Coal Handling System by Rail

TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE
TCE.M12-ME-CL- SHEET (i) OF (iii)

563-030
CHECKLIST FOR PROCUREMENT
OF
COAL HANDLING SYSTEM BY RAIL
REV.NO. R0 R1 R2 ISSUE
INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.
PPD.BY MJ Sd/- BVS Sd/- MG
CHD.BY PS Sd/- VJ Sd/- BVS R2
APD.BY KG/MLN Sd/-/ Sd/- MLN/RL Sd/-/ Sd/- DVL/RL
DATE 17.02.1994 31.03.2000 20.03.2003
FORM NO. 020R2

TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE
TCE.M12-ME-CL- SHEET (ii) OF (iii)
563-030
FILE NAME : M12MECL030R2.DOC
REV.NO. R0 R1 R2 ISSUE
INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.
PPD.BY MJ Sd/- BVS Sd/- MG
CHD.BY PS Sd/- VJ Sd/- BVS R2
APD.BY KG/MLN Sd/-/ Sd/- MLN/RL Sd/-/ Sd/- DVL/RL
DATE 17.02.1994 31.03.2000 20.03.2003
FORM NO. 020R2

TCE CONSULTING ENGINEERS LIMITED SECTION: CONTENTS
TCE.M12-ME-CL- SHEET (ii) OF ( iii)
563-030 CHECK LIST FOR PROCUREMENT OF COAL
HANDLING SYSTEM BY RAIL
CONTENTS
SL.NO. TITLE SH.NO.
1.0 SCOPE 1
2.0 REFERENCE DOCUMENTS 1
3.0 PREPARATION OF SPECIFICATION 1
4.0 REVIEW OF BIDS 23
5.0 GUIDELINES FOR PREPARING PURCHASE

RECOMMENDATION AND PURCHASE ORDER 25
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TCE CONSULTING ENGINEERS LIMITED SECTION:REV.STATUS
TCE.M12-ME-CL- SHEET (iii) OF (iii)
REVISION STATUS
REV. NO. DATE DESCRIPTION
R0 17.02.1994 ------------------------
R1 31.03.2000 GENERALLY REVISED
R2 20.03.2003 GENERALLY REVISED
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TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE UP
TCE.M12-ME-CL- SHEET 1 OF 25
1.0 SCOPE
This checklist covers the general aspects of the following procurement

activities for coal handling system by rail:
1.1 Preparation of specification
1.2 Review of tenders
1.3 Preparation of purchase recommendation
1.4 Preparation of purchaser order, if it is covered in TCE’s scope.
2.0 REFERENCE DOCUMENTS
2.1 Latest issue of plot plan
2.2 Coal handling system basic study with all Exhibits
2.3 General checklist for procurement activities of material handling

system / equipment – TCE.M12-ME-CL-670-085.
2.4 TCE.M12-ME-000-901 – General Procurement guide for Mechanical

Equipment, Systems and site works contracts.
2.5 Railway track layout drawing.
2.6 Cross section drawing of power plant showing bunker bay details with
elevation of tripper floor, width of bunker bay etc.,
2.7 Design guide for belt conveyors – TCE.M6-ME-670-001.
2.8 Design guide for preparation of flow diagram of coal handling system
– TCE.M6-ME-563-015.
3.0 PREPARATION OF SPECIFICATION
3.1 GUIDELINES FOR PREPARATION OF SCOPE OF ENQUIRY
Coal handling system by rail is generally procured under turnkey

contract basis including all mechanical, structural and electrical works.
However scope of civil works associated with the system shall be
clearly brought out in the scope of enquiry since civil works are got
executed separately by some clients. Number of packages shall be
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clearly indicated (usually stacking / reclaiming system and bunker

feeding systems will be different packages).
3.2 GUIDELINES FOR PREPARATION OF INSTRUCTIONS TO

BIDDERS
3.2.1 The instructions to bidders shall be prepared generally as enumerated

in the general checklist for procurement activities of material handling
system / equipment – TCE.M12-ME-CL-670-080 and general
procurement guide No. TCE.M12-ME-000-901. However, the
following aspects to be specified are covered in this section:
(a) Number of packages and description of each package
(b) Any additional services / work expected from the Bidder
(c) Bidder’s qualification requirements, if any .
(d) Optional prices if required for any item specially requested by

the client or required based on system requirements.
3.2.2 In case, the coal handling system is procured through International

Competitive Bidding procedure with the funds from World Bank /Asian
Development Bank / OECF etc., a separate detailed general
conditions of contract in line with the requirement of funding Bank shall
be prepared, which shall comprise, but not be limited to the following :
(a) Invitation for bid
(b) Bidder’s qualification requirements
(c) Instructions to Bidders
(d) General conditions of contract
(e) Erection conditions – general
3.3 GUIDELINES FOR PREPARATION OF SECTION-C
The Section-C shall generally cover the following sub-sections (topics)

in which the aspects as enumerated below are to be clearly covered,
while preparing the specification.
3.3.1 Codes and Standards

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(a) General statement regarding the codes and standards shall be

covered
(b) Governing document in the event of conflict between the

requirements of codes and the specification shall be clearly
indicated
(c) Complete list of codes and standards applicable for this

contract may be added, if possible.
3.3.2 System Description
Brief description of the complete coal handling system operation for

all paths shall be furnished
(a) The rated capacity, number of streams to be installed (present

or future) and duty of the conveyor system shall be spelt out
clearly
(b) Any interconnection facilities with the existing as well as future

shall be described properly
(c) Any other special facilities such as weighing, magnetic

separators, bunker feeding arrangement etc shall also be
furnished
(d) Description of stacking, reclaiming systems
3.3.3 Equipment to be supplied and erected and works to be executed by

the Vendor
(a) There is no need to list out each and every equipment. A

statement shall be made that the list of equipment shall be as
per the flow diagram .
(b) Requirement of painting and its specification for structures,
equipment, ducting, piping etc shall be specified
(c) Civil works, if included in the contract, shall be listed out
(d) Structural works such as conveyor galleries, junction towers,

crusher house(s), etc shall be spelt out.
(e) General works and services like essential spares, start-up

spares, consumables, O&M manuals, drinking water facilities,
etc shall be listed out.
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(f) In electrical section, scope of supply of switchgear and 6.6 kV

cables shall be indicated.
(g) In structural and civil works, the construction of junction towers

and crusher houses specifically in regard to type of floors and
roof, type of cladding, etc shall be included.
(h) Type of controls such as conventional relay based system or

microprocessor based system shall be specified. In case of
micro processor based control system the configuration of
controls such as whether standby processor unit is required or
not, whether standby monitor is required or not, whether
programming unit is required or not, spare I/O capacity in the
panels etc shall be clearly specified.
(i) A general clause shall be added at the end of mechanical,

electrical, civil and structural portions for inclusion of minor
items specifically not covered in this sub-section but required
to make the system complete
j) Miscellaneous Services from the Vendor(part of the main

scope listing )
i) Miscellaneous services such as shop inspection, startup and

commissioning, performance testing, training of the
Purchaser’s personnel, supply of operation and maintenance
manuals.
ii) In case two or three packages (groups) are envisaged in the

specification, the responsibilities of each package contractor
shall be clearly spelt out to avoid contradictions at a later date.
Also, it shall be clearly stated that one package Vendor shall
co-operate with the other package Vendor in furnishing the
details / drawings required so that there will be no hold up in
engineering. Also no extra will be paid by the Purchaser to any
of the Vendors, if his assumptions are different from the
requirements of the other package Vendor.
3.3.4 Equipment and Services to be provided by Others
(a) All equipment / systems connected with the coal handling

system which are not included in the Contractor’s scope shall
be listed out. Particularly, the following equipment / systems
shall be clearly spelt out:
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(j) Tracks on the wagon tippler table
(ii) Tracks for beetle charger, side arm charger weigh

bridges etc
(iii) Locos, dozers and front end loaders
(iv) Fire protection system
(v) Buildings for service water pump house for dust

suppression systems, ventilation equipment, switchgear
and control room and D.E system fans, DE system
compressors, etc., if civil works are not included in
Vendor’s scope.
(vi) Compressors for supplying air to air blasters / bag

filters, if same is to be supplied by others.
(vii) Switchgear and transformers
(viii) 6.6 kV cables
(b) In case two or three packages (groups) are required in the

specification as per the Purchaser’s requirement, the scope for
interfacing equipment like chutes, flanges, suction hoods, skirt
boards, potential free contacts for the various equipment shall
be clearly identified between different package Vendors.
Similarly control system for the entire coal handling system
shall be included in the conveyor system Contractor’s scope
though the control system for wagon tipplers and accessories
and stacker-cum-reclaimer can be included in respective
package Vendor’s scope.
3.3.5 Terminal Points
(a) Water supply terminal point for dust suppression, plant

cleaning, service water and potable water with range of
pressure at supply point
(b) Compressed air supply terminal point for air blaster system,
and bag filter cleaning with range of pressure in case
compressors for air supply are not included under Vendor’s
scope. In this clause, the total quantity of service air that will be
supplied shall be stated with a stipulation that the Vendor shall
supply two compressors (1 operating + 1 standby) in case the
demand is higher than that envisaged.
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(c) Electrical system terminal points for power, control, DC supply,

earthing and lighting system
(d) Terminal points of different packages, if coal handling system

is to be split into two or three packages.
3.3.6 Bid Evaluation / Penalty
(a) Basis of evaluation of bids and essential details to be furnished

with the bid without which the bid will be considered incomplete
shall be furnished in this sub-section.
(b) Penalty amount for differential energy consumption after award

of contract shall be furnished in this sub-section.
(c) Clauses relating to deviations shall be clearly indicated
(d) Evaluation procedure for essential spares shall also be clearly

indicated
(i) All gates, though motorised, shall be possible to be

operated manually in the event of failure of its drive
3.3.7 Layout Requirements
(i) Locations of the wagon tippler, reclaim hopper, Junction

Towers (JT’s), conveyors, etc as shown in the bid
drawing shall be fixed. However, size and height of the
buildings shown in the bid drawings are minimum and
the exact size and height shall be decided by the
Vendor based on his equipment and to meet all the
requirements of the specification. This point shall be
brought out in the specification very clearly without any
ambiguity so that the Vendor will not raise extra claim
after award of contract.
(ii) Radius of curvature of concave curves for conveyors

shall be considered while laying out various facilities
(iii) Minimum side plate angle of transfer chutes and side

plate angle of hoppers shall be 65° based on which the
layout of all transfer points, JTs, crusher houses etc shall
be developed . The minimum transition distance at tail
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end of conveyors shall be considered while fixing the

sizes of junction towers.
(iv) Future equipment space including its layout in the

system shall be taken care of while developing the
layout
(v) Partition wall between crushers in the crusher house to
facilitate the maintenance of standby crusher while the
other is operating. Adequate space for removal of
suspension shafts shall be provided
(vi) Take-up travel as per IS shall be considered and the

take up counter weight shall be brought down to ground
level. As far as possible, automatic gravity take up shall
be provided for conveyors having more than 30 metres
length. Take up pits shall be avoided as far as possible.
Take ups shall be located outside JT’s, crusher houses,
etc.
(vii) As far as possible the discharge chutes of two

conveyors shall not be combined before feeding onto
succeeding conveyors
(viii) Use of surge hoppers in the layout shall be avoided, as
far as possible
(ix) Working / maintenance space of minimum 1500 /

2000mm depending upon project shall be provided all
round the equipment while deciding the sizes of the
buildings
(x) Crusher foundation and its isolation from the building

column foundations shall be provided to avoid vibrations
on the crusher house floors if crushers are not mounted
on springs
(xi) Fans, motors, pumps and respective dust extraction /

dust suppressor systems should be located on
gravitation of respective buildings
(xii) Crusher houses shall be provided with two staircases,

one outside the building and the other inside the
building at two different ends
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(xiii) It should be mentioned that location of tracks / other

structures should be so fixed as to avoid interference
with drains, roads, railway tracks, etc.
(xiv) Passenger cum freight lift shall be provided for

secondary crusher house and JT near bunkerbay if the
same is required by the Purchaser
(xv) All junction towers / crusher houses shall have covered

external staircases. Width of staircases shall be
minimum 1000mm and inclination shall not exceed 38º.
However internal stair cases can also be considered in
projects with space constraints.
(xvi) Location of switlchgear rooms, control room should be

indicated
(xvii) Gallery sheet covering details, ventilation gap of

minimum 250mm should be clearly indicated.
(xviii) Clause related to providing bottom cover plate for

galleries crossing roads, railway tracks, etc. should be
clearly stipulated
(d) Maintenance Requirements
The following maintenance requirements shall be specifically

covered apart from other general maintenance requirements:
(i) Facilities for carrying out on-line and off-line

maintenance of the system
(ii) Adequate handling equipment, working and movement

space, platforms, cross overs and safety devices
(iii) Equipment design shall be such that it can be readily

disassembled, repaired and reassembled in the
shortest period
(iv) Facilities for belt changing either at tail pulley end or at

the take up area with necessary lifted tackles,
monorails, etc
(v) The monorails provided in the junction towers shall

protrude out for a suitable length to lift / lower the
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equipment directly from and to ground floor. Whenever

monorails project suitable doors and protective
projections with hand railings shall be provided
(vi) Inspection and maintenance doors for the chute work
(vii) The chute work shall be of panel type construction so as

to attend / replace the liners easily
(viii) Gates shall be easily accessible for manual operation

and maintenance, if required.
(ix) Door provided for the monorails which protrude out

should be easily operable with minimum manual effort
(x) Chequered plate covered floors should have complete

covering upto AC sheeting without leaving gaps
(xi) All openings should be provided with hand railing

alround
3.3.8 Specific Requirements of Electrical Works
All the general and technical requirements including design codes,

procedures, etc for the electrical works shall be covered in this sub-
section.
3.3.9 Specific Requirements of Civil and Structural Works
All the general and technical requirements including design codes,

procedures, etc for the structural works and civil works (in case civil
works are included in contractor’s scope) shall be covered in this sub-
section.
3.3.10 Safety and Sequential Interlocks and Permissive Conditions
The following aspects shall be covered in this sub-section:
(a) Design considerations for safety interlocking system
(b) Various paths of operation in the coal handling system
(c) Stream selection (A stream, B stream and A&B streams) and

sequential auto start / stop operations
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(d) Type of control system (micro processor or relay based

systems)
(e) Any specific permissive conditions for start and stop of

proposed conveyors/equipment from the existing coal handling
system in case of projects where a new coal handling system
has to be installed in an existing plant.
(f) Any specific requirements for particular equipment start / stop

like crushers, HT motors of conveyors etc
(g) Local controls for equipment like travelling trippers, travel drive
of shuttle feeders, plough feeders, etc
(h) Details of equipment on control panel
(i) Emergency stop
(j) Changeover from one stream to the other stream
(k) Mimic details in case of conventional relay based system.
(l) Mimic-cum-control desk details incase of conventional relay

based system.
(m) Graphic display system incase of microprocessor based

system.
(n) Details of Annunciation system to be adopted and the list of

annunciations
(o) Configuration of PLC / micro processor based controls with

standby requirement, spare capacity of I/O units, requirement
of programming unit, etc. Sketch of PLC configuration and
hard wired panel should also be furnished
(p) Inter phasing with existing control systems in case of existing

plants
3.3.11 System Performance, Guarantee Requirements and Performance

Tests
The following guarantee requirements shall be covered :
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(a) The capacity of all equipment, conveyors and feeders,

crushers, screens and stacker / reclaimers as specified in
Data Sheet-A of Section-D shall be achieved on the positive
side while handling material having specified moisture content
and with maximum fines as specified
(b) Dust concentration in the air exhausted from bag filters of dust
extraction systems shall not exceed 100 mg/N.cu.m
(c) Energy consumption of all equipment, conveyors and feeders

shall be equal or less than the guaranteed figures
(d) Acceptable noise level of equipment
(e) Acceptable vibration level of equipment
(f) Buildup and choking inside the transfer chutes shall not occur
(g) Stacker / reclaimer shall be stable under specific design

conditions
(h) The belts of conveyors shall run truly in the center without any
sway
(i) Crusher shall crush and give specified throughput and of size
specified.
(j) Screens shall screen out material having dimensions stipulated

in data sheet-A and retain oversize material.
(k) Minimum illumination levels specified shall be achieved
(l) The air flow in all the grills of ventilation system shall be
checked for its proper distribution
(m) The effectiveness of dust suppression system shall be checked
(n) Hopper and chute outlets shall be designed to prevent spillage

on the equipment
(o) Endurance test requirements shall be specified
(p) All chutes, feeders, equipment etc shall be completely dust tight
(q) Effectiveness of ventilation systems.

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3.3.12 Procedure for Performance Testing
The procedure to be followed for conducting the performance tests

shall be furnished giving details of responsibilities of each party and
proforma format to be adopted.
3.3.13 Quality Assurance Plan (QAP)
Quality Assurance Plan (QAP) to be followed for all the equipment

shall be furnished in the specification where the specification is
prepared for the international competitive bidding. It is preferable to
include QAP for local competitive bidding specification also.
3.3.14 System Data Sheets
The following system data sheets shall be prepared :
(a) System Data Sheet-A containing coal properties to be

considered for system design. The following minimum
properties of coal shall be included in this data sheet::
(i) Bulk density of coal for volumetric capacity calculations
and for design of components, structural supports, drive
etc.
(ii) Maximum size of coal to be handled at the receipt
(iii) Maximum size of coal required after crushing
(iv) Maximum moisture content of coal including inherent

and surface moisture.
(v) Hand grove grindability index of coal
(vi) Maximum percentage of fines (dust) in the coal.
(b) System Data Sheet-A2 containing typical analysis of water to

be supplied by the client for usage in dust suppression, dust
extraction and service water systems
(c) System Data Sheet-A3 containing the list of essential spares

for 3 years of trouble free operation of plant.
(d) System Data Sheet-A4 containing the list of maintenance tools
.
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(e) System Data Sheet-B containing the list of drawings, literature

and write-up to be submitted by the bidder along with the
proposal. The list should contain the following minimum items:
(i) Experience list and back ground details of the bidder to

meet the pre-qualification requirements
(ii) Scope of supply
(iii) Bid drawings like plan, flow diagram, and section drawings
(iv) Filled in Data Sheets-B of Section-D and filled in

schedules of Section-F
(v) Manufacturer’s catalogues, detail G.A. etc., of all the

equipment
(vi) Bar chart / PERT Network schedule
(vii) Schedule of reinforcement steel and cement

requirement .
(viii) Schedule of electrical feeders with ratings for
procurement of switchgear, if the same is not included in
coal handling system Contractor’s scope
(ix) Schedule of makes of all major bought out items
(a) System Data Sheet-C containing a detailed list of technical

data / drawings / design calculations to be furnished by the
Vendor after the award of contract for the review / approval by
the Purchaser / Consultant. This should be divided into two
lists - one list giving the items requiring approval and the
second list giving the items which will be used for reference /
further engineering.
(b) List of deviations if any as per schedule of deviations.
3.4 GUIDELINES FOR PREPARATION OF DATA SHEET-A OF

SECTION-D:
The following aspects as enumerated under each equipment shall be

specifically covered while preparing Data Sheet – A apart from
general aspects covered in the respective data sheet itself.
3.4.1 Wagon Tippler and Accessories:

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(a) Minimum angle of rotation - 155o for rotaside type

170o for rotary type
(b) Type of wagons to be handled with wagon dimensions
(c) Capacity of the tippler in wagons per hour –
(d) Type of drive - Gear sector type
(e) Hydraulic clamping arrangement for the wagons during the

tippling operation
(f) Passage of mainline loco over the wagon tippler table
(g) Railways Designs and Standard Organisation (RDSO)

approval for the wagon tippler to be obtained by the VENDOR
(h) Weigh bridge shall be located outside the wagon tippler shed.
- Electronic load cell type with digital weight display
recorder and totalizer
(i) Dust control equipment requirement and its details including

pre-spraying arrangement. Dust suppression at wagon tippler
shall be with chemical solution sprays while the pre-spraying
arrangement (for minimum two waiting wagons) shall be of
plain water spray type.
(j) Type and holding capacity of wagon tippler hopper and its
details
- Preferably the hopper shall be of RCC construction with slot

type opening at the bottom and with 5 mm thk. SS liners on all
sides of the hopper upto 4000 mm height from the bottom.
Above that height, TISCRAL liners shall be provided. Hopper
shall be provided with grid of required opening size and shall
be made of flats only.
(k) Type of inhaul and outhaul charger and their details
- Beetle or side arm charger with minimum 10,000 kgs of

tractive effort to pull 24 loaded wagons each of 90 tonnes
gross weight
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(l) Type of equipment below wagon tippler hopper and their

details
- The feeder shall preferably be of Apron feeder type with

dribble conveyor below it. The apron feeder drive shall be
hydraulic with speed variation. Normally dribble conveyor shall
be of belt type. Apron feeder width shall be minimum 200 mm
more than hopper outlet width while that of dribble conveyor
shall be 200 mm more than apron feeder width.
3.4.2 Stacker – Reclaimer
(a) Effective stockpile height above grade level and clearance

between bucket wheel and maximum stock pile height.
(b) Luffing angle – to suit item (a) above
(c) Slewing angle – Minimum 210o

(d) Distance between centre line of bucket wheel to centre line of
track i.e., boom length
(e) Two speeds for travel
(f) Type of bucket shall be cell – less / semi – cell type
(g) Slewing motors shall preferably be hydraulic
(h) No. of discharges per minute of bucket wheel while reclaiming

shall be limited to 50 per minute
(i) A separate auxiliary motor with inching facility shall be provided

for maintenance of bucket wheel
(j) Operator’s cabin and switchgear electrical cabin shall be air

conditioned
(k) Hydraulic cylinder / electric actuator operated skirt board for

adjusting the coal feed centrally to the trunk conveyor shall be
provided
(l) Stockpile width at the base shall be indicated
(m) Luffing of the boom shall be by minimum 2 Nos. of hydraulic

cylinders each capable of sustaining the weight of the boom
when the other cylinder is under maintenance / has failed.
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(n) Anchoring arrangement at track ends for the safety of the

machine during storm conditions
(o) The control of the machine shall be using PLC in auto / manual
mode.
3.4.3 Crushers:
(a) Input and output size of the material
(b) Maximum speed of the crusher
(c) Type of drive and coupling shall be of scoop tube fluid type. It
should also be mentioned that scoop type fluid coupling should
not be used as a speed variation device. Any speed variation
required should be achieved through a belt device.
(d) Material of construction of different parts of the crusher
(e) Performance tests to be conducted
(f) Minimum motor rating to be adopted
(g) Maximum fines generation shall be limited to 10%
(h) Rotary breaker shall be capable of rejecting all uncrushable

material such as rock, tramp Iron pieces, shale, wood, etc.
(i) Acceptable vibration limit
(j) Maintenance door requirements on the crusher
(k) Speed of secondary crusher shall not exceed 750 rpm
(l) Minimum motor rating of secondary crusher shall be specified
(m) For FBC boilers type of crushing system and crusher shall be
as per basic study.
3.4.4 Screens
(a) Size of material to be screened

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(b) Moisture content of the material
(c) Maximum input size of the material and maximum percentage

of fines in it
(d) Requirement of heating facilities for casing, if any
(e) Material of construction
- In case of eccentric disc screens, the disc rolls / spacer

discs / bevel gears shall be of chrome molybdenum steel as
per ASTM 4140 or better.
(f) The minimum thickness of the rolls above the reference line
shall be specified and the same shall be minimum 25mm.
(g) Performance tests at works and at site to be conducted
(h) In case of screens for fluidised bed boilers (FBC) with

recirculation facility, type of secondary screen viz. Flip flow
screen has to be specified if called for in the basic study. Size
of material to be screened should be indicated Further it
should be specified that no over size in two (2) directions
should be passed by screen. The screen material for flip flow
screens should be of high value polyurethane, drive shaft
should be EN-8 steel as per BS 4363 Gr.55C.
3.4.5 Belt Conveyors / Belt Feeders
(a) Rated and design capacities of each conveyor in tonnes per

hour
(b) Belt width, speed, troughing angle of each conveyor
(c) Material handled by each conveyor (crushed, semi crushed,

ROM coal, rejects, etc.)
(d) Idler style and its minimum roll diameter for various services
(e) Idler lubrication, shaft diameter and its spacing for various
services
(f) Pulleys type, width, lagging requirement, method of lagging and

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(g) Type and No. of belt clearances (external / internal) for each
conveyor / belt conveyor
- Two (2) Nos. of external scraper with one sprung blade type
and one torsion arm type and one(1) internal scraper of ‘V’
plough type
(h) Details of skirt board
(i) Chute work and its liner details
- Chutes shall be made of minimum 10 mm thick. MS plates

with 5 mm thick. SS liners and side plate angle of chutes
shall be minimum 65o
(j) Deck plate requirement and its thickness
(k) Brakes / hold back requirements

(l) Safety switches and its spacing for each conveyor
(m) Take up details and take up requirement
(n) Coupling type for high speed / low speed sides and its
requirements
(o) Gear box type and service factor to be considered

- Type of gear box shall be helical / bevel helical and service
factor of minimum 1.8 on shaft kW requirement shall be
considered for its selection.
(p) Belting details like belt width, duck material, cover grade, top
and bottom cover thickness, No. of plies and its breaking
strength, edge type, etc., for all conveyors / belt feeders.
(q) Standardisation of motor ratings, pulley types, belt types, gear

boxes, couplings shall be highlighted.
3.4.6 Coal Sampling System
(a) Material handled
(b) Details of belt conveyor such as capacity, belt width, speed,

etc., on which coal sampler will be mounted.
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(c) Material of construction – cutter, chute, hopper etc. in the

sampler shall be made of stainless steel
(d) Test for sampler performance
(e) Design and performance shall be conforming to BS 1017,

1293 & 2074 , ASTM-D2234
3.4.7 Metal Detector
(a) Detecting capacity
- The same shall be minimum 50 mm aluminum spheres at

conveyor rated speed and for other metals such as, brass,
copper steel or stainless steel the minimum detection
capacity shall depend upon their electrical characteristics.
(b) Details of belt conveyors on which the metal detector will be

mounted
(c) Annunciation / hooter provision
(c) Indicator shall be dropped on detection of metal
3.4.8 Belt Conveyor Scale (Belt weigher)
(a) Type of conveyor scale shall be preferably electronic load cell

type
(b) Details of belt conveyors on which conveyor scale will be

mounted
(c) Range of capacity of the conveyor to be measured
(d) Accuracy of the conveyor scale
- The same shall be +0.5% for stationary conveyors while it

shall be +2% for the boom conveyor
(e) Totaliser to be included
(f) Conveyor scale shall be suitably located on horizontal portion

of the conveyor as far as possible.
3.4.9 Magnetic Separator ISSUE

R2
FORM NO. 120 R1

(a) Details of belt conveyors on which magnetic separator unit will

be mounted.
(b) Operating height of the magnet
(c) Maximum and minimum tramp iron piece to be separated. The

same shall be 50 kgs. And M20 nuts buried under the material
(d) Minimum magnetic gauss value at the face of the magnet –

1700 gauss
(e) Magnetic coil material – Aluminium
(f) The magnetic core material – Carbon steel, Grade – I, as per

IS 4491 / CRGO
(g) Maximum operating temp. of the coil – 140 oC
3.4.10 Travelling Tripper
(a) Motor driven travelling tripper is preferred
(b) Details of belt conveyor on which the travelling tripper will be

mounted
(c) Capacity (rated / design) of the travelling tripper
(d) Two speeds of tripper – 5 m / min. and 10 m / min.
(e) Cable reeling drum arrangement is preferable
(f) Tripper rails and fixtures shall be included in the BIDDER’s

scope
(g) Discharge chute details with flap gate or not
(h) Tripper pulley shall be provided with external scrapers.
3.4.11 Dust Control System
(a) Type, designation and location of dust extraction (D,E) & dust
suppression (D,S) system
- Type of DE system shall be dry type with bag filter as dust

collector. The dust collected shall be put back onto either of
the forward conveyors through air lock feeders. ISSUE
R2
FORM NO. 120 R1

(b) Degree of dust collection required – The same shall be limited

to meet the emission level of 100 mg / N.cu.m of the air being
exhausted to the atmosphere
(c) Type of dust suppression with plain water spray
(d) Dust extraction/ dust suppression system to be designed

based on single or double stream of conveyor operation
(e) No. of DS pumps including standby
(f) Scope with terminal point of water supply
(g) Pump house location
(h) Type and material of construction of dust suppression nozzles
(i) Arrangement of stock pile dust suppression system
(j) Blades of centrifugal fan for DE system shall preferably be of

backward curved type.
(k) Auxiliary systems like service water system, plant cleaning

system shall be specified
(l) Capacity of main water storage tank for these services and
their details
(m) Design of DE system shall be based on pressure balancing

without blast gate method
3.4.12 Ventilation System
(a) All tunnel ventilation systems shall be of supply air system type
with exhaust fans and the fan capacity shall be sized based on
minimum 12 air changes per hour plus the dust extraction
system capacity (if provided in that area) from the concerned
suction points. In case no dust extraction system is provided in
the tunnel, then the minimum number of air changes per hour
shall be considered as 15 for ventilation fan capacity sizing.
(b) Air filters shall be preferably of self cleaning oil wetted

automatic viscous type
ISSUE
R2
FORM NO. 120 R1

(c) Switchgear room shall be provided with pressurised ventilation

type with supply air fans and exhaust fans. The capacity of
exhaust fans shall be about 50% of the capacity of the supply
air fans.
(d) Wall mounted exhaust fans for various places like pent house,
access shafts, toilets, etc. shall be specified.
(e) Type of ventilation duct and grill details
3.4.13 Bunker Ventilation System
(a) Three bunkers of each unit (for 210MW Units) shall be provided
with one bunker ventilation system for PF boilers. For FBC
boilers, since each boiler will be provided with a bunker, each
bunker shall have a bunker ventilation system.
(b) The type of the system shall be dry type with bag filters
(c) Dust concentration in the outlet air should not exceed 100
mg/N.cu.m. at the exhaust.
(d) 12 air changes per hour of the bunker empty volume shall be
specified as minimum fan capacity
(e) Dust collected in the collecting hopper of bag filters shall be fed
back into the bunkers through rotary feeder and discharge
chute work
(f) Design of bunker ventilation system shall be based on

pressure balancing without blast gate method.
3.4.14 Hoists / Trolleys / Cranes
(a) Location, quantity and type (manual/ electrical) of hoists and

trolleys shall be listed. Capacity and lift shall be decided by
bidder based on his equipment and layout. However it shall be
specified that slinging angle shall be minimum 45°. Also it
should be specified that slinging should be across the width of
the equipment, such as from bearing centres of pulleys.
(b) Wagon tippler shed shall be provided with EOT crane for
maintenance of wagon tippler components and its
accessories. The standard detail of EOT crane (write up, data
sheets A,B and C) shall be furnished.
ISSUE
R2
FORM NO. 120 R1

3.4.15 Sump pumps
(a) Number required & location of the sump pumps shall be

indicated.
(b) Sump pumps shall be of submersible and non-clog type to

handle coal slurry with maximum lump size of 25 mm.
(c) Discharge pipe upto nearest plant drain

(d) Material of construction of impeller shall be alloy CI and casing
shall be CI with minimum 340 BHN
(e) Capacity of sump pumps shall be minimum 25 cu.m/hour.

However the exact capacity shall be fixed based on location
extent of tunnel length, etc. Also for calculation of pump head,
length of discharge piping or location of discharge (if known)
should be specified.
3.4.16 Miscellaneous items
(a) Items like sector gates, rack and pinion gates etc., shall be
listed out with their major design requirements.
3.5 GUIDELINES FOR PREPARATION OF SCHEDULES IN SECTION-F
Refer document No. TCE.M12-ME-000-901 for this.
4.0 REVIEW OF BIDS
4.1 For general details refer the general check list for procurement
activities for material handling system / equipment TCE.M12-ME-CL-
670-085.
4.2 The following items shall be checked specifically apart from that
indicated in the check list No.TCE.M12-ME-CL-670-085 during the
review of bids and shall be evaluated suitably.
4.2.1 Belt Conveyors
(a) Motor ratings for all conveyors
(b) Belt ratings for all conveyors
ISSUE
R2
FORM NO. 120 R1

(c) Length, lift and inclination particularly considering the

permissible inclination for all conveyors
(d) Gallery width and height considered and tunnel cross section
along with walkway widths.
(e) Belt speed
(f) Belt profiles including radii of curvatures
(g) Extent of standardisation in regard to gear boxes, pulleys, drive

motors, conveyor belts, types of gear boxes etc.,
(h) Pulley sizes, idler specifications and spacing etc.,
(i) Crusher and screen parameters. For crushers of FBC boilers

re-circulation load, oversize of coal, output size distribution,
percentage fines, etc., should be checked. For screens (Flip
flow type) aperature size suitable for separating coal of size
specified should be checked.
(j) Side plate angles of chutes and hoppers, Chute and skirt
board construction.
(k) Motor rating of feeder below reclaim hoppers. belt feeder

capacity, speeds and belt width etc.,
4.2.2 Size of crusher houses, JTs, buildings as compared to that of

specification drawings.
4.2.3 Capacity of fans and head for all dust extraction and ventilation systems if
furnished by Bidder. Otherwise confirmation should be obtained, that
these should be got approved during detailed engineering stage.
4.2.4 Capacity and head of pumps for dust suppression and service water /
plant cleaning system if furnished by Bidder. Otherwise confirmation
should be obtained that these will be got approved during detail
engineering.
4.2.5 List of manually operated / electrically operated hoists with capacity & lift.
Unit rates shall be obtained for addition / deletion of hoists of different
capacity and lift.
4.2.6 Adequacy of size and model and motor rating of primary and secondary
crushers and screens quoted by bidders. Drive arrangement of
ISSUE
R2
FORM NO. 120 R1

crusher with scoop tube coupling shall be reviewed in line with

specification.
4.2.7 Material of construction of crushers and screens with respect to the

specification requirements.
4.2.8 Stacker reclaimer machine boom length, luffing and slewing angles,
stockpile height considered, accessories as per specification
requirements, controls, etc.
4.2.9 Coal stockpile length with stacker reclaimer travel.
4.2.10 Travelling tripper travel length and bunker feeding arrangement with cable
reeling drum. Wheel size of tripper shall also be checked.
4.2.11 Liner material and extent of lining for chutes and hoppers
4.2.12 Makes of all equipments and bought out items.
5.0 GUIDELINES FOR PREPARING PURCHASE RECOMMENDATION

AND PURCHASER ORDER
Refer ‘General check list for procurement activities for material

handling system / equipment’ No.TCE.M12-ME-CL-670-085.
ISSUE
R2
FORM NO. 120 R1

Coal Handling System by Rail

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TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE

TCE.M12-ME-CL- SHEET (i) OF (iii)

CHECKLIST FOR PROCUREMENT

COAL HANDLING SYSTEM BY RAIL

INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD.BY MJ Sd/- BVS Sd/- MG

CHD.BY PS Sd/- VJ Sd/- BVS R2

APD.BY KG/MLN Sd/-/ Sd/- MLN/RL Sd/-/ Sd/- DVL/RL

DATE 17.02.1994 31.03.2000 20.03.2003

FORM NO. 020R2

FILE NAME : M12MECL030R2.DOC

INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD.BY MJ Sd/- BVS Sd/- MG

CHD.BY PS Sd/- VJ Sd/- BVS R2

APD.BY KG/MLN Sd/-/ Sd/- MLN/RL Sd/-/ Sd/- DVL/RL

DATE 17.02.1994 31.03.2000 20.03.2003

FORM NO. 020R2

SL.NO. TITLE SH.NO.

2.0 REFERENCE DOCUMENTS 1

3.0 PREPARATION OF SPECIFICATION 1

4.0 REVIEW OF BIDS 23

5.0 GUIDELINES FOR PREPARING PURCHASE

FORM NO. 120 R1

REV. NO. DATE DESCRIPTION

R1 31.03.2000 GENERALLY REVISED

R2 20.03.2003 GENERALLY REVISED

FORM NO. 120 R1

This checklist covers the general aspects of the following procurement

1.1 Preparation of specification

1.2 Review of tenders

1.3 Preparation of purchase recommendation

1.4 Preparation of purchaser order, if it is covered in TCE’s scope.

2.0 REFERENCE DOCUMENTS

2.1 Latest issue of plot plan

2.2 Coal handling system basic study with all Exhibits

2.3 General checklist for procurement activities of material handling

2.4 TCE.M12-ME-000-901 – General Procurement guide for Mechanical

2.5 Railway track layout drawing.

2.7 Design guide for belt conveyors – TCE.M6-ME-670-001.

3.0 PREPARATION OF SPECIFICATION

3.1 GUIDELINES FOR PREPARATION OF SCOPE OF ENQUIRY

Coal handling system by rail is generally procured under turnkey

FORM NO. 120 R1

clearly indicated (usually stacking / reclaiming system and bunker

3.2 GUIDELINES FOR PREPARATION OF INSTRUCTIONS TO

3.2.1 The instructions to bidders shall be prepared generally as enumerated

(a) Number of packages and description of each package

(b) Any additional services / work expected from the Bidder

(c) Bidder’s qualification requirements, if any .

(d) Optional prices if required for any item specially requested by

3.2.2 In case, the coal handling system is procured through International

(a) Invitation for bid

(b) Bidder’s qualification requirements

(c) Instructions to Bidders

(d) General conditions of contract

(e) Erection conditions – general

3.3 GUIDELINES FOR PREPARATION OF SECTION-C

The Section-C shall generally cover the following sub-sections (topics)

3.3.1 Codes and Standards

FORM NO. 120 R1

(a) General statement regarding the codes and standards shall be

(b) Governing document in the event of conflict between the

(c) Complete list of codes and standards applicable for this