Operation Control Philosophy PDF

PROJECT NLC TUTICORIN TPP-CHP
L&T O9113-M-BM-CS-DB-0097
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LARSEN & TOUBRO LIMITED TIR1-EPC-CHP-DM-W-0097
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OPERATION & CONTROL

PHILOSOPHY OF
COAL HANDLING SYSTEM
(NLC TUTICORIN-TPP)
TABLE OF CONTENTS
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OPERATION & CONTROL PHILOSOPHY OF Sheet 1 Of 71
CHECKED MS/NH COAL HANDLING SYSTEM FOR NLC TUTICORIN-TPP
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SECTION TITLE
1.0.0 SYSTEM DESCRIPTION
2.0.0 OPERATION & CONTROL PHILOSOPHY
2.0.1 COAL HANDLING PLANT CONTROL ROOM
2.0.2 STACKER / RECLAIMER CONTROL ROOM
3.0.0 SYSTEM OPERATION
3.1.0 CONVEYOR SYSTEM
3.1.1 FLAP GATES / FLOW DIVIDERS
3.1.2 METAL DETECTORS
3.1.3 INLINE MAGNETIC SEPARATOR
3.1.4 IN-LINE CONVEYOR SCALE
3.1.5 COAL SAMPLING UNIT
3.1.6 TRAVELLING TRIPPERS
3.1.7 3-D BUNKER LEVEL TRANSMITTER
3.1.8 HOISTS & CRANES
4.0.0 UTILITIES
4.0.1 SWP/PWP/CWP/WTDP/WTP/DSP/THP/PFP/DFDS SYSTEM:
4.0.2 CYCLONE TYPE DE SYSTEM
4.0.3 VENTILATION SYSTEM
4.0.4 AIR CONDITIONING SYSTEM
5.0.0 SEQUENTIAL INTER-LOCK FOR CONVEYORS & OTHER EQUIPMENTS
6.0.0 THE PERMISSIVE CONDITONS FOR OPERATION OF CHP
COAL FLOW CIRCUIT:
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6.0.1 FLOW PATH- I: SHIP UNLOADERS TO STOCKYARD VIA CRUSHER HOUSE

FLOW PATH-II : SHIP UNLOADERS TO BUNKER UNITS VIA CRUSHER HOUSE
6.0.2
(WITHOUT STACKING)
FLOW PATH-III : SHIP UNLOADERS TO BUNKER UNITS VIA CRUSHER HOUSE
6.0.3
(WITH STACKING)
6.0.4 FLOW PATH-IV: STOCK YARD TO BUNKER UNITS.
6.0.5 COMBINATION OF ABOVE
7.0.0 ANNUNCIATION SYSTEM
8.0.0 STATUS INDICATION ON OWS
1.0.0 SYSTEM DESCRIPTION

This description shall be read in conjunction with the following drawings.
Flow Diagram - L&T drawing no. O9113-M-BM-CS-FD-0002 & Project drawing no.
NTPL/TA2/BE/02/0502
General Plant layout - L&T drawing no. O9113-M-BM-CS-PP-0001 & Project drawing no.
NTPL/TA2/BE/02/0501
COAL HANDLING SYSTEM (CHS) is a Turnkey package including Civil, Structural, Mechanical,
Electrical, Instrumentation & Communication etc. for Stacking, Reclaiming and conveying coal to
Bunker Unit (BU).
The coal handling system shall consist of two conveying streams from unloading to coal bunkers
with one stream normally operating and the second stream as stand by. However, it shall be
possible to operate both the streams simultaneously.
The material to be handled by the proposed system is Coal. Processed coal is required to be
conveyed to Bunkers. Coal would be received at the plant boundary by Ship.
1. Coal will be received at the dedicated new jetty at the Tuticorin port. Coal will be
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unloaded from the ships with help of shore unloaders and will be conveyed to conveyors 1A/1B.
Conveyor 1A/1B conveys coal to Conveyor 2A/B at Junction house JT-1. Two nos Metal
detectors (MD1 mounted on Conv 1A & MD2 mounted on Conv 1B) are provided for detecting
metallic materials present in the “As received” coal. Two nos In line magnetic separators (ILMS
-1 on Conveyor 1A & ILMS – 2 on Conveyor 1B) are mounted on discharge end of respective
conveyors at JT-1 for removal of metallic ferrous tramp present in the “As received “coal. Further
Conveyor 1A/1B is having facility for manual stone picking at a suitable location.
2. Conveyor 2 A/B will feed coal to either of Conv 3A1/B1 in JT-2 by means of flap gates FG
1 & 2. Conveyor 3 A1/B1 will feed coal to either of Conv 3A2/B2 in JT-2A by means of flap gates
FG 1A & 1B. Conveyor 3 A2/B2 will feed coal to either of Conv 4A/B in JT-3 by means of flap
gates FG 2A & 2B. Conveyor 4 A/B will feed coal to either of Conv 5A/B in JT-4 by means of flap
gates FG 3 & 4.
3. Two nos. Belt Weigh scale (BW-1 & BW-2) are mounted on Conv 3A2/3B2 respectively
for metering of “As Received” coal. Two nos Metal detectors (MD3 mounted on Conv 3A1 & MD4
mounted on Conv 3B2) are provided for detecting metallic materials present in the “As received”
coal.
4. Coal from each incoming conveyor 5A/5B to Crusher house will have two paths through
FG 5 & 6. 2 nos Roller Screens each of capacity 1250 MTPH (RS-1 & RS-2) are provided in one
path which permits the coal of size -50mm to their respective conveyors (6A/6B) & by pass the
oversized coal to their respective crushers each of capacity 1250 MTPH (CR-1 & CR-2) for
reducing the coal size to -50mm. The crushed coal is then allowed to fall over the respective
conveyors (6A/6B). The other path by passes the coal from conveyor 5 A/B to conveyor 6 A/B
through FG 5 & 6 if the received coal size is -50mm.
5. Two nos. In line magnetic separators (ILMS – 3 over Conv 5A & ILMS – 4 over Conv 5B)
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are provided at the head end of respective conveyors for removal of metallic tramp from the “As
received” coal. Two nos Metal detectors (MD5 mounted on Conv 5A & MD6 mounted on Conv
5B) are provided for detecting metallic materials present in the “As received” coal.
6. Conveyor 6 A/B will feed coal to either of Conv 7A/7B by means of FG 7 & 8. Conveyor
7A/B will further discharge the coal in JT-5 through Diverter Gate DG 1 & 2 to either Conveyor
18A/B for stacking coal in the crushed coal stockyard or on to Conveyor 8A/B for onward
conveying to Boiler Bunkers. Two nos. Belt scale (BS-3 & BS-4) are mounted on Conv 7A/7B
respectively for metering of “As fired” coal.
7. Conveyor 8A/8B conveys coal to Conveyor 9A/B at Junction House JT-6 through flap
gates FG 9 & 10. Conveyor 9A/B will feed coal on to Conveyor 10A/B at JT-8 through flap gates
FG 11 & 12. Conveyor 10A/10B will feed coal on to the bunker conveyor 11 at JT-9 or Conv
12A/B at JT-9 through flap gates FG 13 & 14. Conveyor 12A/12B will feed coal on to the bunker
conveyor 13 at JT-10 or Conv 14A/B at JT-10 through flap gates FG 16 & 17. Conveyor 14A/14B
will feed coal on to the bunker conveyor 15 at JT-11 or Conv 16A/B at JT-11 through flap gates
FG 21 & 22. Conveyor 16A/16B will feed coal on to the bunker conveyor 17 at JT-12.
8. One no Coal sampling unit (CSU-1) is placed on Conv 9A/9B at JT-8 for sampling of “As
fired coal”. Two nos. In line magnetic separators (ILMS – 5 over Conv 9A & ILMS – 6 over Conv
9B) are provided at the head end of respective conveyors for removal of metallic tramp from the
“As fired” coal. Further Conveyor 9A/9B is having facility for manual stone picking at a suitable
location. Two nos Metal detectors (MD7 mounted on Conv 9A & MD8 mounted on Conv 9B) are
provided for detecting metallic materials present in the “As fired” coal.
9. Two nos. Belt scale (BS-7 & BS-8) are mounted on Conv 10A/10B respectively for
metering of “As fired” coal.
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10. One number Travelling Tripper is mounted on each of the Bunker conveyor 11/13/15/17
(i.e. total four nos. of traveling trippers – TT-1 to TT-4) to feed the coal into Raw coal bunkers of
the boiler units (Unit 1 & 2).
11. From JT-5, Conveyor 18A/18B conveys coal to Yard Conveyor 19 & conveyor 20 A/B in
JT-13 through flap gates FG 27 & 28. Conveyor 20A/20B conveys coal to Yard Conveyor 21.
12. Two nos. unidirectional type stacker reclaimer of 2000 MTPH (stacking) / 1200 MTPH
(reclaiming) capacity are provided on Yard conveyors 19 & 21 respectively. The Stacker
Reclaimer machine operates on rails for stacking / reclaiming the coal in the stock yard area.
During reclaiming operation the reclaimed coal will be conveyed to the yard conveyors 19 & 21
by the Boom conveyor of the respective S/R machine which in turn will feed the same to
Conveyor 22A/B by means of flap gates FG 29 & 30 at JT-15 and at JT-16 respectively. Two
nos. Belt scale (BS-5 & BS-6) are mounted on Conv 19 & 21 respectively for metering of
“Stocking & Reclaiming” coal.
13. The reclaimed coal from Conv 22A/B can be fed on to Conv 9A/B at JT-7. From JT-7, the
coal can be conveyed to the raw coal bunker by Conv 9A/B, 10A/B, 12 A/B, 14 A/B 16A/B &
11/13/15/17 to the desired row of bunkers.
14. Three nos Passenger cum Goods Elevator are installed one each at Crusher house, JT-8
& JT-12 to facilitate movement of man & material in these buildings.
MAJOR EQUIPMENTS IN THE HANDLING PLANT ARE:
 2 nos. Stacker Cum Reclaimer, capacity 2000 TPH (stacking) & 1200TPH (reclaiming).
 2 nos. Roller screens (-50 mm), capacity 2000 TPH.
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 2 nos. Ring Granulator Crushers (-300 mm), capacity 1000 TPH.
 4 nos. Travelling Trippers, capacity 1200TPH
 Conveyor stream capacity 2000 /1200 TPH.
 1 no. Coal sampling Unit.
 3 nos. Passenger cum Goods Elevator.
2.0 OPERATION & CONTROL PHILOSOPHY

The COAL HANDLING PLANT is controlled from the Control Room located in PMCC-2 near to
Crusher House.
2.0.1 COAL HANDLING PLANT CONTROL ROOM
The PLC Automation system for Coal and Handling Package shall be as per Automation System
Configuration diagram L&T Drg No. O9113-E-BM-CS-DD-300 and APML Drg. No. TIR1-EPC-CHP-DI-
F-300.
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Operation of the following equipment of coal handling plant is controlled from the main CHP control
room.
• Conveyors, Flap gates, Scoop Type Fluid Couplings, Crushers & Screens.
• Stacker Reclaimer (ON/OFF status with stop facilities)

• Travelling Trippers (tripper position indications).
• Complete Dust Suppression system
• Complete Service water system, Potable water system, Cooling water system
• Ventilation system (group/individual control as required)
• Inline magnetic separators (ON/OFF control with indication)
• Metal detectors (ON/OFF control with indication)
• Coal Sampling Units
• In line Belt Weigh Scale (ON/OFF control with indication).
The following Sub-Systems will be controlled through Dedicated PLC With Control Desk:
• Stacker-Cum-Reclaimer
The following Sub-Systems will be controlled through Micro-PLC:
• Travelling Tripper
The following Sub-Systems will be controlled through Relay Based Local Control Panels:
• Coal sampling units.
• Scoop Coupling System.
• Inline magnetic separator.
• Inline belt conveying system.
• Metal Detector.
• Sump Pump (Only Local Operation).
• Dust Extraction system.
• Dust Suppression system.
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All the above mentioned local control panels are accessible & located near their respective equipment
& will be complete with all the required controls, interlocks, and annunciations etc. Necessary controls,
indications and annunciations for all the above equipment will also be provided at main CHP control
room. In addition to the remote control of various equipments, Local stop push button stations will be
provided for all equipment.
2.0.2 Stacker / Reclaimer Control Room
The entire control & operation of Stacker Recamier machine will be from the operators’ cabin on
the machine itself.
3.0. SYSTEM OPERATION
Typical operation philosophy of the plant is mentioned below to develop the control & monitoring
scheme of plant & equipment under the package. Coal flow path selection will be done from HMI to
select any one of the following conveying paths.
• Ship Unloaders to Stock yard via Crusher House.
• Ship Unloaders to Bunker Units (BU-1, BU-2, BU-3 & BU-4) via Crusher House.
• Stock yard to Bunker Units (BU-1, BU-2, BU-3 & BU-4) via Crusher House.
• Combination of above.
Operator will select any one of the above paths from HMI located in the Control desk from CHP Control
Room in PMCC-2. The flow stream path is then selected by positioning different Flap Gates/Diverter
gates at desired positions by means of keyboard available at the control desk. Once the system is in
the operation, the gates cannot be moved from their positions and path. After the selected path is in
operation the movement of path selector will not have any effect on the system. Flap gates which do
not come in the stream in which coal flow is taking place, can be operated at any time.
The control system will be designed for “Auto” & “Manual” operation of the conveyors in the selected
path. Auto/Manual selection will be done from faceplate in HMI.
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AUTO MODE: In the ‘auto’ mode, the conveyors and related equipment shall start sequentially when
the ‘system start’ is initiated. During stopping, when the ‘system stop’ is activated, all conveyors will
also stop sequentially (in the reverse sequence) allowing time delays for clearing the belts.
MANUAL MODE: In manual mode, the operator shall start the conveyor system, in the same sequence
as in auto mode from MMI. The operator shall also stop the conveyor system, by pressing ‘system stop’
or individual ‘stop’ command from MMI in the reverse sequence.
During ‘sequence start’ in both auto and manual modes, first the required number of hooters (3 phase
induction motor type) will be energized simultaneously for a preset time of 1 minute or so (adjustable at
site) as per the program. After the preset time, the hooters will stop and a preset time of two minutes
(adjustable at site) as per program will be allowed for the movement of the personnel and for the
permissive of the conveyor system operation. This condition shall be indicated on the panel by glowing
of lamp ‘COAL HANDLING SEQUENCE START’. The starting permissive shall be available for a
period of 5 minutes (pre-programmed and adjustable in the field). In the event the last conveyor /
equipment is not started within this preset time of 5 minutes, the start command for equipment not
activated shall be withdrawn. The system cannot be started again unless the ‘sequence start’ push
button is again pressed and the hooters sound again, as described before. Those conveyors and
equipment, which have already started, shall continue to run.
The status indication in the graphic display against all conveyors and equipment in the selected path /
stream shall start slow flickering. But all status indications against all flap gates in the selected path
shall glow steadily. Therefore, from the selected flow stream path of the flap gates, the operator will
come to know the conveyors and equipment to be started for the selected path / stream. After a
conveyor / equipment are started, the status indications against that conveyor / equipment shall change
to steady glow indicating that it is running.
Graphic display status indicators associated with a particular motor / equipment shall flicker fast in case
of fault / trip.
In addition, emergency stop push button for immediate shut down of complete plant shall be provided in
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the CD Console.
For changeover of feed from one row of bunkers to another row of bunkers without stopping of the
CHP, provision shall be made for interlock bypass on the control panel for flap gates of all conveyors in
boiler area for the preset period. If the changeover, in above specified time, is not completed then the
entire CHP shall stop.
3.1.0 CONVEYOR SYSTEM
• Adequate numbers of Belt sway switches, at every 30m interval, are provided to protect
against the damage to the edge of the belt due to excessive sideways movement. In addition,
each conveyor is provided with one (1) no. Speed detection devices (Zero Speed Switch).
These Zero speed switches will be designed to sense belt speed. In case of speed of belt goes
below 90% of rated speed, it will trip the conveyor.
• The starting sequence of the conveyors will follow a direction opposite to that of
flow of material i.e.
 In case of direct conveying of coal to boiler bunkers, start from bunker conveyor &
end up with Conveyor 1 A/ 1B.
 In case of stacking of coal in stock yard, start from yard conveyor and end up with
Conveyor 1 A/ 1B. However, for yard conveyor to start, the Stacker Cum Reclaimer
should be in operation.
 In case of reclamation of coal from stock yard, start from bunker conveyors and end
up with yard conveyor along with Stacker / Reclaimer.
 The starting of mobile trippers are interlocked with operation of the respective bunker
bay conveyors.
 Once a conveyor trips, flap gate directing coal from this conveyor shall change over
its position with a time delay and shall come back to the original position again.
• Interlocking of yard conveyor with stacker-cum-reclaimer boom conveyor is provided.
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• Any individual equipment (belt conveyor etc.) should not be allowed to start unless the
equipment immediately following the same in the direction of flow of material is already in
operation.
• Stop / Tripping of any equipment from running condition will trip all preceding equipment
in the system, except Crushers but will not affect succeeding ones which will continue to
operate.
• Adequate no of Pull cord switches at 30m intervals are provided along the length of each
belt conveyor, which will enable the respective conveyor to be stopped immediately. Belt
Protection switches, Pull Chord Switch & Belt Sway Switch, will be identified/addressed by a
specific number in the Main Control Room.
• Means are provided to pre-warn personnel working nearby when starting any conveyor,
Stacker – cum - Reclaimer & Travelling Tripper by providing Sirens.
• Interlocking of various conveyors is achieved with Flap gate, Flow Dividers Limit
switches and Zero speed switches.
• Motors will start only when the brake/rail clamp if provided, is in ‘Not applied’ condition.
Limit switches are provided to get the signal from brake for the above purpose.
• Ring granulators are provided with Speed and vibration monitoring instruments. Ring
granulators will trip in case Speed/vibration is going beyond tolerable limits of design.
Temperature sensing devices are installed on all bearings of each of the ring granulator to trip
the same in case of temperature goes beyond limit. Audio-visual annunciation is provided in
OWS.
• Tripping of the respective conveyor is provided in case any of Travelling Trippers starts
running along with conveyor belt at speed higher than the rated speed by providing an over
speed sensing device on the equipment.
• It is possible to bunker conveyor & Yard conveyor from Travelling tripper & Stacker cum
Reclaimer respectively.
• Wherever Scoop type coupling provided for HT motors, the coasting time of respective
conveyor, thrustor brake, actuator selection and the chute size will be so selected such that
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there is no spillage of coal from any downstream conveyors during next start.
INTER-LOCKING:
a) Plant Interlock Scheme:
The entire CHP System will have three modes of control.
• Local de-interlock mode control will be carried out by local push button station (LPBS) for each
individual equipment/mechanism.
• Remote interlocked individual drive control from the HMI at Control Room.
• Remote interlocked route wise control from the HMI at Control Room.
The following material conveying systems/sub-systems shall come under Plant Inter-Locking Schemes:
 Conveyors
 Crushers
 Flap Gates & Flow Dividers.
 In Line Magnetic Separators
 Metal Detectors
 In Line Belt Weigh Scale
 Stacker cum Reclaimer
 Travelling Tripper.
The following Systems will not come under the interlock of Conveyor scheme.
 All dust suppression systems & service water system.
 Ventilation systems.
 Hoist(Local operation only)
 Elevator(Local operation only)
 Crane(Local operation only)
 Sump Pump(Local operation only)
All conveyors & equipment will have local push button stations each consisting of:
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 Pos – I, Pos – II & stop button for flap gate and Pos – I, Pos – II, Pos - III &
stop button for Diverter gate.
 Local Start & Emergency stop push button (Red) for other equipment.
Belt scale shall be started when relevant conveyors are started.
The dust suppression systems will be energized as soon as the conveyors at the transfer points are
energized.
Coal handling plant shall be tripped in case of detection of fire.
b) Interlock Of HT Motor:
HT motors used will continue to run on no load by disengaging the fluid coupling in case of failure of
any process interlock. The HT motors will however be tripped incase of any motor fault like O/L, high
motor winding temperature etc. In addition, in case of normal stop command, after running of the
system, motors will stop.
3.1.1 FLAP GATES/FLOW DIVIDERS
All flap gates / Flow Dividers / Diverter gates will be motorized and remote controlled from the main
control desk. Their position will be indicated on the mimic of main control room. Once a conveyor trips,
flap gate directing coal from this conveyor will change over its position with a time delay and will come
back to the original position again. This is to prevent jamming of gate.
3.1.2 METAL DETECTORS
• It is possible to start the conveyors only after energizing the metal detector and metal
detector ‘reset’ condition. Once the metal is detected, the corresponding conveyor will trip. It will
be possible to restart the conveyors, after local resetting of metal detector & putting back the
marker bag in position. Metal detector ON/OFF facilities is provided in the OWS.
• In case of tripping of conveyor system, metal detector will get de-energized after a time lag.
• Following individual indications are provided on Local Control panel
1. Metal Detector ‘ON’
2. Metal Detected
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3. Metal Detector ‘reset’

4. Metal Detector Faulty
3.1.3 IN LINE MAGNETIC SEPARATORS
• It is possible to start the conveyor only after energizing the magnet of ILMS. Further, if
conveyor system trips magnetic separators will get de-energized after a time lag. Also if drive
motor of cleated belt of ILMS trips, Magnetic separator will not get de energized, but
conveyor system will trip and audio-visual annunciation will appear at main CHP control
room.
• Following individual indications are provided on Local control panel
1. Magnetic separator ON.
2. Incoming supply ON
3. Under current relay operated.
4. Cleated belt motor ON/OFF/TRIP.
5. Oil temperature high
3.1.4 IN LINE BELT WEIGH SCALE
Each Belt scale will give output to DDCMIS for display of flow rate and totalizer on Remote Flow rate
Indicator & Remote Totalizer respectively at main CHP control room. Each Belt scale will also have rate
flow indicator & totaliser mounted near the unit.
3.1.5 COAL SAMPLING UNIT

1 set of Coal sampling unit, CSU-1 in JT-8 building for taking samples of Coal has been provided.
a. Coal sampling unit is controlled through CSU control panel located in the respective
building (JT-8) and Starter Panel/DB for the same shall be located inside the Buildings of MCC-3 &
MCC-6 respectively. Controls & interlocks for proper material flow is provided similar to Conveyor
system.
b. Only one start/stop push button for coal sampling system will be provided for
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automatic operation of complete coal sampling system. In any case, local push button stations will
be provided for all individual equipment of coal sampling system near the equipment.
c. All necessary automatic controls will be provided for meeting the requirements of
ASTM-D-2234.
d. In case of primary cutter getting stuck between parking positions, preceding
conveyor will be tripped.
e. There will be protection in the primary coal sampler to trip the conveyor belt in case
primary sampler falls on running conveyor due to coupling failure etc.
OPERATIONAL WRITE UP FOR COAL SAMPLING SYSTEM -1(CSU-1) AT JT-8
3.1.6 MOBILE TRIPPERS

• Mobile tripper unit is locally controlled from the operating platform suitably located with the unit
as per instructions given from main CHP control room.
• End travel limit switches are also provided.
• Travel drive motor will start only when brake and rail clamps are in disengaged condition.
• It will be possible to trip the bunker conveyors from tripper.
• When the last bunker is full, it will not be possible to change over the tripper flap gate from
bunker feeding position to last bunker feeding position.
• As soon as bunker conveyor trips, tripper flap gate will change over its position after a time lag.
• Operator will operate the mobile tripper on bunker conveyors from its carriage. Two nos.
emergency stop button, one on each side will be provided on tripper to stop the machine at any
position. The control unit on tripper will be provided with start / stop push button and indication lamp
for travel / gate. The tripper brakes & rail clamps will be energized (released) when the tripper
motors are ON and the brakes will be applied when the travel motors are OFF. Two travel limit
switches will be provided at either end of tripper carriage for limiting the travel drive between two
ends of the track. The first one will be normal limit and the second one for over travel limit. In
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addition to above, position indication for bunker position of tripper will be provided through limit
switches in Main control room.
Following individual indications are provided on local control panel.
 Motor ON/OFF/TRIP
 Brakes applied
 Rail clamps applied
 Flap gate position
• Indication of tripper flap gate positions is given in the main CHP control room.
• It is possible for operator to manually trip the coal feeding equipment viz paddle
feeders or Stacker / reclaimers from the tripper.
• Chute blockage switch is provided at each leg of chute & will trip the tripper conveyor in
case of blockage.
3.1.7 3-D Type Level Transmitter

3-D Level Transmitter (4-20mA type) shall be provided for boiler bunkers present in Bunker Unit 1,
Bunker Unit-2, Bunker Unit-3 & Bunker Unit-4. The 3-D level Scanner employs an array of three
antennas to transmit low frequency pulses and to receive echoes of the pulses from the content of the
Bunker/Container. Using three antennas the unit measures not only the time/distance of each echo but
also its direction.
Local display and annunciation shall be provided for High and Low level signals on the instrument and
level reading shall be available for operator at Control Room by means of 4-20mA.
In case of level high LH in bunker level, the feeding conveyor shall be stopped. Bunker level shall be
continuously displayed with low, low-low, high and high-high indications on the HMI.
3.1.8 HOISTS AND CRANES
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The hoists and cranes will be controlled through Pendent. The same will be approachable from the
floor. The pendant control panel will be provided with up / down / forward / reverse travel push buttons
and indicating lamps for operating the same.
4.0.0 UTILITIES.
The Utility System of Coal handling System at NLC Tuticorin-TPP consists of

SWP/PWP/CWP/WTDP/WTP /DSP /THP/DFDS system, DE system, Ventilation system and Air
conditioning system.
4.0.1 SWP/PWP/CWP/WTDP/WTP/DSP/THP/PFP/DFDS SYSTEM:

The pump house is installed near to the coal transfer area, RCC water tanks is placed close to the
pump station. Water from the tank shall be supplied to the service points by the pumping system The
water pumps located in Pump House. The pumps shall be centrifugal multi stage type suited for
continuous operation selected on the basis of best efficiency. The water pumping system shall consist
of Duplex strainer with SS element 250 microns in the suction side of the Pump. . Each pump shall
have a gate valve at the suction and discharge. Each pump shall have a check valve at the discharge.
A pressure relief valve with a bypass Globe & gate valve shall be provided at the return line of each
pumping system so that the excess water is discharged back to the water tank.
Pumping system so that the excess water is discharged back to the water tank. Water tanks shall be
with accessories like motorized butterfly valve/ Gate valve at inlet of tank, Level Switch, Gate valve for
Drain. Motorized valves will be operating /controlled by level switch. In case of low level MOV shall
open and make-up water will be filled-up. In case of high level MOV shall closed. The water pump shall
be interlocked with low level switch of the water tank to prevent the pump from dry running.
The pumps will be operated from control room. Following individual inputs will be provided to
DDCMIS system for alarms / indications:
1. Motor On, Off & Trip
2. Discharge water pressure low
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3. Water level is low in tank

4. Water level is high in tank
5. Compressor On, Off & Trip
6. Air receiver pressure High, Low
Pressure switch is introduced in the delivery line to maintain the minimum set pressure during the
operation. If the pressure falls down below the set pressure the standby pumps will start
automatically after time delay. Even after the pressure is not healthy inside the system the pump
will trip automatically after certain predetermined set time.
The control circuit should be designed to meet the fallowing interlocks.
• Both pumps cannot run together. Only one at a time in any mode.
• Pumps should not be started when the water level is lowest in the tank.
• Low contact of Level switch to be interlocked.
• After starting the pump if the pressure is not built within the specified time the running pump
should be stopped and other pump can be tried. If it is the same case with other pump too then
the system should stop and announce the alarm.
• Differential pressure switch in the duplex strainer gives the filter clogged signal. This No contact
to be used to announce the alarm “FILTER CLOGGED”.
• Along with the above interlocks regular motor protection like OL and SC to be used in the circuit.
4.0.2 SERVICE WATER SYSTEM:

Service water system is primarily intended for cleaning building floors, conveyor galleries / tunnels,
electrical rooms and toilets.
Service water connections shall be provided in conveyor galleries/tunnels at 30 m intervals. Minimum 2
nos of Tap points shall be provided at each floor in the junction towers, 4 nos at each floor of crusher
house, 1 no at toilets of MCC and Control rooms. Each service water connection shall be provided with
a globe valve and quick coupler of 25 NB size. 25 NB flexible hose of 25 m long shall be provided with
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storage boxes at each building and conveyor gallery. The service water pump (SWP-1A/B) located in
Pump House (near Stock pile) takes plain water (cooling tower blow down water) from the on ground
RCC storage tank-1 adjacent to the Pump House and supplies to various service water tapings nearby
surrounding buildings through network of pipe.
The service water pump (SWP-1A/B) capacity has been designed considering one tap point at each
conveyor gallery & JNT/ crusher house and toilets of MCC/control room under simultaneous operation
and each tap point consuming 12.5 lpm at 2.5 kg/cm2.
1000 ltrs. PVC water tanks shall be provided on the top of MCC/control room for storage of service
water.
P.B in Pump
Group Pump Tag No. Application Area OWS
House
As per Schematic
SWS SWP-1A/B Start & Stop Start & Stop
diagram
POTABLE WATER SYSTEM:

Potable water connections shall be provided at all control rooms / MCC rooms, and complex
building of coal handling plant.
Potable water pump (PWP-1A/B) located in Pump House shall take potable water from RCC PW
tank-3 located adjacent to the Pump House and supplies to the overhead PVC potable water
storage tanks (1000 Liters.) located at roof top of above mentioned buildings. No PVC tank shall
be provided for Transfer Points and junction house. Client shall ensure the quality of drinking
water as per IS: 10500.Potable water from the overhead PVC tank shall flow to the potable water
tapping of respective building by gravity.
P.B in Pump
House
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As per Schematic
PWS PWP-1A/B Start & Stop Start & Stop
diagram
STOCKPILE DUST SUPRESSION SYSTEM:

Sprinkler type dust suppression system shall be provided for stockpiles.
The pumps for plain water (CTW & ROW) DS system shall be located in Pump House and takes plain
water from the on-ground RCC storage tank-2 adjacent to the Pump House. It supplies water to a
common header of DS system. Water from the common header goes to the ring headers around
stockpiles (one no for each stockpile). The swiveling sprinklers are mounted on vertical riser, whose
height of spray shall match with the stockpile height 10m), at an interval of 35 meter and the vertical
risers are mounted on the ring headers. Each sprinkler shall be provided with a manually operated
globe valve for controlling of water flow through the sprinkler. 4 nos sprinkler shall be mounted on one
sub-header which will be connected with main header through solenoid valve (with manual over-rider)
as shown in schematic diagram. The pump capacity has been designed considering 6.25 ltrs of water
per hour per ton of coal stocked in section of 90 m length of stock pile. Three nos of 50% capacity
centrifugal pumps (DSP-1A/B/C) shall be provided for the system.2 no of pumps shall be working and 1
no of pump shall be stand by for the system. 4 nos of sprinklers of capacity of each 22.2 m3/hr at
pressure 4.0 kg/cm2 shall work on both side of stock pile when one (1) pump is in operation.
Dust control is accomplished by spraying water on large stockpile areas. Water is sprayed in at regular
intervals depending on the site condition. The dust control is achieved by the agglomeration of dust
particles with finely atomized water droplets equal to / close to / larger than the dust particles as the
case may be, the Collision between the water droplets and dust particles plays an important role in the
process of agglomeration and heavier mass thus formed settles down to the source.
Plain water at a pressure of about 4.0 Bar is sprinkled over the stockpile area. This system is envisaged
to control the dust generated in the stockpile area. Water header will be provided along both sides of
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the coal stockpile, sufficient number of sprinklers suitably installed in a header to cover the entire
tockpile area produces water spray over the stockpile. The sprinklers are of swiveling type.
The operation of the sprinklers for stock piles is automatic by means of Sequential Control Panel and
Solenoid Valves for every two sprinklers. And each stockpile shall have solenoid valve with strainer
at the header inlet. Before each sprinkler globe valve shall be provided.
P.B in Pump
House
As per Schematic
DS-5 DSP-1A/B/C Start & Stop Start & Stop
diagram
Programmed logic control panel is used for sprinkling system of coal stock pile. Total 128 sprinklers are
controlled by 64 solenoids. Two solenoids of opposite side sprinklers are made as pair and they get ON
together. At a time any eight sprinklers can be switch ON.
Manual Mode: Solenoid pairs can be switched ON/OFF by using Push Buttons provided. In the
Solenoid box. These push buttons are provided for Stacking & reclaiming purpose. Any sprinkler
switched ON in manual mode continues in ON status till it is switched off/mode is changed.
Corresponding indicator glows in the panel when any solenoid is ON.
Auto Mode: In auto mode control of the sprinklers are R1 to R32 can be used for this purpose.
Switching the relay R1 turns ON Solenoid 1 and 2. R2 for S3 and S4. Like wise it continues up to S128.
This is maintained type contact. Till the relays are ON solenoids remains ON. Sprinkler ON time and
sequence can be programmed as per the requirement of the client. At a time more than one relay
should not be switched ON, is the only one interlock which client has to take care. Pumps are rated for
only eight sprinklers. If more than one is switched ON at a time, required through will not be available
from the sprinklers.
DRY FOG DUST SUPRESSION SYSTEM:
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The dry fog dust suppression system will consists of centrifugal pump (vertical) with drive motor, air
compressor with drive motor, local control panel, Flow control unit, pressure regulating unit, solenoid
valve, Nozzles, Nozzle headers, displacer operated level switch, pressure gauge, pressure switch,
duplex strainer with differential pressure gauge & differential pressure switch etc.
The pumps will start automatically. Load sensing units will be installed in the MCC, which will measure
the current consumption of each conveyor motor. When the current drawn by conveyor exceeds a
predefined set value, the load sensing unit will send signals to pumps. On receipt of signals from load
sensing unit, pumps will be operated.
The compressor will also start automatically taking signal from pressure switch (low) installed on
compressor and it will trip automatically taking signal (high) from pressure switch installed on air
receiver.
The Flow Activation Stations have provision for both manual and automatic operation. For manual
operation, the system becomes operational with selector switch in manual mode and in auto mode, the
fogging operation starts on receiving a signal either from a Respective conveyor current load monitor
or Flap gate limit switches installed at a strategic location in the material Conveyor line or potential
free contact from the drive motor of equipment as per requirements.
Each application point is provided with requisite number of spray bar assemblies with Air Atomized
Nozzles. FAS are provided at group of application points.
FAS can be connected to one or more PRU. A PRU is used to regulate the air and water pressure for a
group of headers.
Dry Fog type Dust Suppression System will be used for suppressing dust by means of air atomized
nozzles that are caused during the operation of above mentioned areas. This system is envisaged to
control the dust generated during the operation of above mentioned areas, Headers are provided at
dust generating points for respective nozzles. Water will be stored in a tank. In the makeup waterline to
the water tank Float valve will be provided. Water from the water tank shall be supplied to the spray
headers by a pump. The water pump shall be interlocked with low-level switch of the water tank to
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prevent the pump from dry running. A pressure switch at the pump discharge line shall be provided to
bypass water to store tank in case the pressure increases above the set value. The pumping system
along with control panel is placed in a pump house near the water tank. Compressor shall be mounted
in the pump house with an air receiver.A FAS shall be provided for a group of material transfer points.
The FAS shall be interlinked with the signals for running of Conveyors and equipments to ensure that
the spray is activated only when the Conveyors are running with load. Additionally the pressure switch
at the FAS ensures that the solenoid valves at the air and water lines are switched ON only when there
is adequate air pressure at the system.Each application point shall have a set of spray bar of air and
water. The nozzles shall be fixed at the discharge hoods/suction hoods and shall be connected by
flexible tubing with the headers.Each PRU shall have air and water pressure regulators to ensure that
the medium at the required pressure is flowing through the nozzles. This in turn ensures proper
atomization of the water which is essential for the effective dust suppression.
P.B in Pump
House
As per Schematic
DS-6 DFP-1A/B Start & Stop Start & Stop
diagram
As per Schematic
SC-A1/A2/A3 Start & Stop Start & Stop
diagram
FLOW ACTIVATION STATION (FAS)-OPERATION:
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Operation: In FAS Box Electrical Controls are provided in the top compartment. An Isolation from
Mains Incomer is provided by a MCB, Solenoids operation is by both modes Manual & AUTO through
Auto/Manual Selector Switch for Dry fog Dust Suppression System.
Modes
Manual Mode: AIR Line pressure is monitored continuously through PRESSURE Switch inside
FASBox, If the pressure drops below the set point, Pressure Healthy indicator goes off. This will also
not allow switching on any Solenoid in any mode.
AIR & WATER solenoids can be switched on /off by respective Push Buttons. IN auto mode Solenoids
can be switched on by client PF (Potential Free) Signal, or UBS Signal or any other Remote system
Signal, any one of the signal will open solenoids & remain ON condition until contacts in closed
position. Terminals provided for this signal inside FAS Box is X1-3 TO X1-6.
Following Indication are provided:
Type Lamps
 Control supply healthy : L1
 Pressure healthy : L3
 Solenoids open : L2
FLOW CONTROL UNIT (FCU)
Operation: In FCU Box Electrical Controls are provided in the top compartment.
Isolation from Mains Incomer is provided by a MCB, Solenoid operation is by both modes
Manual & AUTO through Auto/Manual selector switch for Plain water system.
Modes
Manual Mode:WATER Solenoid can be switched on /off by respective Push Buttons.
Auto Mode:In auto mode Solenoid can be switched on by client PF (Potential Free)Signal or UBS
Signal or any other remote system signal any one of the signal will open Solenoid & remain ON until
this contacts are closed. Terminals provided for this signal inside FCU Box is X1-3 TO X1-6
Following Indication are provided
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Type Lamps
 Control Supply Healthy : L1
 Water solenoid open (ON) : L2
SOLENOID OPERATING CONDITIONS FOR DS/DFDS SYSTEMS.

1. STOCK PILE DUST SUPPRESSION SYSTEM
Sl.
No. Location Spray Location Signal for Solenoid valve
1 Stockpile Header side-1 From sequential Panel / LCP
Stockpile-1
Stockpile-2
Stockpile-3
Stockpile-4
100 NB Solenoid valves has been considered for each stock
pile at header inlet From sequential Panel / LCP
2. DRY FOG DUST SUPPRESSION SYSTEM
Sl.
No. Location Spray Location Signal for Solenoid valve
1 Discharge of Conv.5A to FG Conv-5A Current load signal
2 Discharge of Conv.5B to FG Conv-5B Current load signal
Conv-5A Current load signal
3 Receipt of Conv.6A from FG 5A +FG signal
JNT - 1

4 Receipt of Conv.6A from FG 5B +FG signal
Conv-5B Current load signal
5 Receipt of Conv.6B from FG 5A +FG signal
6 Receipt of Conv.6B from FG 5B +FG signal
JNT -
7 Discharge of Conv.6A
2
8 Discharge of Conv.6B Conv-6B Current load signal
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9 Receipt of RBF-1 +FG signal
10 Discharge of RBF-1 side- 1 RBF -1 motor signal
12 Receipt of RBF-2 +FG signal
15 Discharge of Conv.7 Conv- 7 Current load signal
16 Discharge of Conv.9 Conv- 9 Current load signal
17 Receipt- 1 of Conv.10A from FG +FG signal
18 Receipt- 2 of Conv.10A from FG +FG signal
19 Receipt- 1 of Conv.10B from FG +FG signal
Conv-10C Current load signal
23 Receipt- 1 of Conv.10C from FG +FG signal
Conv-10C Current load signal
24 Receipt- 2 of Conv.10C from FG +FG signal
RBF- 1 running / discharge
25 Receipt of BCN- 9 Signal
RBF- 2 running / discharge
26 Receipt of BCN- 7 Signal
Apron feeder -1 running
27 Discharge of AFD- 1 signal
TH- 1

28 Receipt of Conv.2A from AFD- 1 +FG signal
29 Receipt of Conv.2B from AFD- 1 +FG signal
H-
30 Discharge of AFD- 2
T
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signal
33 Discharge of AFD- 3 signal
TH- 3

36 Discharge of Conv. 1A Conv-1B Current load signal
37 Discharge of Conv. 1B Conv-1A Current load signal
TH- 4

38 Receipt of Conv.2A from 1A +FG signal
39 Receipt of Conv.2B from 1B +FG signal
40 Discharge of Conv.2A Conv-2A Current load signal
41 Discharge of Conv.2B Conv-2B Current load signal
42 Receipt of Conv.6A from FG 2A +FG signal
TH- 5

43 Receipt of Conv.6A from FG 2B +FG signal
44 Receipt of Conv.6B from FG 2A +FG signal
45 Receipt of Conv.6B from FG 2B +FG signal
4.0.3 CYCLONE TYPE DE SYSTEM

OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR BOILER BUNKER
AREA UNIT- 1, 2, 3 & 4:
The following sequence to be maintained for start the equipment’s
1) Start Screw conveyors of bag filter & cyclone outlet
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2) Start RAV of Cyclone & bag Filter

3) Power to sequential controller
4) Start Centrifugal Fan Motor
5) Open motorized damper of fan inlet
The equipment will be interlocked with following instruments for smooth operation of DE system
1) DPS will energize at pre set pressure and will command to sequential controller for solenoid
valve (24 V DC) energization.
2) After air purging in sequence of solenoid valves through sequential controller with pre set
pause and on time the DPS will be de-energized at fixed differential set pressure.
3) Sequential controller will not provided output to solenoid valve if air pressure at compressed
air line will be low from the desired pressure as per preset pressure of Pressure Switch. In that
case the whole system will be shut down immediately.
4) ZSS of the system will show rotation of rotating part of the RAV during running
Condition. If any RAV of cyclone, Bag filter fail to run then the whole system will be shut down
Immediately.
OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR JUNCTION HOUSE -
4
The following sequence to be maintained for start the equipments
4) Open motorized damper ( 2 nos) installed at receipt points of conv.BCN-12A & 12B depending
on flap gate position and discharge of material from conv.11A & 11B.
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1) DPS will energize at preset pressure and will command to sequential controller for solenoid
3) Sequential controller will not provide output to solenoid valve if air pressure at compressed
airline will be low from the desired pressure as per preset pressure of Pressure Switch. In that
condition. If any RAV of cyclone, Bag filter fail to run then the whole system will be shut down
immediately.
OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR JUNCTION HOUSE –
5 to 9 & 11 to 15

4) Open motorized damper ( 2 nos) installed at receipt points of conv.BCN-12A & 12B; 13A & 13B; 14A
& 14B ;15A & 15B; 16A & 16B; 17A & 17B;18A & 18B; 19A & 19B; 20A & 20B;24A & 24B;25A &
25b;26A & 26B; 27A & 27B; 28A & 28B; 29A & 29B depending on flap gate position, FTR
1A/1B,2A/2B,3A/3B,4A/4B & 5A/5B position and discharge of material from respective conveyors.
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3) Sequential controller will not provided out put to solenoid valve if air pressure at compressed
immediately.
OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR JUNCTION HOUSE –
10 &16
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immediately
OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR CRUSHER HOUSE
1) Open Slide gate at bottom of screw conv. depends on conv. running of 11A/11B/23A/23B.
5) Open motorized damper on line as per followings when stream – 1 & stream -2 (conv.BCN-
10B & conv.BCN-10C running)
Motorized Damper no. 15 & 16 will open & Motorized Damper 17 will close.
Motorized Damper no. 11/12 will open when RSC will discharge material on BCN-11A/B.
Motorized Damper no.13 &14 will open
Motorized Damper no.9/10 will open when RSC will discharge material on BF- 1/2..
Motorized Damper no. 7/8 will open when SC-2 will discharge material on BF-1/2.
Motorized Damper no.5 & 6 will open when BF-1/2 will discharge material .
Motorized Damper no.3/4 will open as per Flap gate position of BF-2 discharge to conv.
BCN- 23A/B.
Motorized Damper no. 1/2 will open as per Flap gate position of BF-1 discharge to conv.
BCN- 23A/B.
Open motorized damper on line as per followings when stream – 2 ( conveyor BCN-10A in
running condition )
Motorized Damper no. 17 will open and Motorized Damper no. 15 & 16 will close. All other
dampers will close.
The schematic is enclosed
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immediately.
4.0.4 VENTILATION SYSTEM:

Below mentioned ventilation system for the application areas can be operated in-group/individual
through keyboard/OWS. The operation of each group/individual indication is available in main CHP
control desk monitor.
All other Ventilation system except for Boiler bunkers can be operated from OWS.
All ventilation fans will have local start/stop facility (wherever required).
i) SCHEDULE FOR MECHANICAL VENTILATION SYSTEM (SUPPLY FAN)
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Sl.No System Catering Area OWS

No.
1 VS-1 to Track Hopper underground portion Start & Stop

VS-3
2 VS-4 Wagon Tippler – 1 & 2 and TH-1 & 2 Start & Stop
underground portion
3 VS-5 Wagon Tippler – 3 and TH-3 underground Start & Stop
portion U/G portion of Conveyor 2A/B tunnel
from TH-3 up to TH-1 & 2
5 VS-7 U/G portion of Conveyor 2A/B tunnel from Start & Stop
TH-1 & 2 up to TH-4, U/G portion of TH-4 and
U/G portion of Conveyor 2A/B from TH-4 up
to TH-5
6 VS-8 U/G portion of TH-5 Start & Stop
7 VS-8A U/G portion of Conveyor 5A/B tunnel up to Start & Stop

pent house
8 VS-9 U/G portion of Crusher house Start & Stop
9 VS-10 U/G portion of Conveyor 23A/B tunnel up to Start & Stop

pent house
10 VS-11 U/G portion of Conveyor 11A/B tunnel up to Start & Stop
pent house
ii) SCHEDULE FOR MECHANICAL VENTILATION SYSTEM (EXHAUST FAN)
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Sl.No. System Catering Area OWS

No.
1 VE-1 to Track Hopper underground portion Start & Stop
VE-3
2 VE-4 Wagon Tippler – 1 & 2 and TH-1 & 2 Start & Stop
underground portion
3 VE-5 Wagon Tippler – 3 and TH-3 underground Start & Stop
portion U/G portion of Conveyor 2A/B tunnel
from TH-3 up to TH-1 & 2
5 VE-7 U/G portion of Conveyor 2A/B tunnel from Start & Stop
TH-1 & 2 up to TH-4, U/G portion of TH-4
and U/G portion of Conveyor 2A/B from TH-
4 up to TH-5
6 VE-8 U/G portion of TH-5 Start & Stop
7 VE-8A U/G portion of Conveyor 5A/B tunnel up to Start & Stop
pent house
8 VE-9 U/G portion of Crusher house Start & Stop
9 VE-10 U/G portion of Conveyor 23A/B tunnel up to Start & Stop
pent house
10 VE-11 U/G portion of Conveyor 11A/B tunnel up to Start & Stop
pent house
11 VE-12 Battery room of MCC-1 Start & Stop
12 VE-13 Battery room of MCC-2 Start & Stop
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iii) SCHEDULE FOR PRESSURISED VENTILATION SYSTEM (SUPPLY FAN)
Sl.No System Catering Area OWS

No.
1 VS-12 MCC-1 Start & Stop
4.0.5 AIR CONDITIONING SYSTEM:
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Air Conditioning system is generally provided for the treatment of air so as to control, simultaneously,
its temperature, humidity, cleanliness and distribution to meet the comfort requirements of occupants,
of the conditioned space. Air Conditioning system consists of hermetic compressor (scroll/rotary type),
direct expansion multi row deep cooling coil of copper having mechanically bonded aluminum fins
complete with refrigerant distributor & thermostatic expansion valve, v-belt driven (in case of Packaged
Air Conditioning system) evaporator with air blower (s) suitable for external static pressure.
All air conditioning systems will have local start/stop facility (wherever required).
SYSTEM SUMMARY FOR PACKAGED AIR CONDITIONING SYSTEM

Sl. No. Building & Location
1. Control Room - 1, near WT-1
4. Main CHP Control Room cum RIO room in MCC-2, Near Crusher House
SCHEDULE FOR WATER COOLED PAC SYSTEM CONDENSER PUMPS

Sl.No System No. Catering Area
1 ACP-1A/B Control room-1
4 ACP-4A/B Main CHP control room

SYSTEM SUMMARY FOR WINDOW AIR CONDITIONER UNIT
Sl. Building & Location
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No.
1. RIO Room in MCC-1 (On wall)
2. RIO Room in MCC-3, 4, 5 , 6 & 7 (On wall)
5.0.0 SEQUENTIAL INTERLOCK FOR CONVEYORS & OTHER EQUIPMENT
System Stop: When system stop command is given, first all feeding equipment (Like Stacker
Reclaimer) will stop &after some time delay all equipments will stop sequentially.
Emergency Stop: In case of emergency stop PB pressed all drives shall be stopped immediately.
Fire Protection: In case of fire detection all drives shall be stopped immediately.
5.0.1 CONVEYOR
When start command to conveyor is given first the command will go to start respective Oil circulating
pump for scoop coupling of conveyor and release the brake (simultaneously), after releasing the brake
command will go to conveyor main motor, after starting main motor, command will go to engage (OUT)
scoop through actuator for scoop coupling of conveyor. If off command is given to conveyor, first the
scoop will get dis-engaged then brake is applied after which main motor stops and finally oil circulating
pump stops.
Main conveyor Motor:

There is no auto-on and auto-off commands for conveyor (except sequence start/stop
commands).Permissive conditions (conveyor can be started from Remote/Local when all the conditions
given below are available)
 All winding temperature less than 120 deg C.
 Bearing temperature (DE and NDE) less than 70 deg C
 Brake for respective conveyor is released
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NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
 Actuator scoop coupling is IN position (dis-engaged position)

 Electrical conditions are healthy.
 Local Stop Not Pressed /Reset.
Trip conditions (conveyor will trip if any of the given below are available):
 Any winding temperature is more than 130 deg C.

 Any bearing temperature (DE and NDE) is more than 80 deg C.
 Electrical trip conditions are present.
 Brake for respective conveyor not released.
Brake for Conveyor:
When command to main conveyor is given, it will auto on (release) the brake and when conveyor
motor is off or fluid coupling dis-engaged then brake will be applied automatically.
Permissive conditions:
1) Electrical conditions are healthy.
Trip condition:
1) Electrical conditions are not healthy.
Oil Circulating Pump for Scoop Coupling of Conveyor:
When command to main conveyor is given, it will auto start oil circulating pump and when conveyor
motor is given off command then oil circulating pump will stop automatically after some time delay (30
Sec Adjustable).
Permissive (All the below conditions should be present to start oil circulating pump for scoop coupling
of conveyor):
 DP across filter < 0.5bar
 Oil Line pressure ≥ 1.2 bar
 Oil temp ≤ 90 deg C.
 Oil Cooler fan started.
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A

 Electrical condition healthy.
Trip conditions (Oil circulating pump will trip if any of the condition will be present):
 DP across filter ˃ 1.1 bar

 Oil Line pressure < 0.8 bar
 Oil temp ˃ 110 deg C.
 Oil Cooler fan motor fails.
 Local Stop Pressed.
 Electrical trip condition present.
Actuator For Fluid Coupling Of Conveyor:
When start command to main conveyor is given, it will engage (OUT) scoop coupling and when
conveyor motor is given off command then it will dis-engage (IN) scoop coupling automatically.
Permissive conditions (actuator for scoop coupling of conveyor will OUT (engaged) scoop automatically
when all the below conditions are present):
 Oil circulating pump for respective conveyor is ON.
 Main motor of respective conveyor is ON.
 Both the CBS (chute block switch) are not operated.
 PCS (Pull cord switch) is not operated.
 BSS (Belt sway switch) is not operated.
 ILMS is energized(On feedback) (if applicable).
 MD is energized (On feedback) (if applicable).
 Succeeding conveyor main motor on & scoop coupling engaged and only one Flap gate/shuttle
head drive is in position to feed succeeding conveyor & other flap gate can be positioned on
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
the same conveyor only if the same upstream conveyor not running (if applicable according to
Down stream Feeders)
 Trip command from machines (Stacker Reclaimer, Travelling Tripper) to respective conveyors.
• Applicable for Conv. 19 & 21 - Trip Command from Stacker
Cum Reclaimer-1 & Stacker Cum Reclaimer-2 respectively.
• Applicable for Conv. 11/13/15/17 - Trip Command from Travelling
Tripper-TTR1, TTR2, TTR3 & TTR4 respectively.
Trip conditions (actuator for scoop coupling of conveyor will IN (dis-engage) scoop if any of the
condition will be present):
 Any of the CBS (chute block switch) is operated.
 PCS (Pull cord switch) is operated.
 BSS (Belt sway switch) is operated.
 ZSS (Zero speed switch) is operated with on delay of 60 sec.
 Oil circulating pump OFF.
 Respective conveyor main motor is OFF.
 Succeeding conveyor main motor off or scoop coupling dis-engaged and running
conveyor feeding to that conveyor.
 Electrical trip conditions are present
 ILMS cleated belt or under current trip. (if applicable)
 Metal is detected (if applicable)
 More than one flap gate are positioned to same conveyor & more than one upstream
conveyor running.
5.0.2 CRUSHER:
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
When start command to crusher is given first the command will go to start respective oil circulating
pump for scoop coupling of crusher then that command will go to crusher main motor, after starting
main motor, command will go to engage (OUT) scoop through actuator for scoop coupling of crusher.
Main Crusher Motor:
There are no auto-on and auto-off commands for crusher (except sequence start/stop commands).
Permissive conditions (crusher can be started automatically or manually when all the conditions given
below are available)
 All winding temperature less than 120 deg C.
 Bearing temperature (DE and NDE) less than 70 deg C.
 Actuator scoop coupling is IN position (dis-engaged position).
 Hydraulic door closed.
Trip conditions (Crusher will trip if any of the given below are available):
 Any winding temperature is more than 130 deg C.
 Any bearing temperature (DE and NDE) is more than 80 deg C.
Coupling Cooling Oil Circulating Pump for Crusher:

When command to main crusher is given, it will auto start oil circulating pump and when crusher motor
is given off command then oil circulating pump will stop automatically after some time delay (30 Sec
Adjustable).
Permissive (All the below conditions should be present to start oil circulating pump):
 DP across filter < 0.5bar
 Oil Line pressure ≥ 1.2 bar
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
 Oil temp ≤ 90 deg C.

 Oil Cooler fan started.
 Electrical condition healthy.
Trip conditions (Oil circulating pump will trip if any of the condition will be present):
 DP across filter ˃ 1.1 bar
 Oil Line pressure < 0.8 bar
 Oil temp ˃ 110 deg C.
 Oil Cooler fan motor fails.
 Electrical trip condition present.
Actuator For Fluid Coupling Of Crusher:
When start command to main crusher is given, it will engage (OUT) scoop coupling and when crusher
motor is given off command then it will dis-engage (IN) scoop coupling automatically.
Permissive conditions (actuator for fluid coupling of crusher will be OUT (engaged) automatically when
all the below conditions are present):
 Oil circulating pump for respective crusher is ON.
 Main motor of respective crusher is ON.
 Crusher ZSS (Zero speed switch) is NOT operated.
 Both the CBS (chute block switch) are not operated.
 Respective Downstream feeder, i.e. BF/SC/RSC, is ON .
 Hydraulic door closed.
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
Trip conditions (actuator for fluid coupling of crusher will be IN (dis-engage) if any of the condition will
be present):
 Any of the CBS (chute block switch) is operated.
 Crusher ZSS (Zero speed switch) is operated with on delay of 60 sec.
 Oil circulating pump OFF.
 Respective crusher main motor is OFF.
 Respective Down stream feeder, i.e. BF/SC/RSC, is OFF.
 Respective Crusher Vibration Trip.
 Hydraulic door open.
5.0.4 TRAVELLING TRIPPER

 Bunker Conveyor running.
 Motor O/L not tripped.
 Over travel limit switch not tripped.
Trip conditions:
 Motor O/L tripped.
 Over travel limit switch tripped.
5.0.5 ILMS (INLINE MAGNETIC SEPERATOR)
There is no Auto ON/OFF Conditions.
 ILMS should be selected in remote.
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
 Under current relay trip signal not available.

 Control supply should be healthy.
 Local stop not pressed / Reset condition
Trip conditions:
 Respective conveyor off with on delay of 600 sec.
 Under current relay trip signal available.
 Control supply not healthy.
 Cleated belt trip.
5.0.6 MD (METAL DETECTOR)
 MD should be selected in remote.
 Metal Detector is in Reset condition.(Metal Not detected)
 Local stop not pressed / Reset condition
Trip conditions:
 Respective conveyor off with on delay of 600 sec.
 Metal detected.
5.0.7 IN-LINE BELT WEIGH SCALE:
 BS should be selected in remote.
 Respective Conveyor is ON.
5.0.8 FG (FLAP GATE)
There is no Auto ON/OFF Conditions:-
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
Feeding conveyor “OFF FEEDBACK” will be permissive for forward and reverse direction ( Not
applicable for bunker flap gate from FG-30 to FG-41 for BU-1,2&3 and FG-52 to FG-59 for BU-
4&5).Flap gate can be changed (FG-30 to FG-41 for BU-1,2&3 and FG-52 to FG-59 for BU-4&5) only
when succeeding conveyor running.
5.0.9 FLOW DIVIDER (FD)
Feeding Conveyor/Equipment “OFF FEEDBACK” will be permissive for forward and reverse directions.
5.0.10 ROLLER SCREEN
 Local stop not pressed / Reset condition.
 Respective Crusher ON
 Respective BF/SC/RSC is ON
 CBS (chute block switch) is not operated.
Trip conditions:
 Respective Crusher OFF
 Respective BF/SC/RSC is OFF
 CBS (chute block switch) operated.
5.0.14 UTILITY PUMP’S (SWP, PWP, THP, WTP, WTDP, DSP, DFP):
When running pump trips standby pump starts automatically.
Electrical Condition: Same as LT drive.
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A

 Centrifugal Pump (Running/Standby) Selected by Selector Switch (In Soft)
 Centrifugal Pump (Running + Standby) Water Level Permissive
 Centrifugal Pump (Standby) Not running.
Trip conditions:
 Centrifugal Pump (Running + Standby) Water Level Low
 Centrifugal Pump (Running) Discharge Pressure low with delay of 60 sec.
Ann. Condition : DP switch (In pump suction) high will be annunciated
5.0.15 SOLENOID VALVES (FOR DUST SUPPRESSION SYSTEM):
Auto ON Conditions
 Current value of respective conveyor above cut-off value (I≥8mA).
Auto OFF Conditions
 Current value of respective conveyor below cut-off value (I< 8mA)
 Centrifugal Pump running.
Trip conditions:
 Centrifugal Pump not running.
5.0.15 VENTILATION SYSTEM: CENTRIFUGAL FAN / AXIAL FAN (For VE, VS):
Electrical Condition: Same as LT drive.
Trip conditions:
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
 Electrical conditions are not healthy.

6.0.0 THE PERMISSIVE CONDITONS FOR OPERATION OF CHP
* Feeding Flap gates to be positioned after selection of path.
6.0.1 FLOW PATH – 1: SHIP UNLOADERS TO STOCKYARD
S.No. Equipment Permissive conditions

CONV. 19(STACKING) STACKER STR-1 IS RUNNING
1 OR OR
CONV. 21(STACKING) STACKER STR-2 IS RUNNING
CONV. 19 (STACKING) IS RUNNING AND FLAP GATE FG 27
IS POSITIONED (POS-1) TO FEED CONV. 19
CONV. 18 A
2 OR
CONV. 20 A IS RUNNING AND FLAP GATE FG 27 IS
POSITIONED (POS-2) TO FEED CONV. 20 A
CONV. 18 B
3 OR
CONV. 20 B IS RUNNING AND FLAP GATE FG 28 IS
POSITIONED (POS-2) TO FEED CONV. 20 B
CONV. 20 A
4 OR CONV. 21 (STACKING) IS RUNNING
CONV. 20 B
CONV. 18 B IS RUNNING AND DIVERTER GATE DG -1 IS

5 CONV. 7 A
POSITIONED (POS-1) TO FEED CONV. 18 B.
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
CONV. 18 A IS RUNNING AND DIVERTER GATE DG -2 IS

6 CONV. 7 B
POSITIONED (POS-1) TO FEED CONV. 18 A.
CONV. 7 A IS RUNNING AND FLAP GATE FG -7 IS

7 CONV. 6 A OR
CONV. 7 B IS RUNNING AND FLAP GATE FG -7 IS

8 CONV. 6 B OR

OR
9 CONV. 5 A
ROLLER SCREEN 1 & CRUSHER 1 ARE IN OPERATION AND
FLAP GATE FG -5 IS POSITIONED (POS-2) TO FEED
ROLLER SCREEN AND CONV. 6 A IS RUNNING.
10 CONV. 5 B CONV. 6 B IS RUNNING AND FLAP GATE FG -6 IS
OR
FLAP GATE FG -6 IS POSITIONED (POS-2) TO FEED
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
ROLLER SCREEN AND CONV. 6 B IS RUNNING.

CONV. 5 A IS RUNNING AND FLAP GATE FG-3 IS
POSITIONED (POS-1) TO FEED CONV. 5 A AND ILMS-3 &
MD-5 ARE ON.
11 CONV. 4 A OR
CONV. 5 B IS RUNNING AND FLAP GATE FG-3 IS
POSITIONED (POS-2) TO FEED CONV. 5 B AND ILMS-4 &
MD-6 ARE ON.
POSITIONED (POS-1) TO FEED CONV. 5 A AND ILMS-3 &
MD-5 ARE ON.
12 CONV. 4 B OR
POSITIONED (POS-2) TO FEED CONV. 5 B AND ILMS-4 &
MD-6 ARE ON.
CONV. 4 A IS RUNNING AND FLAP GATE FG-2A IS
13 CONV. 3 A2 OR
CONV. 4 B IS RUNNING AND FLAP GATE FG-2A IS
CONV. 4 A IS RUNNING AND FLAP GATE FG-2B IS
14 CONV. 3 B2 OR
CONV. 4 B IS RUNNING AND FLAP GATE FG-2B IS
15 CONV. 3 A1 CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1A IS

POSITIONED (POS-1) TO FEED CONV. 3 A2 AND MD-3 IS
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
ON.
OR
CONV. 3 B2 IS RUNNING AND FLAP GATE FG-1A IS
POSITIONED (POS-2) TO FEED CONV. 3 B2 AND MD-4 IS
ON.
CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1B IS

POSITIONED (POS-1) TO FEED CONV. 3 A2 AND MD-3 IS
ON.
16 CONV. 3 B1
OR
CONV. 3 B2 IS RUNNING AND FLAP GATE FG-1B IS
POSITIONED (POS-2) TO FEED CONV. 3 B2 AND MD-4 IS
ON.
CONV. 3 A1 IS RUNNING AND FLAP GATE FG-1 IS
POSITIONED (POS-1) TO FEED CONV. 3 A1.
OR
17 CONV. 2 A
CONV. 3 B1 IS RUNNING AND FLAP GATE FG-1 IS
POSITIONED (POS-2) TO FEED CONV. 3 B1.

18 CONV. 2 B OR
19 CONV. 1 A CONV. 2 A IS RUNNING
20 CONV. 1 B CONV. 2 B IS RUNNING
FROM SHIP CONV. 1 A IS RUNNING AND ILMS-1 & MD-1 ARE ON.
21
UNLOADERS OR
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
CONV. 1 B IS RUNNING AND ILMS-2 & MD-2 ARE ON.
6.0.2 PATH- II: SHIP UNLOADERS TO BUNKER UNITS VIA CRUSHER HOUSE WITHOUT
STACKING
1 TTR-4
BUNKERS OF BUNKER UNIT BU-4 ARE NOT FULL
BUNKERS OF BUNKER UNIT BU-4 IS NOT FULL (AND)

2 CONV. 17
TRAVELLING TRIPPER TTR-4 IS RUNNING AND FLAP GATE
FG-25 OR 26 IS POSITIONED (POS1/2) TO FEED BU-4
CONV. 16 A
CONV. 17 IS RUNNING
3 OR
CONV. 16 B

POSITIONED (POS 1) TO FEED CONV. 16 A.
4 CONV. 14 A
OR
CONV. 15 IS RUNNING AND FLAP GATE FG-21 IS
POSITIONED (POS 2) TO FEED CONV. 15.

POSITIONED (POS 1) TO FEED CONV. 16 B.
5 CONV. 14 B
OR
B
6 TTR-3
UNKERS OF BUNKER UNIT BU-3 ARE NOT FULL
7 CONV. 15
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A


8 CONV. 12 A OR

9 CONV. 12 B OR
10 TTR-2 BUNKERS OF BUNKER UNIT BU-2 ARE NOT FULL
11 CONV. 13

OR
12 CONV. 10 A
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A

13 CONV. 10 B OR
15 CONV. 11 TRAVELLING TRIPPER TTR-1 IS RUNNING AND FLAP GATE
POSITIONED (POS 1) TO FEED CONV. 10 A AND BW7 IS ON.
16 CONV. 9 A OR
POSITIONED (POS 2) TO FEED CONV. 10 B AND BW8 IS ON.
17 CONV. 9 B OR
POSITIONED (POS 1) TO FEED CONV. 9 A AND ILMS5 & MD7
ARE ON.
18 CONV. 8 A OR
POSITIONED (POS 2) TO FEED CONV. 9 B AND ILMS6 & MD8
ARE ON.
19 CONV. 8 B CONV. 9 A IS RUNNING AND FLAP GATE FG-10 IS
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A

ARE ON.
OR
ARE ON.
CONV. 8 A IS RUNNING AND DIVERTER GATE DG-1 IS

20 CONV. 7 A
CONV. 8 B IS RUNNING AND DIVERTER GATE DG-2 IS

21 CONV. 7 B

OR
22 CONV. 6 A
.

23 CONV. 6 B
OR
24 CONV. 5 A
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
OR
FLAP GATE FG -5 IS POSITIONED (POS-2) TO FEED ROLLER
SCREEN AND CONV. 6 A IS RUNNING.
POSITIONED (POS-1) TO FEED CONV. 5 A AND ILMS-3 & MD-
5 ARE ON.
25 CONV. 4 A OR
POSITIONED (POS-2) TO FEED CONV. 5 B AND ILMS-4 & MD-
6 ARE ON.

5 ARE ON.
26 CONV. 4 B
OR
6 ARE ON.
OR
27 CONV. 3 A2

28 CONV. 3 B2
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
OR
CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1A IS

POSITIONED (POS-1) TO FEED CONV. 3 A2 AND MD-3 IS ON.
OR
29 CONV. 3 A1
POSITIONED (POS-2) TO FEED CONV. 3 B2 AND MD-4 IS ON.

30 CONV. 3 B1 OR
OR
31 CONV. 2 A

32 CONV. 2 B OR
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
CONV. 1 A IS RUNNING AND ILMS-1 & MD-1 ARE ON.

FROM SHIP
35 OR
UNLOADERS
PATH- III: SHIP UNLOADERS TO BUNKER UNITS VIA CRUSHER HOUSE WITH
6.0.3
STACKING
CONV. 16 A
3 OR CONV. 17 IS RUNNING
CONV. 16 B
4 CONV. 14 A OR
5 CONV. 14 B OR

DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A

8 CONV. 12 A OR

9 CONV. 12 B OR
10 TTR-2
BUNKERS OF BUNKER UNIT BU-2 ARE NOT FULL


12 CONV. 10 A OR
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A

13 CONV. 10 B OR

15 CONV. 11

16 CONV. 9 A
OR

17 CONV. 9 B
OR

18 CONV. 8 A POSITIONED (POS 1) TO FEED CONV. 9 A AND ILMS5 & MD7
ARE ON.
OR
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A

ARE ON.

ARE ON.
19 CONV. 8 B
OR
ARE ON.
CONV. 8 A & CONV. 18 B ARE RUNNING AND DIVERTER

20 CONV. 7 A
GATE DG-1 IS POSITIONED (POS 3) TO FEED BOTH
CONV. 8 A & CONV. 18 B.
CONV. 8 B & CONV. 18 A ARE RUNNING AND DIVERTER

21 CONV. 7 B
GATE DG-2 IS POSITIONED (POS 3) TO FEED BOTH
CONV. 8 B & CONV. 18 A.
CONV.
STACKER STR-1 IS RUNNING
19(STACKING) OR
22 OR
CONV.
STACKER STR-2 IS RUNNING
21(STACKING)
CONV. 18 A IS POSITIONED (POS-1) TO FEED CONV. 19
23
OR
CONV. 20 A IS RUNNING AND FLAP GATE FG 27 IS
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
POSITIONED (POS-2) TO FEED CONV. 20 A

CONV. 18 B
24 OR
CONV. 20 B IS RUNNING AND FLAP GATE FG 28 IS
CONV. 20 A
25 OR CONV. 21 (STACKING) IS RUNNING
CONV. 20 B

26 CONV. 6 A OR

27 CONV. 6 B
OR
OR
28 CONV. 5 A
SCREEN AND CONV. 6 A IS RUNNING.
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A

OR
29 CONV. 5 B
SCREEN AND CONV. 6 B IS RUNNING.
5 ARE ON.
30 CONV. 4 A OR
6 ARE ON.
5 ARE ON.
31 CONV. 4 B OR
6 ARE ON.
32 CONV. 3 A2 OR
33 CONV. 3 B2
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
OR
CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1A IS
OR
34 CONV. 3 A1

35 CONV. 3 B1 OR
36 CONV. 2 A OR
37 CONV. 2 B OR
FROM SHIP CONV. 1 A IS RUNNING AND ILMS-1 & MD-1 ARE ON.
40
UNLOADERS OR
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
6.0.4 PATH- IV: STOCK YARD TO BUNKER UNITS

CONV. 16 A
3 OR CONV. 17 IS RUNNING
CONV. 16 B
OR
4 CONV. 14 A

5 CONV. 14 B OR
8 CONV. 12 A
OR
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A

9 CONV. 12 B OR
11 CONV. 13

OR
12 CONV. 10 A

13 CONV. 10 B OR
16 CONV. 9 A CONV. 10 A IS RUNNING AND FLAP GATE FG-11 IS
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A

OR
17 CONV. 9 B OR
CONV. 9 A IS RUNNING AND FLAP GATE FG- 31 IS
ARE ON.
18 CONV. 22 A OR
ARE ON.
CONV. 9 A IS RUNNING AND FLAP GATE FG- 32 IS
ARE ON.
19 CONV. 22 B OR
ARE ON.
SR 2 RECLAIMER IS RUNNING & CONV. 22 A IS RUNNING

20 CONV. 19
AND FLAP GATE FG-30 IS POSITIONED (POS 1) TO FEED
CONV. 22 A.
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
OR
SR 2 RECLAIMER IS RUNNING & CONV. 22 B IS RUNNING
CONV. 22 B.
SR 1 RECLAIMER IS RUNNING & CONV. 22 A IS RUNNING

CONV. 22 A.
21 CONV. 21
OR
SR 1 RECLAIMER IS RUNNING CONV. 22 B IS RUNNING AND
FLAP GATE FG-29 IS POSITIONED (POS 2) TO FEED CONV.
22 B.
22 GROUND HOPPER CONV. 22 A OR CONV. 22 B IS RUNNING
6.0.5 COMBINATION OF ANY OF THE ABOVE:
7.0.0 ANNUNCIATION SYSTEM

Alarms shall be available at HMI for the following audio-visual fault annunciation purposes. Wherever
group annunciation is provided, alarm status of individual equipment will be provided on HMI.
a) 6.6 KV Breaker Trip (group wise for each board)
b) 415 V PMCC Breaker Trip (PMCC wise)
c) 415V MCC Breaker Trip (MCC wise)
d) Bus under voltage for LT MCC Buses( Group Wise)
e) Bus under voltage for HT switch gear buses (Group Wise)
f) Following group wise annunciation is provided for transformers: -
1) Buchholz alarm
2) Winding / oil temp. High alarm
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
3) Oil level low alarm

4) Buchholz trip
5) Winding / oil temp. High trip
g) AC control supply failure
h) DC control supply failure
i) Stand-By CPU in service.
j) Both CPU fail.
k) HT motor trip on electrical fault (Group)
l) LT motor overload tripped (Group)
m) Belt sway switch operated (Group)
n) Pull cord switch operated (Group)
o) Zero speed switch operated (Group)
p) Chute blocked (Group)
q) Magnetic separator fault and cleaning belt trip(Group)
r) Metal detector fault (Group)
s) In-line conveyor scale fault (Group)
t) Sampling System faults and trips (Group)
u) Crusher low speed & crusher bearing temperature – high.
For identification of the fault for a particular conveyor or equipment, the status indication against that
conveyor/equipment in the graphics window will start fast flickering and the alarms will be flickering
against the particular fault. Also a buzzer will start sounding. After acknowledgement of the fault, the
buzzer will stop, but the fast flickering on the mimic & the steady glow on the HMI will continue until the
fault is cleared and the alarm is acknowledged. When the fault is cleared and the alarm acknowledged,
the status indication of that conveyor/equipment on the graphic will start slow blinking if it is on selected
path.
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
At the time of fault, the faulty conveyor / equipment as well as the preceding conveyors / equipment in
the interlock sequence, will stop except HT motors will continue to run for process fault. In case of
motor fault, the HT motor will trip but the succeeding conveyors / equipment will continue to run. The
status indication against the preceding conveyors / equipment will start slow blinking while the faulty
conveyor / equipment will be fast blinking.
Start command will not be indicated alarm is acknowledged after clearance of fault.
The sequence of operation of the annunciation system will be as follows:
Sequence Condition Status

Annunciation window. Off
Normal Status Indication Steady Glow
Buzzer Off
Annunciation window. Flickering
Fault Status Indication Fast Flickering
Buzzer Sounding
Annunciation window. Steady Glow
Press Accept PB Status Indication Fast Flickering
Buzzer Off
Annunciation window. Off
Status Indication Steady Blinking (if on Selected path)
Press Reset PB
Off(if not on selected path)
Buzzer Off
. 8.0.0 STATUS INDICATION IN OWS (OPERATOR WORK STATION)
The following individual status indications will be provided in LVS.

1. Conveyor ON
2. Flap Gate/ Flow Divider
3. In-line conveyor scale flow rate indication & totalizer
DOCUMENT TITLE
PREPARED GSRK/ARUN
DOC
NO
APML
DATED 30.11.2010
ECC DIVISION
REV NO: A
4. Belt Sway switch operated for each conveyor

5. Pull cord switch operated for each conveyor
6. Zero speed switch operated for each conveyor
7. Crusher ON
8. Vibrating feeders ON
9. MD / ILMS /CSU ON
10. Bunker level.
DOCUMENT TITLE
PREPARED GSRK/ARUN

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PROJECT NLC TUTICORIN TPP-CHP

OPERATION & CONTROL

6.0.1 FLOW PATH- I: SHIP UNLOADERS TO STOCKYARD VIA CRUSHER HOUSE

1.0.0 SYSTEM DESCRIPTION

MAJOR EQUIPMENTS IN THE HANDLING PLANT ARE:

 2 nos. Roller screens (-50 mm), capacity 2000 TPH.

 2 nos. Ring Granulator Crushers (-300 mm), capacity 1000 TPH.

 4 nos. Travelling Trippers, capacity 1200TPH

 Conveyor stream capacity 2000 /1200 TPH.

 1 no. Coal sampling Unit.

 3 nos. Passenger cum Goods Elevator.

2.0 OPERATION & CONTROL PHILOSOPHY

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

3.1.0 CONVEYOR SYSTEM

3. Metal Detector ‘reset’

3.1.5 COAL SAMPLING UNIT

3.1.6 MOBILE TRIPPERS

3.1.7 3-D Type Level Transmitter

The Utility System of Coal handling System at NLC Tuticorin-TPP consists of

4.0.1 SWP/PWP/CWP/WTDP/WTP/DSP/THP/PFP/DFDS SYSTEM:

3. Water level is low in tank

4.0.2 SERVICE WATER SYSTEM:

POTABLE WATER SYSTEM:

STOCKPILE DUST SUPRESSION SYSTEM:

FLOW ACTIVATION STATION (FAS)-OPERATION:

SOLENOID OPERATING CONDITIONS FOR DS/DFDS SYSTEMS.

Conv-5A Current load signal

8 Discharge of Conv.6B Conv-6B Current load signal

Conv-6A Current load signal

Conv-2A Current load signal

Conv-2A Current load signal

Conv-2A Current load signal

Conv-6A Current load signal

4.0.3 CYCLONE TYPE DE SYSTEM

2) Start RAV of Cyclone & bag Filter

The following sequence to be maintained for start the equipments

4.0.4 VENTILATION SYSTEM:

i) SCHEDULE FOR MECHANICAL VENTILATION SYSTEM (SUPPLY FAN)

Sl.No System Catering Area OWS

1 VS-1 to Track Hopper underground portion Start & Stop

7 VS-8A U/G portion of Conveyor 5A/B tunnel up to Start & Stop

9 VS-10 U/G portion of Conveyor 23A/B tunnel up to Start & Stop

ii) SCHEDULE FOR MECHANICAL VENTILATION SYSTEM (EXHAUST FAN)

Sl.No. System Catering Area OWS

iii) SCHEDULE FOR PRESSURISED VENTILATION SYSTEM (SUPPLY FAN)

Sl.No System Catering Area OWS

4.0.5 AIR CONDITIONING SYSTEM:

SYSTEM SUMMARY FOR PACKAGED AIR CONDITIONING SYSTEM

1. Control Room - 1, near WT-1

2. Control Room - 2, near WT-2

3. Control Room - 3, near WT-3

SCHEDULE FOR WATER COOLED PAC SYSTEM CONDENSER PUMPS

2 ACP-2A/B Control room-2

3 ACP-3A/B Control room-3

4 ACP-4A/B Main CHP control room

2. RIO Room in MCC-3, 4, 5 , 6 & 7 (On wall)

5.0.0 SEQUENTIAL INTERLOCK FOR CONVEYORS & OTHER EQUIPMENT

Main conveyor Motor:

 Actuator scoop coupling is IN position (dis-engaged position)

 Any winding temperature is more than 130 deg C.

 Local Stop Not Pressed /Reset.

 DP across filter ˃ 1.1 bar

Coupling Cooling Oil Circulating Pump for Crusher: