Technical Documents: Puttalam 1X300Mw Coal-Fired Power Plant Project

TECHNICAL DOCUMENTS
FOR
PUTTALAM 1X300MW COAL-FIRED POWER PLANT

PROJECT
CEYLON ELECTRICITY BOARD
CHINA NATIONAL MACHINERY & EQUIPMENT

IMPORT & EXPORT CORPORATION
Jan, 2006
Puttalam 1X300MW Coal-Fired Power Plant
Port Part-Volume 3
GENERAL CONTENTS
VOLUME 1 MAIN POWER BLOCK

VOLUME 2 BALANCE OF PLANT
VOLUME 3 PORT PART
VOLUME 4 TRANSMISSION LINE AND
SUBSTATION
VOLUME 5 SITE DEVELOPMENT, HOUSING
COMPOUND AND RESETTLEMENT
ACTIVITIES
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Port Part-Volume 3
TECHNICAL DOCUMENTS
FOR
PUTTALAM 1X300MW COAL-FIRED POWER PLANT

PROJECT
VOLUME 3 PORT PART
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Port Part-Volume 3
ALTERNATIVE 1 (5000T Wharf)
CONTENTS
CHAPTER 1 GENERAL
CHAPTER 2 COAL HANDLING TECHNOLOGY
CHAPTER 3 GENERAL LAYOUT
CHAPTER 4 MARINE ARCHITECTURE
CHAPTER 5 ACCESSORY FACILITIES
CHAPTER 6 SUGGESTION
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ATTACHED DRAWING LIST
1. GENERAL PLAN FOR 5000T WHARF
2. BERTH DOCK STRUCTURE SECTION VIEW
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1. Chapter 1 General
1.1 General Description
The coal-fired power plant wharf project is located 12km west of

Puttalam. The power plant phase-I project is of 1×300MW capacity,
and total installed capacity is 3x300MW in the long term.
In order to satisfy the coal handling requirement of the power plant, the
design is made according to available hydrological and meteorologic
information and relevant survey and study result. The scope of design
includes handling process, layout, marine structure, water supply and
drainage, fire fighting, powr supply & lighting, and control system. The
transfer machine house is at the tip of the land area, which is the
designed demarcation point of the plant area.
1.2 Standard and Base of Design
(1) The existing “technical specifications on port project” of the

Ministry of Communication, China and related Chinese industrial
standards, such as:
Code for Design of General Layout of Sea Ports (JTJ211-99)
Code for Sea Port Hydrology (JTJ213-98)
Code for Loads in Port Engineering (JTJ215-98)
Code for Foundations in Port Engineering (JTJ250-98)
Code for Pile Foundations in Port Engineering (JTJ254-98)
Code for Design of Concrete Structures in Port Engineering (TJT267-
98)
Code for Design and Construction of Piled Wharves (JTJ291-98)
Code for Design and Construction for Cast in-situ Pile in Port
Engineering (JTJ248-2001)
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Code for Design and Construction of Rock-socketed Piles in Port
(2)Basic information provided by CEB (hydrological, meteorological
and geological information in the plant site area and information about
sand movement and existing site condition):
Port facilities feasibility study Wave climate assessment, Re-12548-
015-01
Environmental impact assessment study report, Mar. 1998
Supporting documents to Environmental impact assessment study
report, Mar. 1998
Field investigations Final report, Dec. 1997
1.3 Principle of Design
In accordance with the CEB’s requirement, the coal handling capacity
for this project shall be 800000T/y in the near future; 2400000T/y in
the long term. The design satisfys the requirement of 800000T/y coal in
phase-I, with provision for future expansion in the long term. A 5000T
wharf including unloading platform and 500m near shore jetty will be
built for coal unloading according to CEB’s requirement.
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2. Chapter 2 Handling Technology
2.1 Design Conditions
(I) Annual transportation amount: 800,000T/y in phase-I, 2,400,000T/y in

phase-II.
(II) Type of cargo: Coal
2.2 Main Designing Parameters
(I) Annual operation days: 280 days (according to available information).

(II) The imbalance coefficient of port production: 1.4
(III) Daily work shifts: 3 shifts
(IV) Goods physical characteristics
1. Average stacking density: 0.85 ton/m3
2. Angle of rest: 35 ~ 50 (degree)
3. Particle: less than 50mm
2.3 Handling process arrangement and scheme
According to the throughput in short and long term, and the different
type of coal transport vessels, the following coal handling process is
proposed. The process system includes the ship unloading system and
the conveyor belt system. The handling process is as follows:
5000T barge => wharf conveyor belt => trestle bridge conveyor belt =>
EAT04 transfer machine room.
2.3.1 Ship-unloading system
Phase I:
The 5000T barge sails to the 5000T wharf to unload the coal by coal
unloading equipment on the dock. The on-dock unloading equipment is
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two gantry cranes with hopper, having 10.5m gauge and 16t lifting
capacity. The hopper is equipped on the crane as the receiving
equipment. Underneath the hopper a vibrating feeder is equipped to
transfer the coal to the horizontal conveyor belt mounted on the crane,
then to the conveyor belt on the dock.
Phase II:
The 5000T wharf will be equipped with 2 additional gantry cranes with
hoppers to satisfy the unloading requirement.
On the 5000T wharf, two rails for gantry crane will be laid, with the
distance of 2.5m between the front edge of the wharf and the outside
track. The width of the wharf is 15m.
2.3.2 Conveyor belt system
The design scope of the conveyor belt system is from the ship unloader
to the EAT04 transfer engine room at the land terminal. Single line
conveyor belt is used. For phase I, the conveyor belt capacity is 750T/h,
band width 1,200mm, speed 4.8m/s, with 1 berth. For phase II, the
conveyor belt capacity is 1500T/h, band width 1,200mm, speed 4.8m/s,
with 1 additional berth.
2.3.3 Temporary unloading facility for heavy equipment
Heavy pieces of equipment will be transported by 1000DWT barge

from Colombo port to the site and landed directly from sea.
2.3.4 Configuration of unloading equipment
Refer to Table 2-1 for the configuration and specification of unloading

equipment.
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Table 2-1
No. Name of equipment Specification Unit Q’ty Q’ty
(Phase I) (Phase II)
1 Gantry crane 16t- 28m Set 2 2
2 Belt conveyor on the B=1.2m, m 75 x 2 95 x 2

wharf V=2.4m/s
3 Belt conveyor on the B=1.2m, m 600 -

trestle bridge V=4.8m/s
2.3.5 Major technical-economic index
Refer to Table 2-2 for main tech. economic index.
Table 2-2
No. Item Unit Qty
1 Design annual transportation capacity 10k tons 80
2 Calculated annual discharge capacity 10k tons 120
3 Berth utilization ratio ％ 35
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3. Chapter 3 General Layout
3.1 Principle of General Layout
1. The wharf is designed according to available hydrological and

meteorological information, and other study result.
2. The number of berths is determined according to the throughput in the

short and long term.
3 A temporary unloading facility is proposed for the unloading of heavy

equipment and will be designed according to site condition.
3.2 Principle Dimensions of the Design Ship
3 Nos. 5000T self propelled barges will be provided in Phase I.

See Table 3-1 for dimensions of the designed ship.
Table 3-1
Tonnage Length Breadth Depth Loaded
Vessel type (T) (m) (m) (m) Draft
(m)
Barge 5000 85 22 4.5
3.3 General Layout
The scope of construction in phase I comprises 2 Nos. 5000T berths

(including 1 berth for phase II). In order to reduce the total investment, the
wharf is located beyond the -6.0m bathymetric line. To avoid the adverse
influence of cross wave on the vessel and improve the working condition,
the 245º azimuth of wharf is adapted according to relevant wave observation
results and analysis statistics. The wharf is in “I” shape. The bottom
elevation of the front edge of the berth is -6.0m.
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The wharf platform is 185m long, 15m wide (partially 20m wide). The
operation room and substation are positioned on the platform, with 1
mooring dolphin at each end of the wharf. A trestle bridge and an approach
levee are arranged between the platform and the land terminal. The trestle
bridge is approximately 500m long and the approach levee 90m long. The
trestle bridge and approach levee are 6m wide, with a conveyor belt and a
inspection path.
The top elevation of wharf platform and mooring dolphin is 7.0m. The land
terminal elevation is 3.5m for the approach levee. The trestle bridge and the
approach levee is linked up by a slope.
3.4 Operation days per year
3.4.1 Standard for coal handling operation
Wind: ≤ class 6
Rain: ≤ medium rain
Mist: visibility ≥ 1km
Wave: Downwind: H4%≤ 0.8m, T≤ 6s
Crosswind: H4%≤1.0m, T≤ 6s
3.4.2 Wharf coal handling operation days
Due to lack of long term and successive observation on local meteorological

and hydrological information at the project site area, estimation is made on
the operation days according to the available short term observation and
analysis result:
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The tentative operation days are estimated at 280 days per year.
3.5 Navigation Facilities
The natural water depth in the deep sea satisfies the shipping and berthing
requirement. To further facilitate the berthing operation, a light is set on top
of the mooring dolphin at either end of the wharf.
3.6 Main Quantities
See the table 3-2 below for main quantity:
Table 3-2
No. Item 5000T wharf
1 Ship unloading berth 2 Nos.(including 1 for phase II and III)
Temporary unloading facility for

2 1 No.
heavy equipment
3 Length of trestle bridge 500m (approximately)
4 Length of approach levee 90m
5 Light on wharf 2 Nos.
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4. Chapter 4 Marine Architecture
4.1 Scale and Grade of Marine Structures
4.1.1 Design Load
(1) The uniformly distributed load of the wharf is q=20kN/m2.

(2) The load for gantry crane with mobile unloading hopper: track gauge
10.5m; cardinal distance 12m; 24 wheels for each crane; the maximum
wheel load 30t/wheel; minimum clearance between two cranes 1.5m.
(3) Load per belt conveyor: 10KN/m.
(4) Mobile machines on the wharf: small maintenance cars (2t weight).
(5) Load of steel trestle bridge: similar to (3) and (4).
(6) Lateral forces on the wharf will be considered.
4.2 Design water level & Wave Factors
4.2.1 Design Water Level
Design high water level: 0.40m;

Design low water level: -0.20m;
Check High Water Level: 1.40m;
Check Low Water Level: -0.80m;
4.2.2 Design Wave Factors
Wave factors in front of the wharf, which may happen once every 50 years:
Design high water level: H1%=5.8m, H13%=4.2m, T =7.8s.
4.3 Structure plan of marine structures
Making reference to the available geological conditions of the project area,

the surface layer of the foundation of this project area is sand; below it is the
layer of sandstone and limestone. Making comprehensive account of the
hydrographic and geological conditions, the wharf structure is a high-pile
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pier structure; the approach levee is a riprap slope structure.
The sand layer on the natural rock surface of this project is about 5~10m.
Therefore, the steel pipe piles of this project shall be cast-in-place piles
embedded in the rock.
4.3.1 Wharf
The wharf is composed of the operating platform (concurrently as the

dolphin), mooring dolphins, and pedestrian steel bridges connecting to
mooring dolphins. The operating platform is 185×15m (partially 20m wide)
for 5000T wharf; the mooring dolphin is 9×9m; the top elevation of the
wharf surface is 7.0m.
The Φ1200mm steel pipe piles are used for the operating platform, and the
space interval between piers is about 20m. After completion of the
foundation, the reinforced concrete pile caps are cast in place, on top of
which are laid the reinforced concrete box girders. 450kN mooring dolphin
is setup on the 5000T wharf. DA-B500H rubber fenders are used for 5000T
wharf. Railing, and other accessory facilities will be provided accordingly.
Nine Ф800m steel pipe piles are driven for each mooring dolphin, on top of
which a reinforced concrete pier is cast in place. On the platform are set the
dolphin and railing.
The operating platform is connected to the shore through the steel trestle
bridge. The steel trestle bridge is about 70m in each span, and 6m in breadth.
The Ф800mm steel pipe piles are used as the foundation piles of the bridge
piers, and on top of the piles the reinforced concrete pier is cast in place.
4.3.2 Approach levee
The approach levee is a slant riprap levee structure. 10~100kg block stones
are used as the exterior protective covering blocks. At the back of the blocks
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the 2-piece ragstones, mixed inverted filtering layer, and earthwork fabric
are laid to prevent loss of backfilled sand.
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5. Chapter 5 Accessory Facilities
5.1 Power Supply and Lighting
5.1.1 Design Scope
The range of this design includes the trestle bridge, the electric
equipment of the handling process system on the platform of the
unloading wharf, and the accessory power supply and lighting facilities
of this process system. The power source from which the inlet power
line is drawn for power supply to this project is not in the scope of this
project design.
5.1.2 Arrangement of power source and transformation and transmission

substation
Two-way 6.3KV, 3 phase power supply and distribution cable line are
provided by the power plant. The low-voltage power distribution
voltage is designed to be 4-wire, 50Hz, 0.4/0.23KV.
It is planned to set up a land-based 10KV transformer substation at

the root of the approach levee, for power supply to the process
equipment, accessory facilities, structures, and lighting facilities
near the land area.
5.1.3 Distribution Line & Installation
All HV or LV circuits shall be the copper core cables.
The cable is laid mainly in the cable tray, partially buried through the
steel conduit.
5.1.4 Full load condition and electrical equipment selected
The load grade of this project on grade II standard shall be considered;

the total installed capacity is 2000kW for phase I; the calculated load is
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2634kW in the long run.
Two 6.3KV/0.4KV, 160KVA trasnformers shall be set up in the land-

based transformer substation. Two sets 6.3KV/0.4KV 315KVA
transformer will be set up at the wharf transformer substation. The
handcart vacuum circuit breaker cabinet is used as the high-voltage
cabinet; the drawer switch cabinet is used as the low-voltage cabinet
with low-voltage capacitor automatic compensation device.
5.1.5 Outdoor Lighting
The road lights are used for outdoor lighting on the road, and the lights
on the platform are used for lighting along the line of the belt conveyor
trestle bridge. The average illumination intensity is 10LX.
5.1.6 Lightning Prevention and Grounding
All the shells of electric equipment and the metal conduits of this
project should be well grounded and protected with zero line
connection. The copper rod is used as the grounded pole and the
galvanized flat steel is used as the earth line, where it is embedded in
concrete, the earth line will be of galvanized steel.
5.2 Water Supply, Drainage and Fire-fighting
5.2.1 Water Supply
1. Water Source
The power plant provides water supply to the wharf and approach levee.
The water quality should accord with the requirement of local hyginic
standard for drinking water. The water supply to this project comes
from the water supply pipeline of the power plant, and the hydraulic
pressure at the connecting point is ≥0.5Mpa.
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2. Water Demand
The water supply points include the water supply points for the ship, for
dedusting spray at the hopper of the ship unloader, for flushing the
wharf surface and the floor of the transfer machine house. The
maximum daily water consumption is about 800m3.
3. Water Supply System
The water supply pipeline is devided into two systems: one system is
for dedusting and domestic water system; another is for fire control.
The water supply pipeline of the dedusting and fire control system is
laid along the belt conveyor support frames through the galvanized
steel pipes of DN250. The flushing stations are set up at the interval of
about 30m, and two sets of flushing stations are set on each level of the
transfer machine house. The water supply for spraying on the ship
unloading hopper on the wharf is offered through rapid connectors. The
domestic water supply is provided through the galvanized steel pipeline
of DN200, laid along the belt conveyor support frames. There are five
cocks on the wharf for water supply to the barges.
5.2.2 Drainage
The rainwater and sewage are discharged separately in this project.
The early-stage rainwater and flushing water on the wharf surface, and
the flushing water on the floor of the transfer house are drained through
the open channel to the sedimentation basin of wastewater containing
coal, treated through the coal-containing wastewater treatment facility
of the power plant, and then recycled for use after the treated water is
up to the standard.
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5.2.3 Fire-fighting
The fire control of this project is arranged on one-time basis.
The biggest fire control object is the transfer houses; the water-use level
for fire control is 30 L/sec.(The volume of indoor fire control water is
10L/s; the volume of outdoor fire control water is 20L/s.) The fire
extinguishing time is two hours. One-time water consumption volume
for fire control is 216m3. The fire control water supply pipeline is
independant, and the galvanized steel pipes are used for this purpose.
The pipeline is laid along the belt conveyor support frames.The fire
hydrant boxs are set indoor at the interval of 50m on the wharf, trestle
bridge and approach levee. Two fire hydrant boxes are available on
each level of the transfer house.
In accordance with the “specifications for designing the disposition of

construction fire extinguishers”, the portable fire extinguishers are
arranged in the transfer house to extinguish the fire of the architecture
at the early stage.
Support from the fire fighting house of the power plant is considered as
a reinforcement.
5.3 Control and Computerized Management
5.3.1 General
In accordance with the requirement of the plant layout and unloading

process control system of this project, the control system equipment are
designed to be economical, rational, technologically advanced, flexible
in operation, and convenient for maintenance, and should meet the
requirement for high efficiency, safety and reliability of the process
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equipment in operation.
The range of control system designing includes the design of the

control systems of the barge unloading system, the belt conveyor
system and related process equipment, and the dedusting spray
equipment, as well as commuication and interlocked control of the
control system of the coal transmission process system of the power
plant, and the industrial TV supervision and control system.
5.3.2 Functions of control system and computer management system
The central control room (CCR) set on the wharf is the control center to
control the unloading process equipment, dedusting spray equipment,
and mobile hopper equipment of the wharf and coal transmission
system, to connect the equipment of coal transmission programmed
control system of the power plant through process control network
system, and to compose the automatic control system of the coal
unloading and belt conveyor system of the whole wharf.
The control system uses the design of the industrial network structure.
The control network equipment mainly include the programmable logic
controller (PLC) of the system, the Computer-vision Graphics
Processor (CGP), belt scale, and control network server. The optical
cable is used for transmission of the control network. The control
system can perform the functions of automatic start and stop. The
operating flow equipment pictures, the on-site operating status, the
handling amount, the operation and breakdown status of various
equipment can be monitored through CGP in CCR. It mainly fulfills the
tasks of various equipment control, system operation, display and
monitoring of flow pictures, and production information management
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in the production process flow. The operation data are saved according
to classification. In accordance with the control requirement of the
transmission process equipment, a real-time control system network is
composed of the PLC remote control substations set up respectively in
the wharf CCR and near the head of 2# belt conveyor, the mobile
hopper PLC single units, and the central control system. It is uniformly
coordinated and controlled by the CCR operator. CGP can
automatically generate corresponding forms of equipment failure and
operational management through the data via PLC transmission.
5.3.3 Operating Mode of the Control System
The control system is divided into CCR automatic control mode and
on-site manual operating mode by the machine side. In automatic
operating mode, the control room operator starts the belt conveyor
system and send normal start signal to each traveling hopper equipment
PLC through the CGP mouse (or operating keyboard), after it is
confirmed that the selected flow equipment is in normal condition and
the downstream equipment have been started. Then the flow equipment
are started in sequence in material counter-flow direction. When the
flow stops normally, the flow equipment stop in sequence in material
flow direction. In emergency breakdown, all the system equipment stop
on the line and failure signal is simultaneously sent out to each
traveling hopper and other equipment in the system, and stop
immediately.
When the system is in operation, the status signals of all the flow
equipment, traveling hopper, dusting spray, flow belt conveyor, and
other equipment can be displayed on the CGP screen of CCR.
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The machine-side manual operating mode is adopted to control the on-

site equipment operation through the machine-side operating box. This
mode is mainly used for maintenance and commissioning, not for
commercial operation.
5.3.4 On-site Safety Inspection Devices
To guarantee the normal operation of the handling process equipment

and the safety and reliability of material transmission, this system has
the following on-site safety inspection devices:
(1) The emergency cord switches set on the two sides of the belt conveyor;
(2) The off-tracking switches set at the head and tail and in the middle of the
belt conveyor;
(3) The blocking detector set at the coal transfer point;
(4) The belt tearing detector set at the planking point of the belt conveyor;
(5) The speed checkout switch of the belt conveyor;
(6) The material flow checkout switch;
(7) The start alarms set along the belt conveyor;
(8) The stretching limit switch of the belt conveyor;
(9) The motor arresting gear release limit push;
(10) The temperature detecting switch of the hydraulic coupler;
(11) Other necessary detecting switches.
All the on-site detecting devices should be the waterproof, dustproof

products, with protection grade IP65.
5.3.5 ITV system
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To enable the CCR operator to timely and accurately know about the
overall practical production situation on the operating site, safely and
rationally make dispatch management, and timely make communication
with the on-site operators, it is planned to set up cameras of the
industrial TV monitoring system on the wharf, and in the transfer
machine house to monitor the on-site operating condition and guarantee
the safety and reliability of the transmission system.
5.3.6 Cable Lying
In accordance with the different types of the control system signals, the
control cable, signal screening cable and optical cable are used for the
control system. The screened cable is used for analog signal
transmission; the optical cable is used in the trunk network of the
control network and computer management system. All the selected
cables should meet the requirement for signal transmission distance and
high anti-interference performance.
The control cable is laid mainly on the cable tray along the belt
conveyor line. The steel duct and flexible metal hose are partially used
when the cable is connected to the equipment. The cable is drawn from
the central control room and then laid overhead on the cable tray or
through cable trench to the users.
To guarantee the safety and reliability of the control system, the

grounding system of the control system should be linked reliably with
the control equipment. The control system has an protection grounding
system with the ground resistance <1Ω.
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6. Chapter 6 Suggestion
Lack of hydrological and geological information in the plant site area at

this stage may largely affect the general layout of the project. In order to
optimize the overall plan, further hydrological and meteorological
observation and site investigation is needed before engineering design.
Table of main equipments and materials

No. Name Specification Unit Q’ty
1 Gantry crane 16t- 28m Set 2
Belt conveyor on the
2 B=1.2m m 150
wharf
3 B=1.2m m 600
trestle bridge
4 Transfer engine room Set 2
5 Belt scale Set 1
6 Transformer 6.3/0.4KV Set 4
7 HV switchgear Set 38
8 HV capacitor panel Set 4
9 LV switchgear Set 24
10 DC panel Set 2
11 Cable km 5
12 Water pump Set 3
13 Galvanized steel pipe km 3
14 Molehead lights Set 2
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ALTERNATIVE 2 (20000T Wharf)
CONTENTS
CHAPTER 1 GENERAL
CHAPTER 2 COAL HANDLING TECHNOLOGY
CHAPTER 3 GENERAL LAYOUT
CHAPTER 4 MARINE ARCHITECTURE
CHAPTER 5 ACCESSORY FACILITIES
CHAPTER 6 SUGGESTION
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ATTACHED DRAWING LIST
1. GENERAL PLAN FOR 20000DWT WHARF
2. BERTH DOCK STRUCTURE SECTIONAL VIEW
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1. Chapter 1 General
1.1 General Description
The coal-fired power plant wharf project is located 12km west of Puttalam.
The power plant phase-I project is of 1×300MW capacity, and total installed
capacity is 3x300MW in the long term.
In order to satisfy the coal handling requirement of the power plant, the
design is made according to available hydrological and meteorologic
information and relevant survey and study result. The scope of design
includes handling process, layout, marine structure, water supply and
drainage, fire fighting, powr supply & lighting, and control system. The
transfer machine house is at the tip of the land area, which is the designed
demarcation point of the plant area.
1.2 Standard and Base of Design
(1) The existing “technical specifications on port project” of the Ministry of

Communication, China and related Chinese industrial standards, such as:
Code for Design of General Layout of Sea Ports (JTJ211-99)

Code for Sea Port Hydrology (JTJ213-98)
Code for Loads in Port Engineering (JTJ215-98)
Code for Foundations in Port Engineering (JTJ250-98)
Code for Pile Foundations in Port Engineering (JTJ254-98)
Code for Design of Concrete Structures in Port Engineering (TJT267-
98)
Code for Design and Construction of Piled Wharves (JTJ291-98)
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Port Part-Volume 3
Code for Design and Construction for Cast in-situ Pile in Port
Code for Design and Construction of Rock-socketed Piles in Port
(2)Basic information provided by CEB (hydrological, meteorological and

geological information in the plant site area and information about sand
movement and existing site condition):
Port facilities feasibility study Wave climate assessment, Re-12548-
015-01
Environmental impact assessment study report, Mar. 1998
Supporting documents to Environmental impact assessment study
report, Mar. 1998
Field investigations Final report, Dec. 1997
1.3 Principle of Design
In accordance with the employer’s requirement, the goods handling capacity

for this project shall be 800000T/y in the near future; 2400000T/y in the
long term. The design satisfys the requirement of 800000T/y in phase-I,
with provision for future expansion in the long term.
A 20000DWT wharf and near shore jetty ( length: 1000 m) for 20000DWT
common bulk cargo vessel is proposed.
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2. Chapter 2 Handling Technology
2.1 Design Conditions
(I) Annual transportation amount: 800,000T/y in phase-I, 2,400,000T/y in

phase-II.
(II) Type of cargo: Coal
2.2 Main Designing Parameters
(I) Annual operation days: 300 days.
(II) The imbalance coefficient of port production: 1.4
(III) Daily work shifts: 3 shifts
(IV) Goods physical characteristics
1. Average stacking density: 0.85 ton/m3

2. Angle of rest: 35 ~ 50 (degree)
3. Particle: less than 50mm
2.3 Handling process arrangement and scheme
20000DWT bulk cargo vessel is considered for the following handling

process:
20000DWT bulk cargo vessel => 20000DWT wharf => wharf conveyor belt
=> levee conveyor belt => EAT04 transfer machine room.
2.3.1 Ship-unloading system
Phase I: 20000DWT common bulk cargo vessel transports the coal to the
20000DWT wharf to unload the coal by coal unloading equipment on the
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dock. The on-dock unloading equipment is a gantry crane with hopper,

having 10.5m gauge and 16t lifting capacity. The mobile hopper is equipped
on the crane as the receiving equipment. Underneath the hopper a vibrating
feeder is equipped to transfer the coal to the horizontal conveyor belt
mounted on the crane, then to the conveyor belt on the dock.
Phase II: The 20000DWT wharf will be equipped with additional gantry
cranes to satisfy the unloading requirement.
On the 20000DWT wharf, two rails for gantry crane will be laid, with the
distance of 2.5m between the front edge of the wharf and the outside track.
The width of the wharf is 15m.
2.3.2 Conveyor belt system
The design scope of the conveyor belt system is from the ship unloader to
the EAT04 transfer engine room at the land terminal. Single line conveyor
belt is used. For phase I, the conveyor belt capacity on the trestle bridge is
500T/h, band width 1,200mm, speed 4.8m/s, with 1 berth. For phase II, the
conveyor belt capacity is 1500T/h, band width 1,200mm, speed 4.8m/s, with
no additional berth added.
2.3.3 Temporary unloading facility for heavy equipment
Heavy pieces of equipment will be transported by 1000T barge from

Colombo port to the site and landed directly from sea.
2.3.4 Configuration of unloading equipment
Refer to Table 2-3 for the configuration and specification of unloading

equipment.
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Port Part-Volume 3
Table 2-3
No. Name of equipment Specification Unit Q’ty Q’ty
(Phase I) (Phase II)
1 Gantry crane 16t- 38m Set 1 2
2 Belt conveyor on the B=1.2m, m 160 -

wharf V=1.6m/s
3 Belt Conveyor on the B=1.2m, m 1100 -

trestle bridge V=4.8m/s
2.3.5 Major tech.-economic index
Refer to Table 2-4 for main tech. economic index.
Table 2-4
No. Item Unit Q’ty
1 Designed annual transportation capacity 10k tons 80
2 Calculated annual discharge capacity 10k tons 85
3 Berth utilization rate ％ 43
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Port Part-Volume 3
3. Chapter 3 General Layout
3.1 Principle of General Layout
1. The wharf is designed according to available hydrological and

meteorological information, and other study result.
2. The number of berths is determined according to the throughput in the

short and long term.
3 A temporary unloading facility is proposed for the unloading of heavy

equipment and will be designed according to site condition.
3.2 Principle Dimensions of the Design Ship
See Table 3-1 for dimensions of the designed ship.

Table 3-1
Tonnage Length Breadth Depth Loaded
Vessel type (DWT) (m) (m) (m) Draft
(m)
20000
Bulk carrier 164 25 13.5 9.8
(17500~22500)
3.3 General Layout
This plan is for the 20000DWT common bulk cargo vessel and the
20000DWT wharf. The scope of construction in phase I comprises 1 No.
20000DWT berths (in phase II and III no additional berth is needed).
According to available information, during southwest monsoon season,
under the relatively bad wave and ocean current condition, the sand dune on
the sea bed along the coast line shifts mainly within the -6.0 isobath line,
whilst the sand shifting beyond the -6.0 isobath line is insignificant. In order
28
Port Part-Volume 3
to reduce the total investment, the wharf is located beyond the -6.0m
bathymetric line. The 245º azimuth of wharf is adapted according to relevant
wave observation results and analysis statistics. The bottom elevation of the
front edge of the berth is -11.5m.
The wharf platform is 160m long, 15m wide (partially 20m wide). The
operation room and substation are positioned on the platform, with 1
mooring dolphin at each end of the wharf. A trestle bridge and an approach
levee are arranged between the platform and the land terminal. The trestle
bridge is approximately 1000m long and the approach levee 90m long. The
trestle bridge and approach levee are 6m wide, with a conveyor belt and a
inspection path.
The top elevation of wharf platform and mooring dolphin is 7.0m. The land
terminal elevation is 3.5m for the approach levee. The trestle bridge and the
approach levee is linked up by a slope.
A channel is excavated on the seabed between the wharf and the -12.0
isobath line. The channel is approximately 2000m long, 130m wide. The
turning point for the 20000DWT vessel is located in front of the wharf. To
facilitate the turning around of the vessel, the turning point area has a
diameter of 492m, 3 times of the vessel body length. The bottom elevation
of the channel is -11.5m, same as that of the front edge of wharf platform
and the turning point.
3.4 Operation days per year
3.4.1 Standard for coal handling operation
Wind: ≤ class 6
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Port Part-Volume 3
Rain: ≤ medium rain
Mist: visibility ≥ 1km
Wave:
Downwind: H4%≤ 1.0m, T≤ 6s
Crosswind: H4%≤ 1.2m, T≤ 6s
3.4.2 Wharf coal handling operation days
Due to lack of long term and successive observation on local meteorological

and hydrological information at the project site area, estimation is made on
the operation days according to the available short term observation and
analysis result:
The tentative operation days are estimated at 300 days per year.
3.5 Navigation Facilities
For 20000DWT wharf, apart from setting up a light on top of the mooring
dolphin at either end of the wharf, 8 fairway buoys are erected along the
channel and the turning area to further facilitate the shipping operation.
3.6 Main Quantities
See the table 3-2 below for main quantity:
Table 3-2
No. Item 20000DWT wharf
1 Ship unloading berth 1 Nos.
2 Temporary unloading facility for heavy 1 No.
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Port Part-Volume 3
equipment
3 Length of trestle bridge 1000m (approximately)
4 Length of approach levee 90m
5 Lamps on wharf 2 Nos.
6 Fairway Buoy 8 Nos.
7 Quantity of dredging work 4 million m3
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Port Part-Volume 3
4. Chapter 4 Marine Architecture
4.1 Scale and Grade of Marine Structures
4.1.1 Design Load
(1) The uniformly distributed load of the wharf is q=20kN/m2.

(2) The load for gantry crane with mobile unloading hopper: track gauge
10.5m; cardinal distance 12m; 24 wheels for each crane; the maximum
wheel load 30t/wheel; the minimum clearance between two cranes
1.5m.
(3) Load per belt conveyor: 10KN/m.
(4) Mobile machines on the wharf: small maintenance cars (2t weight).
(5) Load of steel trestle bridge: similar to (3) and (4).
(6) Lateral forces on the wharf will be considered.
4.2 Design water level & Wave Factors
4.2.1 Design Water Level
Design high water level: 0.40m;

Design low water level: -0.20m;
Check High Water Level: 1.40m;
Check Low Water Level: -0.80m;
4.2.2 Design Wave Factors
Wave factors in front of the wharf, which may happen once every 50
years:
Design high water level: H1%=5.8m, H13%=4.2m, T =7.8s.
4.3 Structure plan of marine structures
Making reference to the available geological conditions of the project

area, the surface layer of the foundation of this project area is sand;
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Port Part-Volume 3
below it is the layer of sandstone and limestone. Making

comprehensive account of the hydrographic and geological conditions,
the wharf structure is a high-pile pier structure; the approach levee is a
riprap slope structure.
The sand layer on the natural rock surface of this project is about
5~10m. Therefore, the steel pipe piles of this project shall be cast-in-
place piles embedded in the rock.
4.3.1 Wharf
The wharf is composed of the operating platform (concurrently as the

dolphin), mooring dolphins, and pedestrian steel bridges connecting to
mooring dolphins. The operating platform is 180×15m (partially 20m
wide) for 20000DWT wharf; the mooring dolphin is 9×9m; the top
elevation of the wharf surface is 7.0m.
The Φ1200mm steel pipe piles are used for the operating platform, and
the space interval between piers is about 20m. After completion of the
foundation, the reinforced concrete pile caps are cast in place, on top
of which are laid the reinforced concrete box girders. 750kN bollard is
setup on the wharf. SUC1450H rubber fenders are used for the wharf.
Railing, and other accessory facilities will be provided accordingly.
Nine Ф800m steel pipe piles are driven for each mooring dolphin, on
top of which a reinforced concrete pier is cast in place. On the platform
are set the dolphin and railing.
The operating platform is connected to the shore through the steel

trestle bridge. The steel trestle bridge is about 70m in each span, and
6m in breadth. The Ф800mm steel pipe piles are used as the foundation
piles of the bridge piers, and on top of the piles the reinforced concrete
pier is cast in place.
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Port Part-Volume 3
4.3.2 Approach levee
The approach levee is a slant riprap levee structure. 10~100kg block

stones are used as the exterior protective covering blocks. At the back
of the blocks the 2-piece ragstones, mixed inverted filtering layer, and
earthwork fabric are laid to prevent loss of backfilled sand. The
approach levee will be restricted to land area.
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Port Part-Volume 3
5. Chapter 5 Accessory Facilities
5.1 Power Supply and Lighting
5.1.1 Design Scope
The range of this design includes the trestle bridge, the electric
equipment of the handling process system on the platform of the
unloading wharf, and the accessory power supply and lighting facilities
of this process system. The power source from which the inlet power
line is drawn for power supply to this project is not in the scope of this
project design.
5.1.2 Arrangement of power source and transformation and transmission

substation
Two-way 6.3KV, 3 phase power supply and distribution cable line are
provided by the power plant. The low-voltage power distribution
voltage is designed to be 4-wire, 50Hz, 0.4/0.23KV.
It is planned to set up a land-based 10KV transformer substation at the

root of the approach levee, for power supply to the process equipment,
accessory facilities, structures, and lighting facilities near the land area.
5.1.3 Distribution Line & Installation
All HV or LV circuits shall be the copper core cables.
The cable is laid mainly in the cable tray, partially buried through the
steel conduit.
5.1.4 Full load condition and electrical equipment selected
The load grade of this project on grade II standard shall be considered;

the total installed capacity is 2000kW for phase I; the calculated load
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Port Part-Volume 3
is 2634kW in the long run.
Two 6.3KV/0.4KV, 160KVA trasnformers shall be set up in the land-

based transformer substation. Two sets 6.3KV/0.4KV 315KVA
transformer will be set up at the wharf transformer substation. The
handcart vacuum circuit breaker cabinet is used as the high-voltage
cabinet; the drawer switch cabinet is used as the low-voltage cabinet
with low-voltage capacitor automatic compensation device.
5.1.5 Outdoor Lighting
The road lights are used for outdoor lighting on the road, and the lights
on the platform are used for lighting along the line of the belt conveyor
trestle bridge. The average illumination intensity is 10LX.
5.1.6 Lightning Prevention and Grounding
All the shells of electric equipment and the metal conduits of this
project should be well grounded and protected with zero line
connection. The copper rod is used as the grounded pole and the
galvanized flat steel is used as the earth line, where it is embedded in
concrete, the earth line will be of galvanized steel.
5.2 Water Supply, Drainage and Fire-fighting
5.2.1 Water Supply
1. Water Source
The power plant provides water supply to the wharf and approach
levee. The water quality should accord with the requirement of local
hyginic standard for drinking water. The water supply to this project
comes from the water supply pipeline of the power plant, and the
hydraulic pressure at the connecting point is ≥0.5Mpa.
2. Water Demand
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Port Part-Volume 3
The water supply points include the water supply points for the ship,
for dedusting spray at the hopper of the ship unloader, for flushing
the wharf surface and the floor of the transfer machine house. The
maximum daily water consumption is about 800m3.
3. Water Supply System
The water supply pipeline is devided into two systems: one system
is for dedusting and domestic water system; another is for fire
control. The water supply pipeline of the dedusting and fire control
system is laid along the belt conveyor support frames through the
galvanized steel pipes of DN250. The flushing stations are set up at
the interval of about 30m, and two sets of flushing stations are set
on each level of the transfer machine house. The water supply for
spraying on the ship unloading hopper on the wharf is offered
through rapid connectors. The domestic water supply is provided
through the galvanized steel pipeline of DN200, laid along the belt
conveyor support frames. There are five cocks on the wharf for
water supply to the barges.
5.2.2 Drainage
The rainwater and sewage are discharged separately in this project.
The early-stage rainwater and flushing water on the wharf surface,

and the flushing water on the floor of the transfer house are drained
through the open channel to the sedimentation basin of wastewater
containing coal, treated through the coal-containing wastewater
treatment facility of the power plant, and then recycled for use after
the treated water is up to the standard.
5.2.3 Fire-fighting
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Port Part-Volume 3
The fire control of this project is arranged on one-time basis.
The biggest fire control object is the transfer houses; the water-use
level for fire control is 30 L/sec.(The volume of indoor fire control
water is 10L/s; the volume of outdoor fire control water is 20L/s.)
The fire extinguishing time is two hours. One-time water
consumption volume for fire control is 216m3. The fire control
water supply pipeline is independant, and the galvanized steel pipes
are used for this purpose. The pipeline is laid along the belt
conveyor support frames.The fire hydrant boxs are set indoor at the
interval of 50m on the wharf, trestle bridge and approach levee.
Two fire hydrant boxes are available on each level of the transfer
house.
In accordance with the “specifications for designing the disposition

of construction fire extinguishers”, the portable fire extinguishers
are arranged in the transfer house to extinguish the fire of the
architecture at the early stage.
Support from the fire fighting house of the power plant is

considered as a reinforcement.
5.3 Control and Computerized Management
5.3.1 General
In accordance with the requirement of the plant layout and

unloading process control system of this project, the control system
equipment are designed to be economical, rational, technologically
advanced, flexible in operation, and convenient for maintenance,
and should meet the requirement for high efficiency, safety and
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Port Part-Volume 3
reliability of the process equipment in operation.
The range of control system designing includes the design of the

control systems of the barge unloading system, the belt conveyor
system and related process equipment, and the dedusting spray
equipment, as well as commuication and interlocked control of the
control system of the coal transmission process system of the power
plant, and the industrial TV supervision and control system.
5.3.2 Functions of control system and computer management system
The central control room (CCR) set on the wharf is the control
center to control the unloading process equipment, dedusting spray
equipment, and mobile hopper equipment of the wharf and coal
transmission system, to connect the equipment of coal transmission
programmed control system of the power plant through process
control network system, and to compose the automatic control
system of the coal unloading and belt conveyor system of the whole
wharf.
The control system uses the design of the industrial network

structure. The control network equipment mainly include the
programmable logic controller (PLC) of the system, the Computer-
vision Graphics Processor (CGP), belt scale, and control network
server. The optical cable is used for transmission of the control
network. The control system can perform the functions of
automatic start and stop. The operating flow equipment pictures, the
on-site operating status, the handling amount, the operation and
breakdown status of various equipment can be monitored through
CGP in CCR. It mainly fulfills the tasks of various equipment
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Port Part-Volume 3
control, system operation, display and monitoring of flow pictures,

and production information management in the production process
flow. The operation data are saved according to classification. In
accordance with the control requirement of the transmission process
equipment, a real-time control system network is composed of the
PLC remote control substations set up respectively in the wharf
CCR and near the head of 2# belt conveyor, the mobile hopper PLC
single units, and the central control system. It is uniformly
coordinated and controlled by the CCR operator. CGP can
automatically generate corresponding forms of equipment failure
and operational management through the data via PLC transmission.
5.3.3 Operating Mode of the Control System
The control system is divided into CCR automatic control mode and
on-site manual operating mode by the machine side. In automatic
operating mode, the control room operator starts the belt conveyor
system and send normal start signal to each traveling hopper
equipment PLC through the CGP mouse (or operating keyboard),
after it is confirmed that the selected flow equipment is in normal
condition and the downstream equipment have been started. Then
the flow equipment are started in sequence in material counter-flow
direction. When the flow stops normally, the flow equipment stop
in sequence in material flow direction. In emergency breakdown, all
the system equipment stop on the line and failure signal is
simultaneously sent out to each traveling hopper and other
equipment in the system, and stop immediately.
When the system is in operation, the status signals of all the flow
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Port Part-Volume 3
equipment, traveling hopper, dusting spray, flow belt conveyor, and

other equipment can be displayed on the CGP screen of CCR.
The machine-side manual operating mode is adopted to control the

on-site equipment operation through the machine-side operating
box. This mode is mainly used for maintenance and commissioning,
not for commercial operation.
5.3.4 On-site Safety Inspection Devices
To guarantee the normal operation of the handling process

equipment and the safety and reliability of material transmission,
this system has the following on-site safety inspection devices:
(1) The emergency cord switches set on the two sides of the belt
conveyor;
(2) The off-tracking switches set at the head and tail and in the middle
of the belt conveyor;
(3) The blocking detector set at the coal transfer point;
(4) The belt tearing detector set at the planking point of the belt
conveyor;
(5) The speed checkout switch of the belt conveyor;
(6) The material flow checkout switch;
(7) The start alarms set along the belt conveyor;
(8) The stretching limit switch of the belt conveyor;
(9) The motor arresting gear release limit push;
(10) The temperature detecting switch of the hydraulic coupler;
(11) Other necessary detecting switches.
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Port Part-Volume 3
All the on-site detecting devices should be the waterproof,

dustproof products, with protection grade IP65.
5.3.5 ITV system
To enable the CCR operator to timely and accurately know about

the overall practical production situation on the operating site,
safely and rationally make dispatch management, and timely make
communication with the on-site operators, it is planned to set up
cameras of the industrial TV monitoring system on the wharf, and
in the transfer machine house to monitor the on-site operating
condition and guarantee the safety and reliability of the
transmission system.
5.3.6 Cable Lying
In accordance with the different types of the control system signals,

the control cable, signal screening cable and optical cable are used
for the control system. The screened cable is used for analog signal
transmission; the optical cable is used in the trunk network of the
control network and computer management system. All the selected
cables should meet the requirement for signal transmission distance
and high anti-interference performance.
The control cable is laid mainly on the cable tray along the belt
conveyor line. The steel duct and flexible metal hose are partially
used when the cable is connected to the equipment. The cable is
drawn from the central control room and then laid overhead on the
cable tray or through cable trench to the users.
To guarantee the safety and reliability of the control system, the

grounding system of the control system should be linked reliably
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Port Part-Volume 3
with the control equipment. The control system has an protection

grounding system with the ground resistance <1Ω.
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Port Part-Volume 3
6. Chapter 6 Suggestion
Lack of hydrological and geological information in the plant site

area at this stage may largely affect the general layout of the project.
In order to optimize the overall plan, further hydrological and
meteorological observation and site investigation is needed before
engineering design.
Table of main equipments and materials
No. Name Specification Unit Q’ty

1 Gantry crane 16t- 28m Set 1
2 B=1.2m m 160
wharf
3 B=1.2m m 1100
trestle bridge
4 Transfer engine room Set 2
5 Belt scale Set 1
6 Transformer 6.3/0.4KV Set 4
7 HV switchgear Set 38
8 HV capacitor panel Set 4
9 LV switchgear Set 24
10 DC panel Set 2
11 Cable km 8.2
12 Water pump Set 3
13 Galvanized steel pipe km 4.8
14 Buoy Set 8
15 Molehead lights Set 2
44

Technical Documents: Puttalam 1X300Mw Coal-Fired Power Plant Project

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TECHNICAL DOCUMENTS

PUTTALAM 1X300MW COAL-FIRED POWER PLANT

CEYLON ELECTRICITY BOARD

CHINA NATIONAL MACHINERY & EQUIPMENT

VOLUME 1 MAIN POWER BLOCK

PUTTALAM 1X300MW COAL-FIRED POWER PLANT

VOLUME 3 PORT PART

ALTERNATIVE 1 (5000T Wharf)

CHAPTER 2 COAL HANDLING TECHNOLOGY

CHAPTER 3 GENERAL LAYOUT

CHAPTER 4 MARINE ARCHITECTURE

CHAPTER 5 ACCESSORY FACILITIES

ATTACHED DRAWING LIST

1. GENERAL PLAN FOR 5000T WHARF

2. BERTH DOCK STRUCTURE SECTION VIEW

1.1 General Description

The coal-fired power plant wharf project is located 12km west of

1.2 Standard and Base of Design

(1) The existing “technical specifications on port project” of the

Code for Design and Construction of Rock-socketed Piles in Port

(2)Basic information provided by CEB (hydrological, meteorological

sand movement and existing site condition):

Port facilities feasibility study Wave climate assessment, Re-12548-

Environmental impact assessment study report, Mar. 1998

Supporting documents to Environmental impact assessment study

report, Mar. 1998

Field investigations Final report, Dec. 1997

1.3 Principle of Design

In accordance with the CEB’s requirement, the coal handling capacity

for this project shall be 800000T/y in the near future; 2400000T/y in

built for coal unloading according to CEB’s requirement.

2. Chapter 2 Handling Technology

2.1 Design Conditions

(I) Annual transportation amount: 800,000T/y in phase-I, 2,400,000T/y in

2.2 Main Designing Parameters

(I) Annual operation days: 280 days (according to available information).

2.3 Handling process arrangement and scheme

2.3.1 Ship-unloading system

2.3.2 Conveyor belt system

2.3.3 Temporary unloading facility for heavy equipment

Heavy pieces of equipment will be transported by 1000DWT barge

2.3.4 Configuration of unloading equipment

Refer to Table 2-1 for the configuration and specification of unloading

No. Name of equipment Specification Unit Q’ty Q’ty

(Phase I) (Phase II)

1 Gantry crane 16t- 28m Set 2 2

2 Belt conveyor on the B=1.2m, m 75 x 2 95 x 2

3 Belt conveyor on the B=1.2m, m 600 -

2.3.5 Major technical-economic index

Refer to Table 2-2 for main tech. economic index.

No. Item Unit Qty

1 Design annual transportation capacity 10k tons 80

2 Calculated annual discharge capacity 10k tons 120

3 Berth utilization ratio ％ 35

3. Chapter 3 General Layout

3.1 Principle of General Layout

1. The wharf is designed according to available hydrological and

2. The number of berths is determined according to the throughput in the

3 A temporary unloading facility is proposed for the unloading of heavy

3.2 Principle Dimensions of the Design Ship

3 Nos. 5000T self propelled barges will be provided in Phase I.

Barge 5000 85 22 4.5