Intent of Specification This specification is intended to cover the following activities and services in respect of all the equipments

of Coal Handling Plant for 2500 MW units !!0 !!! Scheme of Coal Handling System Coal shall "e transported to the plant in "ottom discharge wagon ra#es and shall "e unloaded in under ground $ C C Trac# hopper %i& '() num"er paddle '$otar* plough) feeders+ each of ,00 T-Hr rated capacit* shall "e installed at the "ottom of the Trac# hopper to scoop the coal from trac# hopper and feed coal on to the underground conve*ors !.-!/ There shall "e three paddle feeders on each conve*or of which two shall wor# simultaneousl* and one shall remain stand "* Two '2) nos 1n23ine Magnetic separators to remove tramp iron pieces shall "e mounted on the discharge end of conve*ors 0.-0/ The rated capacit* of each conve*or in coal handling plant shall "e!(00 TPH Conve*or !.-!/ will discharge coal on conve*or 2.-2/ in transfer point TP2! Conve*or 2.-2/ will carr* coal to Primar* Crusher House for crushing coal from 000mm to '2) !50mm 1n the Primar* crusher House each of the conve*or 2. and 2/ shall transfer coal to separate sets of two Crushers through feeders+ such that coal flow ma* "e properl* distri"uted to the crushers in service There shall "e 5our '4) num"ers rotar* "rea#ers each of ,00 TPH capacit* with two '2) normall* wor#ing and two as stand"* Provision shall "e made such that all the four crushers ma* run when "oth streams are required to operate

!!2

!!0

!!4

!!5

Two '2) nos "elt weigh scales shall "e provided on conv !.-!/ for weighing the coal received in the trac# hopper Conve*or 0.-0/ will conve* coal to %econdar* Crusher house which shall have four '4) Crushers each of ,00 TPH capacit* Coal from each incoming conve*or 0.-0/ to crushers will pass through a set of two nos dedicated vi"rating roller screens so that maintenance of equipment+ hopper+ chutes in either stream does not affect the operation of other stream 7ach roller screen shall "e of ,00 TPH capacit* The four '4) Crushers+ each of ,00 MTPH capacit*+ shall crush the coal to '2) 20 mm si8e 1nput coal a"ove 20 mmsi8e shall "e fed to the crushers /oth+ the screened coal "elow 20 mm si8e and crushed coal shall "e discharged either onto conve*or 4.-4/ or to stac#ing *ard Conve*or 9o , 5rom conve*or 4.-4/+ normall* the crushed coal will "e fed on Conve*or 5.-5/ for onward transmission to Conve*or (.-(/ through the transfer point2 'TP22)+ TP20 and TP24 1n TP22 and TP20+ provision shall "e #ept for feeding the coal to one future conve*or for second future %tac#er2 cum2$eclaimer and Conve*or for e&tension stage if required %tac#er2cum2$eclaimer is envisaged for stoc#2 *ard having reversi"le conve*or , as *ard conve*or The feeding of coal from conv , on "oom conve*or of %$ shall ta#e place during stac#ing mode :ard conv , shall discharge coal on conv ;.-;/ at TP2( while on reclaim mode .t TP25+ conve*or (.-(/ will discharge coal onto conve*or 6.-6/ Two '2) nos 1n2line magnetic separators '13M%) shall "e provided over the discharge end of conve*or (.-(/ for e&traction of tramp magnetic pieces

!!(

!!6

!!,

!!;

! ! !0

Two '2) nos "elt scales shall "e provided on conve*or (.-(/ for weighing the coal received from stoc# *ard Conve*or (.-(/ shall discharge coal onto "un#er "a* conve*ors 6.-6/ at TP25 <ne '!) no Travelling Tripper mounted on each of the conve*ors 6.-6/ shall feed coal into $aw coal "un#ers of the "oiler units <ne '!) no stac#er cum reclaimer '%-$) machine of !(00 TPH rated capacit* shall "e provided on *ard conve*or , The %-$ machine shall operate on rails for stac#ing-reclaiming the coal in the stoc# *ard area =uring reclaiming the coal shall "e conve*ed to the *ard conve*or , "* reclaiming operation of %-$ machine and shall "e fed to conve*or ;.-;/ at TP2( =uring stac#ing mode of operation of the machine+ coal from crusher house shall "e fed to *ard conve*or , <ne "elt scale shall "e provided on :ard Conve*or Two nos coal sampling units shall "e installed one each at crusher house and TP24 to sample the coal of '2) !50 mm si8e and '2) 20 mm si8e respectivel* 1n the event of direct flow through !.->/+ 2.-2/+ 0.-0/+ 4.-4/ is not resorted+ then the coal will "e reclaimed from coal heap with the help of %-$ and chain of conve*or 9o ,+ ;.-;/ and !0.-!0/ and will "e transfer crushed coal to conve*or (.-(/ at TP24 1n the case of %-$ "eing out of order and crushed coal is required to "e reclaimed+ si& emergenc* underground reclamation hoppers shall "e provided on conve*or 9o ;.-;/ The coal from crushed coal heaps shall "e do8ed into these hoppers with the help of /ull2=o8er

! ! !!

! ! !2

! ! !0

! ! !4

! ! !5

! ! !(

1.3.0 System Design Basis 1.4.0 Spare Parts

1.6.0 Equipment Specification 1.8.0 Testing and Inspection

V !D "S

1. #$s. %"& 'td.(11( Station "oad(( )amshedp*r+,3100Phone. //-1/,0+/13 &a2. ///-103 /. #$s. lecon ngg. Co. 'td.(4nand So5itra "dfoad( Valla6h Vidya !agar 7 3,,1/0( 8*5arat Phone . /3-010+1- &a2. /30433. #$s. %hyssen9r*pp India 'td.(Pimpri( P*ne 7 41101,( #aharashtra :India; Phone . /-4/3330 4. #$s. '<% 'td.#o*nt Poonamallee "oad( Manapakam, Post Bag No. ! ,
"#ennai $ 600 08 .

5.Tecpro Systems Ltd www.tecprosystems.com 106, Vishwadeep Tower, Plot No.4, District Ce tre, !a a"p#ri, New Delhi$110 05% Ph& '(1 11 450) %*)5 +a,&'(1 11 450) %*)4 6. -.s -c Nally /aharat *th +loor 4 -a 0oe La e 1ol"ata www.mc ally2harat.com *. -.s -/3 Li0 ite 4a dli 0 *th +loor 4 -a 0oe La e 1ol"ata
8.Ene%go Enginee%ing P%o&ects 'td (dd: A-57/4, Okhla Industrial Area, Phase-II, New Delhi 110020 Te)* 011-26 !5 2 /2!/2"/ ! +a,* 011-26 !5 E mai)* ener#$%ener#$india&'$( ---.ene%goindia.com

...........................

www.specahp.wordpress.com www.specmillre5ect.wordpress.com www.speci str#me tatio .wordpress.com

)ea*e a +$((ent

+e2r#ary (, 6010

CHP VENDERS AND SUPPLIERS

1&"/N0 BE'TIN1 a,I-A.. .A,/011+1 2, 3O4O5A-A,6APAN www&7r'&'$&89

Filed under: thermal power plant Tags: CHP VENDERS shiva i!houdhur" # $:%% am

', :A10;34 0;<<10 ,.&4O01A www&taer7uk&en&e'21&'$( d, P5O1NI= 3;)1 www&9h$eni>-'$n*e7$r2elts&'$( 2&ID)10. a, 4A)I,4;-<A4O NA2, ? ? N -@/ ?? NA/A0 ', 1)1+ON, ?? NA/A0 +$((ents A1,

7cto2er )1, 600%

1.2.0 Scope of Work

!20 Scope of =or9

Filed under: thermal power plant Tags: !hp& spe!i'i!ation o' !oal handling plant shiva i!houdhur" # %:() am

The wor# shall include "ut not limited to the following? !2! !2!! #echanical >*ipment %i& '() 9os Paddle feeders+ complete with all electricals+ rails+ supporting structures+ end stops+ ca"le reeling drums+ trailing ca"les and necessar* accessories

!2!2

Complete /elt Conve*ing %*stems including Conve*or 9os !.-!/+ 2.-2/+ 0.-0/+ 4.-4/+ 5.-5/+ (.-(/+ 6.-6/+ ,+ ;.-;/ and !0.-!0/ complete with conve*or supporting structures+ short supports+ stringers+ dec# plate+ seal plate etc drive motors+ drive units+ pulle*s+ idlers+ gravit* ta#e ups+ ta#e up structure upto ground level+ internal and e&ternal "elt wipers+ pull chord switches+ "elt swa* and 8ero speed switches+ electro2h*draulic thruster "ra#es+ all electricals etc including all civil+ structural and architectural wor#s for conve*or galler*+ galler* supporting trestles and their associated foundations Tripper floor "elt conve*ors 6.-6/ in the "un#er "uilding complete with conve*or supporting structures+ short supports+ stringers+ dec# plate+ seal plate etc drive motors+ drive units+ pulle*s+ idlers+ gravit* ta#e ups with guides upto ground level e&cluding the ta#e2up structure+ internal and e&ternal "elt wipers+ pullchord switches+ "elt swa* and 8ero speed switches+ electro2h*draulic thruster "ra#es etc and all electricals etc :ard conve*or , complete with conve*or supporting structures+ short supports+ stringers+ dec# plates+ etc + drive motors+ drive units+ pulle*s+ idlers+ ta#e2ups+ ta#e2up structure+ internal and e&ternal "elt wipers+ pull @ chord switches+ "elt swa* and 8ero speed switches+ electro h*draulic thruster "ra#es+ all electricals+ etc including all civil+ structural and architectural wor#s and their associated foundations 5our '4) 9os Ai"rating feeders in Primar* Crusher House complete with drives+ all mechanical+ electrical and accessories 5our 9os $otar* /rea#ers complete with drives+ all mechanical+ electrical including civil and structural wor#s

!2!0

!2!4

!2!5

!2!(

Two '2) num"ers crusher house 'one primar* crusher house and one secondar* crusher house) complete with all civil+ structural+ architectural and electrical wor#s etc accommodating four nos crushers and associated vi"rating gri88l* feeders+ gates etc + goods cum passenger lift+ conve*ors+ chute wor# alongwith actuator operated flap gates+ hoists and other equipment such as coal sampling unit+ dust suppression B ventilation s*stem etc as specified elsewhere 5our '4) nos roller %creens 'in secondar* crusher house) complete with drives+ all mechanical+ electricals and accessories 5our '4) nos crushers complete with drives+ all mechanical+ electricals including civil B structural wor#s+ vi"ration isolation s*stem with springs B viscous dampers+ vi"ration monitoring s*stem etc 5our '4) sets of Cates each comprising of one rod gate and one actuator operated rac# B pinion gate at inlet to each of the a"ove vi"rating roller screens complete with drives+ all mechanical+ electrical+ structural wor#s etc Transfer point TP! alongwith under ground tunnel and pent house PH21+ TP2( alongwith underground tunnel and pent house PHD and drive house for *ard conve*or , complete with all civil+ structural+ architectural and electrical wor#s including chutes+ monorails+ hoists-chain pulle* "loc#s+ hoist maintenance platforms+ $CC-steel floors+ e&ternal staircases+ hand rails etc .ll transfer points shall have separate de"ris disposal chute right up to the ground floor .ll mechanical+ electrical equipment to "e housed in Transfer points TP2!+ TP22+ TP20+ TP24+ T P25+ T P2(+ T P26+ drive house of *ard conve*or and pent houses including chutes+ maintenance - operating platforms+ Monorails+ electric hoists etc <ne '!) no stac#er cum reclaimer machine having rated capacit* of !(00 TPH- !(00 TPH complete with all equipment and conve*ors+

!2!6

!2!,

!2!;

! 2 ! !0

! 2 ! !!

! 2 ! !2

structural+ electricals+ ca"le reeling drums+ all trailing ca"les and accessories+ rails+ rail foundations+ fi&ing and grouting of rails and other associated civil B structural wor#s to operate in conEunction with *ard conve*or , ! 2 ! !0 Complete chute wor# along with chute "loc# switches and actuator operated flap gates "etween various conve*ors and equipment at all transfer points and crusher house Three '0) 9os passenger @ cum @ goods elevators with drives+ all mechanical+ civil+ structural B associated foundation wor#s+ accessories and electricals to serve various floors of the Primar* and secondar* Crusher House 'CH) and TP25 Two '2) 9os motori8ed Travelling Trippers+ <ne '!) each on conve*or 6.-6/ Trippers shall "e complete with all mechanical+ electrical equipment+ rails+ rail supporting structure 'an* structural stools+ if required)+ ca"les with ca"le reeling drum+ all trailing ca"les+ "ra#es+ rail clamp etc Crid- grating over the "un#er slot on tripper floor is to "e provided "* the "idder The drive chain equipment for conve*or 6.-6/ therefore shall first "e placed at the end of unit no ! "un#ers for commissioning of unit no ! and shall "e later shifted at the end of the "un#er "a* at the time of commissioning of unit no 2 /idderDs scope of wor# shall include shifting of the drive chain equipment for conve*ors 6.-6/ for unit no 2 commissioning including its associated civil and electrical wor#s and ma#ing good the "un#er floor after shifting of the drive chain equipment to its ultimate location for unit no 2 commissioning ! 2 ! !( .dequate num"er of ventilation for ventilating the trac# hopper+ TP2!+ underground portion of conve*or !.-!/+ under ground portion of TP2( and under ground portion of conv ;.-;/ and "un#er "a* 'housing tripper conve*ors)

! 2 ! !4

! 2 ! !5

complete with all mechanical+ electrical+ civil and structural wor#s ! 2 ! !6 Pressurised Aentilation s*stem for all HT %witchgear room+ MCC rooms and %BT room complete with all mechanical+ electricals+ accessories+ civil and structural wor#s .ir conditioning of Main CHP control roomF operatorDs ca"in B MCC room on %tac#er-$eclaimer complete with all electricals+ civil B structural wor#s etc Minimum nine ';) 9os sump pumps si& '() nos in trac# hopper and three '0) nos sump pumps each in underground tunnel and Transfer point of Conve*or no ;.-;/ complete with motors+ local control panel+ level switches+ individual discharge piping with fittings and valves to nearest plant drain as specified and as indicated elsewhere Two '2) 9os coal sampling units+ one for '2) 000 mm si8e coal complete with all accessories and electricals+ supporting structures+ approach- maintenance platforms in unit+ in crusher house and one for '2) 20 mm si8e coal in TP24 complete with all accessories and electricals+ supporting structures+ approach- maintenance platforms <ne '!) 9o "elt vulcanising machines of adequate si8e complete with all mechanical+ electricals+ accessories and consuma"les 5our '4) 9os 1nline Magnetic %eparators+ complete with reEect chutes+ reEect "ins+ and all mechanical+ supporting arrangement+ electricals+ civil+ structural wor#s and accessories 5our '4) 9os 7lectronic /elt weighers complete with all mechanical+ supporting arrangement+ electricals+ and accessories

! 2 ! !,

! 2 ! !;

! 2 ! 20

! 2 ! 2!

! 2 ! 22

! 2 ! 20

! 2 ! 24

Complete dust suppression s*stem for control of fugitive dust in trac# hopper+ paddle feeder+ transfer points+ crusher house+ coal stoc# *ard complete with pump houses+ water tan#s+ pumps+ drives+ piping+ valves etc /elt %ealing arrangement in /un#er "a*s to operate in conEunction with tripper for control of dust coming out of $ C /un#ers %uita"le monorails and electricall* operated hoist "loc#s as well as hand operated chain pulle* "loc#s for servicing- installation - eas* replacement of drive machiner*+ different t*pes of pulle*s for all conve*ors+ CTG and other equipment from ground level to all locations 7lectric hoist provided at "un#er 'Tripper) floor and all transfer houses-crusher house shall also "e a"le to lift one "elt drum 'including wooden- %teel drum) safel* lectricals Two nos !! #A feeders and two nos 0 0 #A suppl* feeders shall "e provided from !! #A B 0 0 #A station "oard for feeding entire CHP The scope of wor# shall include+ "ut not limited to the following?

! 2 ! 25

! 2 ! 2(

!22

!22!

0 0 HA CHP %witchgears to feed HT drives including %tac#er $eclaimer and au&iliar* transformers .u&iliar* Transformers ? a) Two '2) nos !!-0 45 #A+ <9.9+ out door transformers for 0 0 HA CHP %witchgear 0 0 - 0 400 HA+ <9.9+ out door transformers for each of the CHP MCC21+ 11+ 111

!222

")

c)

<ne '!) no 0 0-0 400 HA+ =r* t*pe indoor Transformer for %-$ machine

!220

Three '0) nos of 4!5 A CHP MCCs to feed 3T loads of entire coal handling plant These three CHP MCCs are proposed to "e located as follows ? a) MCC211 in the MCC room near Trac# hopper area ") MCC21 in the switchgear room at CHP control room "uilding near %econdar* Crusher House c) MCC2111 in near Transfer Tower the MCC room

!224 !225

<ne '!) no of 4!5 A %tac#er-$eclaimer MCC 0 0 HA segregated phase "us ducts from !!-0 45 HA transformer to 0 0 HA CHP switchgear alongwith "ends+ terminations+ supports etc Control des# and Programma"le logic controllers

!22( 'P3Cs) ?

a)

Main control des# with C$T-#e*"oard and large video screen+ P3C panels+ remote 1-< rac#s etc for the control of the entire coal handling plant P3C s*stem with control des# and 1-< rac#s etc for %tac#er- $eclaimer machine

")

!226 !22,

.C distri"ution "oards as required %i& '() nos =C distri"ution "oards '2 9os each at the location of MCC21+ 11+ 111 3ocal push "utton stations for all drives

!22;

! 2 2 !0

1nternal and e&ternal illumination s*stem for the complete CHP B coal stoc# *ard+ including trac# hoppers+ TPs- conve*ors in "un#er area etc

! 2 2 !!

0 0 HA and ! ! HA grade 5$3%+ I3P7- PAC+ .1-Cu+ .rmoured power+ control+ trailing and special ca"les for the complete s*stem a) "etween equipment supplied under this specification ") "etween equipment supplied under this specification and PurchaserDs equipments

! 2 2 !2

Ca"le trenches - trestles including tra*s and supporting arrangement etc + required for the ca"les including la*ing B termination - Eointing etc

! 2 2 !0 7arthing and lightning protection s*stem for all equipment and "uildings ! 2 2 !4 ! 2 2 !5 "ase plates ! 2 2 !( Close circuit TA s*stem Crouting of "olt holes and underside of

<ne '!) 9o Main CHP control "uilding located adEacent to the secondar* Crusher House to house Main Control =es#+ P3C panels for the coal handling plant on the first floor and 0 0 HA CHP switchgear+ 4!5A CHP MCCs =C=/+ lighting panels etc on the ground floor .ssociated au&iliar* outdoor transformers shall "e located suita"l* adEacent to the "uilding Two '2) no MCC rooms each to "e located near T P2! and T P25 7ach MCC room shall have 4!5A CHP MCC2! and CHP2MCC211 respectivel*+ lighting distri"ution "oards+ =C=/+ 1-< panel etc .ssociated au&iliar*

! 2 2 !6

outdoor transformers shall "e located suita"l* adEacent to the "uilding ! 2 2 !, <ne '!) no %BT 'signalling B telecommunication) "uilding to "e located at e&it of trac# hopper .ll MCC room "uildings shall "e complete with all electrical+ civil+ structural+ architectural wor#s+ ca"le trenches+ fire safet* walls+ foundation - fencing - earthing for transformers etc

! 2 2 !;

! 2 2 20 .ll ca"le-duct tan#s-trenches-trestles including civil B structural wor#s

!200

Control < Instr*mentation <peration and Control Philosoph* The coal handling s*stem shall "e controlled from the following control points

!20!

Coal Handling Plant #ain Control "oom <verall+ operation of the following equipment of Coal Handling Plant shall "e controlled from the main CHP control room a, +$n*e7$rs, Beeders, Bla9 #ates, 0 C P #ates, 'rushers, ?i2ratin# 0$ller .'reens& Paddle feeders 'running status with stop facilities) Complete =ust %uppression s*stem B service water s*stem Aentilation s*stem 'group-individual control as required) Ai"ration Monitoring %*stem 1n line Magnetic separators '<9-<55 control with indication) Coal %ampling %*stems '<9-<55 control with indication) /elt weigher '<9-<55 control with indication)

") c) d) e) f) g) h)

i) E) !202

%tac#er $eclaimer '<9-<55 status with stop facilities) Mo"ile trippers over "un#ers 'tripper position indications)

'ocal Control Panels 3ocal control stations for following equipmentDs shall "e provided a) ") c) d) e) Paddle feeders along with its dust suppression s*stem Mo"ile trippers over "un#ers Coal %ampling units /elt Weighers 7lectric hoist @ wall mounted control "o& with pendent push "utton controls 1n line magnetic separators %ump Pump %uspended Magnet

f) g) h)

All the a2$*e l$'al '$ntr$l 9anels shall 2e a''essi2le and l$'ated near their res9e'ti*e eDui9(ent and shall 2e '$(9lete with all the reDuired '$ntr$ls, interl$'ks, annun'iati$nEs et'& @urther, ne'essar7 '$ntr$ls, indi'ati$ns and annun'iati$nEs B$r all the a2$*e eDui9(ent shall als$ 2e 9r$*ided at (ain +5P +$ntr$l 0$$( as des'ri2ed under rele*ant 'lause& !200 Stac9er $ "eclaimer Control "oom :he entire '$ntr$l C $9erati$n $B .ta'ker 0e'lai(er (a'hine shall 2e Br$( the $9erat$rEs 'a2in $n the (a'hine itselB& !204 1n addition to the remote control of various equipmentDs+ local stop push "utton stations shall "e provided for all equipment :ra'k h$99er t$ the re'lai( '$n*e7$r shall 2e '$ntr$lled Br$( the 9addle Beeder itselB 2ased $n instru'ti$ns Br$( (ain '$ntr$l r$$(& !) The following equipment will not come under interloc# of the scheme conve*or

2) ,

/elt swa* switch @ not operated ;nder s9eed swit'h F 'l$sed at "0G s9eed $B the '$n*e7$r within desi#ned a''eleratin# ti(e& Motor protection @ not tripped 3ocal stop P/ @ reset Chute /loc# switch @ not operated Two such switches shall "e provided 7nd of travel limit switches @ reset

4) 5) () 6)

!205

4nn*nciation System. :he (i(i' 9anel 'u( +$ntr$l desk shall 2e 9r$*ided with adeDuate nu(2er $B Ba'ia t79e annun'iati$n wind$ws $9eratin# thr$u#h P)+ B$r audi$-*isual Bault annun'iati$n 9ur9$ses& Hhere*er #r$u9 annun'iati$n is 9r$*ided, alar( status $B indi*idual eDui9(ent shall 2e 9r$*ided $n +0:&
+$((ents A1,

1.3.0 System Des !" #$s s

!00 System Design Basis

Filed under: thermal power plant Tags: !hp shiva i!houdhur" # %:(* am

The mechanical and structural - civil s*stem shall "e designed for !(00 TPH rated capacit* and round the cloc# operation with "oth the streams operating simultaneousl* i) The Coal delivered to the power station shall "e of si8e 000 mm B "elow <ccasionall* !22J coal of 400 mm lump si8e ma* also "e encountered ii) HC1 of the Coal shall "e "etween 44 to (5 9ormall* moisture content in coal will var* "etween !2J to !5J However for design purposes+ moisture content of 20J shall "e considered =ue to open cast method of mining involved+ the coal ma* contain shale and sand stone as high as 20J .lso occasionall* metal pieces li#e "ro#en shovel teeth+ "ra#e shoe+

iii)

wires etc + ma* also come alongwith coal from open cast mine iv) The coal Kas receivedL shall contain var*ing percentage of fines Coal with such fines ma* tend to form adhesive lumps+ particularl* during monsoon when surface moisture is at its ma&imum value The si8ing and selection of the vital equipment vi8 crushers+ vi"rating roller screens+ paddle feeders etc covered under the s*stem shall "e "ased on the a"ove characteristic of coal and operating conditions /idder shall ensure that equipment- s*stem efficienc* shall not "e effected particularl* during monsoon when surface moisture is at its ma&imum value 5or the purpose of volumetric computation+ the "ul# densit* of the coal shall "e ta#en as ,00 #g-m0 Therefore for calculation of "elt conve*or capacit*+ for their drives B drive motors #W requirement+ and si8ing 'volume calculations) of chute+ hoppers etc the a"ove "ul# densit* shall "e considered 5or all other purpose vi8 for stresses- load on structures+ torque calculations of paddle wheel of paddle feeder+ "uc#et wheel of stac#er - $eclaimer+ si8ing of actuators for flap gates+ $BP gates+ calculations of plugged chute- hopper loads etc the "ul# densit* of the coal shall "e ta#en as !!00 #g-m0 .ll mechanical+ and structural - civil s*stem design shall consider simultaneous running of "oth the streams+ starting of one stream with the other stream in standstill condition as well as starting of one stream with the other stream in operation !0! System "e>*irement ! 2 Coal Consumption per 500 MW unit Coal consumption for 2500 MW units 0;0 TPH 6,0 TPH

0 4

=ail* Coal consumption for 2500 MW units !,620 T 9o of streams provided for the Coal Two '2) Handling Plant '! operating M ! stand"*) %ince plant is to "e operated generall* on !,620 design coal+ hence capacit* of each coal 26 stream considering 2 no shift dail* 6 hrs per shift N !006 T Capacit* of each coal stream chosen !(04 T considering !20J margin over worst coal requirement Hence capacit* of each coal stream !(00 T

The CHP facilit* shall have two '2) coal streamsF one '!) operating M one '!) stand"* having guarantee capacit* of each stream as !(00 TPH CHP shall "e operated normall* for two shifts per da* 'single stream operation "asis) to meet the dail* coal requirement of the two '2) units However+ all components of CHP facilit* shall "e designed for continuous dut* of 24 hours-da* The CHP shall "e designed B installed such that an* one stream can "e operated and if required "oth the streams can "e operated simultaneousl*
+$((ents A1,

1.%.0 Sp$re P$rts

!40 !4! Spare Parts 8eneral

Filed under: thermal power plant Tags: !hp shiva i!houdhur" # %:(+ am

The Contractor shall indicate and include in his scope of suppl* all the necessar* mandator* spares+ start2up commissioning spares and recommended spares in the relevant schedules The variation in quantit* of spares "ased on

unit rates 'rates as quoted for mandator* spares and rates as mutuall* agreed for recommended spares)+ if desired "* the Purchaser shall "e accepta"le to the contractor The Purchaser reserves the right to "u* an* or all mandator* and recommended spares The contractor shall identif* service e&pectanc* period for all items of spares+ under normal operating conditions "efore order placement The Contractor shall also indicate the unit wise population of each item and the service e&pectanc* period for the spare parts '"oth mandator* and recommended) under normal operating conditions "efore order placement is necessar* .ll spares supplied under this contract shall "e strictl* interchangea"le with the parts for which the* are intended for replacements The spares shall "e treated and pac#ed for long storage under the climatic conditions prevailing at the site+ e g small items shall "e pac#ed in sealed transparent plastic "ags with dissector pac#s as necessar* 7ach spare part shall "e clearl* mar#ed or la"eled on the outside of the pac#ing with the description When more than one spare part is pac#ed in single case+ a general description of contents shall "e on the outside of such case and a detailed list enclosed .ll cases+ containers and other pac#ages must "e suita"l* mar#ed and num"ered for the purposes of identification Purchase specification B addresses of Procurement sources of all mandator* spares B recommended spares shall "e furnished =etails of all t*pes of "earings in the plant shall also "e furnished !4! #andatory Spare Parts

:he list $B (andat$r7 s9ares, whi'h are '$nsidered essential 27 the Pur'haser, is indi'ated in en'l$sed Anne>ure- & :he Pur'haser reser*es the ri#ht t$ 2u7 an7 $r all (andat$r7 s9ares& :he <idder shall in'lude all the (andat$r7 s9ares in his 9r$9$sal& :he <idder shall Burnish in the rele*ant s'hedule $B <id 9r$9$sal sheets, the ite(wise and t$tal 9ri'e B$r these s9ares (enti$ned in the a2$*e Anne>ure& @urther whene*er the s9ares are indi'ated in 9er'enta#e and nu(eri'al Bi#ures, arri*ed is in Bra'ti$n, the sa(e 2e '$n*erted t$ the ne>t wh$le nu(2er& 1n line with the requirements in 1T/+ the prices for mandator* spares indicated separatel* shall "e used for "id evaluation purposes .ll mandator* spares shall "e delivered at site at least two months "efore scheduled date of trial operation of the s*stem However+ spares shall not "e dispatched "efore dispatch of corresponding main equipment !42 "ecommended Spares 1n addition to the spares mentioned a"ove+ the contractor shall also provide a list of recommended spares with unit and total prices for 0 *ears of normal operation of the s*stem for spares of 1ndian origin and 52*ears for spares for non21ndian origin in relevant schedule of /id Proposal %heets The list shall ta#e into consideration the mandator* spares specified in .nne&ure2 and should "e independent of the list of the mandator* spares The Purchaser reserves the right to "u* an* or all recommended spares Prices of recommended spares will not "e used for the evaluation of /ids The prices of these spares will remain valid upto !2 months after the placement of order for main equipment pac#age The Purchaser reserves the right to "u* an* or all recommended spares 5urther+

the prices of recommended spares wherever common with the mandator* spares shall "e the same as those of mandator* spares Prices of recommended spares not listed as mandator* spares shall "e reviewed "* Purchaser and shall "e mutuall* agreed with the contractor However+ the contractor shall "e lia"le to provide necessar* Eustification for the quoted prices for the spares desired "* the Purchaser !40 Start+*p Commissioning Spares %tart2up commissioning spares are those spares which ma* "e required during the start2up and commissioning of the equipment - s*stem .ll spares used until the plant is handed over to the Purchaser shall come under this categor* The contractor shall provide for an adequate stoc# of such start2up commissioning spares to "e "rought "* him to the site for plant erection and commissioning The* must "e availa"le at site "efore the equipment are energised and the unused spares+ if an*+ should "e removed from there onl* after the issue of ta#ing over certificate .ll start up spares+ which remain unused at that time+ shall remain the propert* of the Contractor The list of commissioning spares to "e "rought "* the Contractor to ensure smooth commissioning of the plant shall "e su"Eect to PurchaserDs approval The Contractor shall su"mit a complete list of all such start2up commissioning spares The cost of a"ove spares+ if an*+ and that consumed "efore the handing over of the plant shall "e deemed to have "een included in the lumpsum proposal price of the pac#age and the Contractor shall have no claim on this account to the Purchaser .ll cases+ containers+ other pac#ages are lia"le to "e opened for such e&amination+ as ma* "e considered necessar* "* the ProEect manager 1n case contractor is not a"le to su"mit report of t*pe test's) conducted in last five *ears+ or in case t*pe test report's) are not found to "e

meeting the specification-relevant standard requirements+ then all such tests shall "e conducted under this contract "* the Contractor free of cost to Purchaser+ and reports shall "e su"mitted for approval 7ven if the /idder is furnishing valid test report as indicated a"ove+ Purchaser ma* get some t*pe test conducted under this contract as specified in su"sequent chapters for which /idder shall include in his total equipment price the cost of carr*ing out all such t*pe tests The charges for each of these t*pe tests shall "e given separatel* in the relevant schedule of "idding documents for the price adEustment purpose+ in case waiver of an* test at a later date .ll acceptance and routine tests as per relevant standard and specification shall "e carried out Charges for these shall "e deemed to "e included in the "id price
+$((ents A1,

1.&.0 'est "!

!50

Filed under: ,n!ategori-ed Tags: !hp shiva i!houdhur" # %:(. am

%esting %ests at Site .fter erection at site+ the complete s*stemequipment will "e operated at site to show satisfactor* performance as required "* the applica"le clauses of the specification 5urther+ all piping shall "e h*draulic2tested at site The contractor shall furnish the qualit* procedures to "e adopted for assuring qualit* from the receipt of material at site+ during storage+ erection+ pre2commissioning to final trial run and commissioning of the complete s*stem- equipment
)ea*e a +$((ent

1.(.0 E)* pme"t Spec f c$t o"

Filed under: ,n!ategori-ed Tags: !hp shiva i!houdhur" # %:+) am

!(0 !(!

>*ipment Specification Paddle &eeder Travelling paddle feeders of self2contained+ self2propelled design shall "e furnished and erected to scoop out coal from the hopper and each feeder shall "e capa"le of travelling "ac# and forth along the entire length of the hopper and transfer the coal from the hopper uniforml* onto the conve*ors "elow 7ach paddle feeder shall have capacit* to scoop out coal at the guaranteed capacit* in "oth forward and reverse motions with no indication of wheel slipping 'water tan# full) 7ach paddle feeder shall "e designed for guaranteed capacit* while handling entire range of lump si8es 1t shall operate on the principle of positive discharge and shall not depend on friction or moisture content The Paddle wheel shall "e driven "* a stepless h*draulic drive Carriage travel shall "e achieved through electric motor gear"o& '2 speed) and fle&i"le coupling or through h*draulic drive Minimum num"er of starts-min for chain drive equipments shall "e !5 starts-min 'with minimum !0 consecutive starts) .ll equipmentDs shall "e designed to withstand an* rate of acceleration imparted "* drives or an* strain resulting from a sudden change in load 5urther+ the design of paddle feeder carriage should "e such that it does not run off from its rails due to sudden change in load or other reasons The /idder shall include in his proposal necessar* electricals for paddle feeder and carriage such as motorised ca"le reeling drum with trailing ca"les+ ca"le tra*s for resting the trailing ca"les+ and end limit switches for protection against over travel of the feeder carriage The ca"le reeling drum and trailing ca"le of each feeder shall "e suita"le for the entire length of the hopper Mechanical trac# stops shall also "e provided =ust suppression equipment for paddle feeder shall also "e provided 5or designing the paddle wheel as well as travel drive+ /idder shall consider the hopper full* loaded with coal on either side of the paddle wheel to the ma&imum capacit* The h*draulic s*stem normal average wor#ing pressure shall "e selected considering the a"ove loading condition 5urther h*draulic s*stem shall "e designed to stall - trip "e*ond a certain pressure a"ove the normal average wor#ing pressure The minimum margin "etween the normal wor#ing pressure and the stall - trip pressure shall "e 50J 5eeder carriage drive shall "e suita"l* designed so that the forward B reverse movement of carriage can "e achieved without stopping the scooping operation Tan# filled with water in =% trolle* shall also "e considered for travel drive

$ail having section of ;0 l"-*ard structure shall "e designed considering two2wheel support and accounting no frictional force from the other two wheels and considering h*draulic motor stall condition The h*draulic motor shall "e selected "ased on !!0J of actual power requirement motor output shaft at specified guaranteed capacit* The capacit* of paddle adEustment shall "e 0 to !00J of the guaranteed value /idderDs design of paddle feeder should not incorporate a separate loading ta"le 'impact cradle) "elow the paddle feeders However+ the height of fall of coal "etween paddle wheel and conve*or "elt shall "e #ept minimum 5urther+ the length of the s#irt "oard shall adequatel* e&tended on "oth sides of the paddle wheel so that there is no spillage of coal on to the paddle feeders trolle* Minimum 500 mm e&tension shall "e considered for this purpose H*draulic components shall "e provided with dust proof cover for protection against spillage of coal- dust Complete telephone communication s*stem shall "e provided "etween each paddle feeder and main CHP control room The paddle feeders shall run on rails mounted on the supporting structures of associated conve*ors /oth paddle feeder and carriage drives shall "e mounted on the feeder carriage The paddle feeder wheel shall comprise of suita"le num"ers of vanes with cutting edges The vanes shall "e of high strength steel construction with remova"le tiscral or equivalent liner plates Aanes shall "e easil* remova"le individuall* The feeder carriage shall "e of steel construction and of ro"ust design %#irt plates shall "e provided integral with the equipment for collecting the material drawn "* the paddle feeder from the trac# hopper and discharging on to the conve*or "elt 5eeder s#irts of paddle feeders shall "e e&tended at least "* 500 mm on either side of the paddle wheel to avoid spillage of coal 9ecessar* "affle-retainer plates for suita"l* guiding the flow of coal from trac# hopper to the reclaim conve*or "eing fed "* paddle feeders shall "e provided Hand railing shall "e provided on the top dec# of feeder carriage together with an access ladder The feeder carriage shall "e provided with suita"le num"er of dou"le flange wheels of steel construction+ complete with sealed "earing unit The drive mechanism shall "e suita"le for continuous reversi"le motion of the carriage %tart-stop switches shall "e provided at the local control panel for the operation of paddle wheel and feeder carriage The carriage shall automaticall* reverse its motion+ when two paddle feeders operating on the same trac# come within a predetermined distance %uita"le anti2 collision device 'infrared and mechanicall* operated limit switch t*pe) shall "e provided Provision shall "e made to trip the trac# hopper conve*or from respective

paddle feeder and provision shall "e made for tripping of paddle feeder from CHP main control room %uita"le indication of paddle wheel rpm shall "e provided on the paddle feeder control panel and flow rate indicator of "elt weigh scale shall also "e duplicated on control panel of paddle feeder %uita"le rail cleaners shall "e provided at the leading as well as trailing side of the feeder carriage for "oth trac#s %uita"le ca"le tra*s minimum 000 mm a"ove floor shall "e provided along the travel of paddle feeder for supporting and guiding the trailing ca"les 1n order to save fle&i"le ca"les from damage due to tension-over2tension protection switches shall "e provided %pacing of carr*ing idlers in the loading 8one of paddle feeders shall "e (00mm Aarious equipment of Paddle 5eeder assem"l* shall "e easil* accessi"le 1t shall "e possi"le to replace electrical+ mechanical and h*draulic components of paddle feeder when in position Aarious drive equipment and h*draulic-other components shall "e so arranged that coal spillage from trac# hopper month does not accumulate near-over them 1&6&2 In2'ine Magnetic Sepa%ato% and Suspended Magnet Inline -a#neti' .e9arat$rs shall 2e 9r$*ided B$r '$ntinu$us and aut$(ati' e>tra'ti$n and dis'har#e $B tra(9 (a#neti' 9ie'es Br$( '$al 2ein# dis'har#ed Br$( '$n*e7$rs as s9e'iBied& :he sets shall 2e '$(9lete in all res9e'ts with dri*es, (a#nets, inline 2elts, h$99ers, 'hutes, tra(9-ir$n 2$>es and all ele'tri'al an'illaries like '$ntr$l 9anels et'& .us9ended -a#neti' .e9arat$r shall 2e 9r$*ided B$r 9i'kin# u9 tra(9 (a#neti' 9ie'es Br$( ($*in# '$al $*er +$n*e7$r& Magnetic core material shall "e pure annealed iron or equivalent high permea"ilit* magnetic material The coil shall "e of aluminum wire with class OHD insulation+ to limit the a"solute temperature of the winding to !40 deg centigrade The 13M% shall "e oil cooled The O5orce 1nde&D i e the product of flu& densit* in gauss and rate of change of flu& densit* w r t distance+ at the "ottom of falling material traEector* shall "e !00+000 'gauss & gauss-inch) minimum in hot condition for mounting height of 400 mm However+ the strength of the magnet shall not "e less than !000 gauss in hot running condition at 400 mm distance The minimum strength of the magnet shall "e !000 gauss at the specified mounting height through out the "urden width

-$untin# hei#ht $B 400 (( shall 2e taken 2etween t$9 $B '$n*e7$r 2elt $r 2$tt$( $B Ballin# (aterial tra8e't$r7 and the surBa'e $B (a#neti' se9arat$r 2elt& +hara'teristi' 'ur*e $B (a#net with the *alue $B Blu> densit7 *ar7in# 2etween 50 (( t$ Ba'e $B '$n*e7$r 2elt shall 2e 9r$*ided& :he 'r$ss se'ti$n $B (a#net shall 2e suita2l7 desi#ned t$ 9r$*ide suBBi'ient area B$r (a#netisin# the '$il eBBe'ti*el7 '$*erin# Bull 'r$ss se'ti$n $B the dis'har#e (aterial& :he (a#neti' se9arat$r shall 2e l$'ated su'h that it 9i'ks-u9 tra(9 ir$n Br$( '$al tra8e't$r7 aBter it has 2een dis'har#ed Br$( head 9ulle7& The tramp magnetic pieces pic#ed up "* the magnetic separator shall "e discharged suita"l* to ensure that it falls into the tramp iron chute+ which shall "e provided upto ground level .ll conve*ors with magnetic separator at head end shall have non2 magnetic %% pulle*s B shafts The motor and the gear reduction unit for driving the in2line "elt shall "e adequatel* si8ed with minimum 20J margin to avoid an* over loading during operation %uita"le 8ero speed switch shall "e provided The "elt shall "e designed to withstand high temperature at the "ottom of the magnet and an* serious damage due to the impact of the sharp edges of the tramp iron The "elt shall "e provided with ru""er cleats spaced suita"l* The "elt shall "e of fire resistant grade The magnetic separator units shall "e supported "* suita"le structural mem"er from the top "* ta#ing support from the operating floor "eams with turn "uc#le arrangement to facilitate the necessar* adEustments during operation 5urther+ manual cross travel arrangement shall "e provided to move the magnetic separator awa* to facilitate maintenance of the conve*or discharge pulle* <9-<55 control push "uttons with indicating lamps shall "e provided at the local station /oth local and remote manual control shall "e possi"le The materials of chutes and hoppers associated with magnetic separators a"ove the drive floor shall "e %%2004 in the magnetic 8one <ther chutes shall "e of ! mtr sq dimension and shall "e made of M% chutes shall have po#ing doors at all floors to clear Eammed material %uita"le arrangements shall "e provided in the magnet for #eeping the coil of the magnet dr* from atmospheric condensation when the magnetic separator is not in use 5ollowing items of tramp iron are e&pected to "e handled "* the s*stem? 220 Tramp 1ron 1tems 'i) M% cu"e of 20 mm si8e 'ii) /ra#e shoe of $ailwa* Wagon 'Cast 1ron !5 Hg )

'iii) 'iv)

M% plate of 250 & 250 & !00 mm si8e %hovel Teeth and spi#es Car"on %teel T*pical

Material %i8e 'v) M% round "ar of 50 Hg with 3-= ratio not e&ceeding 5 Coal Sampling ?nit

Coal %ampling Gnit shall "e complete with necessar* samplers+ crushers+ flap valves+ chutes+ hoppers+ "elt feeders and sample collectors etc to give samples from an* of the two streams running at guaranteed capacit* +$al sa(9lin# unit shall 2e aut$(ati' C 9r$*ided at 9la'e s9e'iBied elsewhere& The coal sampling units suita"le to give K%amplesL conforming to .%TM2=22204 shall "e selected "* the /idder for ta#ing samples from an* of the two streams running at guaranteed capacit* The different 7quipment selected for coal sampling unit shall "e such that there shall "e no loss of fines and moisture from the samples The capacit*+ ma#e and model of all equipments of coal sampling unit shall "e su"Eect to approval of ProEect Manager The normal input feed si8e shall "e considered as '2) 250 mm for coal sampling unit "efore coal crushers '$ing granulators) However occasionall* '2) 400 mm lumps ma* also arrive Coal lump si8e after crusher 'as fired coal) shall "e '2) 20mm However occasionall* '2) 50 mm lumps ma* also arrive in as fired coal Primar* samplers 'separate for each conve*or) shall "e rugged+ a"le to withstand severe shoc# loads and operate trou"le free /elt feeders shall "e provided for entire sampling path upto sample collector The feeders shall meter the flow accuratel*+ produce a non2plugging condition and resist stic#* and wet coal @$r re8e'ts 9ath als$, 2elt Beeders shall 2e 9reBerred& .'rew '$n*e7$rs B$r the sa(e shall 2e a''e9ted $nl7 where s9a'e '$nstraints d$ n$t 9er(it distri2uti$n $B '$al re8e'ts t$ re'ei*in# '$n*e7$rs 2el$w& %uita"le sample crushers shall "e provided for reducing the main input feed coal to ;5J minus , mesh si8e and !00J minus 4 mesh si8e %ingle stage crushing shall "e provided There should "e no re2circulation of fines in the crushers O3ot si8eD shall "e equivalent coal quantit* handled in , hours operation assuming average conve*or loading at 65J of rated conve*or capacit* However sampling

s*stem shall also "e suita"le for ta#ing one gross sample for each lot of K0500 TeL coal 'appro& equal to one ra#e load) /elt feeders shall "e positivel* self cleaning and have dust tight construction 1t shall "e provided with flanged "elt+ ru""er lagged head pulle*s and inspection doors 9o chain-"elt drives shall "e accepted The crusherDs "ase should "e "uilt of reinforced concrete and "e sufficientl* large in mass The primar* - secondar* samplers shall "e of dust tight construction and self contained t*pe The sample chutes shall have minimum valle* angle of (0 degrees to hori8ontal and shall "e of stainless steel plates The welding of chutes shall "e done e&ternall* onl* The inside surface of the material near welds shall "e smooth $adius at corners not less than !P shall "e provided in chutewor# .ll solid connected mem"ers shall "e "* means of "olting flanges with atleast ( mm thic# standard grade neoprene gas#et material "etween the metal flanges 9o control gates to regulate the flow of material shall "e incorporated in the chute wor# The materials reEected from samplers shall "e returned to main conve*or stream Minimum 4 nos sample collecting "ins shall "e provided The "ins shall "e provided with air tight connection 1&6& 3o))e% Sc%eens The $oller %creens shall "e of mechanical t*pe :he r$ller s'reens shall 2e 'a9a2le t$ se#re#ate the A-, 20 (( siIe $B '$al al$n#with '$al dust, an7 (u'k C (udd7 '$al Awhi'h is likel7 t$ 2e en'$untered durin# rain7 seas$n, et'& :he se#re#ated (aterial shall 2e dire'tl7 Bed $nt$ the '$rres9$ndin# 2elt '$n*e7$rs/Beeders thr$u#h se9arate h$99ers/'hutes 9r$*ided under ea'h #riIIl7 Beeder& :he width $B *i2ratin# r$ller s'reen shall (at'h t$ Beed the (aterial uniB$r(l7 $*er the entire len#th $B 'rusher r$t$r with$ut an7 deBle't$rs in the Beedin# 'hute& 1nclination of the gri88l* pan shall not e&ceed !0 deg from hori8ontal The equipment shall "e designed in such a manner that cho#ing does not occur during operation+ particularl* during rain* season when the coal gets stic#* The dec# of vi"rating roller screens shall have continuous solid dec# section in the impact 8one under direct coal fall and remaining dec# shall "e fitted with gri88l* "ars

The solid dec# section shall "e provided with replacea"le tiscral or eqvt liner plate of adequate thic#ness The gri88l* "ars shall "e wear resistant The "ars shall "e rigidl* fi&ed with main frame along with the length of gri88l* dec# The vi"rating roller screens shall "e mounted on the floor with the help of helical springs made of allo* steel 9o ru""er-s*nthetic material for the support shall "e accepta"le Ai"rator "earings shall "e grease lu"ricated+ dou"le spherical roller t*pe suita"le for vi"rating equipment The "earings shall "e si8ed for minimum ,+000 hours of operation /earing calculations shall "e furnished during detail engineering for <wnerDs approval %uita"le sealing arrangement shall "e provided "etween the vi"rating structure and chute wor# to avoid dust nuisance in the surrounding area Proper arrangement to avoid dust ingress into lu"ricant of eccentric shafts shall "e provided 1n case of A2 "elt drive to avoid loosening of sheave mounted on eccentric shaft+ suita"le arrangement li#e taper "ush or coupling shall "e provided

1&6&4 S5stem

"%us#e% and 0i4%ation Monito%ing

The Crushers of ,00 T-H shall "e provided The crusher shall "e of ring granulator t*pe such that the crushing action is accompanied "* the minimum of attrition Gniform crushing impact shall "e assured The Crusher shall "e suita"le to handle coal with si8e of '2) 250 mm 'occasionall* !22J coal shall "e @400mm si8e ) ;,J output of the crusher shall "e down to '2) 20 mm Ma&imum crushing efficienc* shall "e of o"tained+ i e + thermo d*namicall*+ the ratio of surface energ* produced to the #inetic energ* e&pended should "e ma&imum .ccordingl*+ the num"er of central discs along the rotor shaft shall "e ma&imum with minimum spacing in "etween The crusher shall "e capa"le of delivering the normal rated output even when handling damp stic#* coal having ma&imum moisture content 9o clogging or "uilding up of material on the crushing element shall develop The material for maEor components of crusher shall not "e inferior to the qualit* and standards as mentioned "elow? $ing Hammers Manganese steel to 1% @ 26( Cr 111

$otor %haft %uspension "ars Cage "ars-cage screens and side screen plates $otor =iscs /rea#er plate 3iners 'a) Material '") Thic#ness

.%TM @ .((,+ Class O7D .%TM2.022+ Crade .1%1 4!40 Manganese %teel '1%?26() .%TM2.!0,+ .1%1 !045 Manganese steel 1%226( Cr 111 Material composition shall "e as that of "rea#er plate a"ove 20 mm minimum

VIB"4%I@! #@!I%@"I!8 SAS% # &@" C@4' C"?SH " Ai"ration monitoring s*stem should "e offered for crushers as indicative "elow ? QQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQ2 %l 9o 7quipment T*pe 9o 9o of Rlocations per 7quipt QQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQ2 ! Coal Crusher $adial 4 2 ring QQQQQQQQQQQQQQQQQQQQQQQQQQQQQQQ B Ai"ration shall "e measured at each location in Hori8ontal as well as vertical direction

1&6&5

Be)t "on6e5o%s S5stem Desi#n $B 2elt '$n*e7$r s7ste( shall 2e suita2le B$r '$al 9ara(eters s9e'iBied elsewhere& %lopes of conve*ors+ wherever applica"le+ shall not e&ceed !5 deg depending on the lump si8e+ and other governing factors The guaranteed capacit* of all conve*ors shall "e the rated capacit* .ll conve*ors 'e&cept "oom conve*or of %-$) shall "e designed for !!0J of rated capacit* The "oom conve*or of %-$ shall "e designed for !25J of rated capacit* =esign capacit* of the conve*or s*stem shall "e considered for the selection of "elt width+ "elt speed and the continuous motor rating at 50oC

The drive chain equipmentDs for various "elt conve*or s*stems shall consist of drive motors+ fluid couplings+ gear reduction units+ low speed fle&i"le couplings and pulle*s Conve*ors and "elt feeders shall "e provided with electro h*draulic thrustor "ra#es to adEust the coasting time of conve*ors such that there will not "e an* "uild up of material in the chutes 5urther conve*or shall come to halt as earl* as possi"le /elt conve*or s*stem shall "e designed as per the latest edition of O/elt Conve*ors for /ul# MaterialsD pu"lished "* Conve*or 7quipment ManufacturerDs .ssociationD or equivalent 1nternational %tandard

!(5!

Constr*ction "e>*irement Belting :he 2eltin# shall 2e $B either s7ntheti' Ba2ri' su'h as N7l$n/N7l$n, P$l7ester/P$l7a(ide et'& with ru22er '$*ers $B adeDuate Ble>i2ilit7 t$ #i*e a tr$u#hin# an#le $B 5 de#& @$r all the '$n*e7$rs the nu(2er $B 9lies, '$*er thi'kness, Ba't$r $B saBet7 et'& shall 2e as 9er the re'$((endati$n $B 2elt (anuBa'turer, 2ut n$t inBeri$r t$ the B$ll$win#s: /elting T*pe %*nthetic 5a"ric of 9*lon - 9*lon+ Pol*ester - Pol*amide+ etc 5ire resistant 'Conforming to Canadian standard association C.9- C%. M24222 M,6 Crade @ C

Cover Crade

Cover Thic#ness 'without 2ve tolerances) 'a) '") 5ace /ottom 5 0 mm 'min ) 2 0 mm 'min Minimum 4

9o of plies =rive .rrangement i) %nu" drive

5or motor ratings upto !(0 #W and motor ratings a"ove 020 #W

for

ii) =ual tandem drive 5actor of %afet*

5or motor ratings not covered a"ove !0 'Minimum) 3ess than ,0J of ma& allowa"le wor#ing tension

9ormal Wor#ing tension at design capacit*

+arr7in# idlers shall 2e 9r$*ided with three eDual r$lls with tr$u#hin# an#le $B 5 de#& and 2 de#& B$rward tilt Ae>'e9t in 'ase $B re*ersi2le '$n*e7$rs,& 1n no case+ shall the diameter of the idler roll "e less than !52 mm for "oth carr*ing side and return side $oller used in idlers shall "e made from 7$W steel tu"e Wall thic#ness shall "e minimum 4 0 mm without an* negative tolerance The rollers shall "e mounted on 792 , or equivalent material spindles "* means of heav* dut* "all "earings+ prefera"l* sei8e resistant t*pe '%H5-7quivalent)+ of 00 mm si8e for carr*ing idlers and 20 mm si8e for return idlers The "earings shall "e adequatel* sealed and lu"ricated for life The rolls shall "e supported from fa"ricated steel "rac#ets 5i&ing arrangement of rollers with "rac#ets shall "e drop2in t*pe 5or adEusting the alignment of the idlers+ slotted holes shall "e provided in idler supporting "ase plates =irection of "elt travel shall "e clearl* mar#ed on the "rac#ets of carr*ing idlers 1dler rollers shall "e waterproof+ dust proof and weather proof against a high velocit* water Eet .ll idlers shall "e provided with minimum tripple la"*rinth dust seal 1mpact idlers used at the loading and transfer point shall "e so designed as to avoid direct loading impact+ "elt damage and e&cessive punishment to the carrier The material used in construction of this t*pe of idlers shall "e of resilient t*pe The return idlers for all conve*ors shall "e single roll t*pe 5or conve*ors longer than 400m+ two roll return idlers with !0 deg troughing angle shall "e provided The self2aligning idlers shall "e direct acting t*pe+ complete with actuating rollers fitted with the "all "earings and mounted inclined towards the "elt The idler frame shall "e suita"l* cradled a"out a vertical pivot+ supported in "earing over a fi&ed plate .dequate sealing arrangement shall "e provided to prevent contamination of the lu"ricant "* dirt and moisture Transition t*pe troughing idlers shall "e used adEacent to all pulle*s to permit proper support of the loaded "elt near the pulle*s without e&cessive stretch of the "elt edges The transition idlers shall "e provided with prefera"l* adEusta"le concentrator 'end) rolls and long center rolls to suit the troughed "elt contour "etween the last regular troughing idler and the adEacent pulle*s The transition length and the num"er of the

transition idlers shall "e selected depending upon the tensions+ t*pe and si8e of "elt+ num"er of plies and other necessar* governing factors .ll the conve*ors shall "e provided with one self cleaning t*pe ru""er disc return idler located near the head pulle* for cleaning the return "elt Proper arrangement shall "e provided in the "rac#ets of all t*pes of idlers for preventing the rollers from coming out of the "rac#ets during normal - a"normal conditions !(52 Belt Cleaners 2ternal Belt Cleaner .9rin# l$aded s'ra9er t79e 'leaner with ($dular se#(ented and re9la'ea2le 9$l7urethane s'ra9ers 2lades '$(9lete with (ain 'leaner, 9re-'leaner al$n# with a''ess$ries and ne'essar7 Bines 'hutes shall 2e Burnished B$r all 2elt '$n*e7$rs, tri99er head 9ulle7 and 2elt Beeders at dis'har#e 9ulle7s& :he ($dular units shall 2e easil7 re9la'ea2le& :he s'ra9er asse(2l7 shall 2e easil7 (aintaina2le Br$( $utside with$ut an7 interBeren'e with the 'hute arran#e(ent and asse(2l7&

Internal Belt Cleaner ?-9l$u#h t79e 2elt 'leaner (ade $B (ild steel Blats and hard ru22er stri9s with aut$(ati' wear ad8ust(ent and ne'essar7 a''ess$ries shall 2e Burnished B$r 'leanin# internal surBa'e $B the '$n*e7$r 2elt& !(50 Belt %a9e+*p 4rrangement Aut$(ati' take-u9 $B #ra*it7 t79e shall 2e #enerall7 9r$*ided with ne'essar7 take-u9 arran#e(ents '$(9lete with 2end 9ulle7s, take-u9 9ulle7, with its su99$rtin# / slidin# asse(2l7, wire r$9es B$r sus9endin# the se9arate take F u9 wei#ht slidin# asse(2l7 'l$se t$ the #r$und, '$unter wei#hts and $ther a''ess$ries& .uita2le #uards, (arked u9 s'ale atta'hed t$ the Bra(e t$ ($nit$r 2elt stret'h and a''ess/(aintenan'e 9latB$r(s with handrails all ar$und et'& shall 2e 9r$*ided& AdeDuate a''ess Br$( '$n*e7$r #aller7/transBer h$use/#r$und et'&, as the 'ase (a7 2e shall 2e 9r$*ided t$ ins9e't, re9air and (aintain the #ra*it7 take-u9 arran#e(ent& .uita2le arran#e(ents shall 2e 9r$*ided B$r 'learin# a''u(ulated '$al Br$( *ari$us 9latB$r(s t$ #r$und le*el& /uides $B take u9 9ulle7/'$unter wei#hts shall 2e suBBi'ientl7 str$n# s$ that the7 d$ n$t 2end durin# 2elt sna99in#&

The prime consideration should "e to locate the automatic ta#e2ups at a place where these will wor# "est+ in relation to the drive+ to #eep "elt tension at a minimum <ther considerations such as availa"le space+ maintenance considerations and the economics of the location should also "e ta#en into account while designing Ta#e up shall not "e located over "uildings Height of ta#e2up guide structure shall "e sufficient to allow the ta#e2up weight movement up and down for all operating conditions of conve*or and to allow minimum two '2) vulcanising lengths margin in the "elt or percentage of conve*or length '2 5J for s*nthetic "elting) whichever is larger %uita"le guides shall "e provided "oth for ta#e up pulle* and ta#e up weight Hoists with monorails for holding ta#e2up pulle* and weight in case of "elt changing+ vulcanising etc shall "e provided 2 M safet* fencing along with suita"le gate and loc#ing arrangement shall "e provided around gravit* ta#e2up at the "ase level - ground level 1rrespective of ta#e2up location+ the travel 8one of ta#e2up weight shall start from a suita"le height a"ove ground %uita"le "uffer arrangement shall "e provided to arrest the fall of ta#e2up pulle* in order to avoid damage of the pulle* assem"l* in case of "elt snapping %imilar "uffer arrangement shall "e provided for ta#e2up weight also in case of ta#e2up weight travel 8one terminating a"ove a "uilding floor %uita"le sandpits shall "e provided at ground "elow the ta#e2up weights 1n case of dou"le stream conve*ors+ a partition of 0mm steel plate shall "e provided "etween the two ta#e2up pulle*s along entire travel 8one of ta#e2up pulle*s 1ntermediate platforms shall "e provided in the ta#e2up 8one for maintenance of ta#e @ up pulle*s - counter weight Ta#e2up weight shall consist of multi2"loc#s and not of single "loc# to facilitate adEustment in weight if required during operation Weight of the "loc#s shall "e in descending order and single heaviest piece shall "e suita"le for eas* handling !(54 Hold Bac9 DeCices %uita"le hold "ac# devices for preventing running "ac# of the conve*or "elt in case of conve*or "eing stopped in loaded conditions due to power failure or during normal operational dela*s shall "e provided to give positive protection The hold "ac# shall instantaneousl* engage without shoc# and "e capa"le of protecting equipment and personnel 1t shall "e released instantl* when OpowerD resumes or the Odela*D is removed The hold"ac# devices shall "e integral with gear"o& !(55 P*lleys

Pulle*s shall "e provided as required for various conve*ors 1n determination of pulle* diameter+ no account shall "e ta#en of the pulle* lagging The nominal diameter and face width of the pulle*s shall "e as stated in 1%?,50! The snu" pulle*s on each conve*or shall "e located to provide a "elt wrap on the drive pulle*s of not less than 220 deg wrap is envisaged for single snu" drive onl* .ll drive pulle* surfaces shall "e hot lagged with vulcanised natural ru""er lagging grooved in diamond pattern .ll non2drive pulle*s shall "e vulcanised natural ru""er lagged 'hot) with plain lagging The ru""er to "e used for lagging of pulle*s shall confirm to following specifications The ru""er lagging of pulle*s and method of lagging and testing the same shall conform to 1%?4(,2 Pulle*s Ceneral 'for all t*pes of Pulle*s) 'i) Minimum shell thic#ness Minimum end disc thic#ness Ma&imum allowa"le deflection of shaft at the hu"s !( mm

'ii)

24 mm

'iii)

5 minutes

'iv) Pulle* shaft diameter Margin of minimum 20J shall "e considered on ma&imum tension for arriving at the shaft dia =rive Pulle*s '!) '2) Minimum shell thic#ness !( mm 3agging Hot lagged with vulcanised natural ru""er thic#ness !2 mm deep mm thic# grooved in pattern with grooves ( mmwide &

'0) diamond (

3agging

'4) '5)

Minimum angle of wrap 220S degrees Ma&imum <ut of roundness 0 5J of nominal diameter

<ther pulle*s '!) '2) Minimum shell thic#ness !( mm 3agging Hot lagged with vulcanised natural ru""er !2 mm thic# plain

'0)

3agging thic#ness

$u""er for lagging '!) T*pe 9atural ru""er "lended with st*rene "utadiene ru""er 55 to (5 durometer '%hore .) <ver 000J !(02200 #g-cm2 250 mm0 as per =19 505!( ! 4 to ! 5 !0 #g-cm 'minimum)

'2) '0) '4) '5) '() '6)

Hardness 7longation %trength ."rasion loss %pecific Cravit* .dhesion %trength

/earings for Pulle*s '!) '2) '0) la"*rinth '4) conical Pulle* Material T*pe Casing %ealing =ust Heav* dut* roller t*pe Hori8ontal %plit T*pe tight seals Creasing with dou"le

3u"rication

arrangement head shape nipples

with

Mild steel conforming 1%?22( - 1% ? 20(2

The pulle*s shall "e made from mild steel conforming to 1%?20(2 'Tested Tualit*) However for conve*ors with in line magnetic separators+ at head end the pulle*s and the shaft shall "e of non2magnetic stainless steel .ll the pulle*s shall "e #e*ed to forged steel shafts of 792, or equivalent material of adequate proportion running in heav* dut* roller "earings with proper greasing arrangement The plummer "loc#s for pulle*s shall "e of hori8ontall* split t*pe construction with minimum '4) nos "olts holding the two split halves and with min '4) nos foundation "olts The plummer "loc#s shall "e dust tight with dou"le la"*rinth seals Conical head shape nipples conforming to 1%?400;+ suita"le drain plug and e*e "olt shall "e provided %ide covers of plummer "loc#s shall "e heav* dut* metallic sheets 9o plastic components shall "e used Pulle*s shall "e mounted on machined B ground surfaces %uita"le guards shall "e provided for all tail pulle*s and "end pulle*s for safet* of operating personnel %uita"le stiffening arrangements shall "e provided in all pulle*s 5or selection of pulle* shaft dia of all the pulle*s+ a margin of atleast 20J shall "e considered on the ma&imum tension %election of pulle* diameter+ shell thic#ness+ stiffening and shaft diameter shall "e su"Eect to approval of ProEect Manager during detailed engineering Pulle*s of same diameter shall "e completel* interchangea"le in totalit* and component wise To have interchangea"ilit* of same diameter pulle*s procured under separate contracts for a station+ the "earing center distance of pulle*s shall "e su"Eect to approval of the <wner The adEustments required shall "e done "* the Contractor at no e&tra cost to the <wner !(5( a) Belt Protection >*ipment P*ll chord SDitch Pull 'h$rd t79e A(anuall7 reset t79e, e(er#en'7 st$9 swit'hes shall 2e l$'ated $n 2$th sides $B 2elt '$n*e7$rs al$n# the walkwa7s B$r the entire len#th $B '$n*e7$rs B$r e(er#en'7 st$99in# $B '$n*e7$r at s9a'in# $B 0 -eters& :he en'l$sure shall 2e $B 'ast alu(inu( with de#ree $B 9r$te'ti$n IP-65& It shall ha*e a se9arate ter(inal 2$> with a se9arate hin#ed '$*er whi'h shall 2e t$tall7 sealed Br$( (ain 2$> '$ntainin# a'tuatin# (e'hanis( / li(it swit'h et'& )$'al 9ull 'h$rd a'tuati$n shall 2e 9r$*ided 27 (eans $B (e'hani'al Bla9& 1a'h swit'h shall ha*e tw$ NO and tw$ N+ '$nta'ts, whi'h shall 2e wired $ut t$ the ter(inal 2l$'k& :he ter(inal 2l$'k shall ha*e Ba'ilities $B 'a2le l$$9in#& :he +$nta't ratin# $B the swit'hes shall 2e rated B$r atleast 5 A(9s, 2reakin# at 240 ?A+ at 0& 9&B& la##in#& AdeDuate len#th $B r$9e and all a''ess$ries shall 2e Burnished&

")

Belt SDay SDitches <elt swa7 swit'hes $B selB resettin# t79e shall 2e Burnished $ne 9air at 50 (eter inter*als t$ li(it 2elt swa7 t$ 9er(issi2le e>tent& :he en'l$sure shall 2e $B 'ast alu(inu( ha*in# de#ree $B 9r$te'ti$n $B IP-65& It shall ha*e a se9arate ter(inal 2$> with a se9arate hin#ed '$*er t$tall7 sealed Br$( the (ain 2$> '$ntainin# a'tuatin# (e'hanis(/ li(it swit'h et'& 1a'h swit'h shall ha*e tw$ NO and tw$ N+ '$nta'ts $ne B$r alar( and $ne B$r tri9, whi'h shall 2e wired u9t$ ter(inal 2l$'k& :he ter(inal 2l$'k shall ha*e Ba'ilities B$r 'a2le l$$9in#& :he '$nta'ts $B the swit'hes shall 2e rated B$r at least 5 A(9s& 2reakin# at 240 ?A+ at 0& 9&B& la##in#&

c)

Eero Speed SDitch Jer$ s9eed swit'h shall 2e n$n-'$nta't A9r$>i(it7, t79e ele'tr$ni' swit'h& -$untin# arran#e(ent/ l$'ati$n shall 2e su'h that $9erati$n, eBBe'ti*e sensin# distan'e, sensiti*it7 et'& shall n$t 2e eBBe'ted 27 a''u(ulati$n $B dust $n r$tatin# 9art $r surBa'e $B 9r$2e& AdeDuate (e'hani'al 9r$te'ti$n 27 (eans $B n$n-(etalli' shields shall 2e 9r$*ided $n t$9 $B the swit'h t$ 9re*ent an7 da(a#e due t$ Ballin# '$al / (etalli' 9ie'es et'& In 2uilt initial start u9 dela7 and nuisan'e, tri99in# dela7 thr$u#h ti(ers shall 2e 9r$*ided& 1a'h swit'h shall ha*e tw$ NO and tw$ N+ '$nta'ts wired $ut t$ the ter(inal 2l$'ks& :he '$nta't $B the swit'hes shall 2e rated B$r atleast 5 A(9s& 2reakin# at 240 ?A+ at 0& 9&B& la##in#& :he ($nit$rin# unit shall ha*e 'ast alu(inu( 2$d7 ha*in# IP-65 de#ree $B 9r$te'ti$n& A se9arate ter(inal 2$> with a se9arate '$*er, whi'h shall 2e t$tall7 sealed Br$( (ain 2$>, shall 2e 9r$*ided& :er(inal 2l$'ks shall 2e suita2le B$r ter(inatin# 1&5 (( sD& standard '$99er 'a2le&

d)

?nder 6elt sDitch :hese swit'hes shall 2e installed under the 2elt B$r dete'tin# the 9resen'e $B (aterial $n the 2elt wh$se '$nta'ts shall in turn 2e used B$r $9eratin# s$len$id *al*es $B dust su99ressi$n s7ste( ela2$rated elsewhere& :he swit'h and its $9eratin# arran#e(ent shall 2e suita2le B$r w$rkin# in dust7 areas& :he (ini(u( de#ree $B 9r$te'ti$n $B swit'h shall 2e IP-62& :he swit'h shall 2e 'a9a2le $B dete'tin# three e*ents si(ultane$usl7 as B$ll$ws : i) ii) iii) /elt loaded /elt running at more than preset speed Preset initial start dela*

e)

Ch*te Bloc9age SDitches

One n$& 'hute 2l$'ka#e swit'h $B 9r$*en t79e Asu28e't t$ a99r$*al $B the 1(9l$7er, shall 2e 9r$*ided at a suita2le hei#ht $n ea'h le# $B the '$n*e7$rs 'hute nearest t$ the skirt 2$ards& +hute 2l$'ka#e swit'h shall tri9 the Beedin# '$n*e7$r in 'ase $B +hute 2l$'ka#e and 9r$te't the Beedin# '$n*e7$r eDui9(ent& :he swit'h and its $9eratin# arran#e(ent shall 2e suita2le B$r w$rkin# in dust7 areas& :he (ini(u( de#ree $B 9r$te'ti$n $B swit'h shall 2e IP-62& )$'al indi'ati$n $B 'hute 2l$'ka#e swit'h a'tuati$n shall als$ 2e 9r$*ided& )$'ati$n $B 'hute 2l$'k swit'h shall 2e su'h that washin#/'leanin# $B 'hute 27 9i9e / r$d d$es n$t aBBe't it& !(56 DriCe >*ipment $ating of all drive motors of conve*ors shall not "e less than !20J of the power required at drive motor output shaft at specified design capacit* %uita"le =rive Chain 7quipmentDs li#e electric motors+ gear"o&es 'where applica"le)+ fluid couplings 'where applica"le)+ fle&i"le couplings and other accessories shall "e provided for all the "elt conve*or s*stems+ paddle feeders+ vi"rating gri88l* feeders+ vi"rating feeders 'if applica"le)+ crushers+ mo"ile trippers+ various pumps of dust suppression s*stem+ fans for ventilation s*stem+ monorail electrical hoists and other equipmentDs specified in this specifications Aarious requirements as spelt out in the Technical %pecifications for individual equipmentDs shall "e ta#en into consideration while designing the associated drive chain equipmentDs 8ear Bo2es Cear /o&es shall "e of sealed t*pe and mounted on machined or ground surfaces The gear"o&es shall "e designed for 24 hours continuous dut* 5or thermal and mechanical rating of the gear"o& the data sheet shall "e referred to Cear"o&es with cooling coils are not accepta"le The gears used shall "e helical conforming to 1%?0(,! 'latest revision) or worm reduction units or spiral "evel speed reduction units conforming to suita"le 1ndian %tandards The dimensions of the shaft end shall conform to 1%?0(,, or its latest revision ."ove 40 #W drive rating+ all gear"o&es shall "e helical or "evel helical t*pe onl* $ecommended oil grade shall "e compati"le with gear internals li#e material of "earing+ cages 5urther+ all gear"o&es shall have suita"le "reather plugs Co*plings

&le2i6le Co*plings A99r$*ed t79e $B '$u9lin#s shall 2e used B$r 9$wer trans(issi$n de9endin# u9$n dut7 reDuire(ents& :he desi#n $B the '$u9lin# shall 2e su'h that it 'an take sh$'k and (isali#n(ent with$ut sa'riBi'in# its eBBi'ien'7& @le>i2le '$u9lin#s shall 2e 9r$*ided $n l$w s9eed side $B #ear2$> B$r all '$n*e7$rs& @le>i2le '$u9lin#s shall 2e #eared t79e& &l*id Co*plings @luid '$u9lin#s shall 2e 9r$*ided in all the dri*e (a'hiner7 B$r 2elt '$n*e7$r s7ste(s and '$al 'rushers iB the a'tual 9$wer reDuire(ent at ($t$r $ut9ut shaBt is ($re than 0 kH& :he Bluid '$u9lin# B$r ): ($t$rs shall 2e $B tra'ti$n t79e& +$$lin# water '$ils B$r tra'ti$n t79e Bluid '$u9lin# shall n$t 2e a''e9ted& .'$$9 tu2e t79e Bluid '$u9lin# shall 2e 9r$*ided B$r '$n*e7$rs with 5: ($t$rs and '$al 'rushers& .uita2le ele'tri'all7 $9erated a'tuat$rs shall 2e 9r$*ided B$r s'$$9 tu2e $9erati$n Br$( l$'al as well as re($te& .uita2le 9r$*isi$n B$r alternate (anual $9erati$n shall als$ 2e ke9t& IB reDuired 27 the eDui9(ent desi#ner, se9arate 9u(9 with ($t$r shall 2e 9r$*ided B$r 'ir'ulatin# the Bluid '$u9lin# $il thr$u#h $il '$$ler& Inde9endent arran#e(ent B$r B$r'ed '$$lin# water su99l7 usin# 2=100G 'a9a'it7 9u(9s t$ $il '$$ler shall 2e 9r$*ided 27 2idder& .uita2le interl$'k usin# Bl$w swit'hes shall 2e 9r$*ided in 2$th $il as well as water lines t$ tri9 the dri*e ($t$r in the e*ent $B Bl$w in either lines Ballin# 2el$w/ a''e9ta2le le*els& .uita2le 9ressure indi'at$rs and Bl$w indi'at$rs shall 2e 9r$*ided in the '$$lin# water lines al$n# with all rele*ant *al*es, strainers and a''ess$ries& Ne'essar7 interl$'k shall als$ 2e 9r$*ided s$ that the 5: ($t$r 'ann$t 2e started Br$( re($te / l$'al unless 9$siti$n $B s'$$9 tu2e 9er(its n$ l$ad start $B the ($t$r& :ri99in# $B d$wnstrea( eDui9(ent while the s7ste( is under n$r(al $9erati$n shall result in s'$$9 tu2e re-9$siti$nin# t$ 9er(it n$ l$ad run $B the '$n'erned 5: ($t$r& !(5, ConCeyor 8alleries All $*er#r$und and $*erhead '$n*e7$rs shall 2e l$'ated in suita2l7 en'l$sed 2rid#e stru'ture& .tru'tural steel 2rid#es $B adeDuate width and de9th A 000 (( 'lear head r$$( B$r under #r$und and 2700(( B$r $*er#r$und, shall 2e 9r$*ided '$(9lete with '$n*e7$r 2$tt$( de'k 9lates, seal 9lates, walkwa7s $B 'heDuered 9lates with anti-skid arran#e(entAs, hand rails A$n 2$th sides $B ea'h '$n*e7$r 2elt e>'e9t where eDui9(ent like 9addle Beeders, sta'ker/ re'lai(ers, tri99ers et'& tra*erse $*er '$n*e7$r,, '$n*e7$r su99$rts et'& The conve*or "ridge shall have permanentl* colour coated steel sheeting covers on roof and "oth sides+ properl* screwed or loc#ed to steel structure as required .dequate provision of windows shall "e #ept . continuous slot opening of 500 mm shall "e provided on "oth sides Eust "elow the roof sheeting

The floors of outdoor conve*or galleries shall "e designed and constructed as follows? All '$n*e7$rs shall 2e 9r$*ided with 12 / steel seal 9lates thr$u#h$ut the len#th $B the '$n*e7$r #aller7 in su'h a wa7 that '$(9lete #aller7 2$tt$( surBa'e area B$r(s a sin#le water 9r$$B Bl$$r& It is en*isa#ed t$ 'lean the '$n*e7$r #aller7 with water 9eri$di'all7& All the water / '$al slurr7 shall 2e suita2l7 #uided t$ d$wn '$(ers A(in 00 (( dia, 9r$*ided at e*er7 trestle& 1a'h d$wn'$(er shall lead the '$al slurr7 int$ a 2 ( 2ri'k wall tank at #r$und le*el ha*in# 2 N$s& de'antin# ta9s at suita2le ele*ati$ns& De'anted water shall 2e led t$ the nearest st$r( water drain $B the Owner& Ne'essar7 arran#e(ent shall 2e 9r$*ided t$ a*$id 'h$kin# $B d$wn'$(ers 27 2i##er '$al lu(9s and B$r 'leanin# $B 'h$ked d$wn'$(ers& The conve*ors shall "e provided with continuous steel dec#ing plate of minimum 0 mm thic#ness %tructures and floors shall "e so designed as to provide suita"le space for routing of 200 9/ fire fighting pipe with water+ and conduits Power and control ca"les shall "e routed outside conve*or galler* %teel trestles to support the conve*or "ridge shall rest upon concrete foundations to "e provided "* the Contractor Complete trestle structures shall also "e supplied "* the Contractor %uita"le approach-access platforms with handrailings shall "e provided to approach the conve*or galler* 'li#e in case of fire) through mon#e* ladders on the trestles %uita"le wire mesh doors on steel frame construction loc#a"le from outside onl* shall "e provided in the conve*or galleries at these locations .ll mon#e* ladders shall have cage for safet* of personnel using them The width of conve*or galleries shall "e decided "* the /idders depending on the equipmentDs si8e and the wal#wa* width as specified Provision shall "e #ept with platforms and ladders for crossing over the conve*ors at appro&imatel* ever* !00m intervals of route length and min one per conve*or 5urther provision shall also "e #ept with platforms and ladders for atleast two '2) crossings over the trac# hopper Wal#wa*s shall "e #ept as follows? Wal#wa*s 'a) Construction Chequered plate with antis#id arrangement Chequered plate steps shall "e provided where conve*or slope e&ceeds !0 degrees 'Totall* sealed so that no water falls down while washing ) !!00 mm clear 'no infringement allowed)

'")

Central wal#wa*

width 'c) %ide wal#wa* width ,00 mm clear 'no infringement allowed) 'for single conve*ors+ the width of side wal#wa*s shall "e ,00 mm on one side and !!00 mm on the other) 'no infringement allowed)

%ide Windows 'a) %pacing 'Center to center) %i8e Window material 25 0 m on each side 'in staggered fashion) !5m&!5m $efer Civil %ection

'") 'c)

!((

Stone Pic9ing -anual .t$ne Pi'kin# arran#e(ent at a suita2le l$'ati$n in the '$n*e7$r #aller7 2eB$re the 9ri(ar7 'rusher h$use shall 2e 9r$*ided '$(9lete with 9latB$r(s, $*erhead li#htin#, hand railin#s, suita2le seatin# C h$ldin# arran#e(ent B$r (anual 9i'kers and dis9$sal 'hutes t$ #r$und le*el et'& @$ur A4, n$s& (anual 9i'kers Atw$ $n ea'h side, shall 2e 9$siti$ned B$r ea'h 2elt& 1a'h (anual 9i'ker shall '$*er ( l$n# 2elt stret'h ad8a'ent t$ ea'h $ther& :he 9i'ked u9 st$ne lu(9s Au9t$ 600 (( siIe, shall 2e '$lle'ted $*er the '$n*e7$r #aller7 walkwa7 le*el Br$( where these st$nes 'an 2e 9ushed int$ the h$99er/'hute u9t$ dis9$sal tr$lle7 at the #r$und le*el&

!(6

Belt V*lcaniFing #achine /elt Aulcani8ing 7quipment shall "e suita"le for hot vulcani8ing of "elt splice and shall "e of eas*2to2handle t*pe 7quipment should "e suita"le for vulcani8ing of entire splice width in single setting 7quipment should "e capa"le of appl*ing uniform pressure over the splice "* pneumatic or h*draulic means Heating element should "e prefera"l* of fle&i"le t*pe

1&6&!

"78TES (N9 7/PPE3S

Chutes B Hoppers+ flap gates and rac# B pinion gates shall "e furnished alongwith all necessar* accessories+ electricals etc shall "e provided to ensure proper flow-storage-"ifurcation of coal as per s*stem requirements The minimum valle* angle of chutes shall "e (0 degrees from hori8ontal The actual valle* angle and chute design shall "e finalised after carr*ing out coal flowa"ilit* studies at worst conditions Transfer chutes shall "e adequatel* si8ed and sloped to ensure smooth flow of coal without an* accumulation an*where Complete chute wor# a"ove the drive floor for conve*ors provided with O1n2line "elt magnetic separatorsD shall "e of !0 mm thic# %% @ 004 in the 8one of magnetic field =irect impact of material on conve*or "elt shall "e avoided "* providing an inclined surface at (0 degrees valle* angle at the feeding point to guide the material in the direction of "elt travel 5urther+ chute construction "elow flap gate shaft shall "e such that there will not "e an* accumulation of coal dust "etween chute and flap gate in that 8one Hoppers and Chutes shall "e made of minimum !0 mm thic# T1%C$.3-M% or equivalent with adequate stiffeners 3ong chutes guiding flow from considera"le height shall "e provided with impact plates wherever change in direction of flow ta#es place Hinged inspection doors 'generousl* si8ed) of lea# proof construction shall "e provided for access- maintenance purpose+ at approacha"le heights+ of the chutes .ll chutes should have one inspection door at ever* floor and for the ones in "etween the floors+ suita"le access ladder and platform etc shall "e provided Ma&imum distance "etween two inspection doors in a chute shall "e 2 mtrs 5or sealing at inspection doors la"*rinth t*pe arrangement 'with ru""er inserted in grooves) to "e provided 1n addition to mounting "olts+ swiveling eccentric handle's) to tighten the door further against ru""er shall also "e provided /ottom side of the chutes on which the coal slides shall "e welded to the side plates to form a trough /ottom sides along with its adEacent sides shall "e flanged and made from T1%C$.3 or equivalent material of !0 mm thic#ness The non stri#ing surface i e the covers of the trough shall "e of !0 mm thic# mild steel and "olted to the flange provided on the trough 1nside welding shall "e provided in the corners for permanent sealing 5urther+ the chute "o&es not more than ! 5 m in length shall "e Eoined through "olted flange connection to form the chute legs <$lted Blan#e 8$ints shall 2e $B dust ti#ht '$nstru'ti$n and ne'essar7 sealin# (aterial shall 2e 9r$*ided in all the Blan#e '$nne'ti$ns B$r adeDuate sealin#& +$(9lete 'hute w$rk in the re#i$n $B Bla9 #ates shall 2e Ba2ri'ated Br$( :I.+0A) $r eDui*alent& In 'ase $B *erti'al 'hute A*alle7 an#le ($re than !0

de#ree, '$(9lete 'hute, w$rk shall 2e $B 10 (( thi'k :I.+0A) $r eDui*alent (aterial& Hhile Binalisin# the 'hute w$rk inside the 2uildin#, arran#e(ent B$r shiBtin# and re9la'in# 'hute le#s, 9r$9er handlin# arran#e(ent/wall $9enin#s, tr$lle7s, h$ists shall als$ 2e 9r$*ided& Hoods over the conve*or head pulle*s shall "e made of suita"l* stiffened minimum 4 mm M % Plates and shall "e provided with hinged and gas#eted inspection doors with suita"le access to them 5urther+ ru""er seal shall also "e provided at the ver* inlet of head chute to minimise dust nuisance Minimum si8e of chute shall "e #ept as 2-0 rd of "elt width or !000I!200 mm which ever is higher !(; S9irt Boards %#irt "oard shall ensure centralised loading of conve*or "elt to avoid coal spillage %uita"le O%#irt PlatesD of minimum 0 0 meters length shall "e provided at each feeding point of conve*or The width of the %#irt /oards shall "e two2third the conve*or "elt width 1n the "elts "efore Crusher House where coal of apprecia"le lump si8e '250 mm) is "eing conve*ed+ the gap "etween the "ottom of the s#irt "oard and the "elt shall "e made to increase uniforml* in the direction of "elt travel The height of the s#irt "oards shall "e sufficient to contain the material volume as it is loaded on the "elt and shall not "e less than 650 mm The s#irt plates shall "e fitted with modular segmented and replacea"le ru""er s#irting pads having facilit* of adEusting the pressure on the "elt conve*or and shall have provision of on line removal for the purpose of eas* maintenance %uch segmented ru""er pads with its holding down adEustment arrangements shall "e of proven design The edges of segmented pads shall "e installed at an angle for providing a "etter seal .ll care shall "e ta#en while designing+ to com"ine good sealing with minimum "elt wear ! ( !0 &lap 8ates The motor operated two position flap gates shall "e provided in transfer chutes as specified and shall "e complete with electricall* operated actuators The gates shall "e of ro"ust construction and suita"le for trou"le free operation The face of the flap gate shall "e mode out of !0 mm thic# T1%C$.3 or equivalent material The equipment shall "e capa"le of "eing operated for at least !5 switchings per hour at rated load and thrust and shall "e suita"le for !0 9os consecutive switchings at rated load and thrust The equipment shall "e shop tested to prove this requirement The motor rating for the actuator shall "e so selected as to provide sufficient thrust for operation of the flop gates against the moving weight of coal and-or flap gate The flap gate travel shall "e in the range of (0 deg to 60 deg The motor shall "e completel* dust tight

3ever arm shall "e provided "etween actuator and flap gate shaft for o"taining required thrust The actuators shall "e capa"le of preventing an* over travel %uita"le travel dependent limit switches controlling the travel of the flop gates on either direction shall "e furnished These shall "e placed internal to the drive unit and shall "e completel* dust2 proof The limit switches shall "e capa"le of adEustments to var* the total length of travel of the gates %uita"le thrust dependent limit switches shall "e provided in the actuator+ which shall trip off the actuator motor in case of e&cessive thrust due to Eamming of the gates during its travel in either direction The same shall also "e integral to the drive unit and shall "e dust proof Provision for alternative manual operation shall also "e made using declutcha"le handwheel The diameter of handwheel shall "e selected considering convenient force to "e applied "* a single operator However+ minimum diameter of hand wheel shall "e 500 mm 3imit switch for safet* of person operating the hand wheel shall "e provided .ll the two wa* chutes+ one wa* of which is leading towards the future conve*or+ shall "e provided with "lind flange and flap gate with a provision to mount an actuator in future .ll the actuators in the plant should "e selected "ased on heaviest loading+ "ut the rating shall not "e less than 2500 #g with a lever arm of ! 0 m in an* case %uita"le stiffening arrangement shall "e provided "etween the two faces of the gate plate .t the end of the travel the total length of edge of the flap gate shall rest on a suita"le proEected surface from chute to prevent lea#age of coal dust through the availa"le clearance "etween chute and flap gate Ma&imum feasi"le counterweights shall "e provided for "etter utilisation of s*stem %uita"le self aligned dou"le row "all "earings in dust tight housing shall carr* the gate shaft %uita"le provision for regreasing shall "e provided 5or standardisation purposes+ onl* one standard t*pe of actuator for flap gates shall "e provided The standard t*pe actuator shall "e selected for ma&imum thrust as calculated for various locations 5lap gate actuator as a whole and individual component wise shall "e completel* interchangea"le for all locations The material of shaft shall "e 792, or equivalent The diameter of the shaft shall "e suita"le for motor stalled condition and associated twisting

.pproach-maintenance platforms complete with the chequered plate floor+ hand rails+ ladders etc shall "e provided for all flap gates %haft B flap gate shall "e tightl* fitted to each other <n "oth faces of flap gate main plate+ !0mm thic# T1%C$.3 liner plate or equivalent material shall "e provided
+$((ents A1,

(.CHP E+UIP,EN'S-2
! ( !0 &lap 8ates

Filed under: ,n!ategori-ed Tags: !hp shiva i!houdhur" # %:/( am

The motor operated two position flap gates shall "e provided in transfer chutes as specified and shall "e complete with electricall* operated actuators The gates shall "e of ro"ust construction and suita"le for trou"le free operation The face of the flap gate shall "e mode out of !0 mm thic# T1%C$.3 or equivalent material The equipment shall "e capa"le of "eing operated for at least !5 switchings per hour at rated load and thrust and shall "e suita"le for !0 9os consecutive switchings at rated load and thrust The equipment shall "e shop tested to prove this requirement The motor rating for the actuator shall "e so selected as to provide sufficient thrust for operation of the flop gates against the moving weight of coal and-or flap gate The flap gate travel shall "e in the range of (0 deg to 60 deg The motor shall "e completel* dust tight 3ever arm shall "e provided "etween actuator and flap gate shaft for o"taining required thrust The actuators shall "e capa"le of preventing an* over travel %uita"le travel dependent limit switches controlling the travel of the flop gates on either direction shall "e furnished These shall "e placed internal to the drive unit and shall "e completel* dust2 proof The limit switches shall "e capa"le of adEustments to var* the total length of travel of the gates %uita"le thrust dependent limit switches shall "e provided in the actuator+ which shall trip off the actuator motor in case of e&cessive thrust due to Eamming of the gates during its travel in either direction The same shall also "e integral to the drive unit and shall "e dust proof Provision for alternative manual operation shall also "e made using declutcha"le handwheel The diameter of handwheel shall "e selected considering convenient force to "e applied "* a single operator However+ minimum diameter of hand wheel shall "e 500 mm 3imit switch for safet* of person operating the hand wheel shall "e provided

.ll the two wa* chutes+ one wa* of which is leading towards the future conve*or+ shall "e provided with "lind flange and flap gate with a provision to mount an actuator in future .ll the actuators in the plant should "e selected "ased on heaviest loading+ "ut the rating shall not "e less than 2500 #g with a lever arm of ! 0 m in an* case %uita"le stiffening arrangement shall "e provided "etween the two faces of the gate plate .t the end of the travel the total length of edge of the flap gate shall rest on a suita"le proEected surface from chute to prevent lea#age of coal dust through the availa"le clearance "etween chute and flap gate Ma&imum feasi"le counterweights shall "e provided for "etter utilisation of s*stem %uita"le self aligned dou"le row "all "earings in dust tight housing shall carr* the gate shaft %uita"le provision for regreasing shall "e provided 5or standardisation purposes+ onl* one standard t*pe of actuator for flap gates shall "e provided The standard t*pe actuator shall "e selected for ma&imum thrust as calculated for various locations 5lap gate actuator as a whole and individual component wise shall "e completel* interchangea"le for all locations The material of shaft shall "e 792, or equivalent The diameter of the shaft shall "e suita"le for motor stalled condition and associated twisting .pproach-maintenance platforms complete with the chequered plate floor+ hand rails+ ladders etc shall "e provided for all flap gates %haft B flap gate shall "e tightl* fitted to each other <n "oth faces of flap gate main plate+ !0mm thic# T1%C$.3 liner plate or equivalent material shall "e provided ! ( !! "ac9 < Pinion 8ates 0$tar7 a'tuat$r $9erated ra'k and 9ini$n #ates shall 2e 9r$*ided at *ari$us l$'ati$ns as s9e'iBied& :he #ate shall 2e ($unted su'h that '$al l$ad d$es n$t a't *erti'all7 $n #ate& %uita"le manuall* operated rod gates shall "e provided over rac# and pinion gates for their eas* operation and maintenance The rac# and pinion gate shall "e guided properl* and suita"le rollers with "earings sealed for life and dust proof shall "e provided

The rac# and pinion gates shall "e of mild steel construction with liner plate of !0 mm thic# tiscral or equivalent material The gates shall "e operated "* means of dou"le rac# and pinion The material for rac# B pinion wheel shall "e cast steel and shaft shall "e 79 2, Provision for alternative manual operation of motorised rac# and pinion gates shall also "e made 3imit switch for safet* of person operating the hand wheel shall "e provided Manual effort required to operate the rac# and pinion gate shall not e&ceed 25 #g Ma&imum time for closing-opening shall "e 25 sec .pproach-maintenance platforms complete with chequered plate floor+ hand railings+ ladder etc shall "e provided for all gates 1&6&12 T3(0E''IN1 T3IPPE3 (N9 B8N:E3 SE('IN1 (33(N1EMENT Mo"ile Trippers on "un#er conve*ors along with "elt sealing arrangement shall "e furnished and erected complete with rails+ including necessar* supporting structures+ approach- maintenance platforms with ladders and hand railings+ trailing ca"les+ all electricals including machine mounted local control panel B control panel on one end of /un#er+ location of which shall "e decided during detail engineering +$(9lete <unker .ealin# arran#e(ent shall 2e 9r$*ided $*er the 2unkers t$ 9re*ent dust e(issi$n int$ tri99er 2a7& ! ( !2 ! %raCelling %ripper The Travelling tripper on "un#er conve*ors shall "e motor driven t*pe 1t shall consist of structures+ supports+ wal#wa*s+ rails+ "elt scrapper with adEusta"le ru""er strip+ ru""er lagged head and "end pulle*s complete with shaft "earings+ chutes+ stops+ limit switches+ "ra#es etc The tripper shall have provision for dropping coal "oth sides of conve*or into the "un#er and "ac# to the conve*or for the purpose of s#ipping intermediate "un#ers The rating of tripper travel motor shall "e adequate to move the tripper smoothl* either in same or opposite direction to "elt direction under full* loaded conditions .dhesive weight requirement and tractive effort calculations shall "e su"Eect to approval of ProEect Manager Coefficient of adhesion shall "e considered as ma&imum 0 !5 Minimum two drive a&les shall "e provided for tripper travel .rrangement shall "e provided at the starting point of the tripper to avoid folding of "elt In 'ase $B tri99er runnin# at a s9eed ($re than its rated s9eed due t$ 'hute 8a((in# $r $ther reas$n, '$n*e7$r shall tri9 and annun'iati$n shall a99ear&

%uppl* of adequate length of rails to cover the runwa* length for the motor driven tripper shall "e included The supporting structures for the rails with necessar* end stops shall also "e supplied under this specification %uita"le "elt hold down guide pulle* shall "e provided over the concave curve of "elt over tripper The /idder shall include in his proposal necessar* electricals for traveling trippers such as motorised ca"le reeling drum with trailing ca"les+ ca"le tra*s for resting the trailing ca"les and end limit switches for protection against over travel of the tripper The ca"le reeling drum and trailing ca"le of each tripper shall "e suita"le for the entire length of the "un#er "a* Mechanical trac# stops shall also "e provided The ca"les shall have copper conductors+ proper insulating material and "raided armouring in accordance with 1%?(;! Complete Telephone Communication s*stem "etween Travelling tripper and CHP control room is in /idder scope The travelling trippers shall "e provided with fail safe . C thrustor operated "ra#e of totall* enclosed t*pe which shall engage as soon as tripper travel motor stops . C thrustor operated rail clamps with hand operation facilit* from either side of the tripper shall also "e provided The specifications of "ra#es and clamps are as discussed elsewhere 5or selection and specification of drive motor+ gear"o&es and all other equipment associated with tripper relevant clauses of this specification shall "e referred to .ll drive equipment shall "e selected "ased on !!5J of actual power requirement at specified guaranteed capacit* 5urther complete drive equipment shall "e suita"le for minimum (0 starts-hours Monorail B electric hoist shall "e provided for lifting conve*or drum to "un#er floors Monorail all along the "un#er conve*or to facilitate maintenance of tripper shall "e provided ! ( !2 2 B*n9er sealing arrangement :he sealin# 2elt shall 2e $B suita2le #rade A(ini(u( 2 9lies, with 5 (( > 5 (( '$*ers ABire resistant, in line with $ther '$n*e7$r 2eltin#& :he 2elt shall rest $n 20(( -. r$und 2ars s9a'ed at 150 (( 9r$*ided $*er the 2unker sl$t A(ini(u( 1100 ((, $n tri99er Bl$$r B$r tri99er '$n*e7$r& Needed #uide r$llers, 2earin#s, 2ra'kets, saBet7 #uards et'& shall 2e 9r$*ided 27 the +$ntra't$r& :he 2unker sealin# arran#e(ent shall kee9 the 2unkers sealed and 9re*ent dust e(issi$n int$ tri99er r$$(& :he width $B the 2unker seal 2elt shall 2e at least 100 (( ($re than the 2unker sl$t $9enin#& .e9arate $9enin#s shall 2e 9r$*ided $n the 2unker Bl$$r $B ea'h 2unker t$ (easure le*el $B '$al in the 2unker& 5in#ed dust sealed d$$r / Bla9s shall 2e 9r$*ided $n these $9enin#s&

%uita"le grating to "e provided in "etween "un#ers in the tripper travel 8one Tripper floor is "* Purchaser <penings on the tripper floor for level measurement will "e provided "* Purchaser <pening si8e will "e informed to successful "idder during the detail engineering stage %uita"le dust cover shall "e provided over tripper head pulle* %errated ru""er seal shall "e provided at open side to prevent dust nuisance %uita"le dust tight access doors shall "e provided Counter2weighted t*pe "elt cleaner shall "e provided "elow the tripper head pulle* for cleaning the carr*ing side of the "elt The tripper shall run on rails ';0 l"s-*ard) with dou"le flanged wheels $ails for tripper travel shall "e mounted on supporting structure of respective conve*ors %uita"le s*stem for monitoring position of tripper shall "e provided 1n addition+ travel end limit switches and end stops shall also "e provided .uita2le a''ess 9latB$r( $B 'heDuered 9late with ladders, handrailin# and walkwa7s $n 2$th sides shall 2e 9r$*ided B$r a''ess/(aintenan'e $B eDui9(ent $n tri99er& In additi$n, 'r$ss$*er 9latB$r( shall 2e 9r$*ided with tri99er s$ that $9erat$r 'an 'r$ss the 2elt thr$u#h the sa(e& %uita"le rail cleaners shall "e provided on leading and trailing edge of tripper for either trac# 0mm dec# plate continuous shall "e provided "elow carr*ing idlers on the trippers 5or specification of flap gates-actuator on trippers relevant clauses of this specification shall "e referred to Wal#wa* of ,00 mm wide shall "e provided on "oth side of the tripper Provision shall "e #ept for automatic tripping of "un#er "a* conve*or in the event of travelling tripper getting dragged 'i e travel speed in e&cess of rated speed)

! ( !0

Belt Scale /elt weigh scale for measurement of coal flow rate and quantit* shall "e provided at specified locations %*stem shall "e complete with flow rate indicator+ totaliser+ control panel etc :he wei#h s'ale shall 2e aut$(ati' and ele'tr$ni' t79e& It sh$uld 2e desi#ned B$r '$ntinu$us aut$(ati' wei#hin#, (eterin# and 9rintin# $B '$al Bl$w&

7ach "elt weigh scale shall comprise of a "elt weigh scale platform with minimum 4 nos weighing idlers 1t shall have unitised construction for ease of installation and shall "e full* floating t*pe 'without pivot points) Minimum 4 nos sealed load cells of precision strain gauge t*pe shall "e applied in tension to support the weigh"ridge The load cells shall have !00J overload protection and shall "e structurall* safe upto to 250J of rated "elt scale capacit* /elt scale shall "e electronic microprocessor "ased with its program stored in non2 volatile memor* 1t shall "e provided with self diagnostic features for trou"le shooting of the entire "elt scale s*stem 5ull* automatic 8ero and span cali"ration facilit* shall "e provided The electronic s*stems offered "* the /idder shall include all signal conditioning+ power amplifiers and printed circuits etc The printed circuits shall "e encapsulated against dust and moisture /elt scale shall "e provided with flow rate+ total quantit* etc $emote flow rate indicators shall also "e provided on paddle feeders The flow rate indicator shall have minimum 4 digits The flow totali8er should have , digits displa* scale with reset facilit* Complete "elt scale s*stem shall "e suita"le for 60SC am"ient temperature and !00J relative humidit* 1t shall "e suita"le for out door installation in a dust* area The electronic circuit enclosure+ sensors housing shall "e dust and watertight+ e&plosion proof conforming to 97M. and 97C '9ational 7lectronic Code) The electronic printed circuits shall "e encapsulated with epo&* or other suita"le material for protection against dust and moisture Minimum three *ears "atter* "ac# up power failure protection shall "e provided /elt scale shall "e designed for a range of 20J to !20J of rated capacit* with an accurac* of atleast 'M) 0 25 percent throughout its range /elt scale provided in %tac#er $eclaimer /oom Conve*or shall have an accurac* 'in the hori8ontal position of /oom) of 'M) ! percent for the range of 20J to !20J of "oom conve*or capacit* 3ocal panel for "elt scale shall "e of 5$P material ! ( !4 %raCelling Stac9er c*m "eclaimer Travelling %tac#er cum $eclaimer operating in conEunction with reversi"le *ard conve*or shall "e provided as specified %tac#er2cum2$eclaimer shall "e capa"le of

"oth stac#ing and reclaiming complete with adequate length of rail trac#+ cantilever "oom conve*or+ intermediate conve*or+ support carriage with vi"rating feeders 'if required)+ "oom hoist+ reclaimer "uc#et wheel+ control panel+ operators ca"in+ electrical power distri"ution s*stem+ motorised ca"le reeling drum+ adequate length of trailing ca"les etc The design capacit* of the *ard conve*or shall not "e less than !!0J of the rated 'guaranteed) capacit* 5or "uc#et si8e calculations and "oom conve*or capacit*+ a pea# reclaim capacit* of !25J of rated capacit* shall "e considered The drive train of *ard conve*or consisting of motor+ scoop t*pe fluid coupling+ gear "o& etc shall "e provided at "oth ends of the *ard conve*or /oth the drive train at each end of the *ard conve*or shall run simultaneousl* in one direction and reversed depending upon stac#ing or reclaiming operation of the machine The continuous motor rating at 50SC .m"ient of the drive motors to "e provided on each side of the *ard conve*or shall "e !20J of the actual power requirement at motor output shaft The actual requirement at motor output shaft of "oth the motors at each end shall "e calculated "ased on 65J of the total load demand at design capacit* %tac#er-$eclaimer shall "e capa"le of operating at high wind velocities upto (5 #m-hr 1t shall also "e a"le to withstand ma&imum wind velocit* as indicated in KCriteria for Wind $esistant =esign of %tructures B 7quipmentL placed in the document on civil aspect+ when it is not operating .n anemometer shall "e provided which shall indicate the wind velocit* in the control ca"in 1le'tr$-h7drauli' thruster $9erated rail 'la(9 shall 2e 9r$*ided B$r h$ldin# the sta'ker-'u(-re'lai(er& .uita2le arran#e(ent shall 2e 9r$*ided B$r kee9in# the sta'ker-re'lai(er in Bi>ed sta2le 9$siti$n when the weather is st$r(7& %tac#er2cum2reclaimer shall operate on rail trac# of 52 #g-mtr running for adequate length to cover the entire coal stoc#*ard The ratio of "oom length 'as specified) to the rail trac# gauge shall not e&ceed 5 Top of rail level shall "e maintained at ! 0 m a"ove the ground level+ i e + coal pile "ase level unless specified otherwise %uita"le num"er of rail scrappers shall "e provided The machine shall "e mounted on traverse carriage provided with driven and non2drive wheels of cast or forged steel and dou"le flange design The trac# wheels shall "e com"ined in pairs in the trac# wheel "ogies The wheels shall rotate on self2aligning roller "earings /etween the motor and the gearing+ electro2h*draulic thrustor "ra#e shall "e provided The reclaimer shall "e traversed "* manual control at an* desired speed within its speed range =uring stac#ing-reclaiming operation+ the equipment travel shall "e limited to its travel 8one and shall automaticall* stop when the machine reaches the e&treme ends of such travel 8one

The lower wor#s of the under2carriage of the machine shall "e designed to transmit load on the wheel sets of the travel carriage in such a manner that the equipment is sta"le during normal operating condition as well as during ha8ardous weather condition with ma&imum permissi"le variation in center distance of rails and rail top levels The rail mounting for under2carriage shall "e four legged s*stem with h*draulic-mechanical equalising arrangement to ma#e it three point suspension s*stem for the "est sta"ilit* during operation The traverse carriage and the under2carriage shall "e interconnected in a manner+ which will permit uniform distri"ution of overloads even if the rails are not level The upper frame of the machine shall "e designed in such a manner that minimum num"er of angular movement points affects the luffing operation 1n addition+ the variation of moment-torque on slew "earing shall "e minimum The ring "earings shall "e dimensioned in such a wa* that all forces can "e safel* transmitted to the structures of the wheels The roller "earing slewing ring shall "e sealed against penetration of water and dust .ngular movement points 'hinge points) namel* "etween equalising "eam and "ase frame+ luff pivots and h*draulic c*linder hinge points shall "e provided with maintenance free "earings requiring no periodic lu"rication during entire life span of "earings Minimum life span of self lu"ricating t*pe "earings shall "e 25 *ears with average !0 hrs dail* operation The luffing motion shall "e through h*draulic pumps and c*linders 1n case of more than one c*linder "eing used for "oom luffing operation+ necessar* provisions shall "e provided such that the differential oil pressure "etween two c*linders are alwa*s maintained within permissi"le limits+ during luffing operation and as well as when the "oom is fi&ed at an* position 1n case of an* undue increase in differential pressure+ the h*draulic circuit shall trip and suita"le alarm indication shall "e provided "efore tripping The h*draulic s*stem of luffing shall "e such that in case of failure of h*draulic s*stem due to lea#age or an* other reason the "oom could "e held in position The "oom shall revolve "* at least 2!0S a"out the center of the receiving hopper and discharge-reclaim material on-from "oth sides of trac# an*where within specified radius of the "oom The "oom conve*or shall "e of adequate design capacit* to match with the rate of pea# reclaiming "* the "uc#et wheel <$$( '$n*e7$r with 41 ( len#th shall 2e 9r$*ided with a <elt Hei#hin# .'ale with wei#hin# a''ura'7 Ain the h$riI$ntal 9$siti$n $B the 2$$(, $B K 1G B$r a ran#e $B 20G t$ 120G $B 2$$( '$n*e7$r 'a9a'it7& :he 2elt s'ale shall 9r$*ide $nl7 Bl$w rate indi'ati$n in the O9erat$rEs +a2in $n the .ta'ker/0e'lai(er&

The "uc#et wheel assem"l* shall consist of , num"ers of "uc#ets of cell2less design and stationar* annular chute The "uc#et shall "e of suita"le shape and design+ which will ena"le to empt* out the material full* from the "uc#et+ and to prevent spilling of the scooped material during transfer to "oom conve*or The "uc#ets shall "e readil* remova"le <u'ket siIe shall 2e sele'ted B$r 9eak re'lai( 'a9a'it7 2ased $n (a>i(u( !0G de#ree $B Bill with res9e't t$ water Bill 'a9a'it7 $B the 2u'ket& @urther, n$t ($re than 50G $B annular rin# *$lu(e shall 2e '$nsidered as eBBe'ti*e *$lu(e& 0ate $B 2u'ket dis'har#es shall n$t e>'eed 55 9er (inute& The "uc#et wheel drive shall "e complete with electric motor+ reduction gear unit moving in oil "ath and suita"le coupling "etween motor and the gear unit /uc#et wheel drive s*stem+ structural mem"ers+ mast+ h*draulic s*stem etc shall "e designed considering completel* wet coal with ma& surface moisture .dequate safet* devices shall "e provided to prevent overloading of the "uc#et wheel drive+ particularl* when wheel will get stuc#2up in the stoc#pile 1n such an event+ the power suppl* of the drive shall get automaticall* cut2off %uita"le electro h*draulic thrustor "ra#e shall "e provided to avoid "ac#ward movement of the "uc#et wheel after the power suppl* is cut2off and during maintenance wor# The "oom conve*or with "uc#et wheel assem"l*+ the mast and counter weight mounted on the upper structure shall rotate on the "earing ring The drive mechanism shall consist of the gear rim and drive unit shall comprise of motor+ safet* coupling+ gear"o& and pinion Protective devices against overloads shall also "e provided The slew speed shall "e varia"le /oom conve*or shall "e provided with self2training arrangement of latest design to avoid "elt swa* in the "oom conve*or <ne tripper shall "e furnished for stac#er2cum2reclaimer unit for wor#ing in conEunction with the *ard conve*or The tripper B intermediate conve*or shall "e complete with supporting structure+ wal#wa*s+ platforms+ railing+ "elt scrapper+ head pulle*s+ "end pulle*s+ hold2down pulle*+ chute and support with adequate num"er of wheels in "ogie construction travelling on the same rails as those of the stac#er2cum2 reclaimer The intermediate conve*or will "e s#ewed longitudinall* to ena"le to receive material 'during stac#ing) from tripper conve*or The intermediate conve*or shall "e of adequate capacit* to match with the design capacit* of stac#ing which shall "e !!0J of rated capacit* of stac#ing 5or other details+ the relevant clauses of "elt conve*or s*stem of this specification shall "e referred to The intermediate conve*or shall "e completed with supporting structure+ wal#wa*+ railings+ platforms+ "elt scrappers+ head pulle*+ tail pulle* and necessar* chute wor# Croup2wise lu"rication s*stem shall "e provided com"ining different 8ones of lu"rication points under different groups depending upon location and num"er of

lu"rication points 7ach group lu"rication unit shall "e independentl* functional through separate pump 'motorised)+ grease container+ valves+ metering devices+ pipes and other accessories etc Prefera"l*+ the grease entr* into various lu"rication points shall "e verticall* downwards The grease container shall have adequate capacit* for suppl* of lu"ricants to all points and grease quantit* for the points to "e greased shall "e adEusta"le 5urther+ all the lu"rication points shall "e easil* accessi"le The stac#er2reclaimer shall receive power through trailing ca"les %eparate motorised ca"le reeling drums for power and control ca"le shall "e provided with arrangements for winding and rewinding of the ca"les The trailing ca"les shall run in a ca"le tra* 5urther+ the trailing ca"le arrangement shall "e such that the ca"les run in2 "etween the trac# rails Cushion shall "e provided in the ca"le reeling drums for a"out 00 m e&tra ca"ling length Complete telephone communication s*stem "etween stac#er2cum2reclaimer operatorDs ca"in and main coal handling plant control room shall "e provided 3imit switches shall "e provided to prevent traverse movement+ slew and hoisting etc "e*ond the respective safe e&tremities 1nterloc#ing shall also "e provided for %-$ rail clamps and travel motors Travel drive equipment and slew drive equipment shall "e suita"le for !50 starts-hr with continuous reversals H*draulic control shall "e provided for ? 'a) '") 'c) Hoisting-luffing <perator ca"in level adEustment 7qualising arrangement for travel carriage 'in case of h*draulic equalising)

A>ial 9ist$n 9u(9s shall 2e 9r$*ided B$r 9ressurisin# h7drauli' '$ntr$l Bluid& .ll drive equipments shall "e selected "ased on !20J of actual power requirement at specified design capacit* In additi$n t$ the reDuire(ents ela2$rated a2$*e, the stru'tural desi#n $B the sta'ker-re'lai(er shall 2e su99le(ented 27 B$ll$win# standards:1%< 504;-! @1? Mo"ile Continuous /ul# Handling 7quipment : @ederati$n 1ur$9eanne De )a -anutenti$n .e'ti$n-I F 0ules B$r Desi#n $B 5$istin# A99lian'es&

%uita"le $CC platform to "e provided at one end of travel of the stac#er2cum2reclaimer to rest the head end of the "oom while either under maintenance or out of operation The under2carriage shall "e fa"ricated of steel plates and section The wheel mounting arrangement shall "e such that the wheels can "e dismantled easil* from their supports ,00 M wide wal#wa*s with hand railings shall "e provided on "oth sides of "oom conve*or The upper structure shall consist of rigid "o& t*pe steel plate construction on which the super2structure supporting mast+ "oom with "uc#et wheel and counterweight "oom with "allast are erected The upper wor#s shall "e mounted on under2carriage "* means of large diameter ring "earing of dou"le roll roller t*pe The "oom shall "e fa"ricated from rolled steel plates and sections and shall "e of luffing t*pe The counterweight "oom with "allast+ which "alances the "oom conve*or+ shall "e mounted on the upper structure and shall "e suita"l* dimensioned The counterweight "oom shall "e fa"ricated with rolled steel plates and sections %uita"le "o&es shall "e provided for placing the counter weights The stac#er2reclaimer shall "e provided with one enclosed dust proof B air conditioned operatorDs ca"in and so located as to ena"le the operator to get clear vision of "oth sides of the trac# and the field of operation The ca"in shall "e suita"le for operation in monsoon and tropical conditions and the inside am"ient temperature shall "e maintained at 26SC The ca"in shall "e provided with toughened glasses with wipers and the arrangement shall "e such that glasses can "e cleaned from outside without an* scaffolding Ca"in door shall "e provided with h*draulic door closures The ca"in shall "e #ept in hori8ontal position through h*draulic c*linders irrespective of the angle of inclination of the "oom conve*or .ll controls for operation of all parts of the stac#er2 reclaim unit shall "e provided in the ca"in within eas* reach of the operator 3ights and fan for operatorDs ca"in and adequate num"er of floodlights for all necessar* illumination for wor#ing at night shall also "e provided 7lectrical-MCC room shall "e fa"ricated of sheet steel with suita"le floor matting The room shall "e dust tight and air conditioned 5ireproof insulation shall "e provided under the roof of MCC room 5urther+ the door shall "e provided with h*draulic door closer

.dequate num"er of impact idlers shall "e provided integral with stac#er2cum2 reclaimer at the region where the "ottom conve*or feeds material through transfer chutes onto the *ard conve*or for the protection of the *ard conve*or %uita"le arrangement shall "e provided at the starting point '"elt ta#e off point) of the tripper to avoid folding of "elt while the tripper is in tension /ra#es shall "e provided for decelerating driven equipment-conve*or as per requirement 0ail 'la(9s shall 2e 9r$*ided B$r *ari$us ($2ile (a'hines tra*ellin# $n rails as s9e'iBied B$r th$se (a'hines& :he ne'essar7 1le'tr$ 57drauli' :hrust$r AA+, 2rakes, t$tall7 en'l$sed and Bail saBe, shall 2e 9r$*ided as reDuired B$r *ari$us eDui9(entEs& <rakin# t$rDue shall 2e ad8usta2le Br$( 0 t$ 100G $B rated 2rakin# t$rDue& :he 2rake shall 2e a'tuated 27 '$(9ressi$n s9rin#s& :he s9rin# shall a99l7 2rakin# B$r'e dire'tl7 t$ the sh$e with$ut usin# le*er ar( linka#es& $ail Clamp shall "e designed for holding the machine stationar* $ating of the rail clamp shall "e su"Eect to the approval of 7ngineer $ail Clamp shall "e actuated "* compression springs+ the spring shall appl* the clamping force directl* on the $ail clamp mechanism without using lever arm lin#ages once power suppl* is cut2off The force transmission mechanism from spring to rail clamp faces shall "e ver* simple with minimum lin#ages The electro h*draulic thrustor shall "e fitted with the "ra#e 3imit switches shall "e provided for "ra#e applied-released positions The windings shall "e provided with class2/ insulation suita"le for 4!5A U !0J at 50 H8 U 5J and com"ined variation of U !0J /ra#e lining shall "e as"estos with inter woven "rass wires capa"le of withstanding 200SC temperature The lining shall "e fi&ed to the shoe "* counter sun# screws 7lectro H*draulic thrustor shall "e fitted directl* a"ove spring without an* intermediate lin#age mechanism $ail clamp shall "e provided "etween the two travel wheels 5urther+ limit switches shall "e provided for $ail clamp O79C.C7=D and O=1%79C.C7=D signals Minimum clearance "etween the $ail clamp face and rail surface shall "e 50mm However+ this clearance ma* not "e uniform for "oth the faces of $ail clamp throughout the length of rails $ail clamp shall operate satisfactoril* under this condition without the need for an* adEustments

Complete $ail Clamp mechanism shall "e manufactured from forged steel

1&6&15

Mono%ai)s and 7oists %uita"le handling arrangements shall "e provided for all equipmentDs to transfer the equipment to maintenance area within the "uilding and-or to transfer the equipment outside the "uilding upto ground level for further transportation 5or this purpose /idder shall provide monorails and hoist "loc#s with cross travel facilit* @$r the 5$ists with ($re than &0 t$nne liBtin# 'a9a'it7 $r ($re than 10&0 - liBt, ($t$r $9erated h$ist 2l$'ks B$r 2$th l$n# tra*el and liBt shall 2e 9r$*ided& Other h$ist 2l$'ks shall 2e $B hand $9erated t79e B$r 2$th tra*el and liBt& 5$we*er, all ($n$rails '$(in# $ut $B the 2uildin# shall 2e 9r$*ided with ele'tri' h$ist 2l$'ks, irres9e'ti*e $B l$ad and liBt& AdeDuate len#th $B +antile*er shall 2e 9r$*ided in ($n$rails t$ l$wer the eDui9(ent t$ #r$und le*el 'learin# the 2uildin# sidewalls& The center line of monorail shall not deviate "* more than 500 mm from the center of gravit* of an* equipment that is to "e lifted /idder shall ta#e clear note of the fact that the num"er and monorail hoisting s*stems shall also "e decided considering the movement of the equipment "eing lifted over-"* the side of other equipmentDs without removing the later The necessar* levels of floors in various "uildings shall "e decided considering the a"ove requirement Monorails shall "e e&tended outside the "uilding to handle the equipment to ground level %uita"le machiner* well- hatch and remova"le handrailing- grating shall "e provided on various floors of "uildings+ as necessar* 7lectricall* operated monogirder t*pe hoists shall consist of following maEor components 'a) 7lectricall* operated trolle* complete with drive motor 'Trolle* travel speed ma&imum !5 m-min ) Hoist ca"le+ hoisting "loc# and hoo#s complete with drive motor 'Hoisting speed ma&imum (m-min ) )i(it swit'h t$ 9re*ent $*erh$istin#, $*er l$werin# and $*er tra*el& 5estoon arrangement of feeding power to trolle* assem"l* 7rection hardware

'")

A', 'd) 'e)

'f)

Pendent control station suspended from hoist

The hoist shall "e designed and constructed in accordance with the latest revision of 1%?0;0, and shall "e suita"le for dut* class 2 Trolle* movement and hoisting shall "e effected "* using two separate motors However the motors shall "e suita"le for !50 starts per hour at 40J C=5 Trolle* shall "e designed to accommodate a wide range of 1 "eams and shall "e capa"le of travelling on straight as well as curved monorails with the design "eing such to maintain uniform distri"ution of pressure on the flanges Motor operated geared trolle* shall have two '2) pairs of wheels+ one pair of which shall "e driven through motor Wire rope shall "e of pre2formed t*pe+ hemp cored+ regular la* (-06 construction with a "rea#ing strength of !(02!65 #gf-mm2 $everse "end of ropes is not accepta"le Minimum num"er of falls of rope shall "e four '4) .ll gears and pinions shall "e of hardened and tempered steel with machine cut teeth in metric modules %urface hardening of steel is not accepta"le .ll running shafts and wheels shall "e fitted with roller "earings with a rated life not less than 20 *ears "ased on equivalent running time as per 1%?0;0, .n electromechanical "ra#e shall provide restraining torque /ra#e lining shall "e of as"estos Cast iron parts+ wherever used+ shall "e of minimum grade 00+ 1%?2!0 .ll hand operated chain pulle* "loc#s shall "e designed to 1%?0,02+ the operating hand chain shall conform to 1%?242;'!) grade 00 pitched and polished and the load chain to 1%?0!0; grade 40 The chain pulle* "loc# shall "e suita"le for dut* class 2 Hoo#s shall "e of high tensile steel and heat treated as per Clause 6 ! '") 1%?0,!5 .ll hoists-chain pulle* "loc#s shall "e selected to have minimum headroom and shall "e selected to lift heaviest piece of equipment 5urther+ it shall "e possi"le to handle an* equipment without distur"ing other equipment The hand chain wheels shall "e of cast steel+ the wheels shall "e with flanges and designed to ensure effective operation of hand chain 5urther+ suita"le local "ra#e shall "e provided as per 1%?0,02 to arrest and sustain loads in all wor#ing positions

The velocit* rates+ effort on chain required to raise the safe wor#ing load and travel and speed shall "e within the limit specified in 1%?0,02 Proof load test shall "e carried out as per 1%?0,02 The hoist mechanism shall consist of a grooved rope drum driven "* electric motor through gears 7ach end of the rope shall "e anchored to the drum in such a wa* as the anchorage is readil* availa"le for maintenance 7ach rope shall have not more than two '2) full turns of the drum when the hoo# is at its lowest position and one '!) spare groove when the hoo# is at its highest position The leading rope ta#en "* the drum should not slope sidewa*s when slac# and it should not "e caught "etween the gear wheel $ope drum+ gear "o&+ "loc# etc should "e fa"ricated out of welda"le qualit* steel Trolle* wheels shall "e of single flange t*pe in the taper treads The wheels shall "e mounted on antifriction "earings and shall "e easil* remova"le for repair-replacement The load hoo# shall "e swiveling t*pe forged circular shan# section and shall confirm to 1%?0,!5 .ll gears and "earings shall "e lu"ricated "* grease .ll lu"ricating points shall "e grouped together in easil* accessi"le position The "ottom "loc# shall "e of enclosed t*pe and shall have guard against rope Eamming in normal use 1t shall have standard forged swivel shan# hoo# fitted on antifriction thrust "earing 3oc# to prevent hoo# from rotation and loc#ing arrangement to prevent accidental unloc#ing shall "e provided Pulle* of the "ottom "loc# shall "e provided with antifriction "earings .ll parts requiring replacement-inspection-lu"rication shall "e accessi"le without need for dismantling of other parts-structures .ll components of hoists of identical capacit* and dut* shall "e interchangea"le Hoists shall have permanent inscription on each side readil* recogni8a"le from floor level stating safe wor#ing load Pendant shall "e provided with up-down-forward-reverse travel push "uttons and indicating lamps 1ts power suppl* shall "e limited to 24A .C The control panel shall "e wall mounted t*pe B easil* approacha"le from the floor "* a standing man 5or 1nspection - maintenance of hoist components a fi&ed platform with ladder shall "e provided for each hoist

! ( !(

D*st Control System The dust control s*stem is required for control of fugitive dust emissions from dust generation points such as transfer points+ feeders+ crushers etc =ust control is achieved "* dust suppression s*stem <idder shall 9r$*ide adeDuatel7 siIed B$$l 9r$$B dust '$ntr$l s7ste(s the 9erB$r(an'e $B whi'h sh$uld 2e #uaranteed 27 the <idder&

! ( !( !

D*st S*ppression System Dust .u99ressi$n s7ste( '$(9lete with water su99l7 s7ste(, *al*es, 9i9in#, s9ra7 heads, 9u(9s, dri*e ($t$rs with 'an$97, '$u9lin#s with en'l$sure ele'tri'als, in'ludin# su99$rtin# stru'tures, a99r$a'h/(aintenan'e 9latB$r(s, handlin# B$r eDui9(ent, 'i*il C stru'tural w$rks, ne'essar7 a''ess$ries shall 2e 9r$*ided at all 9la'es& At s9e'iBied l$'ati$ns dust su99ressi$n s7ste( shall 2e 9r$*ided whi'h '$(9rises s9ra7 eDui9(ent dis'har#in# water in a Bine (ist, t$ 'a9ture air 2$rne dust 9arti'les and dire't the( int$ the (ain '$al Bl$w, a##l$(erate dust in the (ain '$al Bl$w and 9re*ent release $B dust 9arti'les Br$( the (ain '$al Bl$w& Water shall "e drawn from the water storage tan# "* 2!00J electric motor driven pumps+ and delivered through a pipe networ# s*stem to spra* heads at the dust suppression 8ones %olenoid valves shall "e provided for open-close control of solution line to each spra* head 7ach spra* head shall consist of minimum 4 nos no88les %pra* heads shall "e provided at coal loading+ discharge and at s#irt "oard 8one Pressure at inlet to spra* head shall not "e less than 0 5 Hg-cmV'g) Trolle* mounted pumping arrangement shall "e provided for suppl*ing water to the mo"ile paddle feeders 1n this arrangement+ tan#+ suppl* pump's) and spra* no88le header shall "e mounted on paddle feeder trolle* The tan# on P-5 trolle* shall "e filled through fle&i"le hose tapings on a ring header+ which will remain+ flooded through a connection to on ground storage tan# This storage tan# shall have ma#e up connection from the common dust suppression s*stem 7ach spra* head shall have a provision for installing a pressure gauge whenever required 5urther+ pressure gauges shall "e provided at least at two locations .t specified locations dust suppression s*stem shall "e provided which comprises spra* no88les discharging plain water in a fine spra* to capture air "orne dust particles

and direct them into the main coal flow Water shall "e discharged via a pipe wor# s*stem through spra* heads at the dust suppression 8ones ! ( !( 2 %rac9 Hopper D*st S*ppression System Hater shall 2e drawn Br$( the water st$ra#e tank 27 ele'tri' ($t$r dri*en 9u(9s and dis'har#ed *ia a 9i9e w$rk s7ste( thr$u#h s9ra7 heads& :he dust su99ressi$n s7ste( shall '$nsist $B headers with s9ra7 n$IIles r$uted al$n# the entire len#th $B tra'k h$99er $n ea'h side& 1a'h n$IIle header shall 2e 9r$*ided with adeDuate nu(2er $B s9ra7 n$IIles s9a'ed at 1000 (( inter*al in Ii# Ia# wa7& @urther, at the tra'k h$99er the water s9ra7 shall 2e $B B$##in# t79e with a (ini(u( 9ressure $B 2&5 k#/'(2A#, at s9ra7 n$IIle inlet& ! ( !( 0 Coal Aard D*st S*ppression System Hater shall 2e drawn Br$( the water st$ra#e tank 27 ele'tri' ($t$r dri*en 9u(9s and dis'har#ed *ia a 9i9e w$rk s7ste( thr$u#h s9ra7 heads& .9ra7 heads shall '$(9rise $B swi*elin# t79e s9ra7 units s9a'ed at an inter*al $B a99r$>i(atel7 0 (eters ar$und ea'h '$al 9ile& -anuall7 $9erated #l$2e *al*e shall 2e 9r$*ided t$ '$ntr$l water su99l7 t$ ea'h s9ra7 unit& One n$& 9u(9 shall 2e 9r$*ided B$r ea'h indi*idual st$'k 9ile with '$(($n header& Pressure at inlet t$ s9ra7 unit shall n$t 2e less than 4&5 k#/'(2A#,& ! ( !6 S*mp P*mps .u(9 9u(9s al$n#with le*el swit'hes C 9i9in# u9t$ nearest Pur'haserEs drain A(a> u9t$ 50&0 (trs& Br$( $utside the 2uildin#, shall 2e 9r$*ided at all l$'ati$ns where*er natural draina#e is n$t 9$ssi2le& @urther su(9 9u(9s al$n#with drain 9its shall 2e 9r$*ided at $ther l$'ati$ns als$, iB reDuired, durin# detailed en#ineerin# sta#e& The capacit* of each pump shall not "e less than 50 M 0-hr Minimum !0J margin on capacit* and 20J margin on computed head shall "e considered for selection of pumps %i8e of the sump pit shall not "e less than 2 0 meters & 2 0 meters & 2 5 meters <ne no of settling pit shall also "e provided "efore sump pit so that water without heav* coal particles goes into sump pump pit High and low level switches shall "e provided in the sump pump pit 2L100G su(9 9u(9s al$n#with le*el swit'hes and 9i9in# u9 t$ nearest OwnerEs drain A(a>& u9 t$ 50&0 (eters Br$( $utside the 2uildin#, shall 2e 9r$*ided at all l$'ati$ns where*er natural draina#e is n$t 9$ssi2le& .u(9 9u(9s al$n# with drain 9its shall 2e 9r$*ided at $ther l$'ati$ns als$, iB reDuired, durin# detailed en#ineerin# sta#e&

! ( !,

SerCice =ater System .er*i'e water distri2uti$n s7ste( '$(9lete with water su99l7 s7ste(, *al*es, Dui'k '$u9lin#s, h$se 9i9es with n$IIle, 9i9in#, 9u(9s, dri*e ($t$rs with 'an$97, '$u9lin#s with en'l$sure, ele'tri'als, in'ludin# su99$rtin# stru'tures, handlin# B$r eDui9(entEs, 'i*il and stru'tural w$rks and ne'essar7 a''ess$ries shall 2e 9r$*ided thr$u#h$ut the '$al handlin# 9lant area in <idderEs s'$9e&

! ( !, ! -

Pipings( &ittings( ValCes and Specialities :he (aterial t$ 2e su99lied B$r '$(9letin# the 9i9e w$rk shall in'lude 2ut n$t 2e li(ited t$ .trai#ht 9i9in#, 2ends, tees, el2$ws, 2ran'hes, laterals, 'r$sses, redu'in# uni$ns, '$u9lin#s, 'a9s, 2lank Blan#es, saddles et'& ne'essar7 B$r (akin# relia2le 9i9in# s7ste(& Cas#ets+ ring Eoints+ Eointing material etc as required 1nstrument tapping connections+ stu"s Cate+ glo"e and chec# valves to start-stop+ regulate and to prevent "ac# flow =uple& %trainers .nchors+ hangers and supports as required including secondar* steel em"edments etc /olts+ nuts+ fasteners as required for interconnection piping+ valves and fittings as well as for terminal points ;nder#r$und 9i9e 9r$te'ti$n B$r all under#r$und 9i9e w$rk& Paintin#, anti-'$rr$si*e '$atin#s et'& inside and $utside 9i9es as ne'essar7& Welding electrodes and welding rods

2 2 2

2 2

! ( !, 2

SerCice =ater System %ervice water connections are to "e provided in conve*or galleries and tunnels at 50 meter intervals .dequate num"er of these connections shall "e provided in all transfer houses with minimum one no at each floor and with minimum two '2) nos at each floor in crusher house 7ach connection shall "e provided with one '!) no 02 9/

glo"e valve and quic# coupling <ne '!) 9o Hose pipe with no88le shall "e provided in each "uilding %ervice water distri"ution s*stem shall "e designed considering the water scheme and water requirement ! ( !, 0 =ater S*pply P*mps Water suppl* pumps shall "e provided as required The pumps shall "e complete with drive motors+ "ase plate and other accessories The constructional features of the pump shall "e as follows? 'a) Pump casing ma* "e a&iall* or radiall* split The casing shall "e of ro"ust construction Casing drain and vent connections shall "e provided 1mpeller shall "e made in one piece and securel* #e*ed to the shaft 3oc#ing device shall "e provided to prevent its loosening during all conditions of operation Wearing rings shall "e of renewa"le t*pe <pposed wearing surface shall "e of hardened material and shall have a hardness difference of at least 50 /H9 $eplacea"le shaft sleeves shall "e provided to protect the shaft where it passes through "earings and stuffing "o&es The end of the shaft sleeve assem"l* shall e&tend through the pac#ing gland %haft sleeve shall "e securel* loc#ed or #e*ed to the shaft to prevent loosening or rotation %haft and shaft sleeves shall "e machined and assem"led for concentric rotation The design of the shaft shall ta#e into consideration the critical speed+ which shall "e at least 20J awa* from operating speed Pump "earings shall "e of antifriction t*pe /earings shall "e readil* accessi"le without distur"ing the alignment of pump Pac#ed stuffing "o&es shall "e of sufficient length to prevent lea#age along the shaft and shall "e complete with all pac#ing and lantern rings required Pumps shall "e furnished complete with fle&i"le 2coupling Couplings guards made of e&panded metal and "olted to the "ase plate shall "e furnished The common "ase plate for pumps and motor shall "e in one piece and shall "e made of fa"ricated steel

'")

'c)

'd)

'e)

'f)

'g)

'h) 'i)

'E)

'#)

Pump speed shall "e less than !500 rpm for pumps of capacit* more than !0 m0-hr

The power+ head and flow characteristics of each pump shall "e suita"le for parallel operation The Power characteristics of the pumps shall "e of non overloading t*pe .ll rotating parts of the pumps shall "e staticall* and d*namicall* "alanced =esign dut* point of pump shall match with the average value of ma&imum and minimum flow rates of the pump in the sta"le operation 8one Materials of construction of pump components shall "e as follows? C@!S%"?C%I@! " G?I" # !%S Water %uppl* Pumps Casing

1mpeller %haft %haft sleeves /earings Wearing rings Wearing surface Hardness Pump speed Head flow characteristics Materials 'a) Casing '") 1mpeller 'c) 1mpeller Wearing ring 'd) Casing Wearing ring 'e) %haft 'f) %haft sleeve 'g) Cland pac#ing Metering Pumps T*pe

.&ial or radiall* split with drain B vent connection <ne piece+ #e*ed to shaft along with loc#ing device Critical speed atleast 20J awa* from operating speed at "earings B stuffing "o&es .ntifriction t*pe $enewa"le t*pe 50 /H9 difference "etween ring B surface hardness /elow !500 rpm for capacit* more than !0 m0-hr %uita"le for parallel operation Cast 1ron to 1%?2!0+ 5C 2(0 /ron8e conforming to Cr 1 of 1%?0!, /ron8e conforming to Cr 1 of 1%?0!, /ron8e conforming to Cr 1 of 1%?0!, Medium car"on steel %tainless steel conforming to .1%12 4!( hardened 1mpregnated teflon Positive t*pe displacement diaphragm

Capacit* Capacit* control Pressure relief s*stem %ump Pumps T*pe =ut* Materials 'a) Casing and rotor housing '") $otor 'c) %haft 'd) Cland 'e) Wearing rings 'f) %haft enclosing tu"e Pipings B 5ittings Woints 'i) Pipe to pipe Pipe si8e X 50 9/ Pipe si8e Y (5 9/ 'ii) Pipe to valves Pipe si8e X 50 9/ Pipe si8e Y (5 9/ 1solation of flow $egulation of flow Aalves 'i) %i8e Y (5 9/ 'ii) %i8e X 50 9/

.dEusta"le from !0 to !00J through stro#e variation Manual with stro#e positioner 1ntegral with the pump Wet pit t*pe vertical shaft Capacit* to handle large solids or unscreened liquid 9i2Cast 1ron '050 /H9) 9i2Cast 1ron '050 /H9) Medium car"on steel /ron8e %tainless steel Car"on steel

%oc#et welding

welding-screwed

/utt

%crewed 5langed Plug - Cate - %luice valves Clo"e Aalve /olted "onnet outside screw rising t*pe Gnion "onnet with screwed ends for Clo"e valves B screwed ends for plug valves 7$W car"on steel pipes to .P12532 Cr / minimum thic# ( 05 mm or plate fa"ricated and welded pipes to 1%?05,;+ Class22 7$W car"on steel "lac# pipes to 1%?!20; 'Part2Heav* class 7$W car"on steel galvanised pipes to 1%?!20; 'Part21) Heav* class 'a"ove (5 9/) Cast 1ron to 1%?2!0+ Cr 5C2200 Cast 1ron to 1%?2!0+ Cr 5C2 200 valves

Materials for Pipewor# 'a) 5or si8es 200 9/ and 3arger

'") 'a)

5or si8es !50 9/ to ,0 9/

5or si8es "elow ,0 9/ Materials for Aalves B %pecialities 'a) Cast 1ron Aalves 'i) /od* and "onnet 'ii) =isc for non2 return

'iii) %eating surfaces and rings 'iv) Hinge pin for non return valves 'v) %tem for gate and glo"e valves 'vi) /ac# seat "ush '") Cun metal valves '(5 9/ B "elow and upto a wor#ing pressure of !0 #g-cm2) 'i) /od* 'ii) Trim 'c) =uple& %trainer 'i) /od* 'ii) %trainer 'd) Pressure Cauge-%witch 'to "e provided with isolating valves) 'i) =ial si8e 'ii) .ccurac* 'iii) /ourdon 'iv) /loc# 'v) Movement 'vi) Case and /e8el

!0J chromium steel %tainless steel t*pe .1%120!( !0J chromium steel !0J chromium steel

Cun metal to 1%?0!,+ Cr22 Cun metal to 1%?0!,+ Cr22 M% fa"ricated %tainless steel t*pe element .1%120!(

'vii) 9o of contacts 'viii) T*pe of contact 'i&) =egree of protection 'e) %olenoid valve 'to provided with isolating valve) 'i) T*pe

!50 mm M !J of range span .1%1 0!( %% .1%1 0!( %% .1%1 0!( %% =ie cast .lum Weather proof case stove enameled "loc# with screwed t*pe inner "e8el of ./% plastic 2 9< M 2 9C .dEusta"le throughout the range 1P (5

"e 2-2 wa* =iaphragm pilot operated molded s*nthetic ru""er 5orged "rass - %% 0 5 to 20 #g-cm2 1P (5 t*pe

'ii) =iaphragm 'iii) /od* 'iv) Pressure 'v) Protection Class 'f) 5low %witch 'to "e provided with isolating valves) 'i) /od* 'ii) 7&tension $od-wire 'iii) %leeve and %leeve pipe 'iv) Cover 'v) Ma& wor#ing pressure 'vi) $epeata"ilit* 'vii) 9o of contacts

5orged steel %%2004 %%2004 =ie cast aluminum !0 #g-cm2 U 0 5J 2 9< M 2 9C

'viii) T*pe of contact .dEusta"le throughout the range 'i&) Protection class 1P @ (5 'g) 3evel %witch 'i) T*pe =isplacer operated magnetic t*pe 'ii) =isplacer %% @ 0!( 'iii) Wire rope %% @ 0!( 'iv) %pring Housing %pring and %% @ 0!( sleeve pipe 'v) Cover Cast .luminum 'vi) 9o of Contacts 2 9< M 2 9C 'vii) T*pe of Contact .dEusta"le throughout the range 'viii) Protection class 1P @ (5 'h) 3evel gauges 'i) T*pe 5loat t*pe mechanical gauge with arrow scale 'ii) .ccurac* U!J of full scale range 'iii) Material of construction 'a) 5loat B Cuide wire 0!( %% '") 7l"ows %uita"le grade of %% 'c) Housing Mild %teel 'd) Ca"le fastener %% 004 'i) 9o88les 'for Plain and ChemEet =% e&cept %toc#*ard =%) 'i) T*pe 5ogging+ non2clogging t*pe 'ii) Material %tainless %teel 'iii) 9o88le housing To ensure protection of no88le against damage

! ( !;

Special Cleaning( Protection and Painting Piping < &ittings %urfaces to "e painted shall "e thoroughl* cleaned of loose mill scale+ rust etc "* wire "rushing 5or overground e&posed steel pipes+ one shop and one site coat of red o&ide 8inc phosphate and two coats of s*nthetic enamel finishing paints unless specified otherwise shall "e applied . minimum of !20 microns =r* 5ilm Thic#ness '=5T) after finished coat of paint shall "e ensured

5or steel "uried pipeline+ three '0) coats of heav* dut* "itumastic paint shall "e applied on the cleaned surface 5inall*+ it should "e wrapped with minimum 0 mm thic# "itumen impregnated tar felt The lap Eoint of the felt shall "e generall* touched with heav* dut* "ituminous paint 1&6&20 ! ( 20 ! 0enti)ation S5stems 8eneral :he s9e'iBi'ati$n is intended t$ '$*er desi#n, en#ineerin#, (anuBa'ture, su99l7, ere'ti$n, testin# and '$((issi$nin# $B the '$(9lete ?entilati$n C A&+& s7ste(s as s9e'iBied hereinaBter B$r the s($$th and tr$u2le Bree $9erati$n $B +5P& The Contractor shall refer to the other sections enclosed to appraise himself of the wor# and scope of suppl* of the other Contractors-<wners and shall coordinate his wor# with the wor# of other Contractors ! ( 20 2 8eneral Description :he air Duantit7 B$r (e'hani'al *entilati$n s7ste( shall 2e esti(ated 2ased $n eDui9(ent and s$lar heat l$ads and the te(9erature rise inside the 2uildin#& Ne'essar7 air Bilters shall 2e 9r$*ided t$ su99l7 $nl7 'lean air int$ 2uildin#& 1>haust air shall 2e dis'har#ed at a suita2le hei#ht a2$*e 2uildin#& 1>haust Bans shall 2e 9r$*ided B$r tri99er Bl$$r& :he 9ressurised *entilati$n s7ste( ha*in# adeDuate n$s& $B su99l7 air Bans with washa2le (etalli' 9re Bilters, 5DP1 Bine Bilters, and e>haust Bans with selB 'l$sin# Bla9s, du'tin# al$n# with 9hase A+ ($t$r dri*es, ele'tri'als, su99$rtin# stru'tures, a''ess / (aintenan'e 9latB$r(s shall 2e 9r$*ided in all -++/swit'h#ear r$$( areas $B '$al handlin# 9lant t$ 2e Burnished under this s9e'iBi'ati$n& :he 9ressuriIed *entilati$n s7ste( shall 2e desi#ned '$nsiderin# 15 air 'han#es t$ (aintain these areas 9ressurised sli#htl7 a2$*e at($s9heri' 9ressure t$ 9re*ent in#ress $B dust Br$( $utside& Air '$nditi$nin# s7ste( shall 2e Burnished B$r '$ntr$l r$$( area $B (ain '$ntr$l r$$(, -++ r$$( $n ./0 and $9erat$rEs 'a2in and P)+ r$$(s B$r +$al sa(9lin# units& It shall 2e desi#ned '$nsiderin# the eDui9(ent heat l$ads, s$lar heat l$ads, heat #ain int$ the r$$(, adeDuate n$& $B air 'han#es et'& t$ (aintain a uniB$r( te(9erature and relati*e hu(idit7 within the air '$nditi$ned areas& Outside desi#n '$nditi$n shall 2e as s9e'iBied in Data .heet $B this se'ti$n& P)+ r$$( ha*in# the P)+ $B '$al sa(9lin# units near the +.; shall als$ 2e air-'$nditi$ned&

:he *entilati$n s7ste( #enerall7 '$nsistin# $B adeDuate nu(2er $B su99l7 air Bilters, du'tin# al$n# with 9hase A+ ($t$r dri*es, ele'tri'als, su99$rtin# stru'tures, a99r$a'h/(aintenan'e 9latB$r(s, 'i*il and stru'tural w$rks and ne'essar7 a''ess$ries shall 2e Burnished B$r *entilatin# the tra'k h$99er, under#r$und 9$rti$n $B transBer 9$ints, under#r$und '$n*e7$r tunnels and 9ent h$uses& 1>haust Bans shall 2e 9r$*ided B$r tri99er Bl$$r& &or design p*rpose the o*tdoor am6ient temperat*re shall 6e ta9en as 50oC :he *entilati$n s7ste( #enerall7 '$nsistin# $B adeDuate nu(2er $B su99l7 and e>haust Bans, (etalli' 9re Bilters, 5DP1 Bine Bilters, du'tin# al$n# with 9hase A+ ($t$r dri*es, ele'tri'als, su99$rtin# stru'tures, a99r$a'h / (aintenan'e 9latB$r(s, ne'essar7 shed, 'i*il C stru'tural w$rks and ne'essar7 a''ess$ries shall 2e Burnished B$r all -++/swit'h#ear r$$(s& @$r desi#n 9ur9$se the $utd$$r a(2ient te(9erature shall 2e taken as 50$+& 2L100G 'a9a'it7 air '$nditi$nin# 9a'ka#ed units APA+, with r$$B ($unted air '$$led '$ndensers shall 2e 9r$*ided B$r '$ntr$l r$$( area $B (ain '$ntr$l r$$(& <ne '!) no window .C each for MCC room of %-$+ operatorDs ca"in and P3C room for coal sampling unit shall also "e provided %uppl* and return air distri"ution ducting complete with insulation+ of resin "onded mineral wool equivalent of densit* at least 24 Hg-mZ and thermal conductivit* of ma& 0 4; mw-cmSC conforming to 1%?,!,0 including supporting structures+ approach-maintenance platforms+ civil and structural wor#s and necessar* accessories shall "e provided

8 ! "4' Mech Aentilation %*stem 9o of air changes per hour 'a) 5or overground "uilding '") 5or underground areas .rea '!) Trac# Hopper- Gnder2ground tunnel-portion of transfer points and pent houses '2) Tripper floor in "un#er "a* Pressurised ventilation s*stem

To provide ventilation using fans for specified areas 9ot less than !0 9ot less than !5 Centrifugal fans-.&ial 5ans

.&ial fans and - or roof ventilators To provide clean air and to maintain

9o of air changes per hour .rea .ir2conditioning s*stem

Temperature to "e maintained Humidit* to "e maintained 5resh .ir inta#e <utside .m"ient Conditions 'i) %ummer 'ii) Monsoon 'iii) Winter D SI8! < C@!S%"?C%I@! "oof Ventilators Capacit* Head %peed 'a) 1mpeller dia a"ove 450 mm '") 1mpeller dia less than or equal to 450 mm 'c) Critical speed 42ial &ans Capacit* Head %peed 'a) 1mpeller dia a"ove 450 mm '") 1mpeller dia less than or equal to 450 mm 'c) Critical speed Centrif*gal &ans Capacit* Head %peed <utdoor temperature $ating Pac9aged 4ir+Conditioning ?nit T*pe %ervice-application Continuous+ round the cloc# Capacit*

the area pressuri8ed to prevent ingress of dust 9ot less than !5 MCC-%witchgear rooms and %BT room 5or main control room+ MCC room on %-$ and operators ca"in B P3C room of coal sampling units 24 U ! deg C 50 U 5J relative humidit* More than ! 5 air changes per hour .s per weather data given in proEect s*nopsis 2 =o 2 2 =o

!0J more of actual requirement 20J more of actual requirement Ma& ;(0 rpm Ma& !440 rpm 25J a"ove operating speed !0J more of actual requirement 20J more of actual requirement Ma& ;(0 rpm Ma& !440 rpm 25J a"ove operating speed !0J more of actual requirement 20J more than actual requirement Ma& !500 rpm 50 deg C Continuous $oof top mounting

'i) 'ii)

T$ C5M

Condenser 5an 5ilter Cooling Coil 'a) T*pe '") Material 'c) 5ins $efrigerant Piping 1nsulation for P.C parts &ilters Metallic 5ilters '!) Ma& air velocit* H=P7 filters '!) 7fficienc* '2) Ma& velocit* '0) Testing High 7fficienc* 5ilter '!) 7fficienc* '2) Pr drop across '0) Testing 1nsulation for .-C =ucting $esin /onded Mineral wool as per 1%?,!,0 =ensit* Thermal conductivit*

%uita"le %uita"le T*pe of compressor Multiple c*linder hermetic compressor .ir cooled t*pe 5orward curved centrifugal fan High efficienc* filter =irect 7&pansion Copper .luminum mechanicall* "onded Copper 7&panded pol*eth*lene of densit* at least !5 #g-mZ

2m-sec ;0J down to 5 microns 2 5 m-sec .s per /% 2,0! - %qv ;; ;J down to 5 microns !0 mm W C .s per /% 2,0! - %qv

24 #g-mZ 0 4; mw-cm oC

+$((ents A5,

7cto2er )0, 600%

1...0 Co/es $"/ St$"/$r/s

!60

Filed under: ,n!ategori-ed Tags: /010. Codes and Standards shiva i!houdhur" # %:*. am

Codes and Standards to 6e folloDed. :he desi#n, (anuBa'ture, ins9e'ti$n and testin# $B .7ste(s eDui9(ents shall '$(9l7 with all the 'urrentl7 a99li'a2le statutes, re#ulati$ns and saBet7 '$des in the l$'alit7 where the eDui9(ent is t$ 2e installed& :he eDui9(ents shall '$nB$r( t$ the latest editi$n $B the B$ll$win# standards and '$des& Other internati$nall7 a''e9ta2le standards/'$des, whi'h ensure eDual $r hi#her 9erB$r(an'e than th$se s9e'iBied, shall als$ 2e a''e9ted& N$thin# in this s9e'iBi'ati$n shall 2e '$nstrued t$ relie*e the '$ntra't$r $B the reDuired

statut$r7 res9$nsi2ilit7& In 'ase $B an7 '$nBli't in the standard and this s9e'iBi'ati$n, the de'isi$n $B the Pr$8e't -ana#er shall 2e Binal and 2indin#& .merican 1ron B %teel 1nstitute '.1%1) .merican %ociet* for Mech 7ngineers '.%M7) .merican %ociet* for Testing B Materials '.%TM) .merican Wire Cauge '.WC) 1nstitute of 7lectrical B 7lectronic 7ngrs '1777) 1nstrument societ* of .merica '1%.) Nati$nal 1le'tri'al +$de AN1+, 9ational 7lectrical Manufacturers .ssociation '97M.) Gnited %tates of .merica standards 'G%.%) /ureau of 1ndian %tandards '/1%) Conve*or 7quipment Manufacturers .ssociation 'C7M.) 1%?66, I.:7!0 Cun Metal gate+ glo"e B chec# valves for general purpose .lui'e *al*es B$r water w$rks 9ur9$ses A50 t$ 00 ((,

1%?!20; Mild %teel tu"es B fittings 1%?206; Colour for the identification of pipe line 1%?2;0( %luice valves for water wor# purposes 1%?05,; 7lectricall* welded steel pipes for water+ gas B sewage '200 to 2000 mm) 1%?50!2 %wing chec# t*pe reflu& 'non return) valves 1%?!520 Hori8ontal centrifugal pump for clean+ cold fresh water 1%?5!20 Centrifugal pump for clean+ cold B fresh water .9%1 / 0! ! Code for pressure piping

H*draulic institute %tandards of G % . A.:--D-22 4 .tandard -eth$ds B$r '$lle'ti$n $B a /r$ss .a(9le $B +$al& %tandard Method of Preparing Coal %amples for .nal*sis

.%TM2=220!0

1%?0;0, %pecification for 7lectric Wire $ope Hoist 1%?0,02 Hand operated chain pulle* "loc#s 1%?242; $ound steel short lin# chain 1%?0!0; %hort lin# chain grade M'4) I.: !15 P$ints h$$ks with shank B$r #eneral en#ineerin# 9ur9$ses

1%?2!0 Cast 1ron Castings IS.40,/ Code of practice for lining of Cessels and e>*ipment for chemical processes 1%?22( 1%?!!5;2 %tructural %teel '%tandard Tualit*) Code of practice for selection and design of /elt Conve*ors

IS.3,/3 Dimensions for Ci6rating conCeyors and feeders with rectangular or trape8oidal trough 1%?0(,, =imensions for shaft ends 1%?0(,! Ceneral plan for spur B helical gears IS.-403 Code of practice for selection of standard Dorm and helical gear "o&es 97M. 97C 1%?!!546 5or electronic circuit enclosures 7lectronic weighing in motion s*stem

1%?05,, %pecification for electrical a&ial flow fans 1%?20!2 Propeller t*pe .C Aentilation fans 1%?0;(0 %pecification for roof2e&tractor units 1%?4,;4 Centrifugal 5ans 1%?(55 .$1?2!0 .$1?260 %pecification for Metal .ir =uct %tandard for Gnitar* air conditioning equipment %tandard for application+ installation and servicing of unitar* equipment

1%?,!,0 %pecification for "onded mineral wool 1%?((! Thermal insulation for cold surfaces

1%?4(6! 7&panded pol*st*rene for thermal insulation purpose 1%?,!4, Pac#aged .ir conditioners M<elt +$n*e7$rs B$r <ulk -aterialsN 9u2lished 27 +$n*e7$r 1Dui9(ent -anuBa'turersE Ass$'iati$n& I.:7155 +$des $B Pra'ti'e B$r +$n*e7$r .aBet7&

1%?!,;! 'Part21) Ceneral Purpose /elting 1%?,5;, 1dlers and 1dler %ets for /elt Conve*ors Conical Head Crease 9ipples

1%?400; 'Part211) 1%?050! 1%?22( 1%?4(,2

Pulle*s for /elt Conve*ors %tructural %teel '%tandard Tualit*) Codes of Practice for 3ining of Aessels and 7quipment for Chemical Processes Code of practice for selection and design of /elt Conve*ors

1%?!!5;2

C.9 - C.%. @ M422 M,6 ? Canadian standard association

+$((ents A1,

1.0.0 'est "! $"/ I"spect o"

!,0 %esting and Inspection

Filed under: ,n!ategori-ed Tags: /0)0. !hp& Testing and 2nspe!tion shiva i!houdhur" # %:() am

The details of the chec#s-tests to "e carried out in the various equipments are to "e su"mitted "* the Contractor for <wners approval However+ some indicative chec#s on different items are given "elow which should necessaril* form a part of the Tualit* .ssurance Programme to "e agreed with "* the <wner i) P*mps .ll materials should "e of tested qualit* and test certificates to "e provided %haft forgings to "e also su"Eected to ultrasonic testing and hardness chec#s 1mpellers to "e d*namicall* "alanced .ll pumps to "e performance tested as per H*draulic 1nstitute %tandard-1ndian %tandard Performance test to include chec# for noise+ vi"ration level and temperature rise ii) ValCes < Specialties ?al*es C s9e'ialties shall 2e tested as 9er rele*ant standards C '$des& %eat lea#age B h*draulic test to "e carried out as per relevant code iii) Pipes < &ittings Pipes B fittings shall "e tested as per relevant standards B codes iv) Ventilation and 4ir Conditioning &an All (aterials sh$uld 2e $B tested Dualit7 and test 'ertiBi'ates sh$uld 2e 9r$*ided& =*namic "alancing of the fan impellers to "e carried out %hop run test shall "e conducted on all centrifugal fans including chec# for noise and vi"ration level

Performance test shall "e conducted on one fan of each t*pe at shop for capacit*+ pressure+ efficienc* and power consumption Aalves and %pecialties Aalves and %pecialties shall "e tested as per relevant code Pipes and 5ittings Pipes and 5ittings shall "e tested as per relevant code v) %raCelling %ripper and B*n9er Sealing .haBt and wheel B$r#in#s F +he(i'al, -e'hani'al and ultras$ni' test shall 2e '$ndu'ted& %hop running test shall "e carried out and shall include chec# for noise and vi"ration level vi) leCators .ll 9=T operators should "e qualified as per .%9T2TC2!. .ll forgings shall "e su"Eected to ultrasonic test to ensure free from internal defects !0J of the welds selected at random shall "e su"Eected to =P test .ll forged components shall "e su"Eected to =P1-MP1 after machining 9o load shop trial run shall "e conducted on gear /o&es which shall include chec# for gear ratio+ temp rise+ noise and vi"ration /uffer springs shall "e su"Eected to load test as per relevant specifications Material certificates for springs shall also "e furnished .ll components prior to assem"l* shall "e chec#ed for dimensions .ll electrical equipments shall "e of t*pe tested qualit* The /idder shall su"mit t*pe test certificate for the equipment conducted during last five '5) *ears as on date of "id opening for <wnerDs approval+ however if such certificates are not availa"le or not accepta"le+ the same shall "e conducted with out an* e&tra cost to owner

Calvani8ed components- parts shall "e chec#ed for wt of [n coating+ thic#ness of coating+ uniformit* of coating and adhesion test and visual e&amination as per 1% 2(00 and 1% 2(2; vii) Idlers 'a) Chec# for run out and free movement shall "e carried out on idlers $un out shall "e restricted as per 1%?,5;, Test for dust proofness and water proofness of the 1dlers shall "e conducted at shop The detailed procedures for the same shall "e su"mitted for review and approval Chec# for d*namic friction factor for idlers shall "e also conducted Procedure for the same shall "e su"mitted

'")

'c)

viii)

Belting Aa, 0u22er '$*er shall 2e 'he'ked B$r tensile stren#th and el$n#ati$n at 2reak 2eB$re and aBter a#in#& 5or finished "elts+ chec#s for elongation at !0J nominal tensile strength+ tensile and elongation at "rea# in longitudinal 'warp) direction+ tensile and elongation at "rea# in transverse 'weft) direction shall "e carried out .dhesion test "etween individual plies and cover and plies shall "e carried out Trougha"ilit* test shall "e carried out Test for fire resistance of the "elt shall "e conducted Test for procedure qualification for "elt vulcani8ing Eoint 'at site) shall "e done at either shop or site '"efore erection) Procedure for "elt vulcani8ing Eoint shall "e discussed and finalised during TP finalisation There will "e a limitation on the no of repairs allowed on the "elts+ 5ollowing will "e the acceptance norm for the cover repairs 'i) The ma&imum si8e of a repair shall "e limited to a si8e equivalent to one fifth the "elt width The ma&imum num"er of patch repairs shall not e&ceed 5 per !00 mts However+ the total num"er of patch and dough filling repairs shall not e&ceed !0 per !00 meters

'")

'c) 'd) 'e) 'f)

'g)

'ii)

'iii)

%mall local repair of si8e 25 mm & 25 mm to a limited e&tent shall not "e counted of repairs However+ in case of cluster of repairs+ it shall "e counted as a patch repair

'h)

1n no case shall the cover thic#ness or the width of "elt "e less than that given in specification 9o negative tolerances will "e allowed in the same $u""er cover shall also "e chec#ed for a"rasion+ tear strength and hardness

'i) i&)

Belt V*lcanising #achine Chec# for tensile strength shall "e carried out on a sample vulcanised "elt Eoint for each t*pe of "elt

&)

P*lleys 'a) 1n addition to Chemical B Mechanical properties+ pulle*s shaft forging shall "e su"Eected to ultrasonic testing to ensure internal soundness !00J MP1 on welds shall "e conducted and !0J $T-GT on "utt welds shall "e conducted .tati' 2alan'in# $B 9ulle7s shall 2e 'arried $ut aBter ru22er la##in#& +he'ks $n ru22er la##in# t$ in'lude a2rasi$n l$ss, sh$re hardness test, 9eel-$BB stren#th test and 9h7si'al 9r$9erties 9eel F $BB stren#th shall 2e 10 k#/ +(, A2rasi$n l$ss shall 2e less than 250 'u2i'& (( when tested as 9er DIN 5 516&

'")

A', Ad,

&i)

P*ll chord < Belt SDay SDitches T*pe test certificates shall "e furnished for following tests? i) ii) iii) iv) v) the 7ndurance test for mechanical and electrical dura"ilit* =egree of protection test HA B 1$ test .cceptance tests .ll tests as per 1% !0;46 'Part 4 %ec !) shall "e carried out on switches

O*er all di(ensi$n and Bun'ti$nal test shall 2e 'arried $ut& &ii) Eero speed sDitch < *nder 6elt sDitch T*pe test certificates shall "e furnished for following tests? i) ii) iii) 7ndurance test for mechanical and electrical relia"ilit* =egree of protection test The following environmental tests as per 1% ? ;000 a) ") c) d) e) iv) v) =r* test =amp heat c*cle test Ai"ration test /ump test Temp humidit* c*cle test 'for electronic components)

/urn in test at 50oC for 4, hours shall "e done .cceptance test

<ver all dimension and functional test shall "e carried out &iii) Paddle &eeders %haft and wheel forgings @ Chemical+ Mechanical+ Hardness and Gltrasonic Test shall "e conducted %hop trial run to "e conducted and performance test shall include chec#s for noise and vi"ration level &iv) Vi6rating 8riFFly &eeders .h$9 trial run test shall 2e '$ndu'ted and the sa(e shall in'lude all 'he'ks B$r a(9litude, BreDuen'7, te(9erature rise and n$ise le*el& &v) V#S and Cr*sher :he details $B the 'he'ks t$ 2e 'arried $ut B$r *ari$us '$(9$nents are t$ 2e su2(itted 27 the +$ntra't$r B$r OwnerEs a99r$*al& 5$we*er, s$(e indi'ati*e

'he'ks $n diBBerent ite(s are #i*en 2el$w whi'h sh$uld ne'essaril7 B$r( 9art $B the Oualit7 Assuran'e Pr$#ra((e t$ 2e a#reed with the Owner& .ll plates a"ove 20 mm thic#ness to "e ultrasonicall* tested for laminations %haft forgings and suspension "ars to "e chec#ed for hardness+ microstructure and ultrasonic testing in addition to chec# for chemical and mechanical properties 5ollowing minimum 9=T requirements to "e ensured for welds ? 'i) 'ii) /utt welds 5illet welds 2 2 !0J GT-$T and !00J MP1 !0J MP1

Crusher rotor to "e staticall* and d*namicall* "alanced Procedure to "e su"mitted for approval 9o2load trial run test to "e carried out at shop and to include chec# for temperature rise+ noise and vi"ration levels &vi) In 'ine #agnetic Separators i) ii) iii) =imensional+ visual chec# alongwith control panel HA B 1$ <peration+ temperature rise+ lifting capacit*+ force inde& and gauss strength

&vii)

Coal Sampling @ree 'arria#e C 'utter ($*e(ent, s9eed $B 'utter and dust d$$r 'l$sin# C sealin# shall 2e tested B$r sa(9lers& K9o load testL shall "e carried out for crushers 5inal testing of "ra#es shall include load+ HA-1$ B heat run tests

&viii)

Ch*te and Hoppers. $ac# B Pinion Cates-5lap Cates 'a) '") MP1-=P Test shall "e conducted on rac# and pinion 5unctional chec#s on the gates shall "e carried out

&i&)

%tac9er c*m "eclaimer .ll plates used for fa"rication a"ove 20mm thic#ness shall "e ultrasonicall* tested for freedom from laminations %haft forgings shall "e su"Eect to ultrasonic testing and chec# for hardness and microstructure in addition to Chemical B Mechanical properties $ail Wheels+ Cears+ .&les shall "e su"Eected to ultrasonic testing and hardness chec# in addition to chec# for chemical and mechanical properties 1n addition+ = P chec# shall "e carried out on wheel treads after hardening %tructures shall "e fa"ricated meeting the requirement of .W% %tructural Welding Code =! ! or equivalent as a minimum 5ollowing minimum 9=T requirements shall "e followed for welds ? Ai, Aii, 'iii) <utt Helds in :ensi$n - 100G ;:/0: and 100G -PI& <utt Helds in +$(9ressi$n 10G ;:/0: and 10G -PI& 5illet Welds 2 !0J MP1

Trial assem"l* of %-$+ su" assem"lies shall "e carried out at shop Manufacturer shall furnish detail procedure for proEect authorities approval for various su" assem"lies such as wheel "ogies+ "uc#et wheel+ "oom+ "uc#et wheel with shaft and sample "uc#et etc #ono "ail and Hoist .ll materials used shall "e of tested qualit* and test certificates shall "e su"mitted to Purchaser $ope shall "e tested for strength .t manufacturers wor#s+ all monorail hoists shall "e tested for ! 25 times specified load .ll motions including performance of electro2 mechanical "ra#es shall "e tested .t site+ all monorail hoists shall "e tested to full wor#ing load during all motions &&) DriCe >*ipments 8ear Bo2es? 1n addition to ph*sical and chemical properties chec#s+ the shaft and gear forgings shall "e su"Eected to ultrasonic testing and hardness test MP1 to "e carried out on Cears after heat treatment to ensure freedom from defects

9o 3oad shop trial run to "e conducted on gear "o&es which should include chec# for temperature rise+ noise and vi"ration level &&i) &le2i6le Co*pling ;ltras$ni' testin# shall 2e '$ndu'ted $n B$r#in#s B$r #ear slee*e and #ear hu2, iB #ear '$u9lin# is 9r$*ided& MP1 shall "e carried out after heat treatment to ensure freedom from crac#s 5inal inspection of geared coupling shall include chec# for angular misalignment capacit* and interchangea"ilit* &&ii) &l*id Co*pling =*namic "alancing shall "e carried out for the rotating parts Chec# for lea# tightness of the coupling shall "e carried out @un'ti$nal test $n Busi2le 9lu# B$r ea'h t79e $B '$u9lin# shall 2e '$ndu'ted at sh$9& .ll couplings to "e run tested at shop on no load Chec# for temperature rise+ torque2speed+ torque2slip characteristics and over speed test shall "e included during full load performance test of one coupling of each t*pe prefera"l* at full load &&iii) Belt Scales

:he details $B the 'he'ks t$ 2e 'arried $ut in the *ari$us eDui9(entEs are t$ 2e su2(itted 27 the +$ntra't$r B$r Pur'haserEs a99r$*al& 5$we*er, s$(e indi'ati*e 'he'ks are #i*en 2el$w whi'h sh$uld ne'essaril7 B$r( a 9art $B the Dualit7 assuran'e 9r$#ra((e t$ 2e a#reed with the Pur'haser& =imensional chec# shall "e carried out on the /elt %cales /elt scale shall "e cali"rated with test weight-test chain in static and with test weight for d*namic condition .ll electronic modules shall "e su"Eected to "urn in test as per su"2section T7

Ceneral chec# for load cell shall "e carried out T*pe test shall "e carried on load cells 7nclosure test shall "e carried out to chec# degree of protection .ccurac*-performance chec# shall "e demonstrated at site
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