OPERATION PHILOSOPHY

1. Coal will be received by Pay Loader from storage yard and fed to Conveyor CBC-1 through
Ground Hopper GH-1, motorized Rack and Pinion Gates and Vibro Feeders.

2. Before starting conveyors, this is to be ensured by the Conveyor attendants at site and from
Control room that all the field Safety Switches, like, PCS, BSS, ZSS, are un-operated and
Remote/Local switches are in Remote position. After that the Start sequence will start as
follows.

1. Rack and Pinion Gate will Be in open position under the hopper being feed by pay
loader from the operating station/Locally.

2. After start sequence, field Hooter will start.

3 The feedback of Existing conveyor PCC 3A/3B will give feedback in Running
position or conveyor PCC-2 feedback in running position.

4 Motorized Diverter Gate DG-01 that to be positioned by PLC for material receiving
existing conveyor PCC-3A or PCC-3B depending on the conveyor running condition.

5 PLC will give start command to conveyor CBC-1 and will check for the healthy and
Running f/b will be received by PLC.

6 After start the CBC-1 conveyor Vibratory feeder VF-01 will start from PLC , at the
same time Dry Fog Dust suppression system DFDS-1 will be started

STOP sequence will be as follows :

A. PLC will give stop command to Vibratory feeder VF-01 and will check for the Stop
F/B.

B. PLC will give stop command to conveyor CBC1 after 90 sec and will check for the
Stop F/B.
 C. After stopped of CBC-1, PCC3A/PCC 3B can be stopped if required from Control room
operation.(This is from existing Scada)

TRIPPING SEQUENCE

1. CBC1 Fault tripping or by any of the various safety switch like, PCS, BSS, ZSS will trip
that conveyor followed by Vibratory Feeder stopping immediately to avoid unwanted
collection of materials on conveyor.

While the downstream conveyors upto the last loading point will run to clear the
materials upto the loading point.

2. Incase operation of PCC 3A/PCC 3B stopped on fault or stopped due to any sequence
Fault. The stop command will stop the conveyor CBC-1 and feeder immediately.

EMG STOP

In case of Emg Stop of conveyor, The conveyors and system must stop working
immediately.

LOCAL MODE
In case of Local mode, conveyors will be operated manually by Local Push Button Station
in field.
 OPERATING PRINCIPLE & CONTROL PHILOSOPHY

WRITE – UP FOR DRY FOG DS SYSTEM

OPERATING PRINCIPLE: Dry Fog System:

(Refer P & I Diagram for Dry Fog Dust Suppression System)

1 Ball float type valve at the inlet of the tank to control the water level inside the tank.
a) High Level Switch (HLS) LS-SW-1A for water level “HIGH” signal to control
panel,

b) Permissible Level Switch (PLS) LS-SW-1B signal to control panel that water
level goes below Permissible Level will give command to make up valve open and
filter the tank

c) Low Level Switch (LLS) LS-SW-1C which will operate only when Tank water
level is low and will stop the DFDS Pump and also give alarm that water level
“LOW”.

d) Provided necessary DRAIN & OVERFLOW connection in the water tank. In

the Pump House Duplex Filter in the pump Inlet is provoded so that pump
always sucks clean water and DP switch in the Duplex Filter will provide give
the command that Filter clogged / choked, This command will be required to
change the stand by filter.

e) In the Pump House Pump for DFDS system is provided with Gate valve at the
Inlet and Non Return Valve, Pressure Relief Valve, Compound Gauge &
Pressure Gauge and Pressure Switch at the outlet of the Pump.

f) Pump operation can be manually from Pump House from Local Push Button
Station or from PLC located in the Control Room.

g) The DFDS system at each location in each building/Junction Towers (AP-1 to

AP-5) is controlled by Solenoid valve (SV), Pressure Switch (PS)
 h) The Compressor installed in the Pump House will supply compressed air to the
DFDS system Air Receiver (installed outside the Pump House). The
Compressor shall be operated locally from Local Control Panel & from
Remote.after selection of Local/Remote Selector switch AUTO operation by
PLC will Start from PLC in Control Room.

CONTROL PHILOSOPHY OF DFDS System

1. DFDS Pump-1A will “START” when

The water pumps can be started from LPBS manually (in Local mode) or From
PLC (in Remote mode) under the following conditions:
□ Overload relay O/L is not operated.
□ The Low level switch (LLS) not operated (i.e. water level not “LOW” in the water
tank).
□ Emergency Stop push button is not operated.

2. DFDS Pump will stop when

□ Low level switch (LLS) is operated (i.e. water level “LOW” in the Tank).
□ Emergency Stop push button is operated.

3. DFDS Pump-1A will TRIP when

□ Overload relay O/L is operated.

□ Water level in Reservoir is 'LOW / .Emergency Stop Push Button is pressed.
□ Pressure Switch PS-1 (at outlet of Pump DS-1A) activated
i.e. Pump Discharge Pressure is below the set Pressure with a time delay of 60
seconds. If discharge pressure is still not healthy the pump will trip.
CONTROL PHILOSOPHY OF DFDS SYSTEM AT TT-01 & TAIL
PULLEY/HOPPER

TT-01: Application Point:AP-1

FCU- 01 will be automatically energized when:-

□ Compressed air pressure “HEALTHY” signal from Air Pressure Switch PS-AR-3
& water Pressure switch PS-DFDS-1A
□ Conveyor CBC-01 running
□ Position signal is received from flap gate that material is flowing into PCC-3A
□ Selector Switch selected in “AUTO” mode.

FCU- 01 shall be manually energized when:-

□ Selector Switch selected in “MANUAL” mode.

TT - 01: Application Point: AP-2

FCU- 02 shall be automatically energized when:-

□ Compressed air pressure “HEALTHY” signal from Air Pressure Switch PS-
AR-3 & water Pressure switch PS-DFDS-1A
□ Conveyor CBC-01 running
□ Position signal from flap gate that material is flowing into PCC-3B
□ Selector Switch selected in “AUTO” mode.

FCU- 2 shall be manually energized when:-

□ Selector Switch selected in “MANUAL” mode.

TT - 01: Application Point: AP-3

FCU- 03 will be automatically energized when:-

□ Compressed air pressure “HEALTHY” signal from Air Pressure Switch PS-
AR-3 & water Pressure switch PS-DFDS-1A
□ Conveyor CBC-01 running
□ feeder is in operation(running condition)
□ Selector Switch selected in “AUTO” mode in PLC

FCU- 03 will be manually energized when:-

□ Selector Switch selected in “MANUAL” mode

Tail Pulley/Hopper: Application Point: AP-4

FCU- 04 will be automatically energized when:-

□ Compressed air pressure “HEALTHY” signal from Air Pressure Switch PS-
AR-3 & water Pressure switch PS-DFDS-1A
□ Conveyor CBC-01 is running
□ Open Position signal from Rack and Pinion Gate in either Hopper
□ Selector Switch selected in “AUTO” mode.

FCU- 04 will be manually energized when:-

□ Selector Switch selected in “MANUAL” mode.

Hopper: Application Point:AP-5

FCU- 05 will be energized when:-

□ Compressed air pressure “HEALTHY” signal from Air Pressure Switch PS-
AR-3 & water Pressure switch PS-DFDS-1A
□ Local Push Button is pushed to turn on DFDS system nozzles on hopper inlet and
when pay loader is dumping the material in hopper.