CLAUSE NO.

TECHNICAL REQUIREMENTS
A-01 :

1.00.00.

SYSTEM PARAMETERS AND OPERATION &

CONTROL PHILOSOPHY

The specifications as brought out in various Sub-sections for mechanical equipment

shall be applicable to the system of proposed coal handling plant and specifically to
all mechanical including their operation & control philosophy. However, some specific
parameters of the entire system as a whole and the major equipment are brought out
as under.

2.00.00

PARAMETERS

2.01.00

Conveyor System
i.

ii.

2.01.01

(a)

Rated Capacity (Guaranteed) excepting :

conveyor 9A/B.

1600 TPH

(b)

Rated Capacity (Guaranteed)

conveyor 9A/B.

1200 TPH

(a)

For boom conveyor of stacker/ reclaimer :

2000 TPH

(b)

Other conveyors of proposed CHP

excepting conveyor 9A/B

1760 TPH

(c)

Conveyor 9A/B

1440 TPH

Design capacity

iii.

Belt width

Minimum 1400 mm

iv.

Maximum Belt speed

3.2

M/sec.

Belting and Pulleys

(a.) Belt ratings shall be selected in such a way that there are only three (3) ratings
of belting. This however excludes sealing belt (for sealing slots of tripper floor)
and belting of belt feeders. Belting shall be completely interchangeable.
(b)

Minimum number of plies for belting shall be four (4). Other details of belting
shall be as specified else where in the specification.

(c)

For Pulley, following minimum parameters shall be followed:

(1.) Shell thickness

16 mm (Min.)

(2.) End disc plate thickness

24 mm(Min.)

(3.) Maximum allowable deflection of shaft at hubs :

5 Minutes

(4.) Diameter :
(i) All drive pulleys
KODERMA TPP (2 x 500 MW)
COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

800 dia (min.)

Sub-Section - IIIA-01
CHP

Page 1 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS
(ii) All balance pulleys

630 dia (min)

Further approval from belt manufacturers shall be obtained by the contractor

regarding the adequacy of the pulley diameters.
2.01.02

Paddle Feeders
(a)

Nos. required

Four (4)

(b)

Guaranteed (rated) capacity

900 MTPH

(c.)

Capacity adjustment capacity

20% to 100% of
guaranteed capacity

(d)

Maximum coal lump size to be handled

by paddle feeder

400 mm

Total travel by each feeder carriage

250 m

(e)
2.01.03

2.01.04

2.01.05

Coal Crushers & Roller Screen Feeders

(a)

Nos. required

Four (4) each

(b)

Guaranteed (rated) capacity

(considering 100% feed coal
above (+)20 mm size)

900 MTPH

(c.)

Input size (for sizing of crusher)

(-) 350 mm (occasionally

1-2% 400 mm lump)

(d)

Guaranteed size of output from

Ring Granulator type crusher

Min 98% down to (-)20 mm

Travelling Trippers (Mobile)

(a)

Nos. required

Four (4)

(b)

Type

Motor driven rail

mounted, 3-way chute
discharge

Two (2)

Stacker cum Reclaimer

(a)

No. required

(b)

Rated Capacity (Guaranteed)

(i)

Stacking

1600 TPH

(ii)

Reclaiming

1600 TPH

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 2 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS
(c)

(i)

Stacking

1760 TPH

(ii)

Reclaiming (Peak)

2000 TPH

(d)

Height of stockpile to be formed

10 meters

(e)

Width of each stockpile at base

50 meters

(f)

Boom length (Center of slew to center

Of bucket wheel)

41 meters

Lump size to be handled

(-) 20 mm

One (1)

(g)
2.01.06

2.01.07

2.01.08

Design Capacity (With specified

Degree of bucket fill and ring volume

Wagon tippler
(a)

No. required

(b)

Guaranteed (Rated) tippling capacity (min.) :

20 tips/hr

Side arm charger

(a)

No. required

One (1)

(b)

Guaranteed (rated) Hauling capacity

58 wagons

Dust Control System

The capacity of the dust control system specified hereinafter is for Contractors
guidance only. Contractor shall provide adequately sized and fool proof dust control
system, the performance of which should be guaranteed by the Contractor as
required in the Technical specifications. The performance guarantee test procedure
is to be submitted by the Contractor. However, the capacity of the offered system
shall not be less than the specified values below.
(a.) (I) Track Hopper Dust Suppression System
(1)

Capacity of each nozzle

2.0 lpm at 2.5 kg/ cm2

(2)

Nozzle spacing.

500 mm

(3)

No. of dust suppression

:
Zones operating
simultaneously
on both sides of track Hopper

(4)

Total no. of zones

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

min. one sub header of

12.5 mtr length each on
either side of Track Hopper or
max. four (4) headers along the
Track Hopper.
:

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

20 on either side of Track Hopper

Sub-Section - IIIA-01
CHP

Page 3 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS
(II)

Wagon Tippler Dust Suppression System

(1)

Capacity of each nozzle

2.0 lpm (min.) at 4.5 Kg/cm2 (min)

to make suitable fogging.

(2)

Nozzles spacing

500mm

(3)

No of zones

One no (1)

(4)

No. of nozzles operating

simultaneously

All

(b)

Dust Suppression System

(1)

Operation

Water and air sprayed by sonic fogging

nozzle

(2)

Location of spray

All coal loading and discharge

Points on the conveyor

(3)

Capacity / Pressure at
inlet of spray head

Min. 0.5 kg/cm2 for water

Min. 5 kg/cm2 for air

(c)

Stockyard Dust Suppression System

(1)

Maximum number
of nozzles operating simultaneously
Capacity & Pressure of each
spray nozzle

(2)
(d)

Four (4) nos.

500 Lpm / 4.5 kg./ sqcm (g)

Dust extraction system

Type

2.01.09

: Venturi scrubber for crusher house

Dry type roof mounted for bunker floors

Service Water System

Service water connections are to be provided in conveyor galleries & tunnels at 50
meter interval and one (1) no. on each floor of Transfer Points and minimum two (2)
nos. on each floor of crusher house.

2.01.10

(a.) Flow at each valve

: 5 cub.m/hr

(b.) Minimum discharge

Pressure at tap point

: 2 kg/sq.cm

(c.)

No of pumps

: 2 nos.

(d)

No. of valves operated

simultaneously

: 6 nos.

Potable Water System

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

: As specified elsewhere in the spec.

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 4 of 25

CLAUSE NO.

2.01.11

2.01.12

TECHNICAL REQUIREMENTS
Ventilation System
A

Mechanical Ventilation System

i.

Underground Areas

Minimum 20 supply air changes and minimum 10 exhaust air changes per hour.

ii.

Other Areas

Minimum 10 supply air changes per hour.

B.

Pressurized Ventilation System:

Minimum 15 supply air changes per hour

C.

Air Conditioning System

Adequate number of air changes to

Maintain in uniform temp. & humidity as
specified elsewhere.

Chutes
Minimum clear cross section of chute shall be 1000 mm x 1400 mm (inside both
ways).

2.01.13

Hoists
Suitable hoists as specified elsewhere shall be provided for erection & servicing of all
major equipment. The equipment to be covered shall include (but not be limited to) all
conveyor drive units, all pulleys, crushers along with drive units, in line magnetic
separators, sampling units, sump pumps, various DS/service water/potable water
pumps, gravity take up units, removal of equipment from tunnels, lifting of belt drum
at all transfer houses/crusher house/bunker floors etc.

2.01.14

All other equipment under the scope shall be suitable to the system capacities
parameters as specified above.

3.00.00

OPERATION AND CONTROLS

3.01.00

This section is intended to cover control/instrumentation and operational philosophy

as specified hereinafter complete in all respects, required for complete coal handling
plant.

3.02.00

General Requirements
The instruments and controls to be furnished and erected under this specification are
as required for safe and satisfactory operation of the Coal Handling System, as
outlined under mechanical section and as specified elsewhere in the specification.
For the equipment and materials procured by the Contractor from his sub-vendors,
the Contractor shall study the specification, safety requirements, interface drawings
for such equipment and material in detail and shall coordinate his work with his sub
vendors and supply instrumentation and control to suit the actual Coal Handling
equipment.

3.02.01

Standards / Codes
All construction, installation, workmanship, design & equipment shall conform to acts,
rules & regulations of the jurisdiction within which the project is to be located, and to

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 5 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS
the current edition of the following or equivalent standards or codes, in so far as they
apply :
American Iron & Steel Institute (AISI)
American Society for Mech. Engineers (ASME)
American Society for Testing & Materials (ASTM)
American Wire Gauge (AWG)
Institute of Electrical & Electronic Engrs. (IEEE)
Instrument society of America (ISA)
National Electrical Code (NEC)
National Electrical Manufacturers Association (NEMA)
United States of America standards (USAS)
Bureau of Indian Standards (BIS)
Conveyor Equipment Manufacturers Association (CEMA)

3.02.02

This Sub-section shall be read in conjunction with Electrical Sub-sections.

3.03.00

General Construction and Design

3.03.01

General Construction
Control desks/panels and annunciation system shall be as per the requirement of
electrical Section. Annunciations, indications, electrical meters and instrumentation
shall be provided as specified.

3.03.02

Design
The complete coal handling plant except for stacker-reclaimer and wagon tippler
shall be controlled from contractors PLC system as detailed elsewhere.
The Contractor shall provide a comprehensive control indication and annunciation
scheme. Contractor shall furnish block diagram and write-up on the scheme
proposed. The final scheme will be approved by the Employer. In general,
interlocking shall be achieved through feed-back signals from field equipment.
Comprehensive Annunciation and Indication scheme shall be provided such that, it
will be possible for the operator to locate and identify the fault from the face of
PLC/LVS/Control-Panel/ HMI itself. The scheme shall include the basic remote
control instrumentation, indication and annunciation requirements as per various
technical specification requirements.
However, the Contractor may offer any alternative proposal which he considers to be
equal, superior to the scheme as described in subsequent clauses below for

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 6 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS
achieving reliable and trouble free operation of the plant, for consideration of the
employer.

4.00.00

OPERATION AND CONTROL PHILOSOPHY

The coal handling system shall be controlled from the following control points.

4.01.00

Coal Handling Plant Main Control Room

Overall operation of the following equipment of Coal Handling Plant shall be
controlled from the main CHP control room.
(a.) Conveyors, feeders, flap gates, R & P gates, crushers, hydraulic scoop
couplings.
(b.) Paddle feeders (running status with stop facilities).
(c.)

Complete Dust Suppression system & service water system.

(d.) Ventilation system (group/individual control as required).

(e.) In line Magnetic separators and Suspended Magnet (ON/OFF control with
indication).
(f.)

Metal Detectors (ON/OFF control with indication).

(g.) Coal Sampling Units.

(h.) Belt weigher (ON/OFF control with indication)

4.02.00

(i.)

Stacker Reclaimer (ON/OFF status with stop facilities).

(j.)

Mobile trippers over bunkers (tripper position indications).

Local Control Panels

Local control stations for following equipments shall be provided
(a)

Paddle feeders along with its dust suppression system

(b)

Mobile trippers over bunkers

(c)

Belt Weighers

(d)

Metal detectors

(e)

Electric hoist - wall mounted control box with pendent push button controls.

(f)

In line magnetic separators

(g)

Suspended Magnet

(h)

Sump Pump

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 7 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS
(i)

Coal Sampling Units

(j)

Dust suppression system for wagon unloading at track hopper

(k)

Hydraulic scoop coupling.

All the above local control panels shall be accessible and located near their
respective equipment and shall be complete with all the required controls, interlocks,
annunciations etc. Further, necessary controls, indications and annunciations for all
the above equipment shall also be provided at main CHP Control Room as described
under relevant clause.
4.02.01

Stacker / Reclaimer Control Room

The entire control & operation of Stacker Reclaimer machine shall be from the
operators cabin on the machine itself. LCD screens shall be provided instead of CRT
monitors.

4.02.02

Wagon tippler control room

The entire control & operation of wagon tippler machine shall be from the Wagon
tippler control room itself.

4.03.00

In addition to the remote control of various equipment, local stop push button stations
shall be provided for all equipment.

4.04.00

System Operation

4.04.01

Operation philosophy of the plant, in general, shall be as elaborated below:

(a.)

Coal flow path selection shall be done from LCD screen/Keyboard to select
any one of the following conveying paths.
(1.)

Track hopper to boiler bunker

(2.)

Track hopper to stock yard

(3.)

Stock yard to boiler bunkers

(4)

Wagon tippler to boiler bunker

(5)

Wagon tippler to stock yard

(6)

Combination of above

The coal handling system operator will select any one of the above paths from OWS
located on the main control desk. The flow stream path is then selected by
positioning different flap gates/ movable discharge pulley at desired positions by
means of keyboard available at the central control desk. Once the system is in the
operation, the gates/ movable discharge pulley can not be moved from their positions
and path. Flap gates which do not come in the stream in which coal flow is taking
place, can be operated at any time. However, for the flap gates in bunker area
conveyors, it shall be possible to change flap gate position while the conveyor is in
KODERMA TPP (2 x 500 MW)
COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 8 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS
operation and feeding coal using interlock bypass facility, provided that sequential
permissive are available.
The Control system will be designed for Auto & Manual operation of the conveyors
in the selected path. Auto/Manual Selection shall be done from keyboard.
Auto Mode : In the Auto mode, the conveyors and related equipment will start
sequentially when the System Start is activated. During stopping, when the System
Stop is activated, all conveyors will also stop sequentially (in the reverse sequence)
allowing time delays for clearing the belts.
Manual Mode : In Manual Mode, the operator will start the conveyor system, in the
same sequence as in Auto mode from keyboard. The operator will also stop the
conveyor system, by pressing "System stop" or individual Stop push
buttons/command from keyboard in the reverse sequence.
During Sequence Start in both Auto and Manual modes, first the required number of
hooters (3 phase induction motor type) will be energized simultaneously for a preset
time of 1 minute or so (adjustable at site) as per the program. After the preset time,
the hooters will stop and a preset time of two minutes (adjustable at site) as per
program will be allowed for the movement of the personnel and for the permissive of
the conveyor system operation. This condition will be indicated on the panel by
glowing of lamp Coal Handling Sequence Start. The starting permissive will be
available for a period of 5 minutes (Pre-programmed and adjustable in the field). In
the event the last conveyor / equipment is not started within this preset time of 5
minutes, the start command for equipment not started will be withdrawn. The system
cannot be started again unless the Sequence Start push button is again pressed
and the hooters sound again, as described before. Those conveyors and equipment,
which have already started, will continue to run.
The status indication in the graphic display against all conveyors and equipment in
the selected path/stream will start slow flickering. However, all status indications
against all flap gates / movable discharge pulley in the selected path will glow
steadily. Therefore, from the selected flow stream path of the flap gates / movable
discharge pulley, the operator will come to know the conveyors and equipment to be
started for the selected path/stream. After a conveyor/equipment is started, the
status indications against that conveyor / equipment will change to steady glow
indicating that it is running.
Graphic display status indicators associated with a particular motor/equipment shall
flicker fast in case of fault / trip.
In addition, emergency stop push button on the control desk for immediate shut down
of complete plant shall be provided.
For changeover of feed from one row of Bunkers to another row of Bunkers without
stopping of the CHP, provision shall be made for interlock bypass on the control desk
for flap gates of all conveyors in Boiler area for a preset period. If the changeover, in
above specified time, is not completed then the entire CHP shall stop.
(i)

Lamp test facility will be provided for the annunciation and mimic lamps.

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 9 of 25

CLAUSE NO.

4.05.00

TECHNICAL REQUIREMENTS
Conveyor System
(a)

Normally the movement of the paddle feeders feeding coal from the track
hopper to the reclaim conveyor shall be controlled from the paddle feeder
itself based on instructions from main control room.

(b)

The paddle feeder carriages shall move continuously to and fro along their
tracks. Suitable limit switches and anti-collision devices (both mechanical
limit switch operated and infra red type) shall be provided to enable them to
change direction of movement as soon as they come within a specified
distance of each other and at the end of travel in one direction.

(c)

The operation and stoppage of the paddle feeders shall be signaled in the
main control room of the coal handling plant. It shall be possible to stop the
paddle feeder from main control room. It shall be possible to stop the track
hopper conveyor from respective paddle feeder.

(d)

Approach of a Railway wagon rake to the plant shall be signaled (visual and
audible) in the main coal handling plant control room, as soon as the rake
come within 100 meters distances from the track hopper.

(e)

Each conveyor shall be protected against damage to the edge of the belt due
to excessive sideways movement by providing an adequate number of belt
sway switches. In addition, each conveyor shall be provided with one (1) No.
speed detection device (zero speed switch). The zero speed switches shall
be designed to sense belt speed. In case of speed of belt goes below 85% of
rated speed, it shall trip the conveyor.

(f)

All the conveyors shall be protected from reverse running due to power failure
by providing mechanical or electrical locking system.

(g)

The starting sequence of the conveyors shall follow a direction opposite to

that of flow of material i.e. :
(1.)

In case of direct conveying of coal to boiler bunkers, start from bunker

conveyor and end up with reclaim conveyors below track hopper

(2.)

In case of stacking of coal in stock yard, start from yard conveyor and
end up with reclaim conveyors below track hopper/wagon tippler
hopper. However, for yard conveyor to start, the stacker-cumreclaimer shall be in operation.

(3.)

In case of reclamation of coal from stock yard, start from bunker

conveyors and end up with yard conveyor alongwith Stacker/
Reclaimer.

(4.)

The starting of paddle feeder shall be interlocked with operation of the

reclaim conveyors below track hopper.

(5.)

The starting of mobile trippers shall be interlocked with operation of

the bunker bay conveyors.

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 10 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS
(h)

Inter locking of yard conveyor with stacker-cum-reclaimer boom conveyor shall

be provided.

(i)

Any individual equipment (belt conveyor etc.) should not be allowed to start
unless the equipment immediately following the same in the direction of flow of
material is already in operation.

(j)

Stop/tripping of any equipment from running condition shall trip all preceding
equipment in the system, except crushers but shall not effect succeeding ones
which shall continue to operate.

(k)

Adequate number of pull-cord switches shall be provided at suitable intervals

along the length of each belt conveyor, which shall enable the respective
conveyor to be stopped immediately. Each pull chord switch shall be identified
by a specific number on HMI in the main control room. Each belt sway switch
shall also be identified by a specific number on HMI in main control room.

(l)

Means shall be provided to pre-warn personnel working nearby when starting

any conveyor, stacker-cum-reclaimer and mobile tripper.

(m)

Interlocking of various conveyors shall be achieved with Flap Gate, discharge

pulleys, Rack & Pinion gate, limit switches and zero speed switches.

(n)

Suitable indication for paddle wheel rpm shall be provided on the local panels.
Manual facility to control the cutting rate of paddle feeder shall also be
provided.

(o)

Motors shall start only when the brake/rail clamp if-provided, is in not applied
condition. This signal shall be obtained from limit switch provided for that
purpose.

(p)

Ring granulators shall be provided with speed and vibration monitoring

instruments. Ring granulators shall trip in case speed/ vibration is going
beyond tolerable limits of design. Temperature sensing devices shall be
installed on all bearings of each of the ring granulator to trip the ring granulator
in case of temperature goes beyond limit. Audio-visual annunciation shall be
provided in main control room and locally also.

(q)

Once a conveyor trips, flap gate directing coal from this conveyor shall change
over its position with a time delay and shall come back to the original position
again. This is to prevent jamming of gate.

(r)

Tripping of the respective conveyor shall be provided in case any of paddle

feeders and mobile trippers starts running along with conveyor belt at speed
higher than their rated speed by providing an over speed sensing device on
the equipment.

(s)

It shall be possible to trip track hopper conveyor, bunker conveyor and yard
conveyor from paddle feeder, mobile tripper and stacker / reclaimers
respectively.

(t)

Where ever scoop type coupling provided for HT motors, the coasting time of
respective conveyor, thrustor brake, actuator selection and the chute size shall

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 11 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS
be so selected such that there is no spillage of coal from any down stream
conveyors during next start. If required necessary fly wheel may also be
provided in the down stream Conveyor to restrict the speed.

4.06.00

(u)

Wherever the conveyor/belt feeder is provided with the movable discharge

pulleys in place of flap gates, the starting of the conveyor/belt feeder will be
interlocked with the position of the movable discharge pulley.

(v)

Control system shall envisage blending of coal. For this blending can be
considered by suitably mixing coal from reclaim path and direct path are
mixing of coal from two reclaimers.

(w)

Coal flow rate and coal integrator readings of belt scales on track hopper
conveyors shall be repeated at stacker reclaimers & wagon tippler control
room for auto blending of coal.

Interlocking
(a.)

The following conveyors / equipment will come under interlock scheme :-

(1.)

All conveyors

(2.)

All flap gates

(3)

All movable belt feeders

(4)

Rack & Pinion Gates

(5)

Metal detectors

(6)

Magnetic Separators and suspended Magnet

(7)

Crushers

(8)

Paddle Feeders

(9)

Belt scale

(10)

Mobile Trippers

(11)

Stacker/Reclaimer

(12)

Wagon tipplers

(b.)

The following equipment will not come under interlock of the conveyor
scheme.
(1.)

All dust suppression systems & service water system.

(2.)

Ventilation systems

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 12 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS
(c.)

All conveyors and equipment will have local push button stations each
consisting of :
(1.)

Pos - I, Pos - II & stop button for flap gate and R & P gate

(2.)

Emergency stop push button (Red) for other equipment

(d.)

Belt scale shall be started when relevant conveyors are started.

(e.)

The dust suppression systems will be energized as soon as the conveyors

are energized.

(f.)

Coal handling plant shall be tripped in case of detection of fire.

(g.)

Interlock for H.T. Motor :

H.T. motors used will continue to run on no load by disengaging the fluid
coupling in case of failure of any process interlock. The H.T. motors will
however be tripped in case of any motor fault like O/L, high motor winding
temperature etc. In addition, in case of normal stop command, after running of
the system, motors will stop.

(h.)

The following are the various safety interlocks for the conveyors and other
equipment. This list is indicative only and the Contractor shall develop a
comprehensive interlocking scheme.

Conveyors
a).
b).
c).
d).
e).
f).
g).
h).
i).

Pull - Chord switch - not operated

Belt sway switch - not operated
Under speed switch - closed at 90% speed of the conveyor within designed
accelerating time.
Motor protection - not tripped
Local stop PB reset
Chute Block switch - not operated.
Brakes for conveyor not operated.
Trip circuits healthy.
Temp. of fluid coupling oil - not high

Paddle Feeders
a).
b).
c).
d).
e).

Motor O/L - not tripped

Local E-Stop PB - reset
Stop PB in main CHP control room - reset
All Limit Switches reset
Overspeed limit switch not tripped

Travelling Tripper:
a).
b).
c).

Stop PB in Local control station - reset

Motor O/L not tripped.
Over Travel Limit switches - not tripped.

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 13 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS
Magnetic Separators / Metal Detectors / Suspended Magnets
a).
b).

O/L / fault relay - not tripped.

Stop PB (Local & Remote) reset.

c).

Metal detector reset

d).

Oil temperature - not high

Flap Gates/ R & P Gates:

a).

End of travel limit switches - reset.

b).

Torque limit switches - reset.

c).

Local stop - reset.

Ring Granulator
a).

Zero speed - not operated

b).

Temp. of fluid coupling oil - not high.

c).

Local stop push button reset.

d).

Temperature of bearings not high.

e).

Cooling water flow switch - reset

4.06.01

The lists of indications and audio-visual annunciation given in subsequent clauses

are indicative only and the same shall be finalised during detail engineering.

4.06.02

Status indications in Large Video Screen

Following individual status indications shall be provided in LVS with individual
ON/OFF/TRIP indications on HMI.
(a.) Conveyor 'ON'
(b.) Flap Gate/Rack and Pinion.
(c.)

Belt scale flow rate indication and totalizer.

(d.) Belt sway switch operated for each conveyor (individual switch indication on
CRT).
(e.) Pull cord switch operated for each conveyor (Individual switches indication on
CRT).
(f.)

Zero speed switch operated for each conveyor

(g.) Paddle Feeder ON'

KODERMA TPP (2 x 500 MW)
COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 14 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS
(h.) Travelling tripper position.
(i.)

Crusher ON

(j.)

MD/ ILMS/ CSU ON

(k.)

DS/ SW/ Vent ON (System wise)

(l.)

Stacker-cum-reclaimer ON (any travel position)/stacking/reclaiming

(m.) Unit wise MW indication, total coalflow & Bunker level.

(n.) On/Off status of wagon tipplers
Further Mimic lamps for HT and LT SLDs shall be provided on the control desk.
4.07.00

Annunciation System:
PLC/Control desk shall be provided with adequate number of facia type annunciation
windows operating through PLC for the following audio-visual fault annunciation
purposes. Wherever group annunciation is provided, alarm status of individual
equipment shall be provided on OWS.
(a)

3.3 kV Breaker Trip (Group wise for each board)

(b)

415 V MCC Breaker Trip (MCC wise)

(c)

Bus under voltage for each LT MCC & HT switchgear buses.

(d)

Following group wise annunciation shall be provided for transformers :

(1.) Buchholz alarm
(2.) Winding/oil temperature high alarm
(3.) Oil level low alarm
(4.) Buchholz trip
(5.) Winding/oil temperature high trip

(e)

A.C Control Supply failure.

(f)

D.C. Control Supply failure.

(g)

Annunciation supply failure.

(h)

Both CPU fail

(i)

Stand by CPU in service

(j)

H.T. motor overload alarm (individual)

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 15 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS
(k)

HT motor bearing/ winding temp. high alarm (group) and trip (group)

(l)

HT motor trip on electrical fault (Group)

(m) LT motor overload tripped (Group).

(n)

Crusher vibration monitor alarm (Group).

(o)

Belt sway switch operated (Group)

(p)

Pull cord switch operated (Group)

(q)

Zero speed switch operated. (Group)

(r)

Chute plugged (Group)

(s)

Wagon rake arrived.

(t)

Paddle feeder over speed tripped (group)

(u)

Tripper over speed tripped (group)

(v)

Stacker-reclaimer tripped (group)

(w)

Magnetic separator fault and cleaning belt trip.

(x)

(i)

Metal Detector fault (Group)

(ii)

Metal detected / MD not reset (Group)

(y)

Belt Scale fault (Group)

(z)

Sampling system faults and trips (Group)

(ab) Dust suppression/service water system faults and trips (system wise)
(ac) Water level low in tanks (group)
(ad) Oil temperature of fluid coupling high
(ae) Crusher low speed & crusher bearing temperature high.
(af)

Wagon tripper tripped (group)

(ag)

Apron feeder tripped

For identification of the fault for a particular conveyor or equipment, status indication
against that conveyor / equipment in the mimic will start fast flickering and the
annunciation window will be blinking against that particular fault. In addition, a buzzer
(alarm) will start sounding. After acknowledgement of the fault, the buzzer will stop,
but the fast flickering on the mimic and the steady glow on the annunciation window
will continue until the fault is cleared and the Reset push button is pressed. When the
fault is cleared and the Reset push button is pressed, the status indication of that
KODERMA TPP (2 x 500 MW)
COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 16 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS
conveyor / equipment on the mimic will start slow blinking if it is on selected path
otherwise it will go off and the steady glow in the annunciation window will go off.
However, pressing of the Reset push button before clearance of the fault, will have
no effect on the lamps.
At the time of a fault, the faulty conveyor / equipment, as well as the preceding
conveyors / equipment in the interlock sequence, will stop except H.T. motors for
which only scoop coupling will be disengaged and motor will continue to run for
process fault. In case of motor fault, H.T. motor will trip but the succeeding conveyors
/ equipment will continue to run. The status indication against the preceding
conveyors / equipment will start slow blinking while the faulty conveyor / equipment
will be fast blinking.
Start command shall not be initiated unless reset button in pressed after clearance of
fault.
The sequence of operation of the annunciation system shall be as follows :Condition
Normal :

Fault

Press
Accept. PB.

Press Reset
PB (When
fault is
cleared):

Status
Ann. Window

Off.

Status indication

Steady glow

Buzzer

Off.

Ann. Window

Blinking.

Status indication

Fast blinking

Buzzer

Sounding.

Ann. Window

Steady glow.

Status indication

Fast blinking

Buzzer

Off.

Ann. Window

Off.

Status indication

i)

Steady
blinking
selected path)

ii)

Off (if not on selected path)

Buzzer

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

(if

on

Off

Sub-Section - IIIA-01
CHP

Page 17 of 25

CLAUSE NO.

4.08.00

TECHNICAL REQUIREMENTS
Dust Suppression System
(a.) Conveyors / Equipment
(1.) It shall be possible to spray the water on to coal stream only when
corresponding conveyors/equipment are running with material at spray
application points.
(2.) If a running pump trips stand-by pump shall start automatically. It shall be
possible to select any of the pumps as auto standby from main CHP
control room.
(3.) Pump/pumps shall trip with a time delay, if discharge valves fail to open.
Suitable pressure/flow switch shall be provided to sense this condition.
(4.) Pumps shall trip in case of low level of water in tank.
(5.) All feeding pumps to tank shall trip in case of high pressure & no flow by
pressure switch.
(6.) Motorized inlet valve to D.S. tanks shall close in case of High-High level &
open in case of low level.
(7.) All the controls shall be through PLC.
(b.) Wagon unloading (At Track Hopper and wagon tippler)
(1.) System shall be operated from local control panel. However, the controls
shall be through PLC.
(2.) Dust suppression system shall be provided to cover the Track Hopper in
minimum one & maximum twenty sections. Push button for each section
shall be located on each side of track hopper at convenient location.
(3.) Pumps shall be started manually or from PLC. If any of the pump/pumps
trips, stand-by pump/pumps shall start automatically. It shall be possible
to select any of the pumps as auto stand - by.
(4.) Pumps shall trip in case of low level of water in tank.
(5.) Following annunciations shall be provided at local control panel.
(i) Motor electrical protection operated (Group)
(ii) Discharge water pressure low (Group)
(iii) Water level low in tank (Individual)
(6.) Following individual indications shall be provided at local control panel.
Motor ON/OFF/TRIP
Discharge pressure healthy
Water level high in tank.

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 18 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS
(c.)

Stock yard Dust suppression system

(1.) Water supply pumps shall be started in Manual mode from Main CHP
control room. Controls shall be through PLC.
(2.) If any of the running pump/ pumps trip, standby pump/ pumps shall start
automatically (pressure switch signal shall not be used for this purpose).
(3.) Pumps shall trip in case of low level of water in tank.
(4.) All feeding pumps to tank shall trip in case of high level in tank

(d)

Paddle Feeder Dust Suppression System

Trolley mounted dust suppression system arrangement shall be provided as
described else where in the specification and shall be controlled from the local
control panel. Rest of the system to supply ground storage tanks and ring
header etc. shall be controlled from main CHP control room.

(e)

4.09.00

Following individual inputs shall be provided to P system from all the above
dust suppression systems (except trolley mounted system for paddle feeders)
for alarms/indications.
(i.)

Motor ON/OFF/TRIP

(ii.)

Water level low in tank

(iii.)

Water level high in tank

(iv.)

Discharge pressure low

Metal detectors
(a)

It shall be possible to start the conveyors only after energizing the metal
detector and Metal detector reset condition. Once the metal is detected, the
corresponding conveyor shall trip.
It shall be possible to restart the conveyors, after local resetting of metal
detector and putting back the marker bag in position. Metal detector ON/OFF
push buttons shall be provided in main control room also.

(b)

(c)

In case of tripping of conveyor system, metal-detector shall get de-energized

after a time lag.
Following individual indications shall be provided on local control panel.
(1)

Metal detector ON

(2)

Metal detected

(3)

Metal detector 'reset'.

(4)

Metal detector faulty.

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 19 of 25

CLAUSE NO.

4.10.00

TECHNICAL REQUIREMENTS
Sump Pumps
(a)

Sump Pumps shall start and stop by the level switches in the sump
automatically. Further manual override start / stop push button shall be
provided locally on ground level.

(b)

Any of the pumps can be selected as auto-standby.

(c)

If the sump level continues to be high even after the first pump is under
operation second pump shall start automatically.

(d)

The following indications for sump pumps shall be provided on local Control
Panel.
(1.) Water level high
(2.) Motor ON/OFF/TRIP.

4.11.00

Coal Sampling system

(a)

Coal Sampling Unit shall be controlled through main coal handling plant PLC.
Controls and interlocks for proper material flow shall be provided similar to
conveyor system. Mimic shall be provided in the Operator Work Station (OWS)
at main CHP control room.

(b)

Only one start/stop push button along with selector switches for various modes
of operation of coal sampling system shall be provided for automatic operation
of complete coal sampling system. This control facility shall be provided at main
CHP control desk as well as locally. In any case, local push button stations
shall be provided for all individual equipment of coal sampling system near the
equipment.

(c)

All necessary automatic controls shall be provided for meeting the requirements
of ASTM-D-2234.

(d)

Following indications shall be provided on local control panel

(1.) System ON/OFF/TRIP
(2.) Primary cutter stuck up between parking positions.

(e)

In case of primary cutter getting stuck between parking positions, preceding

conveyor shall trip and annunciation shall appear at Main CHP Control room.

(f)

There shall be protection in the primary coal sampler to trip the conveyor belt in
case primary sampler falls on running conveyor due to coupling failure etc.
Individual motor ON/OFF/TRIP indications shall be provided at main CHP
control room.

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 20 of 25

CLAUSE NO.

4.12.00

TECHNICAL REQUIREMENTS
Paddle Feeders
Paddle feeders shall be controlled from the local control panel suitably mounted on
the unit. Requirement of operation as described else where in the specification shall
be complied with. Following indications shall also be provided on the local control
panel:
(a.) Motor ON/OFF
(b.) Motor O/L protection operated
(c.)

Brakes applied (if provided)

(d.) Hydraulic power pack indications such as digital pressure indications of

hydraulic power pack including those of hydraulic pump discharge, return
(leakage), traverse pump discharge (forward and reverse) oil line.
(e.) Coal flow rate
Main Hydraulic pressure of paddle feeder wheel drive system to be reduced to
minimum through its control circuit during each tripping of main drive motor.
4.13.00

Mobile Trippers
(a)

Mobile tripper unit shall be locally controlled from the operating platform suitably
located with the unit as per instructions given from main CHP control room.

(b)

End travel limit switches shall also be provided.

(c)

Travel drive motor shall start only when brake and rail clamps are in
disengaged condition.

(d)

It shall be possible to trip the bunker Conveyors from tripper.

(e)

When the last bunker is full, it shall not be possible to change over the tripper
flap gate from bunker feeding position to last bunker feeding position.

(f)

As soon as the bunker conveyor trips, tripper flap gate shall change over its
position after a time lag.

(g)

Two nos. emergency stop button one on each side shall be provided on tripper
to stop the machine at any position. The control unit on tripper shall be provided
with start / stop push button and indication lamp for travel / gate. The tripper
brakes and rail clamps shall be energised (and released) when the tripper
motors are ON and the brakes will be applied when the travel motors are OFF.
Two travel limit switches shall be provided at either end of tripper carriage for
limiting the travel drive between two ends of the track. The first one shall be
normal limit and the second one for over travel limit. In addition to above,
position indication for bunker position of tripper will be provided in Main control
room. Necessary position encoders/ limit switches shall be provided. Over
speed protection for protection against dragging shall be provided.

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 21 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS
(h)

Following individual indications shall be provided on local control panel :

(1.) Motor ON/OFF/TRIP
(2.) Brakes applied
(3.) Rail clamps applied
(4.) Flap gate position

4.14.00

(i)

Indication of tripper flap gate positions shall be given in the main CHP control
room.

(j)

It shall be possible for operator to manually trip the coal feeding eqpt. viz.
paddle feeders or stacker / reclaimers from the tripper.

(k)

Chute blockage switch shall be provided at each leg of chute and shall trip the
tripper conveyor in case of blockage.

Flap Gates/ R&P Gates

All Flap Gates/ R&P Gates shall be motorised with actuators and remote controlled
from the main control desk. Their position shall be indicated on the mimic of main
control room.

4.15.00

Belt Weighers
Each belt scale shall give output to PLC for display of flow rate indicator and totalizer
on CRT and print out at main CHP control room. 4 Nos. flow rate indicators, one for
each paddle feeder shall also be furnished to display the instantaneous TPH on
respective paddle feeder using the output of belt scale on Conveyors. Each belt scale
shall also have rate flow indicator and totaliser mounted near the unit. Belt weighers
shall also be provided on Stacker-Reclaimer as described elsewhere in the
specification.

4.16.00

Magnetic separator / Suspended Magnet

It shall be possible to start the conveyor only after energising the magnet of ILMS or
SM. Further, if conveyor system trips magnetic separators shall get de-energised
after a time lag and suspended magnet will remain energised and can be deenergised locally. Also if drive motor of cleated belt of ILMS trips, magnetic separator
shall not get de-energised, but conveyor system shall trip and audio-visual
annunciation shall appear at main CHP control room.
Following individual indications shall be provided on local control panel
(a.) Magnetic separator ON.
(b.) Incoming supply ON
(c.)

Under current relay operated

(d.) Cleated belt motor ON/OFF/TRIP

KODERMA TPP (2 x 500 MW)
COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 22 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS
(e.) Oil temperature high

4.17.00

Service water, Cooling Water and potable water pumps

(a)

These pumps shall be started from main CHP control room

(b)

Pump shall trip in case of low water level in tank.

(c)

Following individual inputs shall also be provided to PLC system for

alarms/indications :
(1.) Motor ON/OFF/TRIP
(2.) Discharge water pressure low
(3.) Water level low in tank
(4.) Water level high in tank

4.18.00

Stacker/ Reclaimer
(a)

The Stacker cum reclaimer shall be controlled from the operators cabin in the
machine through PLC system of stacker cum reclaimer.

(b)

Slew speed shall be controlled through Power transducers on Bucket wheel

drive motor for uniform feeding. Setting of Power transducer shall be done from
operators cabin.

(c)

Slew reversal shall be automatic through

(1.) Power transducer on Bucket wheel and/or
(2.) Extreme end limit switches and/or
(3.) Manual command.

(d)

At the end of Slew Pass Stacker - Cum - reclaimer drive shall advance
automatically to required depth of cut. Depth of cut shall be controlled through
the setting of power transducer on Bucket wheel. It shall also be possible to set
the depth of cut through a separate setting knob in operator cabin.

(e)

All controls shall be based on feed back signals from field equipment.

(f)

All electronic circuitry shall have self-diagnostic features.

(g)

Operators cabin shall maintain horizontal level automatically as per Boom

Conveyor position.

(h)

For all drives, zero speed shall be ensured before affecting reversal, by
providing suitable speed sensing device.

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 23 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS
(i)

Motors shall start on when the Brake and/or rail clamp, is in Not Applied
condition. This signal shall be obtained from limit switch provided for that
purpose.

(j)

If wind velocity is high, it shall cut off power supply to stacker - cum-reclaimer
with a time delay, after giving sufficient time to operator to bring the Boom in
minimum wind pressure direction/ position.

(k)

All sequential interlocks for proper material flow shall be provided.

(l)

It shall be possible to operate the lubrication system from operators cabin.

(m) Manual - Local.

With the selector switch in this position all drive functions on the stacker - cum reclaimer can be operated by push buttons local to the drives. All other
operation initiating devices shall be locked out.
(n)

Manual Remote
Manual controls facility shall also be provided in control desk and keyboard
(operators cabin) as below :
(1.) Individual controls shall be provided for each equipment.
(2.) Manual slew speed variation and depth of cut setting facilities shall be
provided.

(o)

Following minimum audio-visual annunciation shall be provided through integral

type annunciation system in operators cabin in stacker - reclaimer.
Annunciation system shall meet the requirements specified in the relevant
electrical sections.
(1.)

Wind velocity high

(2.)

Lubrication system trouble for slew drive

(3.)

Lubrication system trouble for bucket wheel drive.

(4.)

Hoisting system trouble.

(5.)

Chute plugged

(6.)

Coal flow rate high

(7.)

Belt sway switch operated

(8.)

Zero speed switch operated

(9.)

Pull chord switch operated

(10.)

Motor electrical protection operated (Individual)

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 24 of 25

CLAUSE NO.

TECHNICAL REQUIREMENTS

(p)

(11.)

For L.T. transformer Wind temp. high alarm and trip.

(12.)

LT breaker tripped

(13.)

HT switch tripped

(14.)

20% spare windows.

(15.)

Rail clamps of stacker reclaimer not engaged.

Following individual indications shall be provided in operators cabin and HMI:

(1.)

Motor ON / OFF / TRIP

(2.)

Control supply healthy

(3.)

All necessary position/motion/level indications

(q)

Ammeters shall be provided in control desk for all the motors rated 30 kW and
above.

(r)

Wind velocity indication shall be provided in operator's cabin.

(s)

Contractor shall provide a comprehensive interlock and protection scheme and

include a block logic diagram and write up on the scheme proposed. The final
scheme shall be subject to approval of Employer. Sequential interlocking as
applicable shall be provided. This shall be a part of main interlock scheme
/writeup for the entire Coal Handling Plant.

(t)

Boom conveyor shall be interlocked in such that it cannot start in reclaiming

mode unless yard conveyor is running. In addition, yard conveyor would not
start unless boom conveyor is running in stacking mode (with CHP in stacking
mode). Following indications shall also be provided in operators cabin.
(1.) Boom conveyor stacking
(2.) Boom conveyor reclaiming
For indications/interlocks indicated above, and for communication system
between stacker/ reclaimer and main control room, contractor shall provide all
necessary control cables.

(u)

It shall be possible to trip stacker/ reclaimer from main CHP control room also.

(v)

A push button shall be provided in operators cabin to trip the yard conveyor.

KODERMA TPP (2 x 500 MW)

COAL HANDLING PLANT

TECHNICAL SPECIFICATIONS
SECTION VI, PART-B
BID. DOC. NO.:CS-9451-156-2

Sub-Section - IIIA-01
CHP

Page 25 of 25