Design Memorandum - 9962-001-IS-155-PVM-Z-005-03

Digitally
Signature Not Verified

signed by
AMIT KUMAR
Date:
2018.12.04
10:21:56 IST
Reason: CAT
II
Location:
NTPCEOC
UTTAR PRADESH RAJYA VIDYUT UTPADAN NIGAM LTD.
1x660 MW- PANKI TPS
Title : DESIGN MEMORANDUM FOR CHP- LHP- GHP
Doc no 9962-001-IS-155-PVM-Z-005/IS-4-DM-713-100-M005
Revison: 3
S. No. UPRVUNL / NTPC COMMENTS Dtd:09-10-2018 BHEL-ISG eply, Dtd: 09-11-2018
Page 01 of 62:-From C&I perspective this Design Memorandum doesnot cover the design
philosophy adopted for DDCMIS based control of complete CHP / LHP / GHP system, its interfaces DDCMIS based control of complete CHP / LHP / GHP system, its interfaces with PLCs
1 with PLCs for some of the individual subsystems and connectivity with Unit DDCMIS system for some of the individual subsystems and connectivity will be part of a separate
through Station wide LAN. M/s. BHEL to clarify whether the same is to be included in this document by BHEL-EDN.
document or will be a part of a separate document.
2 Page 03 of 62: Please indicate NTPC/UPRVUNL drg ref no Noted and indicated
3 Page 03 of 62: whose scope truck tippler?? UPRVUNL scope
Please ref tender drawing no-14A14-DWG-M-050(sh 1 OF 4), uncrushed stockpile is
4 Page 03 of 62: check crushed or uncrushed stockpile of limestone shown before reclaime hopper. As per tender submitted to UPRVUNL also, 15 days
uncrushed limestone storage is considered.
Conveyor will be started from dewatering building and receipt of Gypsum from vaccum
5 Pgae of 4 of 62: bldg or below vaccume belt filter
beelt filter. Same is revised in DM also.
As per amendment no-2 issued during tender, capacity was revised of CHP conveyors.
6 Pgae of 4 of 62: Not inline with specification
Capacity indicated here is inline with amendment2 only.
7 Page 9 of 62: M/s. BHEL to confirm whether the offer safety switches will be SIL certified or not. SIL certified safety switches are not envisaged for CHP / LHP / GHP system.
Page 11 of 62: M/s. BHEL to note that major C&I items include :-
1. Noted and included.
1. DDCMIS
8 2. PLC systems for some of the CHP sub-systems
3. Stockyard level and profile monitoring
Why the above major C&I systems are not a part of the above list ?
Page 14 of 62: As per comments on layout drawing, some additional conveyors have to be As per discussion held at NTPC office on layout and profile, there is no need of extra
9
planned for lime/gypsum transportation. belt conveyors for transportation.
Page 37 of 62 : How will the Stacker - Cum - Reclaimer be controlled ? Will it be controlled via PLC
10 It will be controlled from PLC
or DDCMIS ?
Redundant wireless link or industrial grade redundant soft link between CHP DDCMIS
Page 39 of 62:Is Fibre optic cabling envisaged from Stacker Reclaimer to main CHP control room ?
11 & Stacker reclaimer PLC will be considered. Actual arrangement will be submitted
If so then how is it envisaged to be laid between SR machine and CHP control room ?
during detail engg.
As per FGD specificatio caluse no 2.7/ sheet 68 of 185 pull cord switch and belt sway
12 Page 49 of 62: Location of pull cord and belt sway switch shall be 20 mtr & 30 mtr respectively.
switch shall be 30mtr & 50mtr.
Plz provide electrical power supply details envisaged for CHP/LHP/GHP.

Plz indicate basis of selection of HT/LT switchgears and and their
selection criteria along with distance with respect to load centers.
BHEL- ISG, BANGALORE
1X660 MW PANKI TPS Document Number

IS-4-DM-713-100-M005
DESIGN MEMORANDUM FOR CHP/ LHP/ GHP Rev-03
BHARAT HEAVY ELECTRICALS LTD

INDUSTRIAL SYSTEMS GROUP
This approval status shall be interpreted as laid down in the contract and
it shall not relive the contractor form the contractual obligation.
Reviewed & Submitted for
CAT I - Approval
CAT II & III - Information
CAT IV - Reference
Name
Lovekush Verma
Engineer
Bharat Heavy Electricals
Limited
ISG-PE CHP
Bangalore -560012
09-11-2018 3 FOR APPROVAL LKV GAN RTR

Date Rev Description of Revision ALT CHD APPD
PROJECT 1X660 MW PANKI THERMAL POWER STATION
CUSTOMER UTTAR PRADESH RAJYA VIDYUT UTPADAN NIGAM LIMITED(UPRVUNL),

LUCKNOW
NTPC LIMITED
REVIEW CONSULTANT A GOVERNMENT OF INDIA ENTERPRISE
CONSULTANT
BHARAT HEAVY ELECTRICALS LTD
INDUSTRIAL SYSTEM GROUP (ISG), BANGALORE
JOB No. IS-1-17-2001 BHEL DRG/DOC. NO: IS-4-DM-713-100-M005

Rev: 03
STATUS CONTRACT NTPC DRG/ DOC NO:- 9962-001-IS-155-PVM-Z-005
DESIGN MEMORANDUM FOR CHP/ LHP/ GHP (Mechanical Works)

TITLE
Issued by: Engineering (Mechanical) Date: 09-11-2018 Rev no. 03 Page 1 of 62

Document Number
1X660 MW PANKI TPS
IS-4-DM-713-100-M005
INDEX
Sl. CONTENTS PAGE NOS.

No.
1.0.0 PROJECT DATA 3 OF 62
1.1.0 REFERENCE DRAWING AND DOCUMENTS 3 of 62
1.2.0 PREFACE 3 OF 62
1.3.0 SYSTEM DESCRIPTION 4 OF 62
2.0.0 SCOPE OF WORK 10 of 62
3.0.0 EXCLUSION 16 of 62
4.0.0 EQUIPMENT SIZING 16 of 62
5.0.0 CHUTE SIZING CALCULATION 52 of 62
6.0.0 HOIST SCHEDULE 53 of 62
7.0.0 CODES & STANDARDS 56 of 62
8.0.0 PERFORMANCE GUARANTEE REQUIREMENTS 57 of 62
ANNEXURE-1-PROJECT INFORMATION 59 of 62
ANNEXURE-2-STOCKPILE CAPACITY 61 of 62


IS-4-DM-713-100-M005
1.0.0 PROJECT DATA:
1.0.1 The site is situated at Panki adjacent to existing Panki Thermal Power Station, Panki, Uttar
Pradesh. Project data is as per enclosed Annexure – ‘1’
1.1.0 REFERENCE DRAWING AND DOCUMENTS 1
Sr Drg/ Doc No Description

No
1. IS-1-FL-713-100- COAL FLOW/ LIMESTONE FLOW/ GYPSUM FLOW DIAGRAM
M001
2. IS-0-PL-713-100- LAYOUT OF CHP/LHP/GHP
M002 2
3. IS-1-GA-713-101- TYPICAL CROSS SECTION OF GALLERY & TUNNEL
M003
4. IS-1-GA-713-101- CONV. PROFILE FOR ALL CONV
M004
1.2.0 PREFACE
1.2.1 This document is to draw out Design memorandum/ Technical specifications for Coal
handling plant for 1 X 660 MW at Panki Thermal Power Station, Panki, Uttar Pradesh.
1.2.2 The plot plan drawing No 9962-001-IS-155-PVM-F-002 and Coal Flow/ Limestone flow/
Gypsum Flow diagram drawing No 9962-001-IS-155-PVM-L-001 of Coal handling/
Limestone handling and gypsum handling plant is considered.
3
The Coal handling plant for Panki Thermal Power Station will commence receipt of coal
from wagon tippler house as per the layout drawing and will terminate it on coal bunkers.
The Coal handling plant will include Wagon tipplers, accessories for unloading uncrushed
coal, all conveyors for in plant conveying and handling, storage of crushed coal, crushers
for size reduction, Stacker / Reclaimer and Reclaim hoppers for stacking and reclaiming &
Trippers for Bunker filling operation. Dust extraction & suppression systems, Ventilation
systems, Elevators and Sump pumps at appropriate locations will be provided as per the
coal flow diagram and plot plan. Bull dozer & Payloaders will be supplied as per
specification.
The limestone handling system will start form reclaim hopper and will terminate it on
limestone silo. LHP will include all conveyors for in plant conveying and handling, storage
of uncrushed limestone, crushers for size reduction and Reclaim hoppers. Dust extraction
& suppression systems, Ventilation systems and Sump pumps at appropriate locations will
be provided as per flow diagram.


IS-4-DM-713-100-M005
The gypsum handling system will commence receipt of gypsum from vacuum belt filter
and will end at gypsum storage shed through conveyor. 3
Firefighting system, Bunker level indicators and Locomotive for the entire CHP will be
covered in the separate package of other BHEL unit, if applicable.
1.2.3 It has been decided to bring coal to the plant site through rail transportation by BOXN
wagons for which new railway track to be laid. However, the work of execution of related
to railway track will be done separately and not in the scope of this specification.
1.3.0 SYSTEM DESCRIPTION:
1.3.1 The Flow diagram and Plot Plan of CHP/LHP & GHP are as per Flow Diagram No 9962-001- 3
IS-155-PVM-L-002 & Plot Plan No-9962-001-IS-155-PVM-F-002 respectively. The CHP /
LHP & GHP has been designed on the basis of the following assumptions:
Coal handling System:-
a) Maximum size of Indian coal : (-) 300 mm
b) Size of crushed coal : (-) 20 mm
c) Maximum moisture content present in the coal : 15% (Max)
d) Hard Groove Index (HGI) : 48-65 (for design)
e) Crushed coal storage yard is required for : 12 days 2
f) Height of crushed coal stockyard : 12 meters
g) Bulk density of coal calculation : 0.8 & 1.2T / M³ for Volume and load
respectively.
h) Belt Speed (approx.) : 3.2 meters / second
i) Belt width : 1400 mm (except reversible Belt Feeder)
2
j) Belt width : 1600 mm (for reversible Belt Feeder)
k) Number of working hours : 08 hours per day
l) Angle of repose of coal : 37 degrees
m) Capacity of coal handling system :Rated : 1500 TPH
Designed : 1650 TPH
Limestone handling system:-

a) Maximum size of Lime Stone : (-) 250 mm
b) Size of crushed limestone : (-) 20 mm


IS-4-DM-713-100-M005
c) Bond Index : 13 kWh/t

d) Limestone storage yard is required for : 15 days 1
e) Height of limestone stockyard : 5 meters max

f) Bulk density of limestone for volumetric calculation : 1.4 MT/M³
Bulk density of limestone for Torque, drive & structural load computations calculation :
1.7 MT/M³ 2
g) Belt Speed (approx.) : 0.5 meters / second
h) Belt width (conveyor & Belt Feeder) : 800 mm
i) Number of working hours : 08 hours per day (Max)
n) Angle of repose of Limestone : 38 degrees (ref CEMA 5th)
o) Capacity of Limestone system :Rated/Design : 75 TPH/82 TPH
Gypsum handling system:- 1

a) Belt Speed (approx.) : 0.5 meters / second
b) Belt width (conveyor & Belt Feeder) : 800 mm
c) Number of working hours : 24 hours per day
d) Capacity of Gypsum handling system :Rated : 13.7 TPH
Designed : 15 TPH
e) Gypsum storage yard is required for : 15 days
f) Height of Gypsum stockyard : 6 meters max
g) Bulk density of Gypsum for volumetric calculation : 1 MT/M³
Bulk density of Gypsum for Torque & Structural load calculation : 1.25 MT/M³
h) Repose angle: 40 degrees (ref CEMA 5th) 2
1.3.2 The CHP consists of two (2) identical and parallel (Coal) streams for main path (1 Working+
1 Standby), each having rated capacity of 1500 TPH commencing from “Wagon Tippler 1 &
2 (WT-1 & WT-2)” up to & including Bunker feeding Tripper conveyors with Bunker sealing
arrangement. Wagon Tippler and pit will be designed as per RDSO G-33 rev-01 standards.
Kindly refer flow Diagram for Coal handling Plant ( Drg No:- 9962-001-IS-155-PVM-L-002/IS- 1
1-FL-713-100-M001) for details.
1.3.3 Coal of (-)300 mm size will be received at Panki TPS site by BOX-N wagons. From BOX-N
wagons coal will be unloaded on Wagon Tippler Hopper.

Document Number
1X660 MW PANKI TPS
IS-4-DM-713-100-M005
1.3.4 Coal received by BOX-N wagons, will be unloaded in Wagon Tippler Hopper by Wagon
Tippler. From W.T. Hopper coal will be evacuated by Apron Feeder and will be fed to
Conveyor# BC-1A or 1B through diverter gate for onward conveying to JT-1. Each Wagon
Tippler hopper is having 290 M3 each (water filled volume) capacity with 50 mm guniting
on the walls. For placing Wagons on the Tippler table, side arm charger will be provided
with a capacity to haul 60 loaded Wagons of 140T gross weight each at a time. After
unloading wagons, it will be placed on wagon shifter and pushed to return railway line
with the help of wagon pusher.
1.3.5 In JT-1 coal from Conveyor # BC- 1A or 1B will either be fed through flap gate to
Conveyor# BC- 2A or to Conveyor# BC-2B for conveying coal to Crusher House( CRH-1).
1.3.6 Suspended Electro-Magnet (SEM-1,2) will be provide at PH-1 over conveyor# BC-2A/B.
Inline Magnetic Separators (ILMS-1, 2) will be provided on conveyer#BC-2A/2B head end
for removal of metallic ferrous tramp from “as received” coal. Two (2) nos. Belt Weighers
(BW-1 & 2), Metal detector (MD-1&2) & Two (2) Nos. Coal Scooper (CS-1&2) will also be
provided, one each on conveyer #BC-2A and 2B for measurement of coal flow rate.
1.3.7 Conveyor# BC-2A will feed coal through diverter gate, Rod Gate and Rack & Pinion gate to
both the Vibrating Grizzly Feeders VGF-1A and VGF-1B in Crusher House. Vibrating Grizzly
Feeder VGF-1A will feed the oversize fraction (+) 20mm coal to Ring Granulator CR-1A.
Undersized (-) 20mm coal will be fed to reversible Belt Feeder RBF-1A. Similarly, Vibrating
Grizzly Feeder VGF-1B will feed (+) 20mm coal to Ring Granulator CR-1B and (-) 20mm coal
to Reversible Belt Feeder BF-1A. Crushed product of CR-1A and CR-1B will be fed to RBF-
1A.
1.3.8 Similarly, Conveyor# BC- 2B will feed coal through diverter gate, rod gate, Rack & Pinion
Gate to both Vibrating Grizzly Feeders VGF-2A and VGF-2B in Crusher House. VGF-2A will
feed the oversize fraction (+) 20mm coal to Ring Granulator, CR¬2A and the under size
fraction, (-) 20 mm coal to Reversible Belt Feeder, RBF-2A. Similarly, VGF-2B will feed the
oversize fraction, (+) 20 mm coal to Ring Granulator CR¬2B and the under size fraction (-)
20 mm coal to Reversible Belt Feeder RBF-1B. Crushed product of CR-2A and CR-2B will be
fed to RBF-1B.
1.3.9 RBF-1A & RBF-1B will feed coal to any one of the Crusher House outgoing Conveyor# BC-
3A/3B or 3C/3D through diverter gate. Conveyor# BC-3A & 3B will convey crushed coal to
JT-2 while Conveyor# BC- 3C & 3D will convey crushed coal to JT-8 as shown in flow
diagram.
1.3.10 In JT-2 Conveyor No.# BC 3A or 3B will feed the coal through diverter gate to Conveyor
No.# BC 4A or 4B. Conveyor# BC- 4A/4B is fitted with Fixed Tripper, FT-1 and FT-2 at JT-3
as indicated in Flow Diagram.
1.3.11 Conveyor# BC-4A/4B conveying coal to JT-3, will either feed direct to it-self Conveyor# BC-
4A/4B or will feed coal Yard Conveyor# YBC-1B, for stacking purpose when bunker feeding
is not required. Uni-directional Stacker Cum Reclaimer (S/R) machine, mounted on Yard
Conveyor# YBC-1B and working in conjunction, will stack crushed coal on either side in
long stock piles.
1.3.12 Conveyor # BC-4A/4B receiving coal in JT-3, will convey coal to JT-4 through fixed tripper
FT-1 & FT-2 and will feed Conveyor# BC-5A or 5B at JT-4 through diverter gate. Inline


IS-4-DM-713-100-M005
Magnetic Separators (ILMS-3,4) will be provided on conveyer# BC-4A/4B discharge head

end for removal of metallic ferrous tramp from coal.
1.3.13 In JT-5, Conveyor# BC-5A/5B will feed coal through diverter gate to Conveyor# BC-6A or
6B. Conveyor# BC-6A/6B is fitted with Fixed Tripper, FT-3 and FT-4 at JT-6 as indicated in
Flow Diagram.
1.3.14 Conveyor # BC- 6A/6B will convey coal to JT-6, and will either feed coal to bunker feeding
Conveyor# TBC-1A or TBC-1B or will feed to itself for onward conveying.
1.3.15 Conveyor# BC- 6A/6B finally conveying coal to JT-7 and feed coal to bunker feeding
Conveyor# TBC-2A or TBC-2B.
1.3.16 In JT-8, Conveyor# BC-3C/3D will feed coal through diverter gate to Conveyor# BC- 4C/4D,
which will further conveyed to the Yard Conveyor# YBC-1A through JT-9 for stacking coal
when coal is not required for bunker feeding. Uni-directional Stacker Cum Reclaimer (S/R) 1
machine, mounted on Yard Conveyor# YBC-1A and working in conjunction, will stack
crushed coal on either side in long stock piles.
1.3.17 As and when required, crushed coal from coal pile will be reclaimed by S/R machine and
will be fed to Yard Conveyor# YBC-1A or YBC-1B, moving in forward direction. Yard
Conveyor#YBC-1A or YBC-1B, in turn will convey the coal to JT-10 & JT-11 and will feed
either to Conveyor# BC-7A or 7B, which further fed to conveyor# BC- 8A/8B for feeding
bunker. CS-5 &6, MD-5&6 & SEM-5&6 will be installed over conveyor# BC-8AB as per
functional requirement.
1.3.18 In addition four (04) nos Reclaim Hoppers (RH) of capacity 75T each have been considered
for feeding crushed coal from stock piles. Stacked coal will be fed into the Reclaim
Hoppers by dozing with Bull Dozers. Coal from Reclaim Hoppers will be fed to Conveyor #
RC-1A/1B through Vibrating Feeders (VF-1,2,3 &4), Rod Gate and Rack & Pinion Gate
fitted at the bottom of the Reclaim Hoppers opening.
1.3.19 Conveyor No.# RC-1A/1B will convey coal to JT-10 and will feed Conveyor# BC- 7A or 7B
for bunker feeding as per flow diagram. CS-3 & 4, MD-3&4, SEM-3&4 & BW-3&4 are
placed over conveyor# RC-1AB as per functional requirement.
1.3.20 The Coal handling plant is provided with two streams of conveyors except yard conveyor
out of which one stream of conveyor will be working while the second stream will be
treated as stand by.
1.3.21 Since coal will be received from different sources, coal stacking will be done by horizontal
spreading and reclaiming will be done by vertical cutting, thus permitting blending of coal
maintaining an almost uniform composition after crushing for onward feeding the steam
generator.
1.3.22 The Coal handling plant is also provided with sump pumps, Electric hoists/manual hoist,
Dust suppression system (DFDS, PWDS), Dust extraction system (DE), Air conditioning
system and mechanical ventilation system at the strategic locations.
1.3.23 For tunnel/Underground portions ventilation system 15 air changes for supply fan & 7 air
changes for exhaust fan is considered.


IS-4-DM-713-100-M005
LHP and GHP handling system:
1.3.24 The LHP consists of two (2) identical and parallel (Lime stone) streams (1 Working+ 1
Standby), each having rated capacity of 75 TPH commencing from “Reclaim hoppers# RH 1
to 4” up to & including bucket elevator. Kindly refer flow Diagram for Limestone Handling
Plant for details.
1.3.25 Limestone of (-)250 mm size will be received at Panki TPS site by truck. From Truck,
Limestone will be unloaded on stockyard (15 days storage).
1.3.26 Four (04) nos Reclaim Hoppers (RH) of capacity 20T each have been considered for feeding
Limestone from stock piles by dozing with Bull Dozers. Lime Stone from Reclaim Hoppers
will be fed to Conveyor No.# Conv-1A/1B through Vibrating Feeders, Rod Gate and Rack &
Pinion gate fitted at the bottom of the Reclaim Hoppers opening. Two Belt weigher (BW-
1&2) will be installed be on conv-1A/B.
1.3.27 In TP-1 Lime Stone from Conv- 1A or 1B will either be fed to Conv- 2A or 2B trough
flapgate for conveying Lime Stone to Crusher House(CRH). Two Inline Magnetic Separator
(ILMS-1&2) will be installed over conv-2A/B.
1.3.28 Conv- 2A & 2B will feed Lime Stone to reversible Belt feeder# RBF-1, which will feed the
limestone to the Vibrating screen SCR-1A or SCR-1B through ROD gate and Rack & Pinion
Gate by reversing the direction of RBF-1. Vibrating Screen SCR-1A or SCR-1B will feed the
oversize fraction (+) 20mm coal to Hammer Mill Crusher#HCR-1A or HCR-1B. Undersized (-
) 20mm coal will be fed to Belt Feeder# BF-1 or BF-2.
1.3.29 Further Lime Stone will be feed to the Bucket Elevator through BF-1A & BF-1B. BE-1A & 1B
will convey Lime Stone to LimeStone Silo through flapgate as shown in flow diagram.
1.3.30 Gypsum will be received at Gypsum Conveyor# Conv-3A/3B at Dewatering Building

through flap gate. Further Gypsum will be discharged to Gypsum storage yard.
1.3.31 Auxiliary systems such as Dust Suppression, Dust extraction, Ventilation / Air-conditioning
arrangement will be provided in the following areas:
Sl.
No. Auxiliary System location
a Mechanical Ventilation 1. CHP Conveyor tunnels for BC-1A/B including W.T
System with supply & complex.
exhaust fans 2. Conveyor tunnels for BC-2A/B
(Please ref DBR- including JT-1. 1
IS-4-DC-713-110-M050) 3. Reclaim Hopper with RC-1A/1B tunnel
4. LHP Conveyor tunnel#Conv-1A/1B including


IS-4-DM-713-100-M005
Sl.
No. Auxiliary System location
reclaim hopper complex.
b Plain Water Dust Coal stockpile with Stacker-Reclaimer, Wagon

Suppression System tippler, prewetting of wagons and ERH top
(Please Ref. DBR-IS-4-DC-
713-110-M053)
c Dry Fog type DS Wagon Tippler, All JTs, CRH and Vibrating feeder
System(Please Ref. DBR-IS-4- discharge at ERH in CHP and LHP
DC-713-110-M053)
d Mechanical dry MCC Rooms
Pressurization System
(Please ref DBR-
IS-4-DC-713-110-M050)
e Propeller type exhaust fan Battery room
f Air-condition System (Split CHP Main control room consisting of control desk
Type) and DCS panel, CHP other MCC DCS RIO panel
(Please ref DBR- rooms, operter cabin at crusher house and
IS-4-DC-713-110-M051) travelling tripper floor, Wagon tippler control room,
Stacker operator cabin.
g Dust extraction system Crusher house in CHP & LHP
h Bunker dust extraction At bunker roof for bunker cells
system
(Please ref DBR-
IS-4-DC-713-110-M054)
I Service water system Conveyor galleries, JTs, Crusher house, WT hopper
(Please ref DBR-IS-4-DC-713- area and conveyor tunnels, Pump house, tripper
110-M052) floor, MCC rooms
J Potable water Tank MCC rooms, control room, JTs, ST, Pump House,
(Please ref DBR-IS-4-DC-713- Tripper floor and crusher house
110-M052)
K Service air One point at each following building:
(Please ref DBR-IS-4-DC-713- WT complex, Tripper floor Crusher House and JTs.
110-M052)
L CHP/LHP/GHP operation hrs Annexure-3
2
The proposed CHP/LHP/GHP will also be provided with safety switches for conveyor, necessary
instrumentation and control system for sequential operation, illumination of conveyor galleries /
tunnels, transfer points, crusher house, reclaim hoppers etc.


IS-4-DM-713-100-M005
2.0.0 SCOPE OF WORK
2.0.1 The major equipment for the coal handling plant are listed below:
SLNO DESCRIPTION QTY UNIT

1. Wagon Tippler along with Weigh Bridge 2 Nos. 1
2. Wagon tippler rails on rail table 1 Lot
3. Side arm charger 2 Nos.
4. Apron Feeder with dribble conveyor 2 Nos.
5. Wagon Shifter and pusher 2 Nos
6. CHP Conveyor BC-1A/B, 2A/B, 3A/B, 3C/D, 4A/B, 4C/D, 5A/B, 20 Nos
6A/B,7A/B, 8A/B
7. Uni-directional yard conveyors (YBC)# YBC-1A and YBC-1B 2 Nos
8. Reclaim conveyors (RC), RC-1A/B, 2 Nos 1
9. Tripper belt conveyors(TBC) # TBC-1A/B and TBC-2A/B, 4 Nos
10. CHP Belting-1400 mm for BC-1A/B, 2A/B, 3A/B, 3C/D, 4A/B, 4C/D, 28 Nos
5A/B, 6A/B,7A/B, 8A/B, TBC-1A/B, TBC-2A/B, RC-1A/B, YBC-1A and
YBC-1B
11. Flap Gates (Motorised) with actuator (for Tripper)-CHP 4 Nos.
12. Diverter gate with acuator 32 Nos 1
13. Rack & Pinion Gate 8 Nos.
1
14. Rod Gate 8 Nos.
15. VGF screens + drive unit with supporting structure 4 Nos.
16. Vibrating feeder+ drive unit with supporting structure below Reclaim 4 Nos.
hoppers
17. Ring Granulator type Crusher wit by-pass facility 4 Nos. 1
18. Vibration Isolation system for crushers 4 Nos.
19. Vibration monitoring System 2 1 Set.
20. Vibrating feeder 4 Nos 1
21. In line Magnetic Separator 4 Nos.
22. Metal Detector 6 Nos.
23. Suspended magnet 2 6 Nos.
24. Belt weigher, 1500/1650 TPH 6 Nos.
25. Coal Scooper 6 Nos
26. Reversible Belt Feeder 1600mm - belt width 2 Nos. 1
27. Chute, liners & deck plates 1 Lot
28. Tramp iron chute, Debris chute 1 Lot
29. Chute block switch 1 Lot
30. Coal Sampling Units (In ST-1) 2 Set
31. Uni-directional Stacker cum reclaimer 2 Nos.
32. Rails for stacker cum reclaimer 1 Lot


IS-4-DM-713-100-M005

33. Travelling tripper with two way chute 4 Nos.
34. Travelling Tripper Rails 1 Lot
35. Fixed Tripper 4 Nos.
36. Electric and Manual Hoist along with Mono rail 1 Lot
37. Passenger cum goods elevator, Rope & sheave type, 2000 Kg in 3 Nos. 1
Crusher house, JT-6 and JT-7
38. DS System - Plain water type (For Coal stock pile, WT hopper, 1 Lot
Reclaim hopper)
1
39. Pre-spray system for waiting wagons-4 nos 1 Lot
40. DS System-Dry Fog type 1 Lot
41. DE System at Crusher House and Bunker 1 Lot
42. Bunker Bay ventilation 1 Lot
43. Vent. System for Tunnel/ underground JTs, ERHC and MCC rooms 1 Lot
44. Bunker sealing belt 1 Lot
45. Air conditioning system 1 Lot
46. Belt Vulcaniser with tool kit-upto 1600 mm BW, Hydro-mechanical 1 No.
press type
47. Submersible Sump Pumps with piping, valves, instruments, support 32 Nos.
complete system
48. Service water system within CHP area 1 Lot 1
49. Drinking water system within CHP area 1 Lot
50. Fluid coupling (Air-cooled type) for ring granulator 1 Lot
51. Maintenance Tools and Tackles as per VOL-III (Mechanical)-Chapter- 1 Lot
1
19 Coal Handling Plant
52. Mandatory Spare 1 Lot
53. Supply of all lubricants, oil, etc. for initial fill, flushing, cleaning, refill 1 Lot
and topping up to for a period of six (6) months from the date of 1
handing over of CHP as per VOL-III (Mechanical)-Chapter-19 Coal
Handling Plant
54. EOT crane (20 T/6.3T) for Wagon tippler complex. 1 No.
55. Bar grid at WT Hopper, ERHC Hopper and Bunker 1 Lot 1
56. Bull dozer (324)BHP with standard accessories. 4 Nos.
57. Pay loader (152) BHP with standard accessories. 2 No.
58. DDCMIS System for CHP including CSU. 1 Lot

59. PLC for WT-1&2 Machines 1 No.
3 60. UPS for PLC of WT-1&2 Machines 1 Set
61. PLC for SCR Machine 1 Lot
62. 3-D stockpile volume/ Qty measurement system for Stockyard 1 Lot
The major equipment for the LHP & GHP are listed below


IS-4-DM-713-100-M005

1. LHP & GHP Conveyors Conv-1A/1B, 2A/B, 3A/3B 6 NOs
2. Belting-800 mm for Conv-1A/B, 2A/B, Conv-3A/B 6 Nos
3. Reversible Belt feeder 1 No
4. Belt Feeder 2 Nos
5. Bucket elevator 2 Nos
6. Vibrating Screen 2 Nos
7. Hammer Mill type crusher 2 Nos
8. Flap Gates (Motorised) with actuator-LHP & GHP 2 10 Nos
9. Rod gate 6 Nos
10. Rack & Pinion gate 6 Nos
11. Vibrating feeder 4 Nos
12. Inline Magnetic separator 2 Nos
13. Metal Detector 2 Nos
14. Belt Weigher 2 Nos
15. Electrical Hoist/Manual hoist 1 Lot
16. Sump pumps-Vertical submerged type (40 m3/hr) 2 Nos
17. DE system at CRH 1 Lot
18. Ventilation system for Tunnel conv-1A/1B with reclaim hopper 1 Lot
19. Ventilation system for MCC 1 Lot
20. DFDS in LHP area 1 Lot
21. Service Water system in LHP area 1 Lot
22. Drinking Water system in LHP area 1 Lot
23. Belt Vulcanizing Machine 1 No
24. Lime sampling unit 1 Set
25. Pay Loader(133) BHP with standard accessories at Limestone and Nos
2
Gypsum storage area 3
26. DDCMIS System for LHP,GHP (Part of FGD DCS) including LSU. 1 Lot 2.0.2 B
uildings we have considered for CHP:
1. WT-1 & WT-2 WAGON TIPPLER COMPLEX 1 No.
2. SHED FOR BOTH WT 1 No.
3. BC-1A/B WITH TUNNEL 1 No.
4. BC-2A/B WITH Tunnel and GALLERY 1 No.
5. BC-3A/B WITH GALLERY 1 No.
6. BC-3C/D WITH GALLERY 1 No.
7. BC- 4A/B WITH GALLERY 1 No.
8. BC- 4C/D WITH GALLERY 1 No.
10. BC- 6 A/B WITH GALLERY 1 No.


IS-4-DM-713-100-M005

12. BC- 8A/B WITH Tunnel and GALLERY 1 No.
13. TBC-1A/B ON BUNKER FLOOR 1 No.
14. TBC-2A/B ON BUNKER FLOOR 1 No.
15. YARD CONVEYOR # YBC-1A/1B SUPPORTS 1 No.
16. RC-1A/B WITH TUNNEL & GALLERY 1 No.
17. JT-1 1 No.
18. CRUSHER HOUSE (CRH-1) 1 No.
19. JT-2 1 No.
20. JT-3 1 No.
21. JT-4 1 No.
22. JT-5 1 No.
23. JT-6 1 No.
24. JT-7 1 No.
25. JT-8 1 No.
26. JT-9 1 No.
27. JT-10 1 No.
28. JT-11 1 No.
29. JT-12 1 No.
30. Sampling Tower (ST-1) 1 No.
31. PENT HOUSE for BCN-2A/B, RC-1A/B and BCN-8A/B 3 Nos. 2
32. RECLAIM HOPPERS (4 - HOPPERS OF EACH 75T CAPACITY) 1 No.
33. RECLAIM HOPPER COMPLEX (ERHC-1) 1 No.
1
34. SHED FOR RECLAIM HOPPER COMPLEX 1 No.
35. STOCK PILE CCS#1(LXWXH - 230X35X12) Mtrs. 1 Nos.
38. STACKER CUM RECLAIMER FOUNDATION 1 No.
39. COAL SETTLING POND 1 No.
40. BULLDOZER SHED 1 NO
41. MCC 1 BUILDING NEAR WAGON TIPPLER ALONG WITH CABLE 1 No.
TRENCH
42. MCC 2 BUILDING AND CONTROL ROOM WITH CABLE TRENCH NEAR 1 No.
CRUSHER HOUSE
43. MCC 3 BUILDING NEAR JT-10 WITH CABLE TRENCH 1 No.
44. MCC 4 BUILDING NEAR JT-6 WITH CABLE TRENCH 1 No.
45. PUMP HOUSE-1 NEAR CRH 1 No.
46. PUMP HOUSE-2 NEAR JT-12 1 No.


IS-4-DM-713-100-M005
Note:- Any other associated equipment/ items/ item of work required for successful completion,
installation, and operation of the CHP, LHP & GHP package shall be under scope of BHEL.
1
2.0.3 Buildings we have considered for FGD:
1. Reclaim hopper complex 1 No.
2. Shed for reclaime hopper complex 1 No.
3. Storage Shed for Limestone 1 No
4. Storage shed for gypsum 1 No
5. CONV. 1A/B WITH TUNNEL & Gallery 1 No.
6. CONV.2A/B WITH GALLERY 1 No.
7. CONV.3A/B WITH GALLERY 1 No.
8. CRUSHER HOUSE FOR LHP 1 No.
9. PENT HOUSE FOR CONV. NO. 1A & 1B 1 No. 1
10. RANSFER POINT (TP)-1 1 No.
2.0.4 The Scope of work covers Design, Engineering, Manufacturing, Supply, Delivery to site,
unloading, storage & security at site, Local transportation at site, Erection and
Commissioning, and PG Test of CHP is not limited to the following, including Mechanical,
Civil & Structural, Electricals, and Control & Instrumentation.
2.0.5 Sump pumps (1W+1S) will be provided at W.T complex, (1W+1S) at JT-1, (1W+1S) at JT-12
and (1W+1S) at ERHC of each having capacity 40CMH and discharge head of 30mwc to
handle Coal particle in slurry form and to discharge the same to the nearest drain along
with necessary piping with fittings. 8 Nos (4W+4S) of Sump Pump for each Coal stock piles
will be provided. 1
2.0.6 Two (02) Nos. of Rotaside, Side Discharge Type Wagon Tippler with side arm charger with
capacity to haul 60 loaded Wagons at a time, shifter and pusher.
1
2.0.7 Travelling tripper will be provided with two way chute (i.e. one side discharge and one
central discharge).
2.0.8 Coal Chutes details: Parent plate for transfer Coal will be 20mm thick SAILHARD/ Equal.
The minimum side plate angle of chutes will be 60 degree from horizontal. Discharge hood
of head pulley will be of 5mm thick M.S. (IS2062) with neoprene rubber curtain [minimum
10thk]. Direct impact of material on conveyor or belt will be avoided by providing an
inclined surface at the feeding point to guide the material in the direction of belt travel. In
chute layout - inspection door, poking holes etc. shall be provided suitably and the
discharge chute shall enclose the snub pulley.
2.0.9 Tramp iron chutes and collecting trolley for ILMS. WhereILMS is provided, chute made out
of non magnetic material (parent plate) of minimum 10mm thk SS-304 steel for a distance
of 1.5m [minimum] from magnet face shall be provided.


IS-4-DM-713-100-M005
2.0.10 Suitable coupling guard will be provided for the drive arrangement of all equipments
covered under the scope of work including belt conveyors / trippers / crushers /screens /
Stacker and Reclaimer etc.
2.0.11 Three (03) No. Elevator rope.& sheave type (Goods cum Passenger) of 2000 kg capacity
with adequate number of landings at crusher house, JT-6 and JT-7.
2.0.12 Pump house and over ground water tank with effective capacity of one hour of total flow
requirement for dry for dust suppression and half an hour for plain water DS & service
water.
2
2.0.13 Coal Run-off pit pump of CSSP
2.0.14 Crossovers has been considered in conveyor galleries at approx. 100m distance.
2.0.15 Painting DFT requirement:

Painting will be as per tender specification.
a. For Surfaces
Primer coat: 1x75 micron DFT
Intermediate coat: 1x100 micron DFT
Finishing coat with Acrylic Aliphatic P.U. Paint(Full Glossy): 2x50 micron DFT
The total minimum DFT will be 275 micron.
b. Surfaces structural steel items / components fabricated at Workshop
Primer coat: 1x75 micron DFT
Intermediate coat: 1x100 micron DFT
Before dispatch to site one coat with Acrylic Aliphatic P.U. Paint(Full Glossy): 1x50
micron DFT
Post transport to site and erection at site one coat with Acrylic Aliphatic P.U.
Paint(Full Glossy): 1x50 micron DFT
The total minimum DFT will be 275 micron.
2.0.16 Consumables like lubricants; oils etc for initial fill, flushing, cleaning, refill and topping up
to for a period of six (6) months from the date of handing over of coal handling plant as per
Vol-III, Chapter-19 of Coal Handling System.
2
2.0.17 Finished Grade Level of CHP buildings
The finished grade level of JT-5, JT-6 and JT-7 in Power Block area is R.L. = 125.80 M.
The finished grade level at CHP area is R.L.= 126.00 M.
The finished grade level of WT-1&2 and TP-1 is R.L.= 126.00 M.
The finished grade level of Reclaim Hoppers is R.L.= 126.00 M


IS-4-DM-713-100-M005
3.0.0 EXCLUSIONS (as per Tender Specification and subsequent resolution/ correspondence
and BHEL internal scope division):
The following supply and services are excluded from our scope of work.
a) Locomotive shed.
b) Locomotives
c) Wagons
d) Any type of boundary wall.
e) Illumination of railway yard
f) Railway Track except WT table, SAC, shifter & pusher .
4.0.0 EQUIPMENT SIZING
EQUIPMENT SIZING OF COAL HANDLING PLANT
Sl. No. Description Value

4.01.00 Conveyor Belt
Material Handled: for conveyors ROM (-)300
BC-1A/B, 2A/B
For conveyors: BC-3A/B,3C/D, ROM (-) 20 Crushed Coal
4A/B, 4C/D, 5A/B, 6A/B, 7A/B,
8A/B, TBC-1A/B, TBC-2A/B, RC-
1A/B & YBC-1A/B
Capacity (MTPH) (Rated/Design) 1500/1650
Belt Speed (m/sec.) 3.2 m/s
Conveyor drive motor KW rating CEMA – 5th edition
Drive for conveyor Electro-Mechanical
Drive for reversible belt feederconventional
Maximum Inclination of belt 14 degree 2
Inclination at feed point Max 6 deg for all conveyor (except bunker
conveyor-TBC-1A/B & 2A/B where inclination
considered 14 deg at feed point.
Condition of Material Wet
Lift & Length As per approved drawing
Hrs. of Operation/Day 8Hrs
Applicable Standard Relevant IS Code (1891, 4776, 7175, 11592) and
Canadian Bureau of Mines Specification, CEMA.
Belt Width (mm) 1400
Troughing Angle 35 deg.
Surcharge Angle 20 deg.
Margin considered for motor 10%
selection on desired power
required
allowable belt sag 2% of idler spacing


IS-4-DM-713-100-M005

Artificial co-efficient of friction 0.025
Friction coefficient considered 0.35
between belt and pulley
Friction coefficient - material & 0.6
belt/Skirt
Friction coefficient - belt & belt 0.65
cleaner
Min. Cover Thickness(mm) 5mm & 3mm for top and bottom respectively.
No. of plies Minimum 4.
Cover Grade Fire resistant as per Canadian Bureau of Mines
Standard No.CAN/CSA-M422-M87, , TYPE –C for
Drum friction and Electrical surface resistance test1
and ISO 340 for flame tests.
Belt Construction Cut Edge Construction
Type of belt joint Vulcanized
Joint Efficiency As per DIN 22102
Minimum Radius of curvature (i) Concave curve : 250 M (ii) Convex curve : 50 M
Stone Picking Zone Before crushed coal & after crushed coal
Normal Working tension at design < 80% of max. allowable working tension
capacity
Deck Plate 3.15 mm thick MS sheet
Seal Plate 3 mm thick MS IS : 1079 (semi-killed quality). 2
Fixed tripper Steel structure
4.02.00 Pulley
Service For head & drive, head snub, bend, take-up, tail &
tail-snub pulleys (if required) to be used in all
conveyors, reversible belt feeders and travelling
trippers.
Conveyor TPH 1500/1650 TPH (rated/designed)
Type of Belt, Belt Speed & Width As per Belt Data-Sheet.
Pulley Width Belt width + 200
Lagging to be provided For all drive and Non-Drive pulleys .
Lagging Material & Thickness Drive- 12mm Thick (4mm ceramic + 8mm rubber)
Non-Drive- 12mm Thick Natural Rubber
Lagging Pattern Diamond shaped for Drive Pulley and plain for
Non-drive
How lagging is secured Vulcanized.
Pulley Construction Welded Steel as per IS: 1891/ IS: 8531
Shaft Material EN-8 or equivalent.
Pulley Diameter As per Belt Manufacturer's standard


IS-4-DM-713-100-M005

Shell thickness Min.14mm for Drive Pulley & 12 mm for other
pulley (Exact to be determined during detail
engineering from Belt Tensions).
At ILMS location - SS-304 of 16 mm thk
Minimum end disc thickness During Detail engineering
Angle of Wrap for drive pulley 210 deg.
Type of Plummer Block Split type. 2
Type of bearing Double Row Self aligning Spherical Roller Bearings
Bearing Life 60,000 hrs

Type of sealing Double Labyrinth With Synthetic Seals And Grease
Nip ples.
Pulley shaft diameter Minimum service factor of 1.5 for bending and 1.0
for torsion. Shaft deflection shall not exceed six (6)
minutes for any pulley.
Rubber for lagging
i) Type Ceramic rubber (92% AL2O3) &Natural rubber.
ii) Hardness Natural rubber-55 to 65 degree hardness on shore
“A” scale
Pulley bearing Centre to Centre During detail engineering
Coefficient of friction Not less than 0.7(Dry Conditions)/0.5(Wet
condition) 2
Bearing Make SKF / FAG make only 2
4.03.00 Gear Box 2
Location Indoor (as applicable).
Duty 24 hours/day.
Type of Prime Mover Squirrel cage Induction Motor, 6.6 KV/415V, 3 Ph.,
50 Hz.
Type of Rotation Uni-directional for all Conveyors
Type of high speed coupling Fluid/other as per Spec.
Type of low speed coupling Gear.
Type of Gear Box Helical – Reversible Belt feeder In general,
Bevel Helical – Conveyor.
Type of Bearing Antifriction Ball/Roller.
Lubrication Splash.
Whether Hold Back Required Not required for belt feeder, (Only conveyors)
Hold Back Type In-built
Frequency of Start As per motor specification.
Base Frame Required.
Material of Construction
Casing Grade FG-260 of IS-210 or equivalent


IS-4-DM-713-100-M005

and stress relieved.
Gear & Pinion high tensile carbon/alloy steel
Shaft Forged/Alloy Steel.
Type of Cooling Natural/fan cooled.
4.04.00 Fluid Coupling
Location Indoor
Position In between Motor and Gear Box of Conveyors, if
applicable. Also, after crusher motor.
Service Belt feeder Drive/Crusher drive.
Type of Drive Sq. cage induction motor.
Type of Fluid Coupling 1- Scoope Type for motor rating above 160KW
2- Traction Type for motor rating 160KW or below
160KW
Drive Power for which provided 30 KW and above.
Whether Fusible Plug to be Yes
Provided
Housing Material Aluminium Alloy Steel
Maximum Slip Allowable 3%
Type of Cooling Air-cooled
Semi-flexible coupling to be Yes, at output side with brake drum, if required.
provided with Fluid Coupling
Maximum Starting Torque Adjustable in the range of 120% to 275%
Direction of Rotation Should be capable of rotating in both directions.
Balancing Dynamically Balanced.
4.05.00 Idlers
General Information
Services Heavy duty, 24 hours/day.
Conveyor Nos. As per system requirement .
Belt Fabric & width As per conveyor belt data sheet.
Material conveyed (-) 300mm, (-) 20mm, coal as applicable.
Rate of flow 1500/1650 TPH rated/designed.
Bulk Density 0.8 T/M3 for volume 1.20 T/Cu.M for weight
calculation
Belt Speed 3.2 m/s (approx)
Idler Particulars
Rolls Manufactured from Friction factor of idler shall not be more than
0.017 while testing at works. Idler shaft shall be of
bright bar (UTS 45 kgf/mm2,IS:9550) 1
Min. shell thickness 4.85 mm (nominal)
Shaft material Bright bar (UTS 45 kgf/mm2,IS:9550)
Type of Bearing Deep grooved ball bearing


IS-4-DM-713-100-M005

Whether Bearings Life Lubricated Yes
Type of Sealing Double Labyrinth (minm.) and Rain Cap
Frame Material IS-2062
Applicable Standard IS-8598
For Return Idler Single roll return idler
NOTES:
1 Minimum six (6) impact idlers are considered at every feeding point with maximum
400mm spacing.
2 Self Aligning return idler will be provided for conveyors at every 30Meters.
Type of Carrying Return Impact Transition Self Aligning Self Aligning
Idler 2 Carrying Return
Roller 152.4mm 139.7mm 190mm 152.4mm 152.4mm 139.7mm
diameter D.D.
3 139.7mm 3
tube
No. of 3 1 3 3 3 1
Rolls
Angle of 35 deg. 10 deg. 35 deg. 35 deg. 35 deg. 10 deg.
Troughing
Max. 1200mm 3000 mm 400 mm As per 12000 mm & 30000mm &
Spacing (600mm in the (1500mm CEMA 5th 5000mm 10000mm
mm region of convex in the edition from either from either
Curve) region of ends. ends.
convex 0
Curve)
4.06.00 Hopper Chutes & Skirt Board
General Information
Material Handled Coal
Bulk density for volume calcn. 0.8 T/Cu.M.
Bulk density for weight calcn. 1.2 T/Cu.M.
Lump Size (-) 300 mm, (-) 20 mm, as applicable.
Belt Width 1400 mm
Maximum Moisture Content 15% (max)
Flow Rate (Rated/Design) 1500/1650 TPH.
Belt Speed (Approx.) 3.2 m/sec.
Pulley Dia As per IS/Manufacturer.
Pulley Width Belt Width + 200 mm 2
Minimum Valley angle 60º.


IS-4-DM-713-100-M005

Hoppers & Chutes (Uncrushed Coal)
Material of Hood above C.L Drive/ 5 mm thk MS plate. Necessary neoprene rubber
head pulley curtain[minimum 10thk] except magnetic zones
where SS-409M (non-magnetic) to be provided.
Thickness of parent plate 20 mm thk. SAILHARD/equal
In the zone of magnetic field 10mm Thick SS-409 M. for a distance of 1.5m
[minimum] from magnet face
Hoppers & Chutes (Crushed Coal)
Material of Hood above C.L Drive/ 5 mm thk MS plate. Necessary neoprene rubber
head pulley curtain[minimum 10thk] except magnetic zones
where SS-409M (nonmagnetic) to be provided.
Thickness of parent plate 20 mm thk. SAILHARD/equal
In the zone of magnetic field 10mm Thick SS-409 M. for a distance of 1.5m
[minimum] from magnet face
Inspection doors Hinged and leak proof construction.
Flange Flange joints with min. M-12 Bolts @ 125 mm C/C
spacing (max.)
3mm thk. Neoprene Rubber Gasket between 2
matching flanges.
Skirt Board
Material of main plate SAILHARD/equal
Side plate 16 mm thk SAILHARD/equal for uncrushed &
crushed coal.
Min. length of skirt per feeding 3.0 M
point
Skirt Board Height mm (min.) 900 for uncrushed coal
900 for crushed coal 2
1000 for RBF
Back Plate 16 mm thk SAILHARD/equal
Thickness of Rubber(molded type) 20 mm (min.) (50 to 55 shore hardness)
Thickness of Top Cover 5 mm MS along with 3mm thk neoprene rubber
gasket.
4.07.00 Flap Gate (FG)
Service Requirement
Type Motor operated linear Actuator with Flap Plate
Location In Travelling Tripper at bunker & JT-1.

Required numbers 6 NOs.
Material handled Coal (crushed).
Material size (-)300mm & (-) 20mm
Bulk density for volume calculation 0.8 T/Cu.M


IS-4-DM-713-100-M005

Bulk density for weight calculation 1.20 T/Cu.M
Moisture content 15%
Hours of operation/day 24
Flap Gate Requirement
No. of switching per hour 15(Minimum) and with ten (10) consecutive starts
[minimum] at rated load
Travel range As required.
Actuator type Electric.
Provision of manual operation Yes
Minimum thrust Thrust will be as per calculation by supplier duly
approved by Plant Owner.
Limit switch Heavy Duty type, Overload protection switch and 1

travel adjustment switch
Travel range 60 to 70 degree (with limit switches on both sides)1
Drive motor Dust tight motor driven with suitable linkages 1
flap gate position indication on Two (2) position

control / mimic panel
1
MATERIAL OF CONSTRUCTION
Flap 2 Nos. of 12 mm thick plate of SAILHARD/ TISCRAL
1
welded together to form the desired shape.
Shaft EN-8.
Type Electro mechanical with provision of manual
operation.
Bearing
Type Dust tight, antifriction, ball or roller bearings.
Life 50,000 hours (min.)
Provision of lubrication To be provided.
4.08.00 Divertor Gate (DG)
Service Requirement
Type Travelling type through rack & pinion arrangement
driven by bevel geared drive
Location In each JT and CRH as per requirement.
Required numbers As per flow diagram.
Material handled Coal (crushed/ROM).
Material size (-)300mm/(-) 20mm
Bulk density for volume caln. 0.8 T/Cu.M
Bulk density for weight caln. 1.20 T/Cu.M


IS-4-DM-713-100-M005

Divertor Gate Requirement
No. of switching per hour 15 (Minimum) and with ten (10) consecutive starts
Travel range As required.
Provision of manual operation Yes
Speed of Travel 30mm/Sec. (min.)
Minimum thrust Thrust will be as per calculation by supplier duly
approved by Plant Owner.
Provision of non reversal of gate Yes
during operation
Divertor gate position indication on Two (2) position
control/ mimic panel
Limit switches Heavy Duty type, Overload protection and travel1
limit switches
Gate Casing 10mm thick MS with liner 10 mm thick liner
Conical portion of the diverter gate 20 mm thick plate of SAILHARD/ TISCRAL
Rack EN-8/equal
Pinion EN-9/equal
Shaft EN-8/equal.
Type Electro mechanical with provision of manual
operation.
Bearing
Type Dust tight, antifriction, ball or roller bearings.
Life 50,000 hours (min.) (L-10)
Provision of lubrication To be provided.
4.09.00 Rack & Pinion Gate
Type Motor operated
Location As per flow diagram

Required numbers As shown in Flow Diagram.
Material Handled Uncrushed Coal, (-) 300mm for Crusher House and
(-) 20mm for Reclaim Hopper.
Bulk Density 0.8 T/Cu.M for volume calculation.
1.20 T/Cu.M for weight calculation.
Hours of Operation/Day 24 hours.
Manual Operating force 25 Kg. (Approx.)
Rack & Pinion Gate Requirement
1

IS-4-DM-713-100-M005

No. of switching per hour 15 (Minimum) and with ten (10) consecutive starts
Size of Opening During detail engineering
Limit switches Heavy Duty type, Overload protection and travel
limit switches shall be provided.
Locking positions Two extreme position
Material of Construction
Slide Gate 20 mm thk. SAILHARD / Equal
Body 12 mm thk. M.S (IS: 2062)
Rack EN-8/equal
Pinion EN-9/equal
Drive Shaft EN-8
Bearing
Type Dust-tight anti-friction bearing
Life 50,000 hours (Min.) (L-10)
Method of lubrication Single shot, pressure Lubrication.
4.10.00 Rod Gate

Type Manually Operated. Minimum two rows of rod
Location As per flow Diagram

Material of Rod MS, Rods (IS: 2062), 38mm Φ
Distances between two adjacent 40 mm (Approx)
rods.
4.11.00 In-Line Magnetic Separator (ILMS)
Conveyor capacity 1500/1650 TPH rated/designed.
Material to be conveyed (-) 300mm size coal & (-) 20mm size coal.
Belt fabric fire resistant belt to withstand high temp. &
impact of tramp iron (FR Grade).
Belt width 1400 mm
Belt thickness As per Belt specification
Magnetic separator belt speed At least 10% higher than main belt speed.
Degree of Protection IP-65 1
Magnetic Separator Belt

Drive Unit Geared motor of Adequately sized with 10%
margin.


IS-4-DM-713-100-M005

Belting EP type FR Garde complete with built- in ribs and
zero speed switch
Discharge Into tramp iron chute.

Magnetic Separator Details
Type Oil cooled type electromagnet with selfcleaning
arrangement complete with Local Panel
Location On Conveyor 2A/B in Crusher House, on Conveyor
4A/B in JT-4.
Operating gap 450mm in Crusher House, 400mm in JT-4.
Tramp iron lifting capacity:
Each Magnetic Separator shall be suitable to lift the following tramp iron piece from the
given belt:- (ROM/Crushed).
A. M.S. cube of 20mm size.
B. 250mm x 250mm size, 50kg[max] MS plate
C. MS round bar of 50 kg with L/D ratio not exceeding 5
D. MS bolt of M12, minimum length equal to 5 times the size
E. Brake shoe of Railway Wagon (Cast Iron 15 Kg)
F. Shovel teeth & spikes
Supply voltage 415V, ±10%, AC 3 phase, 50 Hz ±5%.
Quantity of separator Four (4) nos.
Insulation class ‘H’-(Max temp limited to 140 deg C.)
Core-Material pure annealed iron or equivalent having high
magnetic permeability, IS-4491
Coil-Material Alluminium
Wear plate Wear plate of Stainless steel SS-304 shall be
provided at electromagnet surface
Local control Will be provided for each magnetic separator

complete with all necessary electrical.
Rectifier 3ph, full wave bridge using Silicon diodes forming
rectifier set
Flux density[Minimum] 1000 Gauss at operating height specified above.
Force index[Minimum] 100000 Gauss at operating height specified above
Tramp iron chute Suitable Tramp Iron Chute up to ground level will
be provided with Bin with suitable wheels
Handling Arrangement for inline Magnetic separator suspended magnet 1
a) Height adjustment:- With turn buckle arrangement
b) Cross travel: - Electric Hoist operated cross travel facility.
4.12.00 SUSPENDED ELECTROMAGNET (SEM)
Conveyor capacity 1500/1650 TPH rated/designed.


IS-4-DM-713-100-M005

Material to be conveyed (-) 300mm size coal & (-) 20mm size coal.
Belt fabric fire resistant belt to withstand high temp. &
impact of tramp iron (FR Grade).
Belt width 1400 mm
Belt thickness As per belt specification
Magnetic separator belt speed At least 10% higher than main belt speed.
Degree of Protection IP-65 1
Electromagnet Belt
Drive Unit Geared motor of Adequately sized with 10%
margin.
Belting EP type FR Garde complete with built- in ribs and
zero speed switch
Magnetic Separator Details

Type Oil cooled type electromagnet
Location Over BC-2A/B in PH-1, RC-1A\B in PH-2, BC-8A\B in
PH-3.
Operating gap 450mm in un-crushed, 400mm in crushed
Tramp iron lifting capacity:
Each SEM shall be suitable to lift the following tramp iron piece from the given belt:-
(ROM/Crushed).
A. M.S. cube of 20mm size.
B. 250mm x 250mm size, 50kg[max] MS plate
C. MS round bar of 50 kg with L/D ratio not exceeding 5
D. MS bolt of M12, minimum length equal to 5 times the size
E. Brake shoe of Railway Wagon (Cast Iron 15 Kg)
F. Shovel teeth & spikes
Flux density[Minimum] 1000 Gauss at operating height specified above.
Force index[Minimum] 100000 Gauss at operating height specified above
Control Local & remote
Supply voltage 415V, ±10%, AC 3 phase, 50 Hz ±5%. Silicon
Rectifier Units
Handling Arrangement for Suspended Electromagnet
a) Height adjustment With turn buckle arrangement
b) Cross travel Manual hoist with Electric operated cross travel
facility
Core-Material pure annealed iron or equivalent having high
magnetic permeability, IS-4491


IS-4-DM-713-100-M005

Coil-Material Alluminium
Rectifier 3ph, full wave bridge using Silicon diodes forming
rectifier set
Non-Magnetic Idlers Non-Magnetic Idlers of 6 mm thk. (min) Aluminum
& lagged with 5 mm thk neoprene rubber shall be
provided suitably on conveyor in the magnetic 1
zone.
Quantity of separator Six (6) nos.
Wear plate Wear plate of Stainless steel SS-304 shall be
provided at electromagnet surface
4.13.00 Metal Detector
Type Electronic solid-state type, Each unit shall be
complete with search coil, electronic cabinet,
signal lamp, signal horn, sand bag marker and
provision for testing the unit.
Numbers Required Six (6)
Material Conveyed by Belt Uncrushed/Crushed coal.
Capacity Single channel suitable to detect
a) 25 mm dia. aluminium sphere below coal for
synthetic belting
b) 35 mm dia. aluminium sphere below coal for
steel cord belting
c) MS nut of size M-20.
Annunciation/ Hooter provided Yes
Audible range of Hooter 300m
Indication Type Audio and Visual
Power Supply 230V±15%, 50 Hz±2%, single phase, AC supply
Enclosure Fibre Glass
Control Through local control panel
Calibration Provision for automatic static calibration with
adjustable sensitivity
Search Coil Houses an oscillator coil and a receiver coil
Purpose of Installation To detect presence of metal. Metal detector shall

be designed to operate in conjunction with coal
scooper so that metal contaminated coal can be
scooped by hammer device of coal scooper 1
without stoppage of belt.
4.14.00 Coal Scooper
Type Automatic/ Semiautomatic


IS-4-DM-713-100-M005

Qty. Six(6)
Construction Steel fabricated, Necessary adjustable 5-Roll idler
(min. 2 nos.) at scooper location shall be provided.1
Conveyor Data :
a. Belt Width / Capacity / Speed 1400mm/1500TPH/3.2M/sec
b. Material to be handled Crushed Coal / ROM Coal
c. Lump Size (-)300mm/ (-) 20mm
d.Cutter opening 300mm (minimum)
e. Scooper Discharge Chute Welded Steel construction made out of 5mm thk.
M.S. plate
(IS:2062)
f. Contaminated coal receiving Welded Steel construction made out of 5mm thk.
container M.S plate. (IS:2062)
4.15.00 Belt Weigher (BW)

Type Electronic Load Cell Type, Microprocessor based
Nos. required Six (6) Nos. excluding B.W. on Boom Conveyor of
S/R machine. 1
Location As per Flow diagram
Capacity 1500/1650 TPH (rated/design)
Belt width 1400mm.
Type of conveyor Unidirectional
Inclination 14 deg. (Max.)
Troughing angle 35o
Belt speed (approx.) 3.2 m/sec.
Duty/day 24 hours
Material handled ROM coal/Crushed coal (as applicable)
Lump size (maxm.) (-) 300mm, (-) 20mm Coal as applicable.
Bulk density 0.8 T/Cu.M (for volume calculation) 1.20 T/Cu.M
(for weight calculation)
Weighing capacity (max.) 120% of conveyor rated capacity.
Weighing capacity (min.) 20% of conveyor rated capacity.
Belt Weigher Specification
Min. accuracy (%) ± 0.25% in the full range of 20% to 120% conveyor
rated capacity.
± 1% in the full range of 20% to 120% conveyor
rated capacity (with boom movement)
Totalizing unit Digital totaliser, Eight digit (local) with indicator.
Type Strain gauge type hermetically sealed


IS-4-DM-713-100-M005

Flow Rate indication Electronic Digital Display Minimum 4 digits both
Local as well as remote to be provided
Type Digital
Location of display Control Room/ Local
Calibrating instruments as required To be Provided
Structural Capacity 250% of rated belt scale capacity
Calibration
Automatic Zero & span calibration
Manual With test load chain
a) Test load chain length Two idler spaces more than weighing lengths
b) Chain reel equipment Calibrating Complete with weight adding facility.
equipment needed
4.16.00 Reversible Belt Feeder
Applicable Conveyor Nos. RBF-1 & RBF-2.
Direction of Travel Bi-directional
Material Handled Coal
Lump Size (-) 20 mm
Bulk Density (T/Cu.M) 0.800 (for volume calculation)
1.20 (for weight calculation)
Capacity (MTPH) 1500/1650 TPH rated/designed
Belt Speed 3.2 m/s.(Approx.) 1
Ambient Temperature 50 deg.C Max., 10 Deg.C Min.
Length As per System Requirement.
Hours of Operation 24
Belt Details 1600 mm.
Drive Details Motor drive with helical gearbox at head or tail
end.
Conveyor Details As per component spec. of general conveyors
given in this spec. Carrying idlers will be 20o
troughing angle and return idlers will be flat type.
Take-up Gravity take-up 2
Skirt As per Hopper, Chute & Skirt Board Specification.
4.17.00 Elevator
Drive Rope & Sheave type
Type of service Passenger-Cum-Goods
Location In Crusher House, JT-6 and in JT-7
Design & Construction
2
Type of Drive System VVVF
Controller Micro Computer Based. Simplex Collective Down.
Motor Protection Class IP-55

Document Number
1X660 MW PANKI TPS
IS-4-DM-713-100-M005

Carrying capacity 2000 Kg.
Rated speed Minimum 0.7m/s upto 1.5m/s
Total travel Will be as per actual dimension of the building.
No. of floors to be served As per requirement including ground floor.
Entrance As per requirement.
Min. floor size of cage Wx L 2100mm x 3000mm
Various heights of landing floors to Suitable for all working floors.
be served
Drive Motor (AC) One (1) no. for each.
Cab Flooring Steel Chequered plate, 5thk
Car ceiling Powder coated
Car operating panel Micropush buttons in SS face plate. Floor position
indicator
Car enclosure Powder coated
Car light Fluorescent Light
Miscellaneous provisions (i) Emergency light
(ii) Emergency alarm
(iii) Phase failure & Reversal protection
(iv) Automatic landing call by pass on full load
(v) Half length car operating panel
(vi) Pre-announcing direction indicator with gong
(vii) Automatic rescue device
(viii) Fireman operation
(ix) Position & Direction indicator on all floor.
(x) Vision panel in Car & Landing doors
(xi) Infra-red beam/ Infra-red screen door safety
(xii) Overload device with indicator
(xiii) Intercom in Car & Machine room
(xiv) Digital temperature indicator in Car
(xv) Digital clock in Car
4.18.00 Motorized Travelling Tripper (TTR)
Material handled (-) 20 mm size crushed coal, bulk density - 0.8
T/Cu.M (for volume calcn.) & 1.20 T/Cu.M (for
weight calculation).
Location One each on Conv. TBC-1A, 1B, 2A & 2B.
Hrs. of operation/day 24
No. required Four (4)
Belt width 1400mm
Capacity 1500/1650 TPH rated/designed
Speed of belt 3.2 m/sec. approximately.
Max. moisture 15%
Limit switch to be provided as required
Design & Construction
Type Motor operated travelling tripper
Type of drive unit for tripper Travel Motor (reversible) coupled to gearbox & gear box


IS-4-DM-713-100-M005

coupled to drive axle complete with flexible
couplings or with shaft mounted gear box. No
chain drive
Rail size 52 Kg/M (min)
Rail Gauge To suit requirement
Travel speed of Tripper (approx.) 12 m/min
Type of discharge chute Two-way with flap gate having Linear actuator
Travel Wheels
Type & material of wheel Flanged, Cast Steel, quenched and tempered
wheels
Type & life of Bearings Spherical roller bearing having 60000 hr. (L-10)
life. Method of lubrication through grease nipple
Axle material C-45 / EN-8. One axle assembly (1 pair of wheels)
driven by drive unit.
Rail clamps Manually operated rail clamps, two (2) set per
Tripper
Head, Bend & Hold Down Pulley of Tripper
Type M.S. welded construction (IS:2062)
Material & Thickness of lagging for 12 thk, plain natural rubber lagging
(Tripper head & bend pulley).
Hold down pulley To be provided
Mechanical End Stopper/ Buffer Yes
Post provided
Type of operation Only Local operation to be provided
4.19.00 Hoists
Chain Pulley Block (CPB) 1
Capacity As per requirement but Maximum manual effort

for operation of hoist shall not exceed 30kgf
Quantity and location As mentioned here (Sr. No. 6.00 in DM)
Lift As required.
Type of trolley geared
Manual type, where applicable Effort Less than 30Kgf or lift less than 10 metre.
Type of brake Either of screw and friction disc type, self-
actuating load pressure brake or of any other
standard design.
Electric Hoist
Type Electrically operated hoist & trolley with Pendant
switch, Control panel wall mounted.
Drive Motors SQIM, Separate for travel & lift
No. of starts for drive motor 150 starts per hr at 40%CDF

Document Number
1X660 MW PANKI TPS
IS-4-DM-713-100-M005

Pendant It shall be provided with fluorescent” Up/ Down/
Forward/ Reverse” travel push button & indicating
lamp
Class II as per IS-3938.
Hoist Speed 6 m/min (max.)
Carriage travel speed 5 m/min (max.)
One(1) Inspection cum maintenance To be provided complete with access ladder.
platform
Electrical type, where applicable 1 T & above or more than 10 metre travel.
Lift As required.
Quantity & Location As mentioned here (cl. No. 6.00.00)
Material of construction -
a. Drum & sheave MS/Cast Steel as per IS-3938
b. Load hook Swivelling type forged circular shank section As
per IS-3815
c. Wire rope Construction 6 x 37 as per IS-3938 with hemp core
regular lay with a minimum strength of 160-180
Kgf/Sq.mm. Safety factor of minimum Six (6) or as
specified in IS shall be used to select the rope.
d. Gear Forged/cast steel.
Brake type Electro-mechanical or equivalent.
Brake to be provided for Hoist & trolley
Bearing Ball/Roller, Life: 20 years as per IS: 3938
Lubrication Oil/grease
Electricals -
a. Motors As per relevant motor specification should be
suitable for hoist duty. However, motor will be
suitable for 240 starts per hour.
Separate for travel & lift.
b. Supply voltage 415V ±10%, 50 Hz ±5%, 3 Phase AC.
c. Type of power feeding Festoon cabling with Rail etc. arrangement
d. Type of limit switch i) Over lowering and over hoisting. ii) Over travel
at end position.
e. Control station Weather and dust proof with specified degree of
protection in electrical specification.
f. Necessary electrical protection Yes
devices provided?
Monorail location / layout
Cross section I-Bean
Distance b/w Centre line of Maximum 500mm
Monorail & centre of gravity of
equipment to be lifted.

Document Number
1X660 MW PANKI TPS
IS-4-DM-713-100-M005

Power Cables support Festoon type arrangement
Tests: All tests as per relevant codes and standard, manufacturer’s standard shall be
conducted. Over load test as per IS: 3832 shall be conducted
4.20.00 Belt Vulcaniser
Quantity One (1) no.
Type of Belt to be vulcanized 1 Nylon-Nylon belting
Type of Press Hydro-mechanical type, pressure generated by
Hydraulic pump
Belt Width Upto 1600 mm Belt
Type temperature controller Thermostat
Operating pressure 8kgf/sq.cm./ to suit
Operating temperature 145 -155°C
(approx range)
Method of heating Electrically heated

Connected load 30 KW (Approx.)
Power receiving plug, switch & To be provided
cable
Cable length (Approx.) Minimum 30m length between socket & temp.
Control box & Minimum 6m between control box &
platen
Power supply 415V ±10%, 50 Hz ± 5%, 3 Ph.
Whether portable type Yes - Electrically heated.
Vulcanising Tools & Accessories:
Sl. No. Description Quantity
1 Tool Kit 1 Set
2 Measuring tool 1 Set
3 Belt clamping device 2 pair
4 Roughing machine 1 Set
5 Edge Bars 2 pair
6 Portable motorized Winch 5 tonne 1 No
capacity complete with accessories
4.21.00 Vibrating Grizzly Feeder
Type Vibrating Grizzly Feeder of heavy duty design,
Spring supported, Floor mounted.
Location Before Ring Granulator.
Duty Continuous.
Capacity 900/990 MTPH rated/designed.
Number Required Four (4) Nos.
Material to be Handled ROM coal.
Max. Lump Size (Input Coal) (-) 300mm
Screen Undersize (-) 20 mm
Max. Moisture Content 15%


IS-4-DM-713-100-M005

Bulk Density of Material 0.8 T/Cu.M for volume calculation
1.2 T/Cu.M for weight calculation
Inclination Suitably selected to ensure proper flowability of
Coal without any hindrance
Pan Size
a) Screen area a)Min. 0.75 sq m per 100TPH feed
b) Pan width b)To match with crusher rotor length without
deflector plates
Bearings
a) Type a)Double spherical roller suitable for vibrating
b) Lubrication screens.
c) Life b)Grease
c)8000 hours minimum
Liners on solid deck
-Type Replaceable
-Thickness 16 mm minimum
Capacity adjustment Not required.
Material of Construction:
i) Solid deck ST – 42, IS:2062
ii) Liner plates SAILHARD/ TISCRAL or superior wear resistant
plate
ii) Grizzly Screen Plates. SAILHARD/ TISCRAL or superior wear resistant
plate
iii) Support Springs. Spring Steel (Helical only)
ii) Shafts Forged Steel
4.22.00 Ring Granulator
General Information
Quantity Four (4) nos.
Material to be crushed ROM Coal
Hard groove index 48-65 (Design Value)

2
Maximum moisture content 15%

Hours of operation/day Continuous (24 hours)
Bulk density 0.8 T/Cu.M for volume calculation
1.20 T/Cu.M for structural calculation
Service Requirement
Input size (-) 300mm
Extent of over sized lumps 1– 2% 350 mm (max.) (occasional) in feed coal
Capacity 900/990 MTPH rated/designed.
Output size 98% (-) 20 mm size
Type of crusher Ring granulator with bypass facility at feed end 1
Type of drive Scoop type fluid coupling with H.T. motor


IS-4-DM-713-100-M005

Output fines (-) 1mm size Crusher shall be designed considering worst
conditions
Anti Vibration GERB mounting To be provided
arrangement
Vibration Monitoring System To be Provided one system for Crushers 2
Temperature Monitoring System To be Provided one system per Crusher
Zero speed switch To be Provided for each Crusher
Type of crusher cleaning Water jet type
Number of rows of hammers 4 rows placed at 90 deg
Hammer profile Toothed and plain alternately or only toothed
Weight of each hammer Not to exceed 40 Kg
No. of suspension bars passing Max. of Two (2) number
through each ring hammers
No. of holes in each segment of Max. Three (3) number
central and end discs for
suspension bars (each row of
hammers)
Type of Plummer block Split Type

Type of bearing Spherical Bearing
Type of sealing Labyrinth, dust tight arrangement
Top covers of crushers Hydraulically operated
Material Of Construction
Rotor Assembly
i)Crusher Rings MN Steel, (IS: 276), Gr-III or made of low alloy
(silico manganese) steel in forged condition as per
ASTM-A 322 grade 9260
ii)Spacer Rings 45C8, IS: 1570 / Equal
iii)Rotor Disc 45C8, IS: 1570 / Equal
iv)End Discs 45C8, IS: 1570 / Equal
v)Rotor shaft Forged & heat treated alloy steel, ASTM-668, Class
E, EN-19/C-45 (IS 2004)/ E8D, BS 970/ 1955.
vi)Suspension bars ASTM-A322, Grade AISI 4140/EN24, Bright bar
vii) Rotor Balancing
a)Type of balancing reqd. Both static and Dynamic
b) Grade of balancing Q-16 as per VDI-2060 1966 (However, for purpose
of calculating the unbalanced force for the design
of machine supporting structure, balance grade as
given in the relevant section for foundation design
shall be followed).
Housing/ Cage Frame.


IS-4-DM-713-100-M005

i) Housing/ Frame Heavy MS fabricated steel plates[ IS: 2062 –Gr. B]
ii) Frame liners Material composition shall be as that of breaker
plate below, minimum 20 mm thick
iii) Breaker Plate Heavy cast Mn -Cast steel (IS:276,Gr- III),
minimum 40 mm thick
iv) Cage bars/ cage screens and side Heavy Mn Cast steel (IS:270,Gr-III)
screen plates
v) Guaranteed life Crushing Rings During detail Engineering
vi) Tramp Iron door IS: 2062,Gr.B.
Bearing type Heavy duty 1 Antifriction, Ball/Roller.
Lubrication Arrangement Manual through grease gun or with recommended
grade of oil in which case the plummer block shall
be designed with oil filling, oil draining and visual
oil.
Product size adjustment Manually operated worm screw jack for gap
adjustment between cage & rotor.
Power transmitting device from Scoop Type Fluid Coupling electrically actuated.
motor to crusher Coupling shall be fan cooled type only i.e. no
water to be used for cooling.
Crusher cage. Adjustable type to vary output size shall be
provided
Maintenance door Top to be opened / closed with hydraulic cylinders
and Power Pack. Inspection cover shall be hinged
type.
Testing at Works No load running test to be conducted
NOTE
1 Crusher rpm not to exceed 750.
2 All tests will be as per manufacturer's standards and relevant codes & standards for Ring
Granulator
3 Crusher will be provided with vibration monitoring system with necessary interlocks.
i) Number & Type of Vibration One (1) Microprocessor based monitoring system
able to distinguish between high frequency
vibration caused by bearing trouble and low
frequency vibration caused by imbalance
ii) Number of channels 16 (Rack mounted in cabinet)
iii) Transducer a) Velocity pick-up or a peizo-electric
accelerometer.
Type shall be decided during detail engfineering
based on the details of equipment to be
monitored.
b) Light weight stud mounting.


IS-4-DM-713-100-M005

c) Frequency response 1Hz-10kHz
iv) Connecting cables Low noise fir proof coaxial cable to be laid in
flexible conduit
v) Monitors (to be located in CHP Dual channel monitor for each location along with
control room) a) Buffered signal output & software for vibration
analysis through CHP control desk HMI
b) Recorder signal output
vi) Alarm 0-100% full scale adjustable
vii) Trip 0-100% full scale adjustable
viii) Test Functional checking from inhibiting alarm & trip
4.23.00 Stacker-Cum-Reclaimer (Bucket Wheel Type)
General
Type Uni-directional type boom Stacker with Bucket
Wheel reclaimer.
Quantity One (2) No.
Stacking Capacity 1500/1650 MTPH rated/designed.
Reclaim Capacity-
Design (Peak) 1500 MTPH rated
Rated Average 1200 MTPH Rated
(Average over a period of 4 hours)
Total Travel As per Plot plan / Stockpile
Duty 24 Hours/Day.
Stock pile height 12m 1
Stock pile length CCS#1 & CCS#2-230 M and CCS#3-170M
Stock pile width CCS#1 & CCS#3-35 M and CCS#2-54M
Boom length 45 metre
Wheel Dia. (min.) 630 mm (Tread dia.)
Material
Material Crushed Coal.
Lump Size (-) 20mm
Moisture Content 20% during rain
Bulk Density (T/Cu.M) 0.80 for Volume Calculation
1.20 for Weight Calculation
Structural Design Data
Code of Construction ISO: 5049/1 (Latest)
IS-800 or Equivalent for Structural Work
Wind Pressure
a. Operating wind velocity 20M/Sec
b. Non- Operating wind velocity 50 M/Sec
Type of Rail CR-100 2


IS-4-DM-713-100-M005

Drive equipment for long travel Electric motor with suitable reducer & brake.
Stability Factor:
a) For operating condition with max. 1.3
operating
wind velocity
b) For non-operating condition with 1.2
max. non-operating
wind velocity
Max. Wheel Load permissible with 275 KN
impact
Design live load for Walkways, As per Specification.

Service Platforms, Machinery floors
Equipment Design Data
Track Rail Gauge 9.2 M. Centers
Track Length To suit the stockpile length and maintenance and

anchoring requirements.
Top of Rail Level 0.7m above ground level unless specified
otherwise.
Bucket Wheel a) Type: Cell-less design
b) Drive: Hydraulic Drive.
Indicate rail track tolarances Following tolerance/better for the long travel
track shall be provided.
• Max. Permissible variation in rail level,
vertical [one rail to another] = ±15mm 1
• Max. Permissible track variation (Rail
Centers) = ±10mm
• Rail gradient = 1:500
No. x Yard Rail Size and Rail 2 x CR-100 (Minimum) and 9.2 m centres. 1
Centres
Carriage:
a) Supporting Arrgt. Three Point support system with 4 corners to
take-up irregularity of track as per specification.
b) Long Travel Speed 0 - 40m/min A.C sq. cage VVFC. Peak speed shall
be used for travelling one end of the stockpile to
other While stacking the speed shall be limited to
0 – 20 m/min. 1
slewing speed, 0-0.2 rpm (Hydraulic) or 150 starts/hr (electric
3 drive )
luffing range (approx.), +11° above & -11° below horizontal 1
luffing speed, 3m/min @centre line of Bucket Wheel
1
wheel diameter (min.) 630 mm (Tread dia.)


IS-4-DM-713-100-M005

Luffing Mechanism of Boom Hydraulic.
Luffing Angle To suit the requirement.
Slewing Mechanism of Boom Will consist of horizontal ring bearing with geared
rim. Drive will be Hydraulic drive.
Slewing Range ±110 degrees from the centre line of the yard
conveyor.
Operator's Cabin Will be provided with all standard accessories
including fan, light etc. (Ref. relevant clause of
specification). Operator’s cabin will be located
near bucket wheel
Construction Dust proof & air conditioned.
Door Hydraulic door closer.
Boom Conveyor Details As per Conveyor Specification given elsewhere.
The Boom length 45 metres. 1
Belt weigher to be provided on Yes
Boom conveyor 2
Electricals
Cable Reeling Drum Separate Motorized drum for power and control
cable.
4.24.00 Sump Pump (CHP) 1
Hours of Operation 24 Hours/Day
Minimum Nos. Required 34 nos each Sump Pit, two (2) no. (1W+1S)
Sump Pump Requirements
Type Vertical submersible non-clog type
(Pump & motor will remain submerged in water)
Number of Stages Single.

Fluid Type to be Handled Coal dust laden water
Piping with valves fittings Yes. Piping valve and accessories size shall be
designed and selected based on both sump pumps
working simultaneously.
Total Head 30mwc
Discharge Capacity (m3/hr) 40M3/hr
Auto/Manual selector switch & Yes
Local Panel Provided
Drive Type Motor.
Strainer at the impeller inlet to be Yes,
provided
Type of Bearing Antifriction
Method of Lubrication Grease.


IS-4-DM-713-100-M005

Necessary steel supports/ To be provided
removable grating,
handrails etc. for sump pump and
piping, provided
Local start/ stop control From next higher floor or away from
sump where water accumulation does
not occur.
Local Panel, necessary start/ stop To be provided
push button, auto/ manual selector
switch etc.
Type of mechanism for automatic Electrode type / eqvt.
starting/ stopping
Material Of Construction
Casing Ni-CI/better
Impeller Ni-CI/better
Pump Shaft EN-8
Line Shaft EN-8
Support Pipe MS MS
Cover Plate MS
Strainer MS with SS-304 wire mesh/ or equal
Indication for on/off To be provided
4.25.00 Coal Sampling Unit
Location ST-1
Qty. of sampling unit Two (2) sets for crushed coal.
Lot size shall 6000 tonne/unit.

Run time: 5hrs/unit 1
Type Automatic two stages.

Material handled Crushed coal.
Input lump size (-) 20mm.
Bulk density 0.8 T/Cu.M for volume calculation
1.2 T/Cu.M for weight calculation
Conveyor capacity 1500/1650 TPH Rated & Designed.
Belt width 1400mm
Belt speed 3.2 m/sec.
Material of sampler chutes Stainless steel.
Min. valley angle of chutes/hoppers 60 deg., Chute material 6mm thick SS-304.
Sampling system capacity During detail engineering, preferably as per
ASTM:D-2234 & ASTM-D-2013
Final Sample qty. 18 to 23 kg per run per unit 1
Size of sample particle desired (-) 6 mm


IS-4-DM-713-100-M005

Hours of operation As required for 24 hours of operation of Plant per
day.
Control system DCS based control system. 2
Primary Sampler -
i) Type Swing Hammer Type collecting sample
ii)No of Cuts per Hours Not less than 20 [per conveyor].
iii)Cutter opening Min 100mm
iv) Material SS-304
v) Quantity 2 Nos.
vi) The cycle time will be adjustable yes
through timer.
Primary Sample Belt Feeder
i) Type Reversible
ii) QTY 2 NOs per set
Iii Belting Standard duty x 315/3 x EP belt, Covers: 3mm
topx1.5mm bottom, F.R grade. Belt Width = To
suit capacity , Speed (VARIABLE) : To suit
iv)Idler 63.5 mm OD x 3.65 thk x ERW tube(IS:9295) x 20Ф
bright bar shaft, life lubricated design x deep
grooved ball bearing having Bearing life (L-10) of
minimum 60000hrs.
v)Pulley 5mm thk(min) shell (MS, IS:2062) x EN-8 shaft
with antifriction bearings having Brg. life (L-10) of
minimum 60000hrs.Neoprene rubber lagged head
and tail pulley, lagging thk; 6mm thk (minimum).
Shaft/ hub connection: key fitted.
vi) Can requirement 2 NOs per set
vii) Capacity As per system requirement 1
viii) Belt width & speed During detail engineering
xi) Components During detail engineering.
Sample Crusher -
A) Crushed (as fired) feed coal size (-) 20 mm
B) Output Size 100% (-) 6mm and 95% (-)8 mesh/ As per ASTM.
i) Type Impact type hammer mill /equal, single stage
crushing required
ii) Capacity 0.5 T/Hr
ii) Frame M.S.
iv)Drive V-belt drive & electric motor including Suitable
vibration isolation system
1
vi) The product output size will be adjustable type.
vii) Capacity As per system requirement.


IS-4-DM-713-100-M005

viii) Quantity During detail engineering.
Secondary Sampler -
i) Type Swing Hammer Type collecting sample
ii)No of Cuts per Hours Not less than six times the primary cut/hr
iii)Cutter opening It shall not be less than 30mm
1
iv) Cutter tip SS-304
v) Quantity 1 no. per system.
Sample collection bins SS-304 Material (6mm thick) 1
Motor As per motor specification.
Rotary Sample Collector-
i) Location For Rejects
ii) QTY 1 no per set
iii)Type 8- Station, Rotary Sample Collector[for collection
of final sample]
MS plate(IS:2062)
iv) No of can per Rotary 8
Collector
v) MOC of Cans PVC
Additional can required 10
Rejects Bucket Elevator-
i) Qty 1 NO per set
ii) Capacity each (min.) 0.5 TPH 1
iii)Type Centrifugal type / belt, Minimum 5thk SS-409M
bucket. (Type A1 to IS: 6833), Free standing.
Minimum 650mm wide Access ladder [to drive
unit] complete with cage shall be provided.
iv) Belting Minimum 4ply / EP / HD suitable for Elevator
duty.FR grade cover,
Minimum Cover thk:1.5mm[ pulley side] and
1.5mm [ bucket].
v) Construction
a)Stiffener ISA 75 x 75 x 6 thk (minimum)
vi) Casing 8 mm thk MS (IS: 2062) 1
Chute Work-
i)Qty During Detail Engineering
ii) Material 5mm thk SS-304 plate for Sample Discharge Chute
& 5mm thk SS-409 M for Rejects Chute.
iii) Slope angle 60 Degree
iv) Cross-section Preferably round section or square/ rectangular
with rounded corners.
Note: -
All machine under CSU shall be self-contained and dust tight unit.
4.26.00 Bunker Sealing Arrangement

Document Number
1X660 MW PANKI TPS
IS-4-DM-713-100-M005

Type Single flat belt sealing
Location Over plant bunker slots
Number One (1) for each Travelling Tripper.
Sealing belt specification:
Rating/ Type Minimum Heavy Duty 630/3 N/N
Width (mm, Minimum) Bunker Slot Size + 100 mm.
Number of ply 3 min
Cover grade F.R. Grade
Guide Roller As per requirement
Cover thickness (mm) Top / bottom 5/5
Bunker slot grating
Material of Construction MS Fabricated, out of MS flats & Ø 20 MS rods
Bunker opening size 800 mm (Minm.) continuous
Cross bars over the slot opening 16mmx50mm MS plate
4.27.00 Vibrating Feeder
Location Under Reclaim hoppers
Type Electro-Mechanical
Nos. required 4 Nos. below reclaim hopper.
Capacity 750 MTPH (Rated)
Drive margin over design capacity 10%
Material handled Crushed coal
Lump size (-) 20mm
Bulk Density
i) For volumetric calculation 0.8 MT/Cu.M
ii) For equipment design 1.2 MT/Cu.M
Moisture content Up to 15%[normal] &,up to 20% during rainy
season
Trough 12 mm thk M.S Lined with 8 thk SS-409M steel
plate liner
Trough inclination to horizontal Adjustable,8-10degree down slope
Amplitude 3mm to 8mm
No. of vibrations per minute 950 (approx)
Type of drive Unbalanced motor
4.28.00 Wagon Tippler
Type Rotaside, Side Discharge Type to suit tipping
capacity of Tippler as per latest RDSO technical
pamphlet G-33 Rev-01.
Quantity Two (2) Nos.
Gross Weight of Wagon that can be Min. 140 T
handled at a time
No. of Tips per Hr (Guaranteed) 25tip/hr


IS-4-DM-713-100-M005

Duty 24 hours
Types of wagons to be handled BOX, BOXN, BOXNHA, BOXNLW, BOXNHL,
BOXN25,DFC & other type of open wagons for coal
as per RDSO standard and design used by Indian
Railways to move coal 1
Angle of rotation 160 Degree.
Drive Details
Drive Hydraulic Motors
Brake The brake will be integral to the system.
Clamping Hydraulically Operated.
Integrated Weigh Bridge Required.
Dust Suppression Plane water dust suppression system.
Clamping arrangement of wagons Hydraulic and suitable for all types of wagon,
considering different height and length of wagon
without changing the attachment physically.
Mode of control Semi-automatic/manual, PLC control for remote
operation & control shall be provided.
Lubrication Arrangement. Motorized group Lubrication system of proven
design shall be provided.
EOT Crane 20 T/6.3 T EOT Crane common for both W.T.
4.29.00 Side Arm Charger
Type Rail Mounted, Rack & Pinion Type
Quantity Two NOs
Type of Drive Hydraulic motors (operated by Power Pack)
driving a set of pinions onto ground drive rack.
Hauling Capacity 60 Nos. wagon, each having gross wt. of 140 t
Operating Speed (Forward & Forward: ~ 0.6 m/s (To Suit) ; Reverse: ~1.2 m/s
Reverse) (To Suit)
Travel Brake EHT brake
Side Arm Drive Arm movement by hydraulic cylinders.

Type of traction Land mounted cast steel rack.
Travel For inhaul & outhaul – DDE
Mode of Control Semi Automatic from Remote Control & Local
Lubrication arrangement Manual centralized
Safety features Over Travel Protection / other safety features as
necessary shall be provided for safe operation
1
Mode of power supply arrangement Festooning Cable Arrangement
Types of wagons to be hauled All types as per RDSO Standard.
4.30.00 Apron Feeder
Location Below Wagon Tippler Hopper


IS-4-DM-713-100-M005

Duty Continuous
Capacity 1500/1650 TPH Rated & Designed.
Number required Two (2)
Material to be handled (-) 300 mm
Moisture content (max.) 15%
Bulk density of material 0.8 T/M3 for volume calculation.
1.2 T/M3 for structural design calculation.
Centre to centre distance During detail engineering
Pan width 2000 mm (min.)
Pan type Overlapping
1
Reducer Bevel Helical
Drive VVVF Drive
Pan Speed 0 to 0.2 m/ sec
Tension mechanism Heavy duty screw type
Lubrication Centralized single point grease lubrication
Type of conveyor for dribble Belt conveyor/Scraper chain conveyor.
material
Drive margin over design Capacity 10%
Dribble Conveyor Integral matching Dribble belt conveyor with built-
in drive to handle spillage shall be provided.
Width of dribble conveyor 2200 mm
4.31.00 Wagon shifter and pusher
No. of wagons to be handled 1 (Wagons as per RDSO G33 Rev.1)
Capability to handle Diesel locomotive and/or loaded wagon weighing
upto 140 T
DESIGN & CONSTRUCTION
REQUIREMENTS
Shifter/pusher carriage Robust construction of heavy duty fabricated
steel.
Shifter/pusher Drive Direct hydraulic drive without gear box or electric
motor and reducer unit controlled through VVVF
drive
Travel brake Integral/ independent hydraulic disc brake
Rails on shifter /pusher 52 Kg/m
Working pressure for the hydraulic 250 bar Maxi.
system in Hydraulic Power Pack
4.31.00 Wheel/Pay Loader
Engine Diesel Engine
Quantity Two (2) No.
1
Minimum of Net Power 113 kW (152HP) (ISO: 9249)
Minimum of Bucket volume 1.91 Cum


IS-4-DM-713-100-M005

Driver/operator's cabin To be provided with suitable rain protection
All Standard Control & monitoring To be provided.
features
Dust Seal To be provided.
All Standard accessories as To be provided.
specified and as applicable
4.32.00 Bull Dozer
Nos. Required Four (4)
Handling Material Coal from stock pile to reclaim hopper
Condition of Grade Generally leveled

features
4.33.00 Stringer & Short Post Size considered
Stringer ISMC 150
Short Post ISMC 65x65x6 (Min)
Short Post support distance At 3 m for non Loading area and 2.4m (Maximum)
in impact loading
zone
4.34.00 Roof Extractor
Location Tripper floor roof
4.35.00 Belt Cleaners 1
Multi bladed Type [Secondary Belt Tungsten carbide blades mounted on a carrier
assembly of steel tube
Cleaner]
Primary Belt Cleaner Polyurethane material
V-Plough type MS flats and polyurethane strips 20mm thk
(minimum)
4.36.00 Belt Protection Equipment 1
Pull cord Switch Both side of conveyor at Approx 20 m (minimum 1
pair)
Belt Sway Switches Both side of conveyor at Approx 30 m (minimum 1
pair)
Zero Speed Switches Mounted on Tail pulley.
EQUIPMENT SIZING OF LIMESTONE/GYPESUM HANDLING PLANT


IS-4-DM-713-100-M005
4.35.00 Conveyor Belt

Material Handled: for conveyors
Conv-1A/1B, Conv-2A/2B, RBF-1 1-Limestone (-)250 mm
BF-1 &2 2-Limestone (-)20 mm
BCN-3A/B 3-Gypsum
Capacity (MTPH) (Rated/Design) Limestone conveyor-75/82 TPH
1
Gypsum Conveyor-13.5/15 TPH
Belt Speed (m/sec.) 1.0 m/s approx
Conveyor drive motor KW rating CEMA – 5th edition
Drive for conveyor Electro-Mechanical
Drive for belt feeder conventional
Maximum Inclination of belt 16 degree
Inclination at feed point Max 6 deg for all conveyor
Lift & Length As per approved layout

Hrs. of Operation/Day 8Hr
Applicable Standard Relevant IS Code (1891, 4776, 7175, 11592) and
Canadian Bureau of Mines Specification, CEMA.
Belt Width (mm) Limestone conveyor belt-800mm
Gypsum conveyor belt-500mm
Troughing Angle 35 deg.
Surcharge Angle 20 deg.
Margin considered for motor 10%
selection on desired power
required
allowable belt sag 2% of idler spacing
Min. Cover Thickness(mm) 5mm & 2mm for top and bottom respectively.
No. of plies Minimum 4.
Cover Grade Fire resistant as per Canadian Bureau of Mines
Standard No.CAN/CSA-M422-M87.
Belt Construction Cut Edge Construction
Type of belt joint Vulcanized
Stone PickingZone Near PH
Minimum Radius of curvature (i) Concave curve : 250 M (ii) Convex curve : 50 M
4.36.00 Idler
Carrying Idler Three roll, 35 degree troughing, 2 degree forward
tilt
Return idler Single Roll,
Loading point Impact type

Document Number
1X660 MW PANKI TPS
IS-4-DM-713-100-M005
Spacing
Carrying idlers 1.2 m (0.6 m for convex curves and in the paddle
feeder travel range).
Return idlers 3.0 m (for convex curves not more than 1.5 m.)
Loading point Minimum six (6) with 400 mm spacing.
Self-aligning troughing idlers At 10 m distance from head & Tail pulleys with
intermediate spacing 15m
Self – aligning return idlers At 10 m distance from Head & Tail pulleys with
intermediate spacing 20m. (Not required for
conveyors more than 400m c/c long where 2
roll return idlers are provided).
Bearings
Carrying Ball Bearings of deep groove type or seize
resistance type of min. 35 mm size, lubricated for
life.
Return Ball Bearings of deep groove type or seize
resistance type of min. 25 mm size, lubricated for
life.
Material
Roller ERW Steel tube min. wall thickness 4.0 mm
Spindle E.N. 8 or equivalent.

4.37 Belt Cleaners
External Spring loaded scraper type cleaner with modular,
segmented and replaceable PU blades with
separate main-cleaner & precleaner etc
Internal V-Plough type, mild steel flats with hard rubber
strips.
4.37 Pulley
Pulley shaft diameter Margin of minimum 20% shall be Considered on
maximum tension at design capacity for arriving
at the shaft dia.
Drive Pulleys
Lagging Hot lagged with vulcanised natural rubber
Lagging thickness 12 mm thick grooved in diamond
pattern with grooves 6 mm wide x 6 mm deep
Minimum angle of wrap 210° degrees
Maximum Out of roundness 0.5% of nominal diameter

Other pulleys


IS-4-DM-713-100-M005
Lagging Hot lagged with vulcanized natural rubber
Lagging thickness 12 mm thick plain

Rubber for lagging
Type Natural rubber blended with styrene
Hardness 55 to 65 durometer (Shore A)
Elongation Over 300%
Strength 160-245 kg/cm2

Abrasion loss 250 mm3 (max.) as per DIN 53516
Specific Gravity Max. 1.5
Adhesion Strength 10 kg/cm (minimum)
Bearings for Pulleys
Type Heavy duty roller type
Casing Horizontal Split Type
Sealing Dust tight with double labyrinth seals.
Lubrication Greasing arrangement with conical head shape
nipples.
Pulley Material Mild steel conforming IS:226 / IS :
2062
Shaft Material Forged Steel shaft EN-8 or equivalent material
4.38.00 Belt Protection Equipment
Pull cord Switch Both side of conveyor at Approx 30 m
Belt Sway Switches Both side of conveyor at Approx 50 m (Minimum 1
two (2) pairs)
Zero Speed Switches Proximity switch, mounted on Bend pulley of
GTU.
4.39.00 Drive Motors
Type & Mounting Three Phase Squirrel Cage Induction Motors Base
mounted
Motor rating 120% of actual power requirement at motor
output shaft
4.40.00 BUCKET ELEVATOR
Capacity 75TPH/82.5TPH
Casing Self-Supported
Buckets Bucket width is to be a minimum of four times
the maximum particle size
Belting As stated else where
Pulley
Head Shaft and Bearings antifriction type with one bearing fixed

Document Number
1X660 MW PANKI TPS
IS-4-DM-713-100-M005
Foot Shaft and Bearings and the other expansion

Life L10 60000 hours
Take-up screw or internal gravity type
Drive 100% bucket filling @ minimum material bulk
density, or
75% bucket filling @ maximum material bulk
density, whichever is greater
Inspection and Access Doors loose-hinged type with quick-opening jamb bar
fasteners and gaskets enclosed and retained in
the door. Access doors shall be 1.5m minimum
Dust Vent As stated in NIT
4.41.00 LIMESTONE CRUSHER
Type Hammer mill type Crusher
Quantity/Capacity of each crusher Two (2) / 75 TPH ( minimum ) each
Feed Size & Product size (-) 250mm & (-) 20 mm – 90% (min.)
Drive arrangement Electric motor, scoop type hydraulic coupling,
gearbox.
Rotor Balancing Static
Type of Sealing Labyrinth, dust tight arrangement
Type of bearing Spherical roller
Lubrication Manual through grease gun or With
recommended grade of oil in which case the
Plummer block shall be designed with oil filling,
oil draining and visual oil checking facilities.
Tramp collection Will be provided
Output size adjustment Will be provided
facility
Top cover of crushers Hydraulic Operated
Rotor Shaft Forged Steel
Hammers head Wear resistant cast alloy steel
Hammers arm Forged alloy steel
Housing/Frame Steel, IS:2062
Breaking blocks Cast steel/ MS fabricated
Liners
(a) Material Suitable for duty required
(b) Thickness As required
4.42.00 LIMESTONE SAMPLING UNIT
Type Automatic
DESIGN & CONSTRUCTION:-


IS-4-DM-713-100-M005
Codes & Standard ASTM C-50 for limestone

Uncrushed Limestone feed (-) 250 mm
size
CHUTES:-
Min. angle 60 deg
Cross section Square/rectangular with rounded corners.
Joints Bolted flanges with 6 mm thick standard grade

neoprene
CRUSHER
Uncrushed feed Limestone
size
(-) 20 mm
Output size ASTM C-50
Stages of size reduction Single stage crushing

BELT FEEDER
Belt Flanged type, FR grade
Pulleys Rubber lagged head
Drive Electric Motor

4.43.00 Belt Vulcaniser
Quantity One (1) no.
Type of Belt to be vulcanized 1 Nylon-Nylon belting
Type of Press Hydro-mechanical type, pressure generated by
Hydraulic pump
Belt Width Upto 800 mm Belt
Type temperature controller Thermostat
Operating pressure 8kgf/sq.cm./ to suit
Operating temperature 145 -155°C
(approx range)
Method of heating Electrically heated

Connected load 30 KW (Approx.)
Power receiving plug, switch & To be provided
cable
Cable length (Approx.) Minimum 30m length between socket & temp.
Control box & Minimum 6m between control box
& platen
Power supply 415V ±10%, 50 Hz ± 5%, 3 Ph.
4.44.00 Pay Loader 2
Engine Diesel Engine


IS-4-DM-713-100-M005
Quantity Two (2) No.

features
5.00.00 CHUTE SIZING CALCULATION
CHUTE SIZING CALCULATION FOR CHP
Belt Speed = 3.2m/Sec

Bulk Density of COAL = 800Kg/m³
Design Capacity = 1650 T.P.H.
Cross-sectional Area = Design

capacity/density*Belt Speed
= 0.179 m²
Required Cross-sectional Area =
5* Cross-sectional Area
=0.895m2
Cross section of chute assumed
Length of chute L = 1m
Width of chute W = 1m
Area = 1m²
which is more than 5 times of material cross sectional area
Hence inner cross sectional dimension of chute considered =1meter X 1meter

Cross section of tripper chute will be as per manufacturer’s recommendation & bunker opening
considered.
CHUTE SIZING CALCULATION FOR LHP/GHP
Belt Speed = 1m/Sec

Bulk Density of COAL = 1400Kg/m³
Design Capacity = 75 T.P.H.
Cross-sectional Area = Design

capacity/density*Belt Speed
= 0.015 m²


IS-4-DM-713-100-M005
Required Cross-sectional Area =

5* Cross-sectional Area
=0.075m2
Cross section of chute assumed
Length of chute L = 0.6m
Width of chute W = 0.5m
Area = 0.3m²
which is more than 4 times of material cross sectional area
Hence inner cross sectional dimension of chute considered =600mm X 500mm
6.00.00 HOIST SCHEDULE:-
FOR COAL HANDLING PLANT
SR. Type of Junction Tower Location Selected Qty

NO Hoist Capacity
(TON)
CONV. 1A/B Head Pulley , Drive, 3T * 1 1
1. Electric
JT-1 sump pump
2. Electric TAIL PULLEY FOR CONV. 2A/B 2T * 1
3. Electric BCN 2A Head Pulley , Drive, ILMS 10T* 1
4. Electric BCN 2B Head Pulley , Drive, ILMS 10T* 1
5. Electric CR-1,2 Maintenance 15T* 1
6. Electric CR-3,4 Maintenance 15T* 1
7. REVERSIBLE BELT FEEDER-1&2 2.5 T* 1
Electric
HEAD END, DRIVE
CRH-1
8. REVERSIBLE BELT FEEDER-1&2 2.5 T* 1
Electric
TAIL END
9. CPB BCN- 3A &3B TAIL END 1T * 1
10. CPB BCN- 3C &3D TAIL END 1T * 1
11. Electric VGF -1 & 2 2T * 1
12. Electric VGF -3 & 4 2T * 1
13. Electric CONV. 3A/B Head Pulley , Drive 2T * 1
JT-2
14. CPB TAIL PULLEY FOR CONV. 4A/B 1 T* 1
15. BCN 4A/B FIXED Tripper Head 2T* 1
Electric
Pulley
16. JT-3 BCN 4A/B FIXED Tripper Tail 1T* 1
Electric
Pulley
17. CPB TAIL PULLEY FOR YBC-1B 1 T* 1
18. Electric JT-4 BCN 4A Head Pulley , Drive, ILMS 10T * 1


IS-4-DM-713-100-M005

NO Hoist Capacity
(TON)
19. Electric BCN 4B Head Pulley , Drive, ILMS 10T * 1
20. TAIL PULLEY FOR CONV. BCN- 2 T* 1
Electric
5A/B
21. DISCHARGE PULLEY, SNUB 3T * 3
Electric PULLEY & DRIVE COMPONENT
JT-5
FOR CONV. 5AB & 8A/B
22. Electric TAIL PULLEY FOR CONV. 6A/B 2T * 1
23. BCN 6A/B Fixed Tripper Head 2T * 1
Electric
Pulley
24. JT-6 BCN 6A/B Fixed Tripper Tail 1T * 1
Electric
Pulley
25. Electric TAIL PULLEY FOR TBC-1A/B 1T * 1
26. Electric BCN 6A/B Head Pulley with drive 3T * 1
JT-7
27. Electric TAIL PULLEY FOR TBC-2A/B 1T * 1
28. Electric CONV. 3C/D Head Pulley , Drive 2T * 1
JT-8
29. Manual TAIL PULLEY FOR CONV. 4C/D 1 T* 1
30. Electric CONV. 4C/D Head Pulley , Drive 2T * 1
JT-9
31. CPB TAIL PULLEY FOR YBC-1A 1 T* 1
32. YBC-1A Head Pulley , Drive 5T * 1
Electric
33. JT-10 RC-1A/B Head Pulley , Drive 3T * 2
Electric
34. CPB TAIL PULLEY FOR BC-7A/B 1 T* 1
35. Electric JT-11 YBC-1B Head Pulley , Drive 5T * 1
36. CONV. 7A/B Head Pulley , Drive, 3T * 2
Electric 1 SUMP PUMP
JT-12
37. TAIL PULLEY FOR BC-8A/B 2T * 1
Electric
38. UNDER ACCESS SHAFT ALL 3T * 1
Electric
EQUIPMENTS UNDER ERHC
39. Electric ERHC-1 VIBRATING FEEDER,TAIL 1T * 1
2
PULLEY,SUMP PUMP ETC.
40. CPB TAIL PULLEY FOR RC-1A/B 1T* 1
41. Electric APRON FEEDER DRIVE 3T * 2
WT-1&2
42. BCN1A/1B TAIL END, SUMP 1T * 1 1
CPB
PUMP
43. TBC- 1A/B CONV HEAD PULLEY & 3T * 1
Electric
Bunker Unit-1 DRIVE MAINTAINENCE
44. Manual TRAVELLING TRIPPER 2T * 1


IS-4-DM-713-100-M005

NO Hoist Capacity
(TON)
DISCHARGE/BEND PULLEY FOR
TBC 1A/B
45. TBC 2A/B CONV HEAD PULLEY & 3T * 1
Electric
DRIVE MAINTAINENCE
46. Bunker Unit-2 TRAVELLING TRIPPER 2T * 1
Manual DISCHARGE/BEND PULLEY FOR
TBC. 2A/B
47. Electric ST-1 COAL SAMPLING UNIT 1T * 3
48. Manual PH-1 SEM-1&2 10T * 1
49. Manual PH-2 SEM-1&2 10T * 1
50. Manual PH-3 SEM-1&2 10T * 1
51. Manual BCN 1A &1B BCN 1A &1B Counter wt 2T 2
1
54. Manual BCN 3C &3D BCN 3A &3B Counter wt 2T 1
55. Manual BCN 4A &4B BCN 4A &4BCounter wt 2T 1
56. Manual BCN 4C &4D BCN 4A &4BCounter wt 2T 1 1
60. Manual BCN 8A & 8B BCN 8A & 8B Counter wt 2T 1
61. Manual TBC-1A & 1B TBC 1A & 1B Counter wt 2T 1
62. Manual TBC-2A & 2B TBC 2A & 2B Counter wt 2T 1
63. Manual RC-1A & 1B RC 1A & 1B Counter wt 2T 1
64. Manual YBC-1A & 1B YBC 1A & 1B Counter wt 2T 2
65. Electric PUMP/COMPRESSOR HOUSE 5T * 2
66. EOT WAGON TIPPLER COMPLEX (CAP 20T/6.3T) 20T/6.3T 1
Crane
67. Electric BULL DOZER SHED 2T * 1
68. Manual DIVERTER GATE & FLAPGATE 1 T* 1
LOT
B. FOR LHP & GHP
1. Electric Reclaim Hopper complex Shed 2T * 1
Reclaim hopper
2. Manual For Tail Pulley of Conv-1AB 1T 1
complex
3. Manual For Vibrating Feeder 2T 1
4. Electric For Head end of Con-1A/1B 2T 1
Transfer Tower-1
5. Manual For Tail Pulley of Conv-2AB 1T 1

1

1
IS-4-DM-713-100-M005

NO Hoist Capacity
(TON)
6. Electric Crusher House For Head end of Con-2A/2B 2T 1
7. Electric For Reversible belt feeder 2T 1
8. Electric For screen maintenance 3T 1
9. Electric For crusher maintenance 5T 1
10. Manual For Belt Feeder & Bucket elevator 2T 2
tail end
11. Electric Bucket elevator 3T 2
12. Electric Gypsum conveyor 2T 2
C. CHAIN BLOCK PULLEY SCHEDULE
For handling bend and take up
Manual
pulley in take up tower.
Chain
1 FOR ALL CONVEYOR Necessary hooks of adequate 2T 2
Pulley
capacity will be provided at the
Block
top of gallery
Note: * Type and Capacity Indicated tentatively. Type, Lift and capacity will be decided
during detail engineering.
7.0.0 CODES & STANDARDS

7.1.0 The material used for the equipment will comply with the relevant Indian Standards/
equivalent international standards. Following standards will be followed:
Sl.No. Standard Remarks

a. IS: 4776 (Part-I) Specification for troughed belt conveyor for surface installations
Equivalent
international
standard
b. IS: 4776 (Part-II) Specification for troughed belt conveyor for underground
installations
c. IS: 8598 (Latest) Specification for idler sets for belt conveyors
d. IS: 8531 (Latest) Specification for pulleys for belt conveyors
e. IS: 1891 (Part I) Specification for rubber conveyor & elevator belting
f. IS: 7155 (Latest) Code of practice for conveyor safety
g. IS: 800 (Latest) Code of practice for use of structural steel in general building
construction
h. IS:875–1987 Code of practice for design loads (other than earthquake) for
(Part –3) buildings and structures and will be in line with civil DM
i. IS:11592 (Latest) Code of practice for selection and design of belt conveyors
j. IS: 1893 (Latest) Criteria for earthquake resistant design of buildings
k. CEMA 5th For KW rating calculation / selection of drive motor, belting etc


IS-4-DM-713-100-M005
of conveyors
l. CAN/ CASA- Canadian Standard Association.
M422M87:
m. IS4009 (Part-III Conical Head grease nipples.
n. IS226 Structural steel (Standard Quality)

o. IS 4682 Codes and Practices for lining of Vessels & equipment for
chemical processes.
8.0.0 PERFORMANCE GUARANTEE REQUIREMENTS:

Following capacities / ratings will be guaranteed for CHP:
a) Wagon Tippler 25 Tips / hr guaranteed rate

b) Wagon Shifter shall be capable to shift wagon as per RDSO norms. 2
c) Side Arm Charger-maximum 60 loaded wagons 1
d) Apron Feeder 1500 MTPH guaranteed capacity
e) Vibrating Grizzly Feeder 900 MTPH guaranteed capacity with 85% (-) 20 mm size
underflow for input of (-) 300mm lump.
f) Crushers 900 MTPH guaranteed capacity with (-) 250mm feed & output of 98% (-)
20mm size.
g) Stacker-Cum-Reclaimer 1500 MTPH guaranteed capacity Stacking & 1200 TPH
guarantee average reclaiming.
h) Magnetic Separator Separation of all sizes of tramp iron in stabilized condition
from running belt as specified in Specification data sheet.
i) Vibrating Feeder 750 MTPH guaranteed capacity.
j) Travelling Tripper -1500 MTPH guaranteed capacity 1
k) Conveyor-1500 MTPH guaranteed capacity
1
l) Reversible Belt feeder-1500 MTPH guaranteed capacity
Total power consumption path-wise at 1500 TPH capacity is required at the input terminals of
drive motors of the following equipment at the rated capacity performance requirements.
For calculating power consumption path-wise all Conveyors, Belt Feeders, Wagon Tippler, Apron
Feeder, Vibrating Grizzly Feeder, Crushers, Magnetic Separators, Stacker Cum Reclaimer, as
applicable connected to one stream are considered. Paths are defined as mentioned below:
Flow Path 1 From Wagon Tippler to Boiler Bunker through TBC-1A or 1B.
(Direct Stream)
Flow Path 2 From coal piles 1 & 2 to furthest Boiler Bunker via Stacker Reclaimer on


IS-4-DM-713-100-M005
(Reclaiming Stream) Conveyor YBC-1A.

Flow Path 3 From coal piles 1 & 2 to furthest Boiler Bunker via Stacker Reclaimer on
(Reclaiming Stream) Conveyor YBC-1B.
Flow Path 4 From Wagon Tippler to crushed coal stock piles CCS#1 & 2 through
(Stacking Stream) Stacker-Reclaimer on YBC-1B with Stacker at extreme position.
Flow Path 5 From Wagon Tippler to crushed coal stock piles CCS#2 & 3 through
(Stacking Stream) Stacker-Reclaimer on YBC-1A with Stacker at extreme position.
Flow Path 5 From ERHC to Boiler Bunker through Conv.8A or 8B.

(Reclaiming Stream)
Noise and vibration considered

Noise Individually and collectively Noise Level shall not be more than 85 dBA measured at a
level height of 1.5 m above floor level in elevation and at a distance of 1.00 m horizontally 1
from any equipment in any direction and at any load condition.
Vibration Vibration level shall conform to the limits specific below and will be measured as per
Levels VDI 2056 / BS 4675.
A. At the bearing of drive pulley, motor and gear box for the following equipment
1. Boom conveyor of S/R - 115 micron
2. All other equipment/conveyors etc. - 90 micron
B. On the floors and columns of junction tower and conveyor gallery walkways – 200
micron
C1. Crusher- 80 micron when all hammers are unbroken. Manufacturer’s
recommendation may be reviewed during detail engineering.
C2 Crusher - 160 microns for corresponding rated speed at 750 rpm with broken
hammer. For any other speeds, the vibration level will be calculated as per VDI
2056/BS 4675.
At the outlet of the dust extraction system, the dust concentration shall not exceed 50mg/Nm3.


IS-4-DM-713-100-M005
ANNEXURE-1 PROJECT INFORMATION
Coal handling plant for 1X660 MW Panki Thermal Power Station of Uttar Pradesh Rajya
Vidyut Utpadan Nigam Limited (UPRVUNL) proposed plant as described in the NIT specs.
Salient features of the Project site are,
1.0 Owner UTTAR PRADESH RAJYA VIDYUT UTPADAN

NIGAM LIMITED, LUCKNOW
2.0 Project Title Panki Thermal Power Station (1x660MW)
3.0 Engineer/consultant DEVELOPMENT CONSULTANTS PRIVATE
LIMITED (DCPL)
BLOCK DG‐4, SECTOR‐II, SALT LAKE CITY,
KOLKATA – 700 091, INDIA
4.0 Project Site Location Place Panki
District Kanpur
State Uttar Pradesh
Country India
5.0 Latitude & Longitude North N26028’20”
of project site East E 80014’32”
6.0 Nearest Railway Station Panki 5KM
7.0 Nearest Town Kanpur 16KM
8.0 Nearest Highway National Highway-25
9.0 Nearest Airport Kanpur 25KM
Lucknow 80KM
10.0 Nearest Commercial Delhi 440KM
Airport
11.0 Nearest Water Body Lower Ganga Canal, adjacent to site
12.0 Land Land is in possession of UPRVUNL
13.0 Station Graded Level Plant FGL RL(+) 126.0M El(-) 0.500M
Elevation from Mean sea Plant FFL RL(+) 126.5M El(+/-) 0.000M
level (MSL)
14.0 Water
14.1 Nearest Water Source Lower Ganga Canal system running adjacent
for project site
14.2 Water Requirement for ~ 1927 m3/hr considering closed cooling cycle
station with NDCT. Additional 700m3/hr for ash slurry
preparation during emergency ash disposal to
ash dyke.
14.3 Raw Water Analysis from Refer Appendix – I OF ITB VOL-II
Upper Ganga Canal
15.0 Site Ambient Condition
16.0 Monthly mean (DBT) Maximum 44.40C
Minimum 3.80C
17.0 Extreme Recorded (DBT) Maximum 47.30C
Minimum -0.90C

Document Number
1X660 MW PANKI TPS
IS-4-DM-713-100-M005
18.0 Monthly mean (WBT) Maximum 27.30C

Minimum 9.20C
19.0 Relative Humidity Maximum 84%
Minimum 28%
20.0 Average relative humidity Annual Average 65%
21.0 Rainfall Annual Average 832.6
Heaviest fall 247.4 mm
recorded in 24 hrs
22.0 Basic Wind Speed 47.00 m/s As per IS: 875 part –
III
23.0 For wind resistance design of structure &
equipment refer relevant civil section
24.0 Climatic condition For detailed information refer attached
Climatological data as published by IMD for
Kanpur station.
25.0 Seismic data Zone – III As per IS: 1893
For earthquake resistance design of structure
& equipment refer relevant civil section
26.0 Coal Source Coal requirement for this stage of the project
is estimated as 2.99 million tones/annum
considering 660 MW capacity, GCV of blended
coal 4030 kcal/kg, Heat Rate as 2317
kcal/kwh and 90% PLF as per CERC operative
norms effective from 1/4/2009.
27.0 Coal Transportation Thru BOXN wagons of Indian Railways System
28.0 Coal Analysis Refer Appendix – II ITB VOL-II
29.0 Support Fuel (HFO / LDO) Support fuel will be transported by road
transportation tankers or by Railway system. Start-up /
support fuel for the proposed project will be
LDO/HFO
30.0 Support Fuel (HFO / LDO) Refer Appendix – II ITB VOL-II
analysis


IS-4-DM-713-100-M005
ANNEXURE-2- STOCKPILE CAPACITY
STOCK PILE CAPACITY CALCULATION
Stockpile-CHP
Inputs CCS#1 CCS#2 CCS#3
Total length of stock pile at base L MTRS. 230 230 170
Total width of stock pile at base B MTRS. 35 54 35
Angle of repose of stock pile (coal) DEG 37 37 37
Height of stock pile H MTRS. 12 12 12 1
Density of Coal in (Compacted coal) T/ cu. M 0.8 0.8 0.8
No. of stock Piles Nos. 1 1 1

Document Number
1X660 MW PANKI TPS
IS-4-DM-713-100-M005
Calculations
Length (a) a MTRS. 15.92 15.92 15.92
Length (b) b MTRS. 3.15 22.15 3.15
Length (c) c MTRS. 198.15 198.15 138.15
1. Calculation of Volume for 'A' Portion
Where, A = A1 + A2 + A3 + A4
V1 = Total volume of A (i.e cone) is given
as, = (1/3 xΠ x a² x h)
V1 in Cu.M 3186.72 3186.72 3186.72
2. Calculation of Volume for 'B' Portion
Where, B = B1 + B2
V2 = Total volume of B is given as, =
2x(1/2 X (a x b) x h )
V2 in m³ = 602.12 4232.92 602.12
3. Calculation of Volume for 'C' Portion
V3 = Total volume of Trepezoid C is given
as, = (B + b)/2 x h x c
V3 in m³ = 45357.85 90536.26 31623.51
Then,
Total Volume of Stockpile = V1 + V2 + V3 49146.69 97955.89 35412.35
Total Capacity of Each Stockpile C = Total

39317.35 78364.71 28329.88
Volume x density of coal
Total Capacity of Stockpile ( in tonnes) = C

39317.35 78364.71 28329.88
x no. of stock piles
Worst Coal Consumption TPH 464

Total All stockpile capacity
146011.9
(CCS#1+CCS#2+CCS#3)
NO. OF UNITS 1
Total Capacity of Stockpile ( in DAYS) 13.1

Design Memorandum - 9962-001-IS-155-PVM-Z-005-03

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Plz provide electrical power supply details envisaged for CHP/LHP/GHP.

1X660 MW PANKI TPS Document Number

BHARAT HEAVY ELECTRICALS LTD

09-11-2018 3 FOR APPROVAL LKV GAN RTR

PROJECT 1X660 MW PANKI THERMAL POWER STATION

CUSTOMER UTTAR PRADESH RAJYA VIDYUT UTPADAN NIGAM LIMITED(UPRVUNL),

BHARAT HEAVY ELECTRICALS LTD

INDUSTRIAL SYSTEM GROUP (ISG), BANGALORE

JOB No. IS-1-17-2001 BHEL DRG/DOC. NO: IS-4-DM-713-100-M005

DESIGN MEMORANDUM FOR CHP/ LHP/ GHP (Mechanical Works)

Issued by: Engineering (Mechanical) Date: 09-11-2018 Rev no. 03 Page 1 of 62

Sl. CONTENTS PAGE NOS.

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1.0.0 PROJECT DATA:

1.1.0 REFERENCE DRAWING AND DOCUMENTS 1

Sr Drg/ Doc No Description

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1X660 MW PANKI TPS Document Number

1.3.0 SYSTEM DESCRIPTION:

Limestone handling system:-

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c) Bond Index : 13 kWh/t

e) Height of limestone stockyard : 5 meters max

Gypsum handling system:- 1

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1X660 MW PANKI TPS Document Number

Magnetic Separators (ILMS-3,4) will be provided on conveyer# BC-4A/4B discharge head

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LHP and GHP handling system:

1.3.30 Gypsum will be received at Gypsum Conveyor# Conv-3A/3B at Dewatering Building

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b Plain Water Dust Coal stockpile with Stacker-Reclaimer, Wagon

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2.0.0 SCOPE OF WORK

SLNO DESCRIPTION QTY UNIT

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SLNO DESCRIPTION QTY UNIT

58. DDCMIS System for CHP including CSU. 1 Lot

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SLNO DESCRIPTION QTY UNIT

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1X660 MW PANKI TPS Document Number

SLNO DESCRIPTION QTY UNIT

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2.0.15 Painting DFT requirement:

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1X660 MW PANKI TPS Document Number

4.0.0 EQUIPMENT SIZING

EQUIPMENT SIZING OF COAL HANDLING PLANT

Sl. No. Description Value

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