
2) Required quantities of armoured signal cable, control cable and mains cable with
cabling accessories, junction boxes, PDBs as per requirement.
3) Any other accessory or equipment as required for the proper functioning of the above
mentioned loudspeaker communication system.

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4) STRUCTURAL WORK:
4.1 TECHNOLOGICAL STRUCTURES
S
NO.

Description

QTY.

Stringer, Short post, Head and

Tail pulley frame & Guide column
for Vertical gravity take-up.

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.

Conveyor Discharge Chutes &

Liners

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

Building /Normal Structures

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.

Walkway for galleries

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.

The other major structural work shall be as follows:

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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