TECHNICAL SPECIFICATION FOR FLOWABILITY STUDY FOR COAL BUNKERS

SPECIFICATION NO. PE-TS-STD-161-14000-A001

BHARAT HEAVY ELECTRICALS LIMITED POWER SECTOR PROJECT ENGINEERING MANAGEMENT NOIDA

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TECHNICAL SPECIFICATION FOR FLOWABILITY STUDY OF COAL BUNKER

SPECIFICATION NO. PE-TS-STD-16114000-A001 VOLUME II-B REVISION 00 PAGE 1 of 3 SECTION C DATE:

1.0

SCOPEOFWORK A comprehensive flowability study of crushed coal shall be conducted by the bidder, for the coal bunker to ensure smooth flow of coal in all seasons with different moisture contents and different percentage of fines. The bunkers are required to promote mass flow without choking and rat holing problems. Typicalcapacityofcoalbunkersareasfollows: PlantRating(MW) 210/250/300 500/600 660 800 CapacityRange(Tonnes) Upto500 700800 8001050 9001150 Typeofbunker Rectangular Circular Circular Circular

Thereportofstudyshallcontainthefollowings: a) Sample preparation & Size analysis Preparation of required samples of coal for flowability studies, Sizeanalysisofasreceivedsample. b) Bulkdensitydetermination. c) Bulkdensityvariationwithnormalstress(compressibilitytest). d) Coal flowability tests (Shear tests) at minimum four different moisture levels (out of these one moisture level shall be as per project specific coal analysis) to establish wall angle of friction against liner like mild steel (MS), stainless steel (SS 304), stainless steel (SS409), UHMWPE, Effective angle of friction, Flow Functions, Flow Factor and Storage time effect at 24 and 72 hours for all flowability condition. e) Evaluation of Mass Flow design parameters viz, slope of hopper with specified material of constructionandcriticaloutletdiametertopreventcohesivearching. f) EstimationofpeakbunkerwallpressuresduringfillingandextractionasperIS9178partIIIstandard

g) Values of critical outlet dimensions and hopper slopes for mass flow bunkers with different moisture levelsandhoppermaterial. 2.0 The following tentative information based on which flowability study for the bunker shall be conducted:

a) Type of bunker circular on top with conical/hyperbolic hopper profile for circular bunkers OR rectangularbunkerwithtrapezoidalhopper. b) Outletdiameter/sizeofbunker914mm. c) No liner is provided in the cylindrical/rectangular portion of bunker. Liner shall only be provided in conical/trapezoidalportionofthebunker. d) Maximumextractionrateofthebunkershallbeinformedprojecttoprojectbasis.

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TECHNICAL SPECIFICATION FOR FLOWABILITY STUDY OF COAL BUNKER

SPECIFICATION NO. PE-TS-STD-16114000-A001 VOLUME II-B REVISION 00 PAGE 2 of 3 SECTION C DATE:

e) FlowabilitytestshallbeconductedconsideringthepointsindicatedinAnnexureI. f) Capacity and tentative size of the bunker will vary based on coal consumption, number of mills and bunkerbaydimensionsandsameshallbeprovidedbasedprojecttoprojectbasis.

g) Coalanalysiswillbeprovidedbasedonprojecttoprojectbasis. 3.0 In addition to above inputs, any other inputs required for carrying out the flowability study shall be includedinbiddersoffer. ANNEXUREI Pointstobeconsideredwhileconductingflowabilitytest a) FordesignofcoalbinsandloadinghopperIS:9178(partItoIII)shallbefollowed. b) Transversecoalpressureonbunker/silo/hopperwallsshallbecalculatedusingWalkerstheoryand IS:9178.Thecoalbunker/silo/hoppershallbedesignedforthefollowingconditions: i. ii. Thebunker/silo/hopperisfulluptoitsfullcapacitywithtopsurfacenearlyhorizontal. The bunker / silo / hopper is partially empty with the top surface of coal at an angle of repose of 37degrees.

c) Particle size inside the bunker shall be25 mm. Flowability test shall be conducted for25 mm coal size. In case, its not feasible to conduct on lumps, bidder shall conduct the test on coal fines and extrapolatetheirfindingsforlumps(25mmcoalsize). d) Testshallbecarriedoutatdifferentmoisturesaturationlevel. e) In addition to the result for worst condition, results at project specific moisture content shall also be includedinthestudyreport. f) Bunker outlet size shall be 914 mm. Bidder shall recommend valley angle for different liners and at different moisture content for 914 mm outlet size. In case, under storage effect, ratholing or any other flow problem is anticipated, bidder shall recommend flow assisting measures e.g., poke holes, Vibrators,Airblastingetcwithcompletedetailsandelevationsfortheinstallation.

g) For all capacity (volume) calculation and structural design (load calculation) unit weight of coal shall beassumedas800kg/m3and1200kg/m3respectively. InputVariationforCoalFlowabilityStudy Sl.no Parameters 1 OutletSize 2 Bunkerprofile 3 4 Storageeffect Liner

Value/Details 914mm(Standard) CircularwithConical/hyperbolichopperprofile ORRectangularwithtrapezoidalhopper. Instantaneous/24hours/72hours SS304/409/MSrusted/UHMWPEetc,Surface finishoflinershallbeinformedbasedon projectrequirement.

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TECHNICAL SPECIFICATION FOR FLOWABILITY STUDY OF COAL BUNKER

SPECIFICATION NO. PE-TS-STD-16114000-A001 VOLUME II-B REVISION 00 PAGE 3 of 3 SECTION C DATE:

Moisture

Anychangeinlinermaterialbasedonproject requirementwillalsoberequiredtobe considered. Projectspecificbasedoncoalanalysis.Other percentageshallbedecidedbybidderbasedon criticalmoistureandsaturationlevel.