ESSAR PARADIP TERMINALS LIMITED

10 MTPA DEEP DRAUGHT COAL BERTH

AT PARADIP PORT

DESIGN BASIS FOR DUST SUPPRESSION SYSTEM

ESSAR ENGINEERING SERVICES LTD.

HAZIRA

DOC. NO: 3503-H000-Z58000-0015-1505-0001 May-2010

                                                                                                     
                                                                                                                                                            Page 1 of 14
 10 MTPA DEEP DRAUGHT COAL BERTH
AT PARADIP PORT
ESSAR PARADIP
TERMINALS LIMITED.
DESIGN BASIS FOR DUST SUPPRESSION
SYSTEM ESSAR ENGINEERING
DOC. NO – 3503-H000-Z58000-0015-1505-0001 SERVICES LTD

INDEX
CLAUSE DESCRIPTION PAGE

1.0 PURPOSE 3
2.0 SCOPE 3
3.0 SITE INFORMATION 3
4.0 MECHANICAL DESIGN CRITERIA 4

PREPARED BY CHECKED BY APPROVED BY APPROVED BY

(EESL) (EESL)
(EESL)

KARTHIK KSELVAN R.A.NAIDU

Confidential

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 10 MTPA DEEP DRAUGHT COAL BERTH
AT PARADIP PORT
ESSAR PARADIP
TERMINALS LIMITED.
DESIGN BASIS FOR DUST SUPPRESSION
SYSTEM ESSAR ENGINEERING
DOC. NO – 3503-H000-Z58000-0015-1505-0001 SERVICES LTD

1.0 Purpose
1.1 M/s Paradeep Port trust Intends to set up a conveyor & Storage system for Coal
Handling near Paradeep Existing Port. The Pollution Control Facilities envisaged
for Coal Handling System are as follows.

1.2 Dust emission at conveyor transfer point & stock piles have become a significant
problem of increased emphasis on improving the work place environment and strict
adherence to environment regulation & norms. High efficiency Air pollution control
systems are therefore envisaged in preserving the environment quality for human
comfort and efficient running of plant & machinery itself.

1.3 The Purpose of this document is to detail all the basic design information required
to form the basis of detailed engineering for Air Pollution Control System.

1.4 This specification also refers to other document/s which allows a more detailed
insight into the design basis.

2.0 Scope
2.1 The design basis contains a description of the work, as well as guidance
documents, references, and methodologies to be used in the design process of Air
Pollution Control Systems.

2.2 This design basis is applicable to the Air Pollution Control systems, including
design and preparation of drawings for construction activities.

2.3 In case of conflict between the document and other project specific standards /
specifications, reference should be made to the Project Engineering Manager for
resolution.

The order of superiority of documents to be used on this project is as follows:

i) Applicable Indian Government Rules and Regulations

ii) Requisition Data Sheets and Specifications
iii) Project Procedures and Department Procedures.
iv) Applicable International Codes and Standards.

3.0 SITE INFORMATION

S.
Description Parameters
No
1 Temperature
Confidential

Highest temperature recorded 35.96 ºC

Minimum temperature recorded 13.30 ºC

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 10 MTPA DEEP DRAUGHT COAL BERTH
AT PARADIP PORT
ESSAR PARADIP
TERMINALS LIMITED.
DESIGN BASIS FOR DUST SUPPRESSION
SYSTEM ESSAR ENGINEERING
DOC. NO – 3503-H000-Z58000-0015-1505-0001 SERVICES LTD

Wet bulb temperature 28.1 ºC

2 Humidity
Average Max Relative Humidity
90%
(Summer : Mar. – May)
Average Min Relative Humidity
55%
(Winter : Dec – Feb)
3 Rainfall
Avg. annual rainfall 1426.98 mm
4 Wind
Avg. speed(as per IS 875) (part III) 40-50 km/hr
6 Location of the plant Paradeep Port (Near Existing Port)
7 Latitude & longitude Latitude: 20۫ 15’ 55.44’’ N
Longitude: 86۫ 40’ 34.62’’ E

4.0 MECHANICAL DESIGN CRITERIA

i) The Proposed Air Pollution control System for Coal handling system (CHS) is
based on the following Drawings/Documents.
ii) 3503-H000-A00000-0016-1605-0002 Rev-0 : General Layout of Coal Handling
System
iii) High efficiency Air pollution control systems envisaged in preserving the
environment quality for human comfort and efficient running of plant &
machinery itself for the proposed Coal Handling Facilities are as follows:
• Dust Suppression System (DSS)

4.1 Dust Suppression System

4.1.1 Dust suppression system shall be provided for control of fugitive dust emissions
from dust generation points such as transfer points, Storage Piles etc. The areas
provided with Dust Suppression system are as follows:

S. No Area Envisaged System Envisaged

Plain water sprinkling type dust
1 Coal Stock Piles
control system
Junction Houses (CRJH-1, CRJH-2,
Plain Water sprinkler type Dust
2 CRJH-3, TH-1, TH-2, TH-3, TH-4,
Suppression System
TH-5) & Wagon Loading System
One Stacker
Mobile Mist generating type dust
3 One Stacker cum Reclaimer
control system
Two bucket wheel Reclaimer
Confidential

SUL-1 & SUL-2 are Rail Mounted Mobile Mist generating type dust
4
Travelling Ship Unloaders. control system

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 10 MTPA DEEP DRAUGHT COAL BERTH
AT PARADIP PORT
ESSAR PARADIP
TERMINALS LIMITED.
DESIGN BASIS FOR DUST SUPPRESSION
SYSTEM ESSAR ENGINEERING
DOC. NO – 3503-H000-Z58000-0015-1505-0001 SERVICES LTD

4.1.2 Plain water sprinkling type dust control system

i) The sprinkling system is nothing but an artificial rain and purpose of this system
is to wet the entire surface of Stock Pile, so that micron size dust particle cannot
be emission from stock pile due to wind velocity.
ii) Suitable number of Part circle heavy-duty sprinkler of appropriate throw radius
shall be considered for stock pile accordingly and shall be mounted on either
side of the Stock Piles.

iii) Each Sprinkler shall be provided with Solenoid Operated Diaphragm Valve,
Electric Operated Globe Valve, Manual Ball Valve and Mechanical type flow
switch for Suitable control and operation of Sprinkling System. Manual by-pass
arrangement with Ball valves shall be considered as per requirement for manual
operation of sprinkling system at Site.

iv) All the Sprinkler risers shall be supported with structural support on RCC
foundation of drain on each side of stock pile according to sprinkler requirement.

v) All Pipes & Fittings would be of GI/MS heavy duty, ERW as per IS-1239/3589,
Part-I & II.

vi) For entire length of stock pile, main header Pipe shall be laid over ground on
PCC Pedestal on either side of stock pile and riser pipe with pipe fittings and
Sprinklers shall be placed accordingly.

vii) Underground pipe line shall have wrapping and coating as per IS-10221 and
Hume pipe protection shall be laid at road crossing wherever required,
otherwise pipe shall be laid over ground on PCC pedestal.

viii) Pipes and Pipe Fittings shall be designed considering velocity of water as
1.5m/sec.

ix) At a time Sprinkling system on any 2 Nos. of stock pile shall be under operation
and as a total 4 Nos. of sprinkler shall be in operation (1 No. from each side of
stock pile for 2 Nos. of Stock Pile). For water quantity and design, 3 cycles of
operation shall be considered per day at equal intervals of time.
Confidential

x) Pump capacity shall be designed considering the above sequence of operation

considering 4 Nos. sprinklers will be working at a time.

Page 5 of 14
 10 MTPA DEEP DRAUGHT COAL BERTH
AT PARADIP PORT
ESSAR PARADIP
TERMINALS LIMITED.
DESIGN BASIS FOR DUST SUPPRESSION
SYSTEM ESSAR ENGINEERING
DOC. NO – 3503-H000-Z58000-0015-1505-0001 SERVICES LTD

xi) 3 Nos. of centrifugal Pumps (2Working + 1Standby) of suitable capacity and

pressure shall be considered for the system generating 6-7 kg/cm2 consisting of
suction line, Strainers, NRV, By-Pass Line, Supply line, Balance valve units &
instruments to suit the system.

xii) Complete sprinkling system can be operated through PLC. Main PLC panel to
be installed in the pump house. Remote I/O rack to be installed near stock pile
area. Main PLC will be connected with remote I/O rack by floppy-bus cable. All
the Solenoid Valve will be terminated with remote I/O rack by control cable
combination of stock piles for which operation can be selected by main PLC.

xiii) The list of all the locations required to be covered by plain water sprinkling
system are as follows:

S. No Area Envisaged Size (L x W x H), m

1 Coal Stock Yard – 1 650 x 46 x 10

2 Coal Stock Yard – 2 650 x 46 x 10

3 Coal Stock Yard – 3 650 x 46 x 10

4 Coal Stock Yard – 4 650 x 46 x 10

JUNCTION HOUSE

1 Junction House CRJH-1

2 Junction House CRJH-2

3 Junction House CRJH-3

4 Junction House TH-1

5 Junction House TH-2

6 Junction House TH-3

7 Junction House TH-4

8 Junction House TH-5

9 Wagon Loading System

Confidential

Page 6 of 14
 10 MTPA DEEP DRAUGHT COAL BERTH
AT PARADIP PORT
ESSAR PARADIP
TERMINALS LIMITED.
DESIGN BASIS FOR DUST SUPPRESSION
SYSTEM ESSAR ENGINEERING
DOC. NO – 3503-H000-Z58000-0015-1505-0001 SERVICES LTD

4.1.3 High Pressure mist Generating type dust suppression system

‐ The Dust suppression system for Stacker, Reclaimer, Stacker cum Reclaimer,
SUL -1 & SUL -2 shall be of High Pressure mist generating type dust control
system without any compressed air or chemical addition, working on the principle
of agglomeration with moisture addition of less than 1% to the total material
Handled.
‐ The system should use high-pressure mist type nozzle capable of producing the
super-fine atomization of water droplets that increase the dust particle to water
droplets contact which adhere to each other resulting in settlement of dust and the
mist type droplets evaporate before wetting and arresting only dust.
‐ Suitable Nos. of headers compressing of strainers, socket and couplings shall be
provided as per design requirement for effective dust control. The headers shall
be fabricated from high pressure tubing drilled and tapped for connection of high
pressure type nozzle adaptors. Suitable Nos. of specially designed and stainless
steel high pressure mist Generators (Nozzles) for mist/fog generation to tune of 5
to 200 microns shall be considered for Boom Conveyor and Yard Conveyor of
Reclaimer System.
‐ Two Nos (1 Working + 1 Standby), high-pressure pumps shall be considered for
the system consisting of Suction Line, NRV, Basket strainers, Return line, Supply
Line, Balance valve unit & Instruments, self cleaning filtration unit, etc to suit the
system.
‐ Suitable length and diameter high-pressure pipe lines shall be considered as per
design requirements to deliver high pressure water to high-pressure headers of
mist generators. Steel Fabricated Tank of Capacity approx. 5m3 shall be
considered for the system with appropriate Pipes & fittings and Manual Ball Valve
for Tank inlet Pipe. Tank shall be mounted on all the machines and Water shall
be filled from the Tapping Line provided in the Yard at Desired Locations.
‐ Necessary Control Panel for the Dust Suppression System shall be mounted on
the Machine. Power Supply shall be arranged in the machine for Dust
Suppression System. Feedback from Control panel to plant PLC shall be made
available.
Confidential

Page 7 of 14
 10 MTPA DEEP DRAUGHT COAL BERTH
AT PARADIP PORT
ESSAR PARADIP
TERMINALS LIMITED.
DESIGN BASIS FOR DUST SUPPRESSION
SYSTEM ESSAR ENGINEERING
DOC. NO – 3503-H000-Z58000-0015-1505-0001 SERVICES LTD

4.1.4 Systems for both Plain Water Sprinkling and Mist generating system

i) Pump house shall be considered near coal stock yard for mist generating
system and Plain water sprinkling system to accommodate pump, motor, MCC,
PLC etc.

ii) RCC storage tank capacity shall be designed at least for one cycle of operation
as standby for Plain water sprinkling system taking into account the continuous
operation of Mist generating System.

iii) Two Nos. of Power feeders shall be considered one in the Pump House & Other
one in Compressor House from main MCC. An adequately sized local control
Power panel (MCC) shall be considered in the pump house for distribution of 3
phase 415V AC power to the water pumps (Plain water Sprinkling System and
High Pressure Mist generating system), flow activations stations, Solenoid
Valves, Instrumentation for auto-operation, interlocking works etc including
pump house illumination & earthing.

iv) Suitable Control and Power cables consisting of cable trays, supports (structural
steel channels and angles), fittings (such as elbows, bends, reducers, enlargers,
coupling cap nipples, bushings, tee, crosses etc), Conduits/Pipes, Junction
Boxes, cable glands, accessories and hardware’s (such as side couple plates,
bolts, nuts, spring washers, strap, and hook etc) shall be considered for safe
operation of complete system.
Confidential

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