Professional Documents
Culture Documents
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TABLE OF CONTENTS
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DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
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Sheet 1 Of 70
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SECTION
TITLE
1.0.0
SYSTEM DESCRIPTION
2.0.0
2.0.1
2.0.2
3.0.0
SYSTEM OPERATION
3.1.0
CONVEYOR SYSTEM
3.1.1
3.1.2
METAL DETECTORS
3.1.3
3.1.4
3.1.5
3.1.6
TRAVELLING TRIPPERS
3.1.7
3.1.8
4.0.0
UTILITIES
4.0.1
SWP/PWP/CWP/WTDP/WTP/DSP/THP/PFP/DFDS SYSTEM:
4.0.2
4.0.3
VENTILATION SYSTEM
4.0.4
5.0.0
6.0.0
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6.0.1
6.0.2
6.0.3
6.0.4
6.0.5
COMBINATION OF ABOVE
7.0.0
ANNUNCIATION SYSTEM
8.0.0
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unloaded from the ships with help of shore unloaders and will be conveyed to conveyors
1A/1B. Conveyor 1A/1B conveys coal to Conveyor 2A/B at Junction house JT-1. Two nos
Metal detectors (MD1 mounted on Conv 1A & MD2 mounted on Conv 1B) are provided
for detecting metallic materials present in the As received coal. Two nos In line
magnetic separators (ILMS -1 on Conveyor 1A & ILMS 2 on Conveyor 1B) are mounted
on discharge end of respective conveyors at JT-1 for removal of metallic ferrous tramp
present in the As received coal. Further Conveyor 1A/1B is having facility for manual
stone picking at a suitable location.
2. Conveyor 2 A/B will feed coal to either of Conv 3A1/B1 in JT-2 by means of flap gates FG
1 & 2. Conveyor 3 A1/B1 will feed coal to either of Conv 3A2/B2 in JT-2A by means of
flap gates FG 1A & 1B. Conveyor 3 A2/B2 will feed coal to either of Conv 4A/B in
JT-3
by means of flap gates FG 2A & 2B. Conveyor 4 A/B will feed coal to either of Conv 5A/B
in JT-4 by means of flap gates FG 3 & 4.
3. Two nos. Belt Weigh scale (BW-1 & BW-2) are mounted on Conv 3A2/3B2 respectively
for metering of As Received coal. Two nos Metal detectors (MD3 mounted on Conv 3A1
& MD4 mounted on Conv 3B2) are provided for detecting metallic materials present in the
As received coal.
4. Coal from each incoming conveyor 5A/5B to Crusher house will have two paths through
FG 5 & 6. 2 nos Roller Screens each of capacity 1250 MTPH (RS-1 & RS-2) are provided
in one path which permits the coal of size -50mm to their respective conveyors (6A/6B) &
by pass the oversized coal to their respective crushers each of capacity 1250 MTPH (CR1 & CR-2) for reducing the coal size to -50mm. The crushed coal is then allowed to fall
over the respective conveyors (6A/6B). The other path by passes the coal from conveyor
5 A/B to conveyor 6 A/B through FG 5 & 6 if the received coal size is -50mm.
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5. Two nos. In line magnetic separators (ILMS 3 over Conv 5A & ILMS 4 over Conv 5B)
are provided at the head end of respective conveyors for removal of metallic tramp from
the As received coal. Two nos Metal detectors (MD5 mounted on Conv 5A & MD6
mounted on Conv 5B) are provided for detecting metallic materials present in the As
received coal.
6. Conveyor 6 A/B will feed coal to either of Conv 7A/7B by means of FG 7 & 8. Conveyor
7A/B will further discharge the coal in JT-5 through Diverter Gate DG 1 & 2 to either
Conveyor 18A/B for stacking coal in the crushed coal stockyard or on to Conveyor 8A/B
for onward conveying to Boiler Bunkers. Two nos. Belt scale (BS-3 & BS-4) are mounted
on Conv 7A/7B respectively for metering of As fired coal.
7. Conveyor 8A/8B conveys coal to Conveyor 9A/B at Junction House JT-6 through flap
gates FG 9 & 10. Conveyor 9A/B will feed coal on to Conveyor 10A/B at JT-8 through flap
gates FG 11 & 12. Conveyor 10A/10B will feed coal on to the bunker conveyor 11 at JT-9
or Conv 12A/B at JT-9 through flap gates FG 13 & 14. Conveyor 12A/12B will feed coal
on to the bunker conveyor 13 at JT-10 or Conv 14A/B at JT-10 through flap gates FG 16
& 17. Conveyor 14A/14B will feed coal on to the bunker conveyor 15 at JT-11 or Conv
16A/B at JT-11 through flap gates FG 21 & 22. Conveyor 16A/16B will feed coal on to the
bunker conveyor 17 at JT-12.
8. One no Coal sampling unit (CSU-1) is placed on Conv 9A/9B at JT-8 for sampling of As
fired coal. Two nos. In line magnetic separators (ILMS 5 over Conv 9A & ILMS 6 over
Conv 9B) are provided at the head end of respective conveyors for removal of metallic
tramp from the As fired coal. Further Conveyor 9A/9B is having facility for manual stone
picking at a suitable location. Two nos Metal detectors (MD7 mounted on Conv 9A & MD8
mounted on Conv 9B) are provided for detecting metallic materials present in the As
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fired coal.
9. Two nos. Belt scale (BS-7 & BS-8) are mounted on Conv 10A/10B respectively for
metering of As fired coal.
10. One number Travelling Tripper is mounted on each of the Bunker conveyor 11/13/15/17
(i.e. total four nos. of traveling trippers TT-1 to TT-4) to feed the coal into Raw coal
bunkers of the boiler units (Unit 1 & 2).
11. From JT-5, Conveyor 18A/18B conveys coal to Yard Conveyor 19 & conveyor 20 A/B in
JT-13 through flap gates FG 27 & 28. Conveyor 20A/20B conveys coal to Yard Conveyor
21.
12. Two nos. unidirectional type stacker reclaimer of 2000 MTPH (stacking) / 1200 MTPH
(reclaiming) capacity are provided on Yard conveyors 19 & 21 respectively. The Stacker
Reclaimer machine operates on rails for stacking / reclaiming the coal in the stock yard
area. During reclaiming operation the reclaimed coal will be conveyed to the yard
conveyors 19 & 21 by the Boom conveyor of the respective S/R machine which in turn
will feed the same to Conveyor 22A/B by means of flap gates FG 29 & 30 at JT-15 and at
JT-16 respectively. Two nos. Belt scale (BS-5 & BS-6) are mounted on Conv 19 & 21
respectively for metering of Stocking & Reclaiming coal.
13. The reclaimed coal from Conv 22A/B can be fed on to Conv 9A/B at JT-7. From JT-7, the
coal can be conveyed to the raw coal bunker by Conv 9A/B, 10A/B, 12 A/B, 14 A/B 16A/B
& 11/13/15/17 to the desired row of bunkers.
14. Three nos Passenger cum Goods Elevator are installed one each at Crusher house, JT-8
& JT-12 to facilitate movement of man & material in these buildings.
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Conveyors, Flap gates, Scoop Type Fluid Couplings, Crushers & Screens.
Complete Service water system, Potable water system, Cooling water system
The following Sub-Systems will be controlled through Dedicated PLC With Control Desk:
Stacker-Cum-Reclaimer
Travelling Tripper
The following Sub-Systems will be controlled through Relay Based Local Control Panels:
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Metal Detector.
All the above mentioned local control panels are accessible & located near their respective equipment
& will be complete with all the required controls, interlocks, and annunciations etc. Necessary controls,
indications and annunciations for all the above equipment will also be provided at main CHP control
room. In addition to the remote control of various equipments, Local stop push button stations will be
provided for all equipment.
2.0.2
The entire control & operation of Stacker Recamier machine will be from the operators cabin on
the machine itself.
3.0.
SYSTEM OPERATION
Typical operation philosophy of the plant is mentioned below to develop the control & monitoring
scheme of plant & equipment under the package. Coal flow path selection will be done from HMI to
select any one of the following conveying paths.
Ship Unloaders to Bunker Units (BU-1, BU-2, BU-3 & BU-4) via Crusher House.
Stock yard to Bunker Units (BU-1, BU-2, BU-3 & BU-4) via Crusher House.
Combination of above.
Operator will select any one of the above paths from HMI located in the Control desk from CHP Control
Room in PMCC-2. The flow stream path is then selected by positioning different Flap Gates/Diverter
gates at desired positions by means of keyboard available at the control desk. Once the system is in
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the operation, the gates cannot be moved from their positions and path. After the selected path is in
operation the movement of path selector will not have any effect on the system. Flap gates which do
not come in the stream in which coal flow is taking place, can be operated at any time.
The control system will be designed for Auto & Manual operation of the conveyors in the selected
path. Auto/Manual selection will be done from faceplate in HMI.
AUTO MODE: In the auto mode, the conveyors and related equipment shall start sequentially when
the system start is initiated. 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 shall start the conveyor system, in the same sequence
as in auto mode from MMI. The operator shall also stop the conveyor system, by pressing system stop
or individual stop command from MMI 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 shall be indicated on the panel by glowing
of lamp COAL HANDLING SEQUENCE START. The starting permissive shall 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
activated shall 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, shall continue to run.
The status indication in the graphic display against all conveyors and equipment in the selected path /
stream shall start slow flickering. But all status indications against all flap gates in the selected path
shall glow steadily. Therefore, from the selected flow stream path of the flap gates, the operator will
come to know the conveyors and equipment to be started for the selected path / stream. After a
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conveyor / equipment are started, the status indications against that conveyor / equipment shall 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 for immediate shut down of complete plant shall be provided in
the CD Console.
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 panel for flap gates of all conveyors in
boiler area for the preset period. If the changeover, in above specified time, is not completed then the
entire CHP shall stop.
Adequate numbers of Belt sway switches, at every 30m interval, are provided to protect against
the damage to the edge of the belt due to excessive sideways movement. In addition, each
conveyor is provided with one (1) no. Speed detection devices (Zero Speed Switch). These
Zero speed switches will be designed to sense belt speed. In case of speed of belt goes below
90% of rated speed, it will trip the conveyor.
The starting sequence of the conveyors will follow a direction opposite to that of flow of
material i.e.
In case of direct conveying of coal to boiler bunkers, start from bunker conveyor &
end up with Conveyor 1 A/ 1B.
In case of stacking of coal in stock yard, start from yard conveyor and end up with
Conveyor 1 A/ 1B. However, for yard conveyor to start, the Stacker Cum Reclaimer
should be in operation.
In case of reclamation of coal from stock yard, start from bunker conveyors and end
up with yard conveyor along with Stacker / Reclaimer.
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The starting of mobile trippers are interlocked with operation of the respective bunker
bay conveyors.
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.
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.
Stop / Tripping of any equipment from running condition will trip all preceding equipment in the
system, except Crushers but will not affect succeeding ones which will continue to operate.
Adequate no of Pull cord switches at 30m intervals are provided along the length of each belt
conveyor, which will enable the respective conveyor to be stopped immediately. Belt Protection
switches, Pull Chord Switch & Belt Sway Switch, will be identified/addressed by a specific
number in the Main Control Room.
Means are provided to pre-warn personnel working nearby when starting any conveyor, Stacker
cum - Reclaimer & Travelling Tripper by providing Sirens.
Interlocking of various conveyors is achieved with Flap gate, Flow Dividers Limit switches and
Zero speed switches.
Motors will start only when the brake/rail clamp if provided, is in Not applied condition. Limit
switches are provided to get the signal from brake for the above purpose.
Ring granulators are provided with Speed and vibration monitoring instruments. Ring
granulators will trip in case Speed/vibration is going beyond tolerable limits of design.
Temperature sensing devices are installed on all bearings of each of the ring granulator to trip
the same in case of temperature goes beyond limit. Audio-visual annunciation is provided in
OWS.
Tripping of the respective conveyor is provided in case any of Travelling Trippers starts running
along with conveyor belt at speed higher than the rated speed by providing an over speed
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It is possible to bunker conveyor & Yard conveyor from Travelling tripper & Stacker cum
Reclaimer respectively.
Wherever Scoop type coupling provided for HT motors, the coasting time of respective
conveyor, thrustor brake, actuator selection and the chute size will be so selected such that
there is no spillage of coal from any downstream conveyors during next start.
INTER-LOCKING:
a)
Local de-interlock mode control will be carried out by local push button station (LPBS) for each
individual equipment/mechanism.
Remote interlocked individual drive control from the HMI at Control Room.
Remote interlocked route wise control from the HMI at Control Room.
The following material conveying systems/sub-systems shall come under Plant Inter-Locking Schemes:
Conveyors
Crushers
Flap Gates & Flow Dividers.
In Line Magnetic Separators
Metal Detectors
In Line Belt Weigh Scale
Stacker cum Reclaimer
Travelling Tripper.
The following Systems will not come under the interlock of Conveyor scheme.
All dust suppression systems & service water system.
Ventilation systems.
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Pos I, Pos II & stop button for flap gate and Pos I, Pos II, Pos - III &
stop button for Diverter gate.
Local Start & Emergency stop push button (Red) for other equipment.
b)
HT motors used will continue to run on no load by disengaging the fluid coupling in case of failure of
any process interlock. The HT motors will however be tripped incase 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.
3.1.1 FLAP GATES/FLOW DIVIDERS
All flap gates / Flow Dividers / Diverter gates will be motorized and remote controlled from the main
control desk. Their position will be indicated on the mimic of main control room. Once a conveyor trips,
flap gate directing coal from this conveyor will change over its position with a time delay and will come
back to the original position again. This is to prevent jamming of gate.
3.1.2 METAL DETECTORS
It is possible to start the conveyors only after energizing the metal detector and metal
detector reset condition. Once the metal is detected, the corresponding conveyor will trip. It
will be possible to restart the conveyors, after local resetting of metal detector & putting back
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the marker bag in position. Metal detector ON/OFF facilities is provided in the OWS.
In case of tripping of conveyor system, metal detector will get de-energized after a time lag.
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a.
Coal sampling unit is controlled through CSU control panel located in the respective
building (JT-8) and Starter Panel/DB for the same shall be located inside the Buildings of MCC-3 &
MCC-6 respectively. Controls & interlocks for proper material flow is provided similar to Conveyor
system.
b.
Only one start/stop push button for coal sampling system will be provided for
automatic operation of complete coal sampling system. In any case, local push button stations will
be provided for all individual equipment of coal sampling system near the equipment.
c.
All necessary automatic controls will be provided for meeting the requirements of
ASTM-D-2234.
d.
e.
There will 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.
Mobile tripper unit is locally controlled from the operating platform suitably located with the unit as
per instructions given from main CHP control room.
Travel drive motor will start only when brake and rail clamps are in disengaged condition.
When the last bunker is full, it will not be possible to change over the tripper flap gate from bunker
feeding position to last bunker feeding position.
As soon as bunker conveyor trips, tripper flap gate will change over its position after a time lag.
Operator will operate the mobile tripper on bunker conveyors from its carriage. Two nos. emergency
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stop button, one on each side will be provided on tripper to stop the machine at any position. The
control unit on tripper will be provided with start / stop push button and indication lamp for travel /
gate. The tripper brakes & rail clamps will be energized (released) when the tripper motors are ON
and the brakes will be applied when the travel motors are OFF. Two travel limit switches will be
provided at either end of tripper carriage for limiting the travel drive between two ends of the track.
The first one will 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 through limit switches in Main control
room.
Following individual indications are provided on local control panel.
Motor ON/OFF/TRIP
Brakes applied
Rail clamps applied
Flap gate position
Indication of tripper flap gate positions is given in the main CHP control room.
It is possible for operator to manually trip the coal feeding equipment viz paddle feeders
or Stacker / reclaimers from the tripper.
Chute blockage switch is provided at each leg of chute & will trip the tripper conveyor in case of
blockage.
3.1.7 3-D Type Level Transmitter
3-D Level Transmitter (4-20mA type) shall be provided for boiler bunkers present in Bunker Unit 1,
Bunker Unit-2, Bunker Unit-3 & Bunker Unit-4. The 3-D level Scanner employs an array of three
antennas to transmit low frequency pulses and to receive echoes of the pulses from the content of the
Bunker/Container. Using three antennas the unit measures not only the time/distance of each echo but
also its direction.
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Local display and annunciation shall be provided for High and Low level signals on the instrument and
level reading shall be available for operator at Control Room by means of 4-20mA.
In case of level high LH in bunker level, the feeding conveyor shall be stopped. Bunker level shall be
continuously displayed with low, low-low, high and high-high indications on the HMI.
3.1.8 HOISTS AND CRANES
The hoists and cranes will be controlled through Pendent. The same will be approachable from the
floor. The pendant control panel will be provided with up / down / forward / reverse travel push buttons
and indicating lamps for operating the same.
4.0.0 UTILITIES.
The Utility System of Coal handling System at NLC Tuticorin-TPP consists of
SWP/PWP/CWP/WTDP/WTP /DSP /THP/DFDS system, DE system, Ventilation system and Air
conditioning system.
4.0.1 SWP/PWP/CWP/WTDP/WTP/DSP/THP/PFP/DFDS SYSTEM:
The pump house is installed near to the coal transfer area, RCC water tanks is placed close to the
pump station. Water from the tank shall be supplied to the service points by the pumping system The
water pumps located in Pump House. The pumps shall be centrifugal multi stage type suited for
continuous operation selected on the basis of best efficiency. The water pumping system shall consist
of Duplex strainer with SS element 250 microns in the suction side of the Pump. . Each pump shall
have a gate valve at the suction and discharge. Each pump shall have a check valve at the discharge.
A pressure relief valve with a bypass Globe & gate valve shall be provided at the return line of each
pumping system so that the excess water is discharged back to the water tank.
Pumping system so that the excess water is discharged back to the water tank. Water tanks shall be
with accessories like motorized butterfly valve/ Gate valve at inlet of tank, Level Switch, Gate valve for
Drain. Motorized valves will be operating /controlled by level switch. In case of low level MOV shall
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open and make-up water will be filled-up. In case of high level MOV shall closed. The water pump shall
be interlocked with low level switch of the water tank to prevent the pump from dry running.
The pumps will be operated from control room. Following individual inputs will be provided to
DDCMIS system for alarms / indications:
1.
2.
3.
4.
5.
6.
Pressure switch is introduced in the delivery line to maintain the minimum set pressure during the
operation. If the pressure falls down below the set pressure the standby pumps will start
automatically after time delay. Even after the pressure is not healthy inside the system the pump
will trip automatically after certain predetermined set time.
The control circuit should be designed to meet the fallowing interlocks.
Both pumps cannot run together. Only one at a time in any mode.
Pumps should not be started when the water level is lowest in the tank.
After starting the pump if the pressure is not built within the specified time the running pump
should be stopped and other pump can be tried. If it is the same case with other pump too then
the system should stop and announce the alarm.
Differential pressure switch in the duplex strainer gives the filter clogged signal. This No contact
to be used to announce the alarm FILTER CLOGGED.
Along with the above interlocks regular motor protection like OL and SC to be used in the circuit.
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SWS
SWP-1A/B
Application Area
As per Schematic
OWS
P.B in Pump
House
diagram
POTABLE WATER SYSTEM:
Potable water connections shall be provided at all control rooms / MCC rooms, and complex
building of coal handling plant.
Potable water pump (PWP-1A/B) located in Pump House shall take potable water from RCC PW
tank-3 located adjacent to the Pump House and supplies to the overhead PVC potable water
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storage tanks (1000 Liters.) located at roof top of above mentioned buildings. No PVC tank shall
be provided for Transfer Points and junction house. Client shall ensure the quality of drinking
water as per IS: 10500.Potable water from the overhead PVC tank shall flow to the potable water
tapping of respective building by gravity.
Group
PWS
PWP-1A/B
Application Area
As per Schematic
OWS
P.B in Pump
House
diagram
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intervals depending on the site condition. The dust control is achieved by the agglomeration of dust
particles with finely atomized water droplets equal to / close to / larger than the dust particles as the
case may be, the Collision between the water droplets and dust particles plays an important role in the
process of agglomeration and heavier mass thus formed settles down to the source.
Plain water at a pressure of about 4.0 Bar is sprinkled over the stockpile area. This system is envisaged
to control the dust generated in the stockpile area. Water header will be provided along both sides of
the coal stockpile, sufficient number of sprinklers suitably installed in a header to cover the entire
tockpile area produces water spray over the stockpile. The sprinklers are of swiveling type.
The operation of the sprinklers for stock piles is automatic by means of Sequential Control Panel and
Solenoid Valves for every two sprinklers. And each stockpile shall have solenoid valve with strainer
at the header inlet. Before each sprinkler globe valve shall be provided.
Group
DS-5
DSP-1A/B/C
Application Area
As per Schematic
OWS
P.B in Pump
House
diagram
Programmed logic control panel is used for sprinkling system of coal stock pile. Total 128 sprinklers are
controlled by 64 solenoids. Two solenoids of opposite side sprinklers are made as pair and they get ON
together. At a time any eight sprinklers can be switch ON.
Manual Mode: Solenoid pairs can be switched ON/OFF by using Push Buttons provided. In the
Solenoid box. These push buttons are provided for Stacking & reclaiming purpose. Any sprinkler
switched ON in manual mode continues in ON status till it is switched off/mode is changed.
Corresponding indicator glows in the panel when any solenoid is ON.
Auto Mode: In auto mode control of the sprinklers are R1 to R32 can be used for this purpose.
Switching the relay R1 turns ON Solenoid 1 and 2. R2 for S3 and S4. Like wise it continues up to S128.
This is maintained type contact. Till the relays are ON solenoids remains ON. Sprinkler ON time and
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 22 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
sequence can be programmed as per the requirement of the client. At a time more than one relay
should not be switched ON, is the only one interlock which client has to take care. Pumps are rated for
only eight sprinklers. If more than one is switched ON at a time, required through will not be available
from the sprinklers.
DRY FOG DUST SUPRESSION SYSTEM:
The dry fog dust suppression system will consists of centrifugal pump (vertical) with drive motor, air
compressor with drive motor, local control panel, Flow control unit, pressure regulating unit, solenoid
valve, Nozzles, Nozzle headers, displacer operated level switch, pressure gauge, pressure switch,
duplex strainer with differential pressure gauge & differential pressure switch etc.
The pumps will start automatically. Load sensing units will be installed in the MCC, which will measure
the current consumption of each conveyor motor. When the current drawn by conveyor exceeds a
predefined set value, the load sensing unit will send signals to pumps. On receipt of signals from load
sensing unit, pumps will be operated.
The compressor will also start automatically taking signal from pressure switch (low) installed on
compressor and it will trip automatically taking signal (high) from pressure switch installed on air
receiver.
The Flow Activation Stations have provision for both manual and automatic operation. For manual
operation, the system becomes operational with selector switch in manual mode and in auto mode, the
fogging operation starts on receiving a signal either from a Respective conveyor current load monitor
or Flap gate limit switches installed at a strategic location in the material Conveyor line or potential
free contact from the drive motor of equipment as per requirements.
Each application point is provided with requisite number of spray bar assemblies with Air Atomized
Nozzles. FAS are provided at group of application points.
FAS can be connected to one or more PRU. A PRU is used to regulate the air and water pressure for a
group of headers.
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 23 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
Dry Fog type Dust Suppression System will be used for suppressing dust by means of air atomized
nozzles that are caused during the operation of above mentioned areas. This system is envisaged to
control the dust generated during the operation of above mentioned areas, Headers are provided at
dust generating points for respective nozzles. Water will be stored in a tank. In the makeup waterline to
the water tank Float valve will be provided. Water from the water tank shall be supplied to the spray
headers by a pump. The water pump shall be interlocked with low-level switch of the water tank to
prevent the pump from dry running. A pressure switch at the pump discharge line shall be provided to
bypass water to store tank in case the pressure increases above the set value. The pumping system
along with control panel is placed in a pump house near the water tank. Compressor shall be mounted
in the pump house with an air receiver.A FAS shall be provided for a group of material transfer points.
The FAS shall be interlinked with the signals for running of Conveyors and equipments to ensure that
the spray is activated only when the Conveyors are running with load. Additionally the pressure switch
at the FAS ensures that the solenoid valves at the air and water lines are switched ON only when there
is adequate air pressure at the system.Each application point shall have a set of spray bar of air and
water. The nozzles shall be fixed at the discharge hoods/suction hoods and shall be connected by
flexible tubing with the headers.Each PRU shall have air and water pressure regulators to ensure that
the medium at the required pressure is flowing through the nozzles. This in turn ensures proper
atomization of the water which is essential for the effective dust suppression.
Group
DS-6
DFP-1A/B
Application Area
As per Schematic
OWS
P.B in Pump
House
diagram
SC-A1/A2/A3
As per Schematic
diagram
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 24 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 25 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
Auto Mode:In auto mode Solenoid can be switched on by client PF (Potential Free)Signal or UBS
Signal or any other remote system signal any one of the signal will open Solenoid & remain ON until
this contacts are closed. Terminals provided for this signal inside FCU Box is X1-3 TO X1-6
Following Indication are provided
Type Lamps
Control Supply Healthy : L1
Water solenoid open (ON) : L2
SOLENOID OPERATING CONDITIONS FOR DS/DFDS SYSTEMS.
JNT - 1
4
5
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 26 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
9
10
11
Receipt of RBF-1
Discharge of RBF-1 side- 1
Discharge of RBF-1 side- 2
12
13
14
15
16
Receipt of RBF-2
Discharge of RBF-2 side- 1
Discharge of RBF-2 side- 2
Discharge of Conv.7
Discharge of Conv.9
17
18
JNT - 2
6
7
8
20
21
22
23
24
25
Receipt of BCN- 9
26
Receipt of BCN- 7
27
PREPARED
TH1
19
GSRK/ARUN
Discharge of AFD- 1
+FG signal
Conv-5B Current load signal
+FG signal
Conv-6A Current load signal
Conv-6B Current load signal
Conv-6A Current load signal
+FG signal
RBF -1 motor signal
RBF -1 motor signal
Conv-6B Current load signal
+FG signal
RBF -2 motor signal
RBF -2 motor signal
Conv- 7 Current load signal
Conv- 9 Current load signal
Conv-10A Current load signal
+FG signal
Conv-10A Current load signal
+FG signal
Conv-10B Current load signal
+FG signal
Conv-10B Current load signal
+FG signal
Conv-10B Current load signal
+FG signal
Conv-10B Current load signal
+FG signal
Conv-10C Current load signal
+FG signal
Conv-10C Current load signal
+FG signal
RBF- 1 running / discharge
Signal
RBF- 2 running / discharge
Signal
Apron feeder -1 running
signal
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 27 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
29
30
Discharge of AFD- 2
31
TH- 2
28
33
Discharge of AFD- 3
35
36
37
38
TH- 4
34
TH- 3
32
42
43
TH- 5
39
40
41
44
45
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 28 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR BOILER BUNKER
AREA UNIT- 1, 2, 3 & 4:
The following sequence to be maintained for start the equipments
1) Start Screw conveyors of bag filter & cyclone outlet
2) Start RAV of Cyclone & bag Filter
3) Power to sequential controller
4) Start Centrifugal Fan Motor
5) Open motorized damper of fan inlet
The equipment will be interlocked with following instruments for smooth operation of DE system
1) DPS will energize at pre set pressure and will command to sequential controller for solenoid
valve (24 V DC) energization.
2) After air purging in sequence of solenoid valves through sequential controller with pre set
pause and on time the DPS will be de-energized at fixed differential set pressure.
3) Sequential controller will not provided output to solenoid valve if air pressure at compressed
air line will be low from the desired pressure as per preset pressure of Pressure Switch. In that
case the whole system will be shut down immediately.
4) ZSS of the system will show rotation of rotating part of the RAV during running
Condition. If any RAV of cyclone, Bag filter fail to run then the whole system will be shut down
Immediately.
OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR JUNCTION HOUSE 4
The following sequence to be maintained for start the equipments
1) Start Screw conveyors of bag filter & cyclone outlet
2) Start RAV of Cyclone & bag Filter
3) Power to sequential controller
4) Open motorized damper ( 2 nos) installed at receipt points of conv.BCN-12A & 12B depending
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 29 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
on flap gate position and discharge of material from conv.11A & 11B.
5) Start Centrifugal Fan Motor
6) Open motorized damper of fan inlet
The equipment will be interlocked with following instruments for smooth operation of DE system
1) DPS will energize at preset pressure and will command to sequential controller for solenoid
valve (24 V DC) energization.
2) After air purging in sequence of solenoid valves through sequential controller with pre set
pause and on time the DPS will be de-energized at fixed differential set pressure.
3) Sequential controller will not provide output to solenoid valve if air pressure at compressed
airline will be low from the desired pressure as per preset pressure of Pressure Switch. In that
case the whole system will be shut down immediately.
4) ZSS of the system will show rotation of rotating part of the RAV during running
condition. If any RAV of cyclone, Bag filter fail to run then the whole system will be shut down
immediately.
OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR JUNCTION HOUSE
5 to 9 & 11 to 15
The following sequence to be maintained for start the equipments
1) Start Screw conveyors of bag filter & cyclone outlet
2) Start RAV of Cyclone & bag Filter
3) Power to sequential controller
4) Open motorized damper ( 2 nos) installed at receipt points of conv.BCN-12A & 12B; 13A & 13B; 14A
& 14B ;15A & 15B; 16A & 16B; 17A & 17B;18A & 18B; 19A & 19B; 20A & 20B;24A & 24B;25A &
25b;26A & 26B; 27A & 27B; 28A & 28B; 29A & 29B depending on flap gate position, FTR
1A/1B,2A/2B,3A/3B,4A/4B & 5A/5B position and discharge of material from respective conveyors.
5) Start Centrifugal Fan Motor
6) Open motorized damper of fan inlet
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 30 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
The equipment will be interlocked with following instruments for smooth operation of DE system
1) DPS will energize at pre set pressure and will command to sequential controller for solenoid
valve (24 V DC) energization.
2) After air purging in sequence of solenoid valves through sequential controller with pre set
pause and on time the DPS will be de-energized at fixed differential set pressure.
3) Sequential controller will not provided out put to solenoid valve if air pressure at compressed
air line will be low from the desired pressure as per preset pressure of Pressure Switch. In that
case the whole system will be shut down immediately.
4) ZSS of the system will show rotation of rotating part of the RAV during running
condition. If any RAV of cyclone, Bag filter fail to run then the whole system will be shut down
immediately.
OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR JUNCTION HOUSE
10 &16
The following sequence to be maintained for start the equipments
1) Start Screw conveyors of bag filter & cyclone outlet
2) Start RAV of Cyclone & bag Filter
3) Power to sequential controller
4) Start Centrifugal Fan Motor
5) Open motorized damper of fan inlet
The equipment will be interlocked with following instruments for smooth operation of DE system
1) DPS will energize at pre set pressure and will command to sequential controller for solenoid
valve (24 V DC) energization.
2) After air purging in sequence of solenoid valves through sequential controller with pre set
pause and on time the DPS will be de-energized at fixed differential set pressure.
3) Sequential controller will not provided out put to solenoid valve if air pressure at compressed
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 31 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
air line will be low from the desired pressure as per preset pressure of Pressure Switch. In that
case the whole system will be shut down immediately.
4) ZSS of the system will show rotation of rotating part of the RAV during running
condition. If any RAV of cyclone, Bag filter fail to run then the whole system will be shut down
immediately
OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR CRUSHER HOUSE
The following sequence to be maintained for start the equipments
1) Open Slide gate at bottom of screw conv. depends on conv. running of 11A/11B/23A/23B.
2) Start Screw conveyors of bag filter & cyclone outlet
3) Start RAV of Cyclone & bag Filter
4) Power to sequential controller
5) Open motorized damper on line as per followings when stream 1 & stream -2 (conv.BCN10B & conv.BCN-10C running)
Motorized Damper no. 15 & 16 will open & Motorized Damper 17 will close.
Motorized Damper no. 11/12 will open when RSC will discharge material on BCN-11A/B.
Motorized Damper no.13 &14 will open
Motorized Damper no.9/10 will open when RSC will discharge material on BF- 1/2..
Motorized Damper no. 7/8 will open when SC-2 will discharge material on BF-1/2.
Motorized Damper no.5 & 6 will open when BF-1/2 will discharge material .
Motorized Damper no.3/4 will open as per Flap gate position of BF-2 discharge to conv.
BCN- 23A/B.
Motorized Damper no. 1/2 will open as per Flap gate position of BF-1 discharge to conv.
BCN- 23A/B.
Open motorized damper on line as per followings when stream 2 ( conveyor BCN-10A in
running condition )
Motorized Damper no. 17 will open and Motorized Damper no. 15 & 16 will close. All other
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 32 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 33 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
i)
PREPARED
Sl.No
System
No.
Catering Area
VS-1 to
VS-3
VS-4
VS-5
VS-7
VS-8
VS-8A
VS-9
VS-10
10
VS-11
GSRK/ARUN
OWS
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 34 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
ii)
System
No.
VE-1 to
VE-3
VE-4
VE-5
VE-7
6
7
VE-8
VE-8A
8
9
VE-9
VE-10
10
VE-11
11
12
VE-12
VE-13
PREPARED
GSRK/ARUN
Catering Area
OWS
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 35 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
iii)
System
No.
VS-12
VS-13
VS-14
VS-15
VS-16
VS-17
VS-18
Catering Area
MCC-1
MCC-2
MCC-3
MCC-4
MCC-5
MCC-6
MCC-7
OWS
Start & Stop
Start & Stop
Start & Stop
Start & Stop
Start & Stop
Start & Stop
Start & Stop
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 36 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
2.
3.
4.
Main CHP Control Room cum RIO room in MCC-2, Near Crusher House
System No.
ACP-1A/B
Catering Area
Control room-1
ACP-2A/B
Control room-2
ACP-3A/B
Control room-3
4
ACP-4A/B
Main CHP control room
SYSTEM SUMMARY FOR WINDOW AIR CONDITIONER UNIT
Sl.
No.
1.
2.
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 37 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
scoop through actuator for scoop coupling of conveyor. If off command is given to conveyor, first the
scoop will get dis-engaged then brake is applied after which main motor stops and finally oil circulating
pump stops.
no
auto-on
and
auto-off
commands
for
conveyor
(except
sequence
start/stop
commands).Permissive conditions (conveyor can be started from Remote/Local when all the conditions
given below are available)
All winding temperature less than 120 deg C.
Bearing temperature (DE and NDE) less than 70 deg C
Brake for respective conveyor is released
Actuator scoop coupling is IN position (dis-engaged position)
Electrical conditions are healthy.
Local Stop Not Pressed /Reset.
Trip conditions (conveyor will trip if any of the given below are available):
Any winding temperature is more than 130 deg C.
Any bearing temperature (DE and NDE) is more than 80 deg C.
Electrical trip conditions are present.
Brake for respective conveyor not released.
Brake for Conveyor:
When command to main conveyor is given, it will auto on (release) the brake and when conveyor
motor is off or fluid coupling dis-engaged then brake will be applied automatically.
Permissive conditions:
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 38 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 39 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
When start command to main conveyor is given, it will engage (OUT) scoop coupling and when
conveyor motor is given off command then it will dis-engage (IN) scoop coupling automatically.
Permissive conditions (actuator for scoop coupling of conveyor will OUT (engaged) scoop automatically
when all the below conditions are present):
Oil circulating pump for respective conveyor is ON.
Main motor of respective conveyor is ON.
Both the CBS (chute block switch) are not operated.
PCS (Pull cord switch) is not operated.
BSS (Belt sway switch) is not operated.
ILMS is energized(On feedback) (if applicable).
MD is energized (On feedback) (if applicable).
Electrical conditions are healthy.
Succeeding conveyor main motor on & scoop coupling engaged and only one Flap gate/shuttle
head drive is in position to feed succeeding conveyor & other flap gate can be positioned on
the same conveyor only if the same upstream conveyor not running (if applicable according to
Down stream Feeders)
Local Stop Not Pressed /Reset.
Trip command from machines (Stacker Reclaimer, Travelling Tripper) to respective conveyors.
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 40 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 41 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 42 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
When start command to main crusher is given, it will engage (OUT) scoop coupling and when crusher
motor is given off command then it will dis-engage (IN) scoop coupling automatically.
Permissive conditions (actuator for fluid coupling of crusher will be OUT (engaged) automatically when
all the below conditions are present):
Oil circulating pump for respective crusher is ON.
Main motor of respective crusher is ON.
Crusher ZSS (Zero speed switch) is NOT operated.
Both the CBS (chute block switch) are not operated.
Respective Downstream feeder, i.e. BF/SC/RSC, is ON .
Electrical conditions are healthy.
Local Stop Not Pressed /Reset.
Hydraulic door closed.
Trip conditions (actuator for fluid coupling of crusher will be IN (dis-engage) if any of the condition will
be present):
Any of the CBS (chute block switch) is operated.
Crusher ZSS (Zero speed switch) is operated with on delay of 60 sec.
Oil circulating pump OFF.
Respective crusher main motor is OFF.
Electrical trip conditions are present.
Respective Down stream feeder, i.e. BF/SC/RSC, is OFF.
Respective Crusher Vibration Trip.
Hydraulic door open.
5.0.4 TRAVELLING TRIPPER
Permissive conditions:
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 43 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 44 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
Metal detected.
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 45 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
Respective BF/SC/RSC is ON
CBS (chute block switch) is not operated.
Trip conditions:
Electrical trip conditions are present.
Respective Crusher OFF
Respective BF/SC/RSC is OFF
CBS (chute block switch) operated.
5.0.14 UTILITY PUMPS (SWP, PWP, THP, WTP, WTDP, DSP, DFP):
When running pump trips standby pump starts automatically.
Electrical Condition: Same as LT drive.
Permissive conditions:
Electrical conditions are healthy.
Local stop not pressed / Reset condition.
Centrifugal Pump (Running/Standby) Selected by Selector Switch (In Soft)
Centrifugal Pump (Running + Standby) Water Level Permissive
Centrifugal Pump (Standby) Not running.
Trip conditions:
Electrical trip conditions are present.
Centrifugal Pump (Running + Standby) Water Level Low
Centrifugal Pump (Running) Discharge Pressure low with delay of 60 sec.
Ann. Condition : DP switch (In pump suction) high will be annunciated
5.0.15 SOLENOID VALVES (FOR DUST SUPPRESSION SYSTEM):
Auto ON Conditions
Current value of respective conveyor above cut-off value (I8mA).
Auto OFF Conditions
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 46 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
Trip conditions:
Centrifugal Pump not running.
5.0.15 VENTILATION SYSTEM: CENTRIFUGAL FAN / AXIAL FAN (For VE, VS):
There is no Auto ON/OFF Conditions.
Electrical Condition: Same as LT drive.
Permissive conditions:
Electrical conditions are healthy.
Local stop not pressed / Reset condition.
Trip conditions:
Electrical conditions are not healthy.
6.0.0 THE PERMISSIVE CONDITONS FOR OPERATION OF CHP
* Feeding Flap gates to be positioned after selection of path.
6.0.1 FLOW PATH 1: SHIP UNLOADERS TO STOCKYARD
S.No.
Equipment
CONV. 19(STACKING)
Permissive conditions
STACKER STR-1 IS RUNNING
OR
OR
CONV. 21(STACKING)
CONV. 18 A
PREPARED
CONV. 18 B
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 47 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
OR
CONV. 20 B
CONV. 7 A
CONV. 7 B
CONV. 6 A
OR
CONV. 7 B IS RUNNING AND FLAP GATE FG -7 IS
POSITIONED (POS-2) TO FEED CONV. 7 B.
CONV. 7 A IS RUNNING AND FLAP GATE FG -8 IS
CONV. 6 B
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 48 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
CONV. 5 A
OR
ROLLER SCREEN 1 & CRUSHER 1 ARE IN OPERATION AND
FLAP GATE FG -5 IS POSITIONED (POS-2) TO FEED
ROLLER SCREEN AND CONV. 6 A IS RUNNING.
CONV. 6 B IS RUNNING AND FLAP GATE FG -6 IS
POSITIONED (POS-1) TO FEED CONV. 6 B.
10
CONV. 5 B
OR
ROLLER SCREEN 2 & CRUSHER 2 ARE IN OPERATION AND
FLAP GATE FG -6 IS POSITIONED (POS-2) TO FEED
ROLLER SCREEN AND CONV. 6 B IS RUNNING.
CONV. 5 A IS RUNNING AND FLAP GATE FG-3 IS
POSITIONED (POS-1) TO FEED CONV. 5 A AND ILMS-3 &
MD-5 ARE ON.
11
CONV. 4 A
OR
CONV. 5 B IS RUNNING AND FLAP GATE FG-3 IS
POSITIONED (POS-2) TO FEED CONV. 5 B AND ILMS-4 &
12
CONV. 4 B
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 49 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
CONV. 3 A2
OR
CONV. 4 B IS RUNNING AND FLAP GATE FG-2A IS
POSITIONED (POS-2) TO FEED CONV. 4 A.
CONV. 4 A IS RUNNING AND FLAP GATE FG-2B IS
POSITIONED (POS-1) TO FEED CONV. 4 A.
14
CONV. 3 B2
OR
CONV. 4 B IS RUNNING AND FLAP GATE FG-2B IS
POSITIONED (POS-2) TO FEED CONV. 4 A.
CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1A IS
POSITIONED (POS-1) TO FEED CONV. 3 A2 AND MD-3 IS
15
ON.
CONV. 3 A1
OR
CONV. 3 B2 IS RUNNING AND FLAP GATE FG-1A IS
POSITIONED (POS-2) TO FEED CONV. 3 B2 AND MD-4 IS
ON.
CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1B IS
POSITIONED (POS-1) TO FEED CONV. 3 A2 AND MD-3 IS
16
ON.
CONV. 3 B1
OR
CONV. 3 B2 IS RUNNING AND FLAP GATE FG-1B IS
POSITIONED (POS-2) TO FEED CONV. 3 B2 AND MD-4 IS
17
PREPARED
CONV. 2 A
GSRK/ARUN
ON.
CONV. 3 A1 IS RUNNING AND FLAP GATE FG-1 IS
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 50 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
CONV. 2 B
OR
CONV. 3 B1 IS RUNNING AND FLAP GATE FG-2 IS
19
20
CONV. 1 A
CONV. 1 B
FROM SHIP
21
6.0.2
UNLOADERS
PATH- II: SHIP UNLOADERS TO BUNKER UNITS VIA CRUSHER HOUSE WITHOUT
STACKING
TTR-4
CONV. 17
CONV. 16 A
3
OR
CONV. 17 IS RUNNING
CONV. 16 B
4
PREPARED
CONV. 14 A
GSRK/ARUN
CHECKED
MS/NH
Sheet 51 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
CONV. 14 B
TTR-3
CONV. 15
CONV. 12 A
OR
CONV. 13 IS RUNNING AND FLAP GATE FG-18 IS POSITIONED
(POS 2) TO FEED CONV. 13.
CONV. 14 B IS RUNNING AND FLAP GATE FG-18 IS
POSITIONED (POS 1) TO FEED CONV. 14 B.
CONV. 12 B
OR
CONV. 13 IS RUNNING AND FLAP GATE FG-18 IS POSITIONED
(POS 2) TO FEED CONV. 13.
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 52 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
10
TTR-2
11
CONV. 13
12
CONV. 10 A
OR
CONV. 11 IS RUNNING AND FLAP GATE FG-14 IS POSITIONED
(POS 2) TO FEED CONV. 11.
CONV. 12 B IS RUNNING AND FLAP GATE FG-14 IS
POSITIONED (POS 1) TO FEED CONV. 12 B.
13
CONV. 10 B
OR
CONV. 11 IS RUNNING AND FLAP GATE FG-14 IS POSITIONED
(POS 2) TO FEED CONV. 11.
14
TTR-1
15
CONV. 11
16
CONV. 9 A
OR
CONV. 10 B IS RUNNING AND FLAP GATE FG-11 IS
POSITIONED (POS 2) TO FEED CONV. 10 B AND BW8 IS ON.
CONV. 10 A IS RUNNING AND FLAP GATE FG-12 IS
17
CONV. 9 B
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 53 Of 70
PROJECT
L&T
DOC
NO
APML
DATED
ECC DIVISION
REV NO:
CONV. 8 A
OR
CONV. 9 B IS RUNNING AND FLAP GATE FG-9 IS POSITIONED
(POS 2) TO FEED CONV. 9 B AND ILMS6 & MD8 ARE ON.
CONV. 9 A IS RUNNING AND FLAP GATE FG-10 IS
POSITIONED (POS 1) TO FEED CONV. 9 A AND ILMS5 & MD7
ARE ON.
19
CONV. 8 B
OR
CONV. 9 B IS RUNNING AND FLAP GATE FG-10 IS
POSITIONED (POS 2) TO FEED CONV. 9 B AND ILMS6 & MD8
ARE ON.
20
CONV. 7 A
21
CONV. 7 B
22
CONV. 6 A
OR
CONV. 7 B IS RUNNING AND FLAP GATE FG -7 IS
POSITIONED (POS-2) TO FEED CONV. 7 B
.
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 54 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
CONV. 6 B
24
CONV. 5 A
OR
ROLLER SCREEN 1 & CRUSHER 1 ARE IN OPERATION AND
FLAP GATE FG -5 IS POSITIONED (POS-2) TO FEED ROLLER
SCREEN AND CONV. 6 A IS RUNNING.
CONV. 5 A IS RUNNING AND FLAP GATE FG-3 IS POSITIONED
(POS-1) TO FEED CONV. 5 A AND ILMS-3 & MD-5 ARE ON.
25
CONV. 4 A
OR
CONV. 5 B IS RUNNING AND FLAP GATE FG-3 IS POSITIONED
(POS-2) TO FEED CONV. 5 B AND ILMS-4 & MD-6 ARE ON.
CONV. 5 A IS RUNNING AND FLAP GATE FG-4 IS POSITIONED
26
CONV. 4 B
27
CONV. 3 A2
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 55 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
CONV. 3 B2
OR
CONV. 4 B IS RUNNING AND FLAP GATE FG-2B IS
POSITIONED (POS-2) TO FEED CONV. 4 A.
CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1A IS
POSITIONED (POS-1) TO FEED CONV. 3 A2 AND MD-3 IS ON.
29
CONV. 3 A1
OR
CONV. 3 B2 IS RUNNING AND FLAP GATE FG-1A IS
POSITIONED (POS-2) TO FEED CONV. 3 B2 AND MD-4 IS ON.
CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1B IS
POSITIONED (POS-1) TO FEED CONV. 3 A2 AND MD-3 IS ON.
30
CONV. 3 B1
OR
CONV. 3 B2 IS RUNNING AND FLAP GATE FG-1B IS
POSITIONED (POS-2) TO FEED CONV. 3 B2 AND MD-4 IS ON.
CONV. 3 A1 IS RUNNING AND FLAP GATE FG-1 IS
POSITIONED (POS-1) TO FEED CONV. 3 A1.
31
CONV. 2 A
OR
CONV. 3 B1 IS RUNNING AND FLAP GATE FG-1 IS
POSITIONED (POS-2) TO FEED CONV. 3 B1.
CONV. 3 A1 IS RUNNING AND FLAP GATE FG-2 IS
32
CONV. 2 B
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 56 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
6.0.3
1
2
CONV. 1 A
CONV. 1 B
FROM SHIP
UNLOADERS
PATH- III: SHIP UNLOADERS TO BUNKER UNITS VIA CRUSHER HOUSE WITH
STACKING
TTR-4
CONV. 17
CONV. 16 A
3
OR
CONV. 17 IS RUNNING
CONV. 16 B
CONV. 16 A IS RUNNING AND FLAP GATE FG-21 IS
POSITIONED (POS 1) TO FEED CONV. 16 A.
4
CONV. 14 A
OR
CONV. 15 IS RUNNING AND FLAP GATE FG-21 IS
POSITIONED (POS 2) TO FEED CONV. 15.
CONV. 16 B IS RUNNING AND FLAP GATE FG-22 IS
POSITIONED (POS 1) TO FEED CONV. 16 B.
CONV. 14 B
OR
CONV. 15 IS RUNNING AND FLAP GATE FG-22 IS
TTR-3
CONV. 15
PREPARED
GSRK/ARUN
CHECKED
MS/NH
Sheet 57 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
CONV. 12 A
OR
CONV. 13 IS RUNNING AND FLAP GATE FG-18 IS
POSITIONED (POS 2) TO FEED CONV. 13.
CONV. 14 B IS RUNNING AND FLAP GATE FG-18 IS
POSITIONED (POS 1) TO FEED CONV. 14 B.
CONV. 12 B
OR
CONV. 13 IS RUNNING AND FLAP GATE FG-18 IS
POSITIONED (POS 2) TO FEED CONV. 13.
10
TTR-2
11
CONV. 13
CONV. 10 A
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 58 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
CONV. 10 B
OR
CONV. 11 IS RUNNING AND FLAP GATE FG-14 IS
POSITIONED (POS 2) TO FEED CONV. 11.
14
TTR-1
15
CONV. 11
16
CONV. 9 A
17
CONV. 9 B
18
CONV. 8 A
CONV. 9 A IS RUNNING AND FLAP GATE FG-9 IS
POSITIONED (POS 1) TO FEED CONV. 9 A AND ILMS5 & MD7
ARE ON.
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 59 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
OR
CONV. 9 B IS RUNNING AND FLAP GATE FG-9 IS
POSITIONED (POS 2) TO FEED CONV. 9 B AND ILMS6 & MD8
ARE ON.
CONV. 8 B
ARE ON.
OR
CONV. 9 B IS RUNNING AND FLAP GATE FG-10 IS
POSITIONED (POS 2) TO FEED CONV. 9 B AND ILMS6 & MD8
ARE ON.
20
CONV. 7 A
21
CONV. 7 B
CONV.
22
19(STACKING) OR
CONV.
21(STACKING)
23
CONV. 18 A
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 60 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
CONV. 18 B
CONV. 20 A
25
OR
CONV. 20 B
CONV. 7 A IS RUNNING AND FLAP GATE FG -7 IS
POSITIONED (POS-1) TO FEED CONV. 7 A.
26
CONV. 6 A
OR
CONV. 7 B IS RUNNING AND FLAP GATE FG -7 IS
POSITIONED (POS-2) TO FEED CONV. 7 B.
CONV. 7 A IS RUNNING AND FLAP GATE FG -8 IS
27
CONV. 6 B
28
CONV. 5 A
OR
ROLLER SCREEN 1 & CRUSHER 1 ARE IN OPERATION AND
FLAP GATE FG -5 IS POSITIONED (POS-2) TO FEED ROLLER
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 61 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
CONV. 5 B
OR
ROLLER SCREEN 2 & CRUSHER 2 ARE IN OPERATION AND
FLAP GATE FG -6 IS POSITIONED (POS-2) TO FEED ROLLER
SCREEN AND CONV. 6 B IS RUNNING.
CONV. 5 A IS RUNNING AND FLAP GATE FG-3 IS
POSITIONED (POS-1) TO FEED CONV. 5 A AND ILMS-3 & MD5 ARE ON.
30
CONV. 4 A
OR
CONV. 5 B IS RUNNING AND FLAP GATE FG-3 IS
POSITIONED (POS-2) TO FEED CONV. 5 B AND ILMS-4 & MD6 ARE ON.
CONV. 5 A IS RUNNING AND FLAP GATE FG-4 IS
POSITIONED (POS-1) TO FEED CONV. 5 A AND ILMS-3 & MD5 ARE ON.
31
CONV. 4 B
OR
CONV. 5 B IS RUNNING AND FLAP GATE FG-4 IS
POSITIONED (POS-2) TO FEED CONV. 5 B AND ILMS-4 & MD6 ARE ON.
CONV. 4 A IS RUNNING AND FLAP GATE FG-2A IS
POSITIONED (POS-1) TO FEED CONV. 4 A.
32
CONV. 3 A2
OR
CONV. 4 B IS RUNNING AND FLAP GATE FG-2A IS
33
PREPARED
CONV. 3 B2
GSRK/ARUN
CHECKED
MS/NH
Sheet 62 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
OR
CONV. 4 B IS RUNNING AND FLAP GATE FG-2B IS
POSITIONED (POS-2) TO FEED CONV. 4 A.
CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1A IS
POSITIONED (POS-1) TO FEED CONV. 3 A2 AND MD-3 IS ON.
34
CONV. 3 A1
OR
CONV. 3 B2 IS RUNNING AND FLAP GATE FG-1A IS
POSITIONED (POS-2) TO FEED CONV. 3 B2 AND MD-4 IS ON.
CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1B IS
POSITIONED (POS-1) TO FEED CONV. 3 A2 AND MD-3 IS ON.
35
CONV. 3 B1
OR
CONV. 3 B2 IS RUNNING AND FLAP GATE FG-1B IS
POSITIONED (POS-2) TO FEED CONV. 3 B2 AND MD-4 IS ON.
CONV. 3 A1 IS RUNNING AND FLAP GATE FG-1 IS
POSITIONED (POS-1) TO FEED CONV. 3 A1.
36
CONV. 2 A
OR
CONV. 3 B1 IS RUNNING AND FLAP GATE FG-1 IS
POSITIONED (POS-2) TO FEED CONV. 3 B1.
CONV. 3 A1 IS RUNNING AND FLAP GATE FG-2 IS
POSITIONED (POS-1) TO FEED CONV. 3 A1.
37
CONV. 2 B
OR
CONV. 3 B1 IS RUNNING AND FLAP GATE FG-2 IS
38
39
40
PREPARED
CONV. 1 A
CONV. 1 B
FROM SHIP
UNLOADERS
OR
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 63 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
CONV. 17
CONV. 16 A
3
OR
CONV. 17 IS RUNNING
CONV. 16 B
CONV. 16 A IS RUNNING AND FLAP GATE FG-21 IS
POSITIONED (POS 1) TO FEED CONV. 16 A.
4
CONV. 14 A
OR
CONV. 15 IS RUNNING AND FLAP GATE FG-21 IS
POSITIONED (POS 2) TO FEED CONV. 15.
CONV. 16 B IS RUNNING AND FLAP GATE FG-22 IS
POSITIONED (POS 1) TO FEED CONV. 16 B.
CONV. 14 B
OR
CONV. 15 IS RUNNING AND FLAP GATE FG-22 IS
TTR-3
CONV. 15
CONV. 12 A
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 64 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
CONV. 12 B
OR
CONV. 13 IS RUNNING AND FLAP GATE FG-18 IS
10
TTR-2
11
CONV. 13
12
CONV. 10 A
OR
CONV. 11 IS RUNNING AND FLAP GATE FG-14 IS
POSITIONED (POS 2) TO FEED CONV. 11.
CONV. 12 B IS RUNNING AND FLAP GATE FG-14 IS
POSITIONED (POS 1) TO FEED CONV. 12 B.
13
CONV. 10 B
OR
CONV. 11 IS RUNNING AND FLAP GATE FG-14 IS
POSITIONED (POS 2) TO FEED CONV. 11.
14
TTR-1
15
CONV. 11
16
CONV. 9 A
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 65 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
CONV. 9 B
OR
CONV. 10 B IS RUNNING AND FLAP GATE FG-12 IS
POSITIONED (POS 2) TO FEED CONV. 10 B AND BW8 IS ON.
CONV. 9 A IS RUNNING AND FLAP GATE FG- 31 IS
POSITIONED (POS 1) TO FEED CONV. 9 A AND ILMS5 & MD7
ARE ON.
18
CONV. 22 A
OR
CONV. 9 B IS RUNNING AND FLAP GATE FG-31 IS
POSITIONED (POS 2) TO FEED CONV. 9 B AND ILMS6 & MD8
ARE ON.
CONV. 9 A IS RUNNING AND FLAP GATE FG- 32 IS
POSITIONED (POS 1) TO FEED CONV. 9 A AND ILMS5 & MD7
ARE ON.
19
CONV. 22 B
OR
CONV. 9 B IS RUNNING AND FLAP GATE FG-32 IS
POSITIONED (POS 2) TO FEED CONV. 9 B AND ILMS6 & MD8
ARE ON.
20
CONV. 19
SR 2 RECLAIMER IS RUNNING & CONV. 22 A IS RUNNING
AND FLAP GATE FG-30 IS POSITIONED (POS 1) TO FEED
CONV. 22 A.
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 66 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
OR
SR 2 RECLAIMER IS RUNNING & CONV. 22 B IS RUNNING
AND FLAP GATE FG-30 IS POSITIONED (POS 2) TO FEED
CONV. 22 B.
SR 1 RECLAIMER IS RUNNING & CONV. 22 A IS RUNNING
AND FLAP GATE FG-29 IS POSITIONED (POS 1) TO FEED
21
CONV. 22 A.
CONV. 21
OR
SR 1 RECLAIMER IS RUNNING CONV. 22 B IS RUNNING AND
FLAP GATE FG-29 IS POSITIONED (POS 2) TO FEED CONV.
22
22 B.
CONV. 22 A OR CONV. 22 B IS RUNNING
GROUND HOPPER
ANNUNCIATION SYSTEM
Alarms shall be available at HMI for the following audio-visual fault annunciation purposes. Wherever
group annunciation is provided, alarm status of individual equipment will be provided on HMI.
a)
b)
c)
d)
e)
f)
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 67 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
r)
s)
t)
u)
For identification of the fault for a particular conveyor or equipment, the status indication against that
conveyor/equipment in the graphics window will start fast flickering and the alarms will be flickering
against the particular fault. Also a buzzer will start sounding. After acknowledgement of the fault, the
buzzer will stop, but the fast flickering on the mimic & the steady glow on the HMI will continue until the
fault is cleared and the alarm is acknowledged. When the fault is cleared and the alarm acknowledged,
the status indication of that conveyor/equipment on the graphic will start slow blinking if it is on selected
path.
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 68 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
At the time of fault, the faulty conveyor / equipment as well as the preceding conveyors / equipment in
the interlock sequence, will stop except HT motors will continue to run for process fault. In case of
motor fault, the HT 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 will not be indicated alarm is acknowledged after clearance of fault.
The sequence of operation of the annunciation system will be as follows:
Sequence
Normal
Fault
Press Accept PB
Press Reset PB
Condition
Annunciation window.
Status Indication
Buzzer
Annunciation window.
Status Indication
Buzzer
Annunciation window.
Status Indication
Buzzer
Annunciation window.
Status Indication
Status
Off
Steady Glow
Off
Flickering
Fast Flickering
Sounding
Steady Glow
Fast Flickering
Off
Off
Steady Blinking (if on Selected path)
Buzzer
Conveyor ON
2.
3.
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 69 Of 70
PROJECT
DOC
NO
L&T
APML
DATED
ECC DIVISION
REV NO:
4.
5.
6.
7.
Crusher ON
8.
Vibrating feeders ON
9.
MD / ILMS /CSU ON
10.
Bunker level.
PREPARED
GSRK/ARUN
DOCUMENT TITLE
OPERATION & CONTROL PHILOSOPHY OF
CHECKED
MS/NH
Sheet 70 Of 70