FEEDER BREAKER WITH INTEGRATED DOUBLE ROLL CRUSHER:

1.1 Duty Requirements

x Feeder breaker will operate on an average for 15 hours a day

over 330 days per year in general, but the design of the
assemblies/ parts of Roll Crusher should be such that it can be
operated for all the 365 days, for 24 hours per day, if required.

x The Feeder breaker will be operated continuously and therefore,

provision for running and preventive maintenance should be
incorporated in such a way that it can be performed during
operation period. The Roll Crusher shall be mounted on rails so
that it can be shifted sideways easily for maintenance. There
shall be enough room on the Roll Crusher platform for
maintenance.

x The Feeder breaker design should be such that it should be able

to start in the full load condition and choke feeding condition.
x The Feeder breaker is required to operate in high dusty
atmosphere and for this, necessary design measures should be
taken especially for electrical, lubrication and hydraulic
installations.

x Occasionally, ROM feed may contain some metallic pieces of

large size such as excavator teeth and track pads etc. Necessary
protection should be incorporated in the design to take care of
this. Also the Roll Crusher shall be able to be scrolled and
arrangement shall be made to remove tramp metals.

x
 1.2 Operational Parameters, Characteristics and Basic Data

Nominal Crushing capacity (tph) : 400tph

Peak Crushing capacity (tph) : 20% higher than nominal.

Receiving Hopper size (minimum) (t) : 60

1.3 Compliance with Standards

The design, selection, and construction of equipment,

components and material shall conform to relevant Indian
Standard Specifications and Codes of Practice (latest revisions)
or in their absence to equivalent BS/ DIN/ ANSI Standards. Copy
of the relevant standard(s) shall be furnished along with the
drawing.

1.4 FEEDER BREAKER

1.4.1 INTRODUCTION:

The Feeder breaker will be installed at the receiving end of ROM

coal. The coal shall be received by the feeder breaker hopper
through the normally 35t dump trucks.

1.4.2 SCOPE

The scope shall cover design, manufacturing, testing before

dispatch, delivery at site, installation at site. This shall be read in
conjunction with the specifications described below. The scope of
supply shall consist of the following:

Feeder consists of receiving hopper Under carriage chain

conveyor with drive head Single crusher drum Dust suppression
system First fill oil and grease. Maintenance, operation manuals,
spare parts catalogue. Drawing showing the dimensions.
 1.4.3 DUTY

The Feeder breaker will normally operate for 15 to 18 hours in a day

however it will be designed and constructed for round the clock operation.

The equipment shall operate in the range of 4-50 degree

centigrade ambient temperature, up to 100% relative humidity and
dusty environment.

It shall be able to receive coal from the hopper. It shall be able to

start at full load and meet the required duty requirement.

1.4.4 TECHNICAL PARAMETERS FOR DESIGN

i. Rated capacity - 400 tph

ii. Material to be conveyed - ROM coal mixed with shale sand

stone, small quantity of clay, soil

iii. Bulk density of coal - 1.0 t/cum.

iv. Largest lump size/ minimum lump size - (-)1500 to (-) 1200 mm

v. % of largest lump size - 40%

vi. Abrasively of coal - slightly abrasive

vii. Presence of clay - small quantity

viii. Presence of tramp iron - small quantity

ix. Method of feeding to the feeder - from hopper.

x. Receiving hopper capacity - 60t

1.4.5 CONSTRUCTION FEATURES

The feeder breaker shall be robust in construction, requires

minimum head room, requires minimum maintenance gives
uninterrupted operation with minimum down time.

Crushing unit will be skid mounted, low height, semi-mobile type,

consisting of features for primary and secondary crushing with
discharge chute (integral part of Roll Crusher unit, but it can be
easily dismounted for relocation) etc.

The unit shall have a single horizontal crusher drum, for primary
crushing, which is placed on the chain conveyer and integrated
double roll secondary Roll Crusher. Additionally:

Ǧ The feeder breaker should be provided with an automatic

 centralized greased lubrication system to ensure proper, trouble
free running.

Ǧ The crusher drum and the gearbox are coupled through a shear-
head arrangement to prevent excessive load on the gear box;

Ǧ A hydraulic hammer with swivel arm is fitted near the crusher

drum to tackle abnormal size coal lumps;
Ǧ A speed monitor is mounted directly on the shaft on the crusher
drum. The feeder breaker shall have quick starting smooth
stopping feature and shall operate at low noise level. The noise
level shall be under 80 db within one meter of the unit with the
tray empty.

1.4.8 DRIVE UNIT

The Speed variation by VFD controller for achieving variable quantity

discharge will be 40% to 100%. Separate drive units shall be provided for
crusher rolls as well as chain conveyor. Further The crusher drum and
the gearbox are coupled through a shear-head arrangement to prevent
excessive load on the gear box.

1.4.9 MOTOR

The motor shall be squirrel cage, induction motor, foot mounted, high
torque, TEFC enclosure, IP54 protection, DOL starting, continuously
rated, class ‘B’ insulation, synchronous speed 1500 RPM, suitable for
415V, 3 phase 50 Hz supply, suitable to withstand +/- 10% voltage
variation, +/- 3% frequency variation, cable end boxes shall be suitable
for PVC insulated PVC sheathed cables of three core wit copper
conductors of suitable size. The motor shall conform to IS 325, IS 1231.
This shall be of reputed make.
1.5 SPECIFICATION OF ASSOCIATED EQUIPMENT
1.5.1 HOPPER:
The coal receiving hopper of minimum 60 te capacity shall be
constructed by building up side skirts on chain Feeder. Steel plate
sections shall be bolted to feeder sections to build up capacity of the
receiving hopper. Hopper includes suitable rail /structural stiffeners at its
outer side with 16 mm thick MS base plate and 16 mm thick suitable Mn-
steel liners to be fitted with counter sunk bolts.
1.5.2 CHAIN FEEDER
1.5.2.1 Duty
The chain feeder will be of robust construction and extra heavy-duty type.
It will be able to take impact of coal / shale lump size indicated elsewhere
from a height as indicated in Operational Parameters. It will be able to
handle wet material during rainy season without loss of efficiency. The
working place may be quite dusty. Inclination of the Feeder may be up to
20 degree.
1.5.2.2 Operational Parameters

Free fall height : To be kept as minimum as possible.

Feeder size : a) Width between skirts to suit system design.

b) Length between sprocket centers to suit

system design.
i) Capacity (tph) :
a) Nominal : 400 tph
b) Peak : 20% higher than nominal capacity.
c) Lower limit : not less than 50% of nominal capacity.
1.6.5 Drive and Control
The Roll Crusher shall be driven by an AC induction motor of
suitable rating which provides high starting torque for above
mentioned duty conditions. Drive shall be direct type or with
reduction unit of suitable type of gearbox and controlled torque
coupling. Necessary protective devices will be incorporated in the
system to protect the motor from severe surge load resulting from
large piece of tramp iron in the crushing chamber.

The hydraulic lubrication and electro-mechanical controls, which

forms inherent part of the Roll Crusher and its auxiliaries will be in
the scope of supply and will be properly designed to achieve the
desired signaling and protective requirements. The power supply
to the main motor and auxiliary motors will be fed from the CHP
motor control centres. The sequence control and inter-lock of all
auxiliary motors and other protective devices of the Roll Crusher
will also form part of the scope of supply and included in the offer.

Suitable protective devices shall be provided for mechanical

overload. Suitable speed monitor shall also be provided to prevent
damage in the event of jamming and inter locking in case speed
falls below the pre-determined speed.
1.7 Electrical

1.7.1 Motor

The Roll Crusher motor shall be suitable for 6600 V, 3 phase 50hz
supply system with +/-10% voltage variation, complete with cables
boxes with glands, Other LT motors will be suitable for 415V,
3phase, 50Hz supply system with +/-10% voltage variation,
complete with cables boxes with glands. The Motor shall have
high power factor say 0.9 lagging approx. at 75% to 100% full
load and shall have low weight/ kW ratio.
1.7.2 Starter and Control panel :

This shall be adequately rated for the operation of the Roll

Crusher. The control panel shall have the following features and
confirm to relevant IS specifications.
Off-load isolator
Circuit breaker with under voltage release and electrical/ mechanical inter
lock
Interlock with the door for the isolator

1.7.3 Protections
Motor control center
Motor protection relay with over load, earth fault, single phase stall
protection and unbalance condition, solid state.

Cable entry box for incoming and out going entry

Enclosure shall be suitable for outdoor duty dust/ vermin proof and top
canopy as per IS:55.
Space heater shall be provided for motor rating 30 kW and above.
ELETRICAL SPECIFICATION

A. Motor

1. The motor shall be squirrel cage, induction motor, foot mounted, high torque, TEFC enclosure,
IP54 protection, DOL starting, continuously rated, class ‘B’ insulation, synchronous speed
750/1000 RPM, suitable for 415V, 3 phase 50 Hz supply, suitable to withstand +/- 10% voltage
variation, +/- 6% frequency variation, cable end boxes shall be suitable for PVC insulated PVC
sheathed cables of three core wit copper conductors of suitable size. The motor shall conform to
IS 325. This shall be of reputed make.
2. Starter: The starter shall be of push button type with ON and OFF facilities for starting and
stopping locally. The motor will receive power through a MCC.

B. Local Control Station: The inter-locking and selector switch, start stop push buttons and
indication lamps on the local control station shall be mounted on the front face of the enclosure.
The local

C. Selector Switch: All the selector switches shall be dust proof and oil tight, rotary switches with
pistol handle operating facility. The rating of contact shall be minimum 10 amps at 230 Volts. The
switches shall conform to IS: 2628 (latest).

D. Start – Stop Push Buttons: Push buttons shall be dust and oil tight and the face of the button
shall be flushed with the retaining ring. ‘Start’ buttons should be green and stop buttons should
be red in color.

E. Indicating Lamps: The indicating lamps shall be LED type and shall be so fitted that it is
removable from the front of the unit without disturbing the internal wiring and the holder. The
indicating lamps shall conform to relevant IS.

F. Emergency Stop Push Button: All hand operated emergency stop push buttons shall have
mushroom type head, Red in color with manual resetting facility. Emergency stop switches shall
be dust and oil tight with necessary NO and NC contacts rated for 10 Amps. at 230 Volts A.C.

G. Legend Plate: The legend plates shall be provided to identify the rating and function or operation
of all control components/indications. All the legend plates shall be of block anodized aluminium
with text engraved thereon.

H. Push buttons

1. Push buttons shall be spring return, push to actuate type suitable for 240 V AC and 220 V DC.
The push buttons shall have sufficient NO and NC contacts as per requirement. All contact faces
shall be of silver or silver alloy.
2. Every push button shall be provided with integral escutcheon plate marked with its function.
3. The colour of push buttons shall be as follows:
a. GREEN - for motor START breaker CLOSE,
b. BLACK - for all annunciator functions, overload reset and miscellaneous

I. Indicating lamps

1. Indicating lamps shall be of the panel mounting, LED type and capable of clear status indication.
The lamps shall have escutcheon plates marked with their functions, wherever necessary.
2. Lamps shall be of the following colours:
a. RED - for motor ON, breaker OPEN /CLOSED
b. GREEN - for motor OFF, breaker OPEN
c. WHITE - for breaker TRIP
d. BLUE - for all HEALTHY conditions (e.g. control supply, lube oil pressure)
e. AMBER - for all ALARM conditions
J. Indicating instruments

1. All indicating and integrating meters shall be flush mounted on panel front. The instruments shall
have an accuracy class of 2.0 or better.
2. Ammeters for measuring 3 phase current shall be provided for all motors rated 22 kW and above.

K. Name plates and labels

1. Each panel shall be provided with prominent, engraved identification plates for all front mounted
equipment. Panel identification name plates shall be provided at front and rear.
2. All name plates shall be of non-rusting metal with white engraved lettering on black back ground.
Inscription and lettering sizes shall be subject to Purchaser's approval.
3. For easy identification of all equipment inside the panel, they shall be marked with suitable, clear,
indelible paint markings. Labels for fuses shall also clearly indicate current ratings of the
respective fuses.

L. Local Motor Starter

1. The Local Motor Starters shall be provided for manual switching of 415 V, 3 phase squirrel cage
motors.
2. The starters shall be metal enclosed, suitable for outdoor/indoor mounting on wall or steel
structures. The enclosure shall be die-cast aluminium or cold rolled sheet steel of atleast 1.6 mm
thickness. The enclosure shall be provided with a hinged guard at the front, covering full length,
to avoid inadvertent operation of push buttons. The starters shall be painted to shade no. 692 of
IS:5 in accordance with relevant code and shall be dust and vermin proof and shall have a degree
of protection of IP-52 as per relevant code.
3. The Starters shall be suitable for both top and bottom cable entry (either of which may be used
depending on cabling convenience) and shall be provided with removable undrilled gland plates
or knockouts. Adequate space shall be available inside the starter enclosure for terminating
external cables directly on push button terminals. Overall size of Starters shall be subject to
Purchaser’s approval.
4. Each Starter shall comprise of:
a. A 3-pole contactor, mechanically latched type
b. Start Push Button, coloured GREEN
c. Stop Push Button, coloured RED
5. Ambient temperature compensated thermal overload relay with single phasing protection. The
continuously variable relay setting range shall be suitable for the motor rating.
6. The start push button when pressed shall preferably remain in depressed position and shall be
released along the contactor when the stop push button is pressed or when thermal overload
relay operates. Local starters shall be suitable for loop-in and loop-out of incoming cable and for
one outgoing cable to a motor.