BHS O&M Manual Vol - 1 - English Version

TAN SON NHAT INTERNATIONAL AIRPORT
BAGGAGE HANDLING SYSTEM

BHS SYSTEM INTRODUCTION
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© Inter Roller Engineering Limited

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Copyright © Inter Roller Engineering Limited 2007. All Rights Reserved.
Transmittal, reproduction, dissemination and/or editing of this document as well as utilization of its contents
and communication thereof to others without express authorization are prohibited. Offenders will be held
liable for payment of damages. All rights created by patent grant or registration of a utility model or design
patent are reserved. In case the contractual agreement allows the customer to change the document such
changes shall be clearly highlighted and shall name the person changing the document. In any case Inter
Roller Engineering Limited is not liable for any amendments or changes in the document and any possible
consequences there from.
All trademarks and registered trademarks are the property of the respective owners. The use of registered
names, trade names, description of goods etc. in this document, even if not specially identified as such,
does not imply that such names may be regarded as free in the sense of legislation pertaining to registered
trademarks and the protection of trademarks and may therefore be used by anyone.
Responsible for the contents

Inter Roller Engineering Limited
Singapore

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TABLE OF CONTENTS
Page
TABLE OF CONTENTS................................................................................................................................................ 3
1. REVISIONS................................................................................................................................................................. 5
2. PREFACE.................................................................................................................................................................... 6
2.1 DOCUMENT OBJECTIVE ............................................................................................................................................ 6
2.2 AUDIENCE ................................................................................................................................................................ 6
3. ABBREVIATION ....................................................................................................................................................... 7
4. BAGGAGE HANDLING SYSTEM OVERVIEW .................................................................................................. 8
4.1 OVERVIEW ................................................................................................................................................................ 8
4.2 PASSENGER HANDLING CAPACITY .......................................................................................................................... 10
4.3 SYSTEM FLOW DECSRIPTION ................................................................................................................................... 10
4.3.1 System Flow for Check-in Baggage ............................................................................................................... 10
4.3.2 System Flow for Arrival Baggage .................................................................................................................. 12
4.3.3 System Flow for Transfer Baggage ................................................................................................................ 12
4.3.4 System Flow for Early Baggage..................................................................................................................... 12
4.4 FALL BACK MODE ................................................................................................................................................... 12
4.5 BAGGAGE CHARACTERISTICS ................................................................................................................................. 13
4.5.1 Normal Baggage ............................................................................................................................................ 13
4.5.2 Oversize Baggage........................................................................................................................................... 13
4.5.3 Cargo ............................................................................................................................................................. 13
4.5.4 Non-Acceptable .............................................................................................................................................. 13
4.5.5 Tub Usage ...................................................................................................................................................... 13
5. SYSTEM MAIN COMPONENTS INTRODUCTION.......................................................................................... 14
5.1 MECHANICAL CONVEYOR SYSTEM ........................................................................................................................ 14
5.1.1 Check-in weighing conveyor .......................................................................................................................... 14
5.1.2 ABS 950 Baggage Weighing Scale................................................................................................................. 14
5.1.3 Check-in Dispatch Conveyor ......................................................................................................................... 14
5.1.4 Transport Conveyor ....................................................................................................................................... 15
5.1.5 Queuing Conveyor ......................................................................................................................................... 15
5.1.6 Power Curves................................................................................................................................................. 16
5.1.7 Arrival and Make-up Carousels ..................................................................................................................... 16
5.1.8 45 Degrees Merge Conveyor.......................................................................................................................... 16
5.1.9 Single-plow Diverter ...................................................................................................................................... 16
5.2 CONVEYOR PLC CONTROL AND AUXILIARY SYSTEM ............................................................................................ 17
5.2.1 Conveyor PLC Control System ...................................................................................................................... 17
5.2.2 Auxiliary Systems ........................................................................................................................................... 18
5.2.2.1 Closed Circuit Television (CCTV)............................................................................................................................. 18
5.2.2.2 BHS Intercom............................................................................................................................................................. 21
5.3 HIGH LEVEL CONTROL SYSTEM: MAINTENANCE AND DIAGNOSTICS SYSTEM (MDS) AND SORT ALLOCATION
COMPUTER SYSTEM (SAC).......................................................................................................................................... 23
5.3.1 Maintenance and Diagnostics System (MDS) ................................................................................................ 23
5.3.2 Sort Allocation Computer System (SAC)........................................................................................................ 24
5.4 TILT TRAY SORTER SYSTEM (TTS)........................................................................................................................ 24
5.4.1 General Description....................................................................................................................................... 24
5.4.2 Description of Sorter...................................................................................................................................... 24
5.4.3 Description of Induction System, Discharge Chute and Bag Tag Reader...................................................... 24
6. SYSTEM APPLICATION & SAFETY .................................................................................................................. 24

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6.1 APPLICATION, IMPROPER USE, MIS-USE ................................................................................................................... 24

6.1.1 Application ..................................................................................................................................................... 24
6.1.2 Improper use .................................................................................................................................................. 24
6.1.3 Mis-use ........................................................................................................................................................... 24
6.2 SAFETY ................................................................................................................................................................... 24
6.2.1 General Safety................................................................................................................................................ 24
6.2.2 Objectives....................................................................................................................................................... 24
6.2.3 Operation and Maintenance Personnel ......................................................................................................... 24
6.2.4 Safety Devices ................................................................................................................................................ 24
6.2.5 Safety instruction on conveyor system............................................................................................................ 24
6.2.5.1 Operational safety instruction .................................................................................................................................... 24
6.2.5.2 Precautions to be taken in case of manual retrieval of baggage items........................................................................ 24
6.2.5.3 Prerequisites for operation.......................................................................................................................................... 24
6.2.5.4 Protective Clothing..................................................................................................................................................... 24
6.2.5.5 Retrofitting and Modification..................................................................................................................................... 24
6.2.5.6 Spare Parts.................................................................................................................................................................. 24
6.2.6 Safety Regulations.......................................................................................................................................... 24
6.2.6.1 General Safety Regulation.......................................................................................................................................... 24
6.2.6.2 Specific Safety Regulations........................................................................................................................................ 24
6.2.7 Cleaning Machinery....................................................................................................................................... 24
6.2.8 Safety Summary.............................................................................................................................................. 24
7. GENERAL START UP AND SHUTDOWN PROCEDURES.............................................................................. 24
7.1 INTRODUCTION ....................................................................................................................................................... 24
7.2 CASE 1: SORTER IS RUNNING .................................................................................................................................. 24
7.2.1 Starting of Sorter System................................................................................................................................ 24
7.2.2 Starting of Departure System - 01.................................................................................................................. 24
7.2.3 Starting of Departure system -02 ................................................................................................................... 24
7.2.6 Starting of No-read, (NR1) Transfer (TR1) and Early baggage (ER1) system .............................................. 24
7.2.7 Starting of No-read, (NR2) Transfer (TR2) and Early baggage (ER2) system .............................................. 24
7.3 CASE 2: SORTER IS NOT RUNNING ..................................................................................................................... 24
7.4 STARTING OF ARRIVAL SYSTEM .............................................................................................................................. 24
7.5 SHUT-DOWN PROCEDURES ...................................................................................................................................... 24
8. GENERAL MAINTENANCE INSTRUCTIONS .................................................................................................. 24
8.1 GENERAL ............................................................................................................................................................... 24
8.2 GUIDELINES FOR A PREVENTIVE MAINTENANCE PROGRAMME................................................................................ 24
8.2.1 Daily informal programme............................................................................................................................. 24
8.2.2 Periodic program ........................................................................................................................................... 24
9. LIMITED WARRANTY .......................................................................................................................................... 24

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1. REVISIONS
Rev. Issues Date Init. Description
0 00 24-Apr-07 Revised format

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2. PREFACE
2.1 DOCUMENT OBJECTIVE
This document “BHS System Introduction”, Provides the General information of the BHS system.
2.2 AUDIENCE
1. Operation and Maintenance Operators

2. Control Room Operators

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3. ABBREVIATION
1. BHS Baggage Handling System

2. CCS Conveyor Control System
3. CI Check-in System
4. CT Check-in Take-away / Check-in Transport System
5. DCS Departure Control System
6. ETA Estimated Time of Arrival
7. ETD Estimated Time of Departure
8. FDS Functional Design Specifications
9. FIDS Flight Information Display System
10. FIFO First-In First-Out
11. FSD Fire Shutter Door
12. GUI Graphical User Interface
13. HBS Hold Baggage Screening
14. HLC High Level Control System
15. IATA International Air Transport Association
16. IB Inbound Race track (Reclaim / Arrival Carousel)
17. IRBS Inter-Roller Integrated Baggage System
18. MBR Main Bag Room
19. MCP Main Control Panel
20. MDS Maintenance Diagnostic System
21. MSB Main Switch Board
22. OS Over-Size
23. OWS Operator Workstation
24. PEC Photo Electric Cell
25. PLC Programmable Logic Controller
26. RT Racetrack (Make-up carousel)
27. SAC Sortation Allocation Computer
28. SCADA Supervision Control & Data Acquisition
29. STD Scheduled Time of Departure
30. TCP/IP Transmission Control Protocol / Internet Protocol
31. UIN Unique Identification Number
32. UPS Uninterruptible Power Supply

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4. BAGGAGE HANDLING SYSTEM OVERVIEW
4.1 OVERVIEW
The Tan Son Nhat International Airport Baggage Handling System consists of an integrated Departure
and Transfer System as well as a stand alone Arrival System. The operation of the Departure and
Transfer System is controlled from the BHS Central Control Room (CCR) which is located at the ground
floor in the baggage handling area. The operational status of the Arrival System is fully monitored from
the CCR.
The Check-in Islands are located at the second floor level of the terminal building. There is a total of
four check-in islands, each comprising two collecting conveyors with twenty check-in counters making
for a total of eighty check-in counters for the Departure System. Check-in is available on an anytime-
anywhere basis, twenty-four (24) hours a day, 365 days per year. Over-height and over-length baggage
are detected by sensors installed at the collecting conveyors with alarm indications both at the check-in
positions and BHS CCR. Initiation of the over-height or over-length alarm automatically stops the
collecting conveyor until the alarm is removed and reset.
The baggage handling area is located at the ground floor level of the terminal building and comprises
one Tilt-tray Sorter, four inclined make-up carousels and two breakdown conveyors for transfer and
early baggage. Six units of flat arrival claim carousels are also located at the ground floor level.

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System Overview

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4.2 PASSENGER HANDLING CAPACITY
The Departure and Arrival Systems are each capable of handling 1,780 passengers per hour with an
average of 1.5 bags per passenger. Total annual passenger (arrivals, departures, transfers) handling
capacity is 6,973,000 passengers
4.3 SYSTEM FLOW DECSRIPTION
4.3.1 System Flow for Check-in Baggage
The check-in baggage tag is an IATA License Plate with a 10-digit barcode for automatic baggage
sorting. The baggage is labelled at the weighing conveyor and is conveyed to the dispatch conveyor
where it is automatically inducted onto the collecting conveyor. The tipping roller assists in properly
loading the baggage from the dispatch conveyor to the collecting conveyor by tipping over the baggage.
The baggage is then conveyed to the Customs Inspection Area to be scanned by an off-line x-ray
machine. If the baggage is rejected by this customs inspection, the inspector at the x-ray machine will
activate the single-plow diverter to divert the baggage to the visual inspection room to be manually
inspected by the inspectors. Cleared baggage will pass the Customs Inspection and continue on its way
via the transport conveyors to the tilt-tray sorter. All departing baggage including transfer baggage are
conveyed from the transport conveyor lines the induction conveyors adjacent to the tilt-tray sorter to be
sorted to the allocated make-up carousel or to the Early Baggage Storage facilities at the ground floor
level. Induction scanners installed below the induction units read tags on the underside of baggage to
identify the baggage for sorting. Baggage with tags that are not read by the induction scanners will also
be inducted into the tilt-tray sorter and be scanned by an overhead sorter scanner. ‘No-read’ baggage is
injected by the tilt-tray sorter to ‘No-read’ lines NR1 or NR2 each with one enclosed air-conditioned
Manual Encoding Booth manned by personnel who will manually encode the baggage using handheld
scanners or by manual key coding and then send the baggage on its way back to the tilt-tray sorter for
sorting to the allocated make-up carousel.
Departure baggage is manually loaded onto dollies parked alongside the make-up carousels to be
transported to the respective aircraft.

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Departure System

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4.3.2 System Flow for Arrival Baggage
Arrival baggage is transported by the dollies from the aircraft to the breakdown position for the allocated
Arrival Conveyor where it is manually loaded to be conveyed to the Arrival Carousel at the baggage
claim area.
Arrival System
4.3.3 System Flow for Transfer Baggage
International-to-international and international-to-domestic transfer baggage are transported to the

nearest Manual Coding Station at one of the two Transfer Lines TR1 or TR2 to be manually encoded
and then conveyed to the tilt-tray sorter for sorting to the allocated make-up carousel.
International-to-domestic transfer passengers are required to collect their baggage at the claim
carousels and pass through immigration and customs before proceeding to the domestic terminal.
Transfer baggage arriving before the opening time of the connecting flight make-up will be kept on the
dollies within the departure baggage handling area or stored at one of the two Early Bag Storage areas.
4.3.4 System Flow for Early Baggage
In accordance to the make-up open information displayed on the Allocation Monitor Terminals mounted
on the Early Bag Storage racks, the early baggage stored in the Early Bag Storage racks are manually
discharged and loaded to the nearest Transfer Line TR1 or TR2 to be manually encoded and then
conveyed to the tilt-tray sorter. The early bag storage racks are able to accommodate 30 bags as well
as over-size baggage.
4.4 FALL BACK MODE
There are a total of four main conveyor lines, each main conveyor line serving one check-in island.
Each main conveyor line also has a dedicated fallback conveyor line leading to its make-up carousel. In
case of tilt-tray sorter failure, the single-plow diverter at each of the main conveyor lines will divert the
baggage to their fallback conveyor line. The over-conveyors at the fallback conveyor lines enable the
baggage to bypass the tilt-tray sorter and be conveyed directly to the make-up carousels.

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4.5 BAGGAGE CHARACTERISTICS
4.5.1 Normal Baggage
Acceptable normal size baggage by the BHS conveyor system shall be maximum of 1000 mm x 750
mm x 600 mm in dimensions and maximum and average weight shall be 50 kg and 25 kg per bag
respectively. The minimum acceptable size shall be 250 mm x 100 mm x 50 mm and weight shall be 2
kg per bag.
The categories of acceptable baggage shall include as a minimum suitcases in plastics, leather,
aluminium, and cloth, rucksacks, travel bags, hold-all suit bags, boxes and/or trunks in cardboard,
wood, steel and aluminium.
4.5.2 Oversize Baggage
Over-size baggage exceeding the above size but with weight below or within the airline check-in limit
may be handled by use of elevator or lift and shall not be transported by the BHS.
4.5.3 Cargo
Over-size baggage exceeding the above categories and rejected overweight baggage shall be handled
as freight cargo.
4.5.4 Non-Acceptable
Non-Acceptable baggage items are:
3. Round, cylindrical or oval items

4. Items larger or smaller than specified (dimensions and weight)
5. Items with straps or other loose strings and soft fabric bags
6. Items with gluey surface
7. Items with wheels turning downward etc.
8. Items wrapped in loose packing or with an unstable shape (i.e. the shape of the item changes at
e.g. acceleration and deceleration).
9. Tool boxes
10. Baby seats and push chairs
4.5.5 Tub Usage
Tubs are to be used to handle the following baggage items:
1. Round, cylindrical or oval items

2. Items with straps or other loose strings and soft fabric bags
3. Items wrapped in loose packing or with an unstable shape (i.e. the shape of the item changes at
e.g. acceleration and deceleration).
4. Tool boxes
5. Baby seats and push chairs

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5. SYSTEM MAIN COMPONENTS INTRODUCTION
5.1 MECHANICAL CONVEYOR SYSTEM
5.1.1 Check-in weighing conveyor
Each check-in weighing conveyor is equipped with an integrated weighing scale. The check-in weighing
conveyor is inclusive of the frame, belt and side guards are mounted directly on top of the weighing
scale. The conveyor weight is permanently balanced within the weighing system to provide zero
indication when the conveyor is not loaded with baggage.
The check-in weighing conveyors are portable and rail mounted, allowing the units to be easily removed
and/or serviced.
General Specifications
Manufacturer : Inter-Roller Engineering Ltd
Belt Type : Flexam Ex 8/2 0+A20 Black As FR
Belt Width : 600 mm.
Belt Manufacturer : Ammeraal Beltech
Motorized Drive Pulley : Dia 138 x 550 Roller Length
End Roller : Dia 76.6 x 550 Roller Length
Snub Roller : Dia 60 x 600 Roller Length
5.1.2 ABS 950 Baggage Weighing Scale
The Baggage Weighing scale consists of an electronic weighing platform mounted to form an integral
part of the weighing system. The weighing platform is connected to a weighing controller unit with 2
displays -- one for the operator and another for the passenger.
The weight is displayed on two display panels visible to both the passengers and the operator. Pressing
the ‘Add Total’ button once on the check-in control station will add the displayed weight to memory (the
‘Total LED will illuminate momentarily, indicating that the total has been updated).
Manufacturer : Atrax Group
Type : Single frame with 4 load cells
Style : With conveyor
Capacity : 300 kg
Resolution : 0.1 kg, 0.2 kg, 0.5 kg.
Accuracy : ± 0.05 kg
5.1.3 Check-in Dispatch Conveyor
The check-in dispatch conveyor is installed between the weighing conveyor and the collecting conveyor.
The baggage is labelled on the weighing conveyor before it is conveyed to the induction conveyor. The
induction conveyor provides the queuing and indexing function to facilitate the discharge of baggage to
the collecting conveyor.
Manufacturer : Inter-Roller Engineering Ltd.
Belt : Flexam Ex 8/2 0+A20 Black As FR
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Belt Width : 6050 mm.

Motorized Drive Pulley : Dia 138 x 670 Roller Length
End Roller : Dia 76.6 x 550 Roller Length
Snub Roller : Dia 89.5 x 670 Roller Length
5.1.4 Transport Conveyor
Baggage from Induction conveyors are conveyed via the Transport conveyors to the sorting racetracks
or the Tilt-tray sorters and distributed to the departing aircraft.
Belt Type (Horizontal Conveyors) : Flexam Ex 10/2 0+05 Black M2 As FR
Belt Type (Inclined Conveyors) : Flexam Ex 8/2 0+A42 Black As FR
Belt Width : 950 mm
Motor : Sumitomo Heavy Industries
Drive Pulley : Crown-faced with Rubber Lagging
Head / Tail Pulley : Crown-faced
Take-up Pulley : Crown-faced
Snub Pulley : Flat faced, Welded construction
Return Rollers : 60 mm Diameter
Bearings : Synthetic Nitrile Rubber Seal,
One-piece Gray Cast Iron Housing
Incline / Decline conveyors : Same configuration as level
Slope of belt < 18 degree.
5.1.5 Queuing Conveyor
The queuing conveyor facilitates the queuing of baggage.

Motor : 0.75 kW with Inverter and Brake
Belt : Flexam Ex 10/2 0+A42 Black M2 As FR
Belt Width : 950 mm
Belt Manufacturer : Ammeraal
Drive Pulley : Dia 165 x 960 RL
Crown-faced with Rubber Lagging
End Pulleys : Dia 114 x 880 RL
Take-up Pulley : Dia 140 x 960 Crown Face
Snub Pulley : Dia 102 x 960 RL
Bearings : Synthetic Nitrile Rubber Seal

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5.1.6 Power Curves

The power curve conveys baggage through curves whilst maintaining a continuous baggage flow.
The belt speed of the power curve is measured at the centre of the curve and matches the speed of the
adjacent conveyor.
Manufacturer : Transnorm System
Motor : Sumitomo Heavy Industries
Belt : Transilon E12/2 U0/V6 GSTR-C-SE
Belt Width : 1,000 mm
Belt Manufacturer : Siegling Belting
Centerline Radius : 1500 mm
Pulley : Tapered
5.1.7 Arrival and Make-up Carousels
Inclined make-up carousel is constructed of articulating contoured slats of flights forming a continuous,
sloped rotating surface to receive bags directly from the feeding conveyors. The baggage moving on
this loop is manually transferred to dollies.
Drive : Friction Drive
Motor : 2 x 2.2 kW
Sumitomo Heavy Industries
Width of Rubber Slat (Make Up) : 1400mm
Useable Pallet width (Claim) : 1000mm
Chain : Die-cast Aluminium Moulded Block
Chain pitch : 250 mm
5.1.8 45 Degrees Merge Conveyor
The 45 deg merge conveyor is designed to merge baggage flow smoothly from an in feed line to the
transport conveyor and racetrack.
Motor Manufacturer : Sumitomo Heavy Industries
Motor : 2.2 kW with Inverter and Brake
Belt : Transilon E12/2 0/U2 MT-C-SE Black
Conveyor Length : 1500 mm
5.1.9 Single-plow Diverter
The single-plow diverter is used for diverting baggage from the horizontal conveyor to adjacent
conveyors or ball transfer tables.
Manufacturer : Inter Roller Engineering Ltd,
Motor Manufacturer : Sumitomo Heavy Industries

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Motor : 0.75 kW for Arm Belt

0.75 kW for Swing Drive
Divert angle : 45o
Belt : Flexam 2XO 265 A42 FR
Belt Width : 250 mm
5.2 CONVEYOR PLC CONTROL AND AUXILIARY SYSTEM
5.2.1 Conveyor PLC Control System
Overall operation and control of the BHS will be achieved by using a fully integrated system of
Computers, Programmable Logic Controllers (PLC) and electro-mechanical hardware.
The control system is a network of PLCs constructed to provide the physical control of the conveyors,
co-ordination of other functions like merge, and monitoring and reporting occurrences and emergency
conditions to MDS, while the MDS & SAC provide the commands and display the operational status of
the system.
The control system design is based on the multiple PLCs interconnected to each other by industrial
standard communication highways.
The PLC consists of a Central Processor Unit (CPU), Power Supply Unit (PSU), Communication
modules, Interface modules, Input and Output modules.
Remote I/O cards will be used at various field locations to simplify the wiring and are connected to the
PLC through the PLC Field bus card (PFC). Typical PLC configuration is shown below:
PSU CPU Ethernet
Field bus
PFC INPUT OUTPUT

TCP/IP Switch
PFC INPUT OUTPUT
To Remote Box

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The PLC control grouping is arrived based on the layout, subsystem control and the complexity and the
number of the conveyors lines.
The primary function of the PLC is to control all conveyors and receipt and response to the computers,
including:
Emergency stop reaction
Baggage jam detection
Auto-stop and start-up routines
Cascade control
Manual coding Interfaces
Baggage tracking in Manual coding line
Feedback to the SAC & MDS computers
The system can be operated in basic two modes namely Auto and Manual mode. In Auto mode all the
conveyors will be automatically controlled by the PLC by initiating a one-button command. In Manual
mode, the conveyors are controlled individually by the PLC by switching on the two position Toggle
switch (with clear On/Off identification positions) inside the MCP.
In Manual mode Emergency stop interlocks operate to protect personnel and equipment from damage.
However in Manual mode, the interlocks between the conveyors of the system will not be operable as it
is the responsibility of the operator to monitor this. It is envisaged that the Manual mode is used for
Maintenance purposes.
In Auto mode it is the responsibility of the operator to clear all alarms and interlock violations before
initiating the start. The system will start the equipment in the pre-programmed reverse cascade
sequence after checking all the start permissive is met.
5.2.2 Auxiliary Systems
5.2.2.1 Closed Circuit Television (CCTV)
The purpose of the CCTV system incorporated in Tan Son Nhat International Airport Terminal is to
monitor the entire BHS operation.
There are total of 17 digital CCTV cameras. Cameras will be deployed particularly to paid attention
at critical operational and potential problem areas as approved CCTV layout drawings JV-T-BHS-
6701 and JV-T-BHS-6702. There are 04 Indoor PTZ dome Cameras at Check-in area and 13
Indoor Fixed Cameras in the main Baggage Handling Area at Ground floor.
A total of 04 TFT (19” size) monitors are located in the BHS control room to provide visualization of
the system. The CCTV monitors are controlled independently of one another (i.e. views selected for
each monitor independently).
The CCTV cameras are of digital and allow for zoom and pan within the field of view (for dome
cameras only). In order to control 17 camera/ 4 Monitor, the control have the final capacity to
provide camera selections, 4 monitor selections, run, hold, next camera, pan/tilt joystick, zoom,
focus, iris, extender in/out, camera alarm on/off, monitor alarm on/off, programme time/date.
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The configuration of the CCTV system for Baggage Handling System as follow:
CCTV Configuration for BHS

(The photos are for illustration only)
The CCTV Rack layout is as below:

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EQUIPMENT LIST
Camera & CCTV Monitor:
No Description Quantity Manufacturer

1 Indoor Fixed Colour camera 13 pc Sanyo
2 Indoor Dome camera PTZ 04 pc Sanyo
3 Matrix switcher 01 pc Sanyo
4 Joystick control keyboard 02 pc Sanyo
5 19” TFT Monitor 04 pc Sanyo
DVD recorder, Printer, CCTV Rack:
No Description Quantity Manufacturer

1 16 channel DVR (Each DVR connects with 02 pc Sanyo
maximum 16 cameras.)
2 Desktop Computer 01 pc HP
3 Desktop Computer Monitor 17” 01 pc HP
4 Colour Photo Printer 01 pc HP
5 CCTV Rack 42U 01 pc HP
5.2.2.2 BHS Intercom
The push dial type intercom system is provided between the BHS CCR and each principal operation
area for the exclusive use of the BHS. The BHS Intercom System can also be used as a loudspeaker
system for announcements within the BHS area.

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BHS Intercom Configuration
Intercom Station Employment
There are total of 12 intercom stations. Intercoms will be deployed at principal operational areas as
indicated in the tender drawings. One Intercom is located at the control room and other 11 intercoms at
various locations as indicated in our Intercom layout drawings.
Intercom exchange consists of a power supply board, a fan, a processor board, and 03 subscriber line
boards (expandable up to 6). With 03 subscriber line boards, the system provides 18 subscribers and
03 speech channels.
Intercom station includes the following features:

• 10 Programmable Single touch keys
• Handset
• 2X16 character alphanumeric display providing caller identification
• Private / open switch for choosing between direct incoming calls and announcement
• 1W speaker
• Volume control

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5.3 HIGH LEVEL CONTROL SYSTEM: MAINTENANCE AND DIAGNOSTICS SYSTEM (MDS) AND
SORT ALLOCATION COMPUTER SYSTEM (SAC)
5.3.1 Maintenance and Diagnostics System (MDS)
The Maintenance and Diagnostics System (MDS) is used to monitor the various devices, equipments as
well as the operation of the entire Baggage Handling System (BHS). This includes, but is not limited to,
the conveyors, the tilt-tray sorter, the Programmable Logic Controllers (PLCs), as well as the various
network devices. Besides this, reports that detail the various faults and events that have occurred in the
BHS can be generated on the MDS when required.
The diagram below shows the Overview Screen of the MDS. The Overview Screen is used as the main
monitoring and controlling interface of the TSN-BHS. Displayed in the Main Area is the status for the
Arrival Lines, Departure Lines, Check-In Lines, Transfer Lines and Tilt-Tray Sorter in the Tan Son Nhat
International Airport BHS System.
MDS Overview Screen
The MDS comprises the MDS IO Server, database storage and operator workstations. The PLC System
and Printer are interconnected with the MDS by an integrated Local Area Network. The Local Area
Network also integrates closely with the information system of the customer such as master clock.
Based on the standardised design and implementation concept, the system offers a very clear system

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structure, which is fundamental both for efficient operation and maintenance. The general concept
therefore is in terms of the system a hierarchical architecture (MDS System Configuration Diagram
below):

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MDS system Configuration Diagram
5.3.2 Sort Allocation Computer System (SAC)
The schematic system architecture and network structure is depicted in below figure which shows the
hierarchical levels of the control system. On the top level the interface to the airport Host computers are
visualised.
The BHS level computers handle the daily operation of the system and include the workstations, the SAC
computer, and the MDS computer. Daily operation is solely performed from the workstations (OWS, MES
and EBS/MES) by means of keyboard, mouse and hand held bar code scanners.
The lower level consists of a number of PLC’s controlling the conveyors and the sorter. Via interfaces
FIDS
FIS ECS CUTE
Frame / BagLink /
NTP
SAC-FIS SAC-BSI (RP1745)
OWS
Frame /
SAC-OWS
SAC Frame / MES
SAC-MES
HTTP RFC 1006 /
AMT
ManualEncoding
RFC 1006 /
RFC 1006 /
FKI-CMC5-SAC
ItemTracking
Frame /
LS Citect
PLC PLC
SCADA conveyor
sorter RFC 1006 / Citect S7
FKI-CMC5-SCADA
Red text/underlined: not

BMS
within IR's scope of supply
information is exchanges between lower level and BHS level.
The main functions of the SAC and the related workstations are:
• Communication with the Host computers, Work stations and the PLC’s
• Handling of operator controlled planning of the allocations

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• Data server for the sorter control computers and PLC systems
• Collection of data regarding sorting statistics
• User authorisation manager
• Time server for the BHS
On the basis of information from the Airport Computers and flight allocation table in the SAC, the SAC will
control the logistic-part of the sorting flow in co-operation with the MDS machine control functions as well as
the PLC systems.
The SAC functions are established on a powerful server, which also includes the SAC database and the
communication tasks. The SAC handles the database, including data inquiries and updates from relevant
systems and operators. The SAC forms a link between the Airport Host Computers and the sorter/conveyor
control system. The SAC is based on Windows 2003 server application with an Oracle database.
The SAC functions are operated from the Workstations (OWS, MES, EBS/MES), used for presentation and
manipulation of the database information via the SAC. These machines run the user interface of the SAC.
The SAC consists of two identical servers (Master and Standby machine) running in a “Cluster Pack” with a
“hot” standby facility. Further, in order not to lose data in the event of failure, the SAC has redundant disks
running in RAID 1 configuration.
In case of a critical error the SAC switches from Master to Standby machine. The switch-over to the
Standby server is done automatically and takes up to 120 seconds.
In addition, the SAC computers have a CD/DVD back-up solution for further back-up of software and data.
Functions are built in for easy back-up/restore operations.
The SAC major functions are as follows:
EBS MES function
The EBS MES function is used for handling both transfer and EBS baggage, which needs to be identified
and sorted to a discharge.
The EBS Manual Encoding refers to the process whereby manual handling of EBS baggage is performed.
This includes manually identifying bags in the EBS area, encoding the tags using a hand held scanner, and
inserting the bags on the conveyor line for sorting to a discharge.
Allocation Monitor Terminal (AMT)
The AMT is a project specific functionality, which will be an add-on to the system. The AMT has no user
interface as it is used for information purposes only. The AMT will at any time show what is stored in the
EBS storage.
Flight Alloc Open time No. Bags Other EBS

SQ113 17-04 11:35 3 1
SQ114 SQ112 12:05 M T CPH
17-040800 1 0
SQ115 SQ112
17-040800 6
14:00 M T CPH 0
SQ116 17-04 14:35 10 3
SQ118 17-04 18:00 5 0
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AMT information: The AMT shows the following flight and baggage properties:
• Flight (a concatenation of the Airline identifier and Flight number)
• Allocation open time
• Number of bags currently in the EBS for this flight
• Number of bags currently in the other EBS for this flight
Time and location: Flights are shown when there is baggage in the EBS for a specific flight. The background
colour of the flight indicates the state of the allocation (open/closed). When all baggage for a flight has been
removed from the EBS, the line stays on the screen for 5 minutes after the last bag was removed. This
helps the operator keeping track of when all bags have been removed for a specific flight.
The MES Station
This function is used for handling no-read and other problem baggage, which needs to be identified and
handled correctly. The following features exist in the Manual Encoding product:
• Identification of license plate on the bag using hand scanner or typing using keyboard.
• Send to flight (actually send to allocation, through choice of flight).
• Send to discharge
• Send to problem bag discharge
In case of the SAC is down, it will still be possible to send bags to
discharge from the MES. Sorting destination is sent directly to the PLC for
the conveyor in this case.

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Departure Allocation
The Departure Allocation view is the view used during daily operation.
Departure allocation supplies the functions for creating, viewing and updating allocation of resources
(discharges) to flights and functions. A flight can be allocated to multiple discharges and each allocation can
be set up to match certain fine-grained criteria based on class, destination and transfer for the baggage.
Also functions can be created and allocated for special handling of too early, rush and too late baggage.
The user interface is based on a graphical Gantt chart, which view supplies a strong visual overview of the
resource allocation and the state of the flights currently being handled.
Allocations are automatically kept updated through FIDS interface given changes in departure times.
Template Planning (Master Flight Plan)
Templates for departure allocations can be created in LIBS-Enterprise. These templates can then be
assigned to production days into the future. Based on the assigned templates the system automatically
creates allocations when flight data from FIS is received. Templates are grouped by the operator and relate
to a certain weekday.

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Reporting
The system has several standard reports for operations (utilisation and baggage related reports) and
maintenance (equipment statistics and status reports).
The following reports are provided: (Some contents of the reports depends on information coming from the
PLC-system).
• Baggage per discharge report
• Baggage per flight report
• Baggage time distribution report
• Baggage trace report
• Departure allocation list report
• Flight reconciliation report
• MES utilisation report
• Track error rate report
Data from reports can be exported to various formats for instance, CSV, HTML and Text.

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Interface Monitoring
The operator can monitor details for the FIDS and Bag Message interfaces. This includes information on:
• Number of correct telegrams
• Number of error telegrams
• Total number of telegrams (correct telegrams + error telegrams)
For each of the above mentioned groups the numbers are given since last connection establishment, during
the last hour, and the timestamp for the last telegram.
Also an error log is given that contains the timestamp and an error description of the last 100 error
telegrams. The error telegrams themselves can also be viewed.

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Security
The system utilizes a strict security policy for controlling which users are allowed to operate specific tasks
and functions. This is done by applying profiles to users.
The following is a listing of profiles present
Profile Functions Computers

Allocation Planner Template Manager OWS
Template Editor
Backup Operator Backup and Restore All
Computer System Security Manager OWS
Administrator
Manual Encoder Manual Encoding MES
Process Analyst Report Viewer OWS
Production Superviser Airline Reference Data OWS
BHS Configuration
Departure Allocation
Monitor Interfaces Connections
Monitor Interfaces Details (FIS and BagMessage)
A user, e.g. a Manual Encoder, is required to log in using a standard Windows login prompt before being
able to operate the Manual Encoding Station.

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5.4 TILT TRAY SORTER SYSTEM (TTS)
5.4.1 General Description
The Tilt-tray sorter system consists of four induction units with 90° automatic tag readers (ATR), a single
270° sorter scanner and the S3000M tilt-tray sorter. The bags convey to the induction units randomly, and
the induction units synchronize the bag with the tilt-tray sorter to induct the bags precisely onto the free
trays of the tilt-tray sorter.
The tilt-tray sorter consists of a carriage system of carts, which are equipped with tilting devices and trays. It
conveys bags to predetermined discharge chutes. The conveyance takes place with one bag on one tray.
When the occupied trays arrive at their destination, they are activated to tilt, and the bag slides into the
discharge. The tilting of trays is completely controlled and guided, partly by the tilting device, on which the tray is
mounted, partly by the shifting device, which activates the tilting device. The shifting devices are incorporated in
the sorting machine at each discharge. The tilting devices, which can tilt to either side, are provided with a built-
in locking device, which is active in the two extreme positions - horizontal and tilted. Tracking of trays as well as
activation of the shifting devices at the discharges are controlled and supervised by the electronic control
system.
The induction scanners are located below the induction units and read tags that are facing down. The single
overhead sorter scanner consists of a portal of individual scanner heads that automatically read tags that
are not facing down.
Tilt Tray Sorter System Layout

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General Specifications of Tilt-tray Sorter:

Type: S3000M
Tray Width: 1000 mm
Pitch: 1250 mm (Distance between the centers of two adjacent tilt-trays)
Speed: 1.8 m/sec
Sorter Capacity: (5184 trays/hour)
5.4.2 Description of Sorter
The machine frame, which is assembled on site, consists of prefabricated modules containing guide rails for
the carts with tilting devices. Mounting flanges are provided for shifting devices and for safety
netting/guarding. The machine frame also has built-in cable trays.
The carts are internally connected with a ball link that allows vertical and horizontal movement. Each cart is
equipped with carrying wheels, which travel in the rails of the module frames.
Furthermore, each cart is equipped with a code plate, which provides unambiguous tracking of the cart. The
code plate is also used to control the velocity. The code plates are read by code readers distributed in an
adequate number on the sorter loop.
To facilitate inspection and service, each cart is equipped with detachable covers. The top covers also serve
the purpose of preventing product parts from falling into the sorter.
The shifting devices making the trays tilt at the discharge are mounted on a suspension, which allows
horizontal adjustment in relation to the discharge.
On each suspension one or two opposing shifting devices and a code reader can be mounted. The shifting
devices have sensors supervising the activation and reset function.
Tilted trays are automatically realigned by means of preset return devices.
The carts are driven by one or more linear motor driving units placed in the machine frame. The linear
motors function as the stator part in a normal electric motor whereas the passing carts function as the rotor
part. In relation to the carts, the linear motor is vertically adjustable which allows optimising of the force field.
The drive units can be built into the machine frame at the most convenient place. The number of drive units
required depends on the length of the sorter loop and its velocity.
The sorting machine is in its entire length equipped with easily detachable bottom covers and cart covers,
which allow easy access for service and inspection.

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Sorter
Sorter Parts:
Pos.1: Tray
Pos.2: Tilting device
Pos.3: Cart
Pos.4: Shifting device
Pos.5: Code plate

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Cart
The cart consists of the following main components:

Pos. 1 Cart frame
Pos. 2 Carrying wheel
Pos. 3 Ball and socket joint
Pos. 4 Flange
Pos. 5 Guide wheel
Pos. 6 Code plate
The carts are joined by guiding the ball-and-socket joint into the fork on the flange of the next cart. Then a
fitted bolt is put through the ball-and-socket joint and screwed into the flange. This constitutes an endless
train of carts that can move both horizontally and vertically.
In order to secure a low noise level, the carrying wheels are equipped with bandages of synthetic material.
Tray

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The trays carry the encoded bags to the discharges.

The trays are made of beech plywood and fixed to the tilting device by means of 4 countersunk screws.
Dimensions of Tray: 1000 mm wide x 1135 mm long x 13.5 mm thick.
Distance between the edges of two adjacent tilt-trays: 115 mm
Tilting Devices
The tilting device carries the tray and tilts when the device is activated by the shifting device.
The tilting device consists of the following main components:

Pos.1: Fixed body part connected to the cart
Pos.2: Top part, which can tilt to either side
Pos.3: Activation arm for the tilt movement
Pos.4: Centre Shaft
Shifting Devices
The shifting device activates the tilting device on a signal from the electronic control.

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The shifting device consists of the following main components:

Pos.1: Curve body
Pos.2: Electromagnet
Pos.3: Angular grip piece
Pos.4: Wedge
Pos.5: Torsion spring
Pos.6: Inductive sensor
Pos.7: Locking pin.
When the shifting device is neutral, the wedge (Pos.4) is in the inner position, allowing the tilting device to
pass without activation. When the electromagnet (Pos.2) is activated, the locking pin (Pos.7) moves and the
spring (Pos.5) swing out the wedge (Pos.4). Thus the activation arm of the tilting device is set in its rail for
the tilt movement. The catch device (Pos.3) serves the purpose of keeping the activation arm in its rail
during the tilt movement. Reset of the wedges into the original neutral position is carried out by the
activation arm. If the shifting device fails, the inductive sensor (Pos. 6) transmits a signal to the controller.
Driving System
The driving system drives the carts on the sorter at the required velocity.

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The driving system consists of the following main components:

Pos.1: Cart
Pos.2: Linear motor
Pos.3: Power box
The driving system comprises a linear motor (Pos. 2), which functions as stator part and is mounted to the
machine frame by means of the suspension. The rotor part is the carts (Pos. 1).
The linear motors are mounted in the machine frame at the best possible places. The number depends on
the length of the sorter and its velocity. The power box contains:
Circuit breaker and contactor for motor supply
Communication net adaptor with remote I/O points
Power supply unit 240 VAC with circuit breaker
Terminal strips
Tracking System
The tracking system is an electro-mechanical system, which registers the positions of the carts and
transmits the information to the control system
The code system consists of the following main components:

Pos. 1 Clock pulse unit
Pos. 2 Code plate on the carts
Pos. 3 Suspension
The code plate that is attached to each cart has a hole pattern which divides the cart in a number of pulses.
The code plate is also used for control of the velocity of the sorter.
Safety guarding
There are 02 kinds of safety guarding: steel guarding and netting.

The safety guarding consists of steel guarding and/or netting and/or the posts where the guarding and/or
nets are fastened.

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Steel guarding
Pos. 1 Rail post guarding for net
Pos. 2 Steel guarding, straight Pos. 3 Posts for guarding
Height of side-guard from top of tilt-tray: Approximately 270 mm
Netting
Pos.1: Rail post guarding for net

Pos.2: Net, straight
Material of Netting: Black Nylon Rope Mesh Size: 40mmx40mm
5.4.3 Description of Induction System, Discharge Chute and Bag Tag Reader
Induction System
The purpose of the induction stations is to make a precise induction of bags onto free trays on a Tilt-Tray
sorting machine. The bags arrive to the induction randomly, and the induction synchronises the bag with the
sorting machine.
The airport induction unit basically consists of separation belt, induction belts, and transition belt as
illustrated below.

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1. Separation belt 3. Induction belt 2

2. Induction belt 1 4. Transition belt
Baggage flow across induction:

Bags are conveyed to the induction station oriented in the length direction by means of a supply belt
conveyor. The separation belt provides for a suitable spacing between the bags coming from the supply
system, but also ensures that only one bag at a time is conveyed to the subsequent induction belts. On this
belt the position and the length of the bag are measured by means of a photocell.
As the bag moves at a constant speed towards the first and second induction belt, the control system
searches for a free tray on the Tilt-Tray sorting machine. As soon as a free tray is allocated, the starting
time for acceleration of the second induction belt is calculated. Based on this calculation the bag is brought
to a complete stop on the second induction belt until the time for acceleration. The bag is accelerated with a
fixed acceleration characteristic. When the bag is transferred to the transition belt, the speed will be relative
to the speed of the sorting machine. The transition belt runs at constant speed and functions as transport
means only between induction belts and sorting machine. The transition belt inducts the bag onto the
allocated tray.
The induction consists of an open frame constructed of specially designed aluminium profiles, which are
bolted to a rigid construction. The aluminium profiles are designed mainly from a mechanical point of view.
The open frame construction allows for easy maintenance access. Due to the aluminium profiles the
induction frame itself is not painted. The complete induction unit is designed as one unit including all
electrical cabling, motors, frequency inverters, contactors, I/O modules, etc.
Inside the aluminium frame, each belt is connected to a motor, a sliding plate beneath the belt and drums.
The individual belt modules consist of belts that are clamped between a driving drum and a reversing drum.
The belt can both serve as a split belt and a conventional flat belt of full width. The split belt can be used
when the belt width is larger than the belt length. Due to its shape, the transition belt always consists of a
split belt. An AC motor separately drives each belt module. Power transmission from the AC motor to the
driving drum is established via timing belt and pulleys. The timing belt is screened by a cover. This low-
noise belt transmission requires only little maintenance. For safety reasons, transition rails are mounted
between the belts. Below an induction belt module with its main components is illustrated.

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1. Reversing drum 5. Tension roller for timing belt

2. Drive drum 6. Motor cover
3. Belt, black, antistatic 7. Motor and frequency inverter
4. Timing belt, Power Grip
Electrical components
All electrical components required to run the induction are placed on the induction. Distributed I/O modules
are placed in a power box. These I/O modules communicate with the central PLC that executes the overall
control of both the Tilt-Tray sorting machine, chutes and induction units. Beside the power box, an operation
panel is placed in a separate box (can be located on the induction according to customer wishes).
In order to ensure an exact delivery of the bag on the sorter tray, a fast response digital frequency converter
drives each motor so that the acceleration/deceleration of the belts can be controlled and adjusted from the
Crisplant Machine Controller (CMC). A high-speed network is also used. The CMC controls the induction of
baggage and the sorting process.
The induction is equipped with an operation panel containing lamps, start/stop, push buttons and
emergency push buttons from which the induction can be operated. For example when 'item too long' errors
occur, the bag in question will be stopped on the induction belts, and the error lamp will be turned on. The
bag must be removed, and then the error must be acknowledged on the reset push button.
Discharge Chute
The transition chute is used to make a safe transfer of bags from the Tilt-Tray sorter to the belt conveyors at
floor level. The chute is made of painted mild steel plates of 2.5 mm thickness. Each chute is equipped with
a jam photocell.
Automatic Bag Tag Reader
Laser scanners are used for reading the standard baggage tags and fallback sortation tags. The scanner
system is divided in two parts:
Sorter scanners (270 degrees)

Induction scanners (90 degrees) located below the induction conveyors.
Sorter scanner: After the last induction (in a group) a portal of scanner heads will be mounted on/around the
sorter trays. The portal consists of a number of individual scanner heads working together. One or more of

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the heads will read tags not facing down. The system includes a controlling unit with the software needed to
integrate the different readings. The portal arrangement includes a transmitting unit communicating with the
CMC in question via the local PLC-controller.
Induction Scanner: Two-line scanners are mounted in each of the sorter induction stations to read bar codes
facing down. The system includes a controlling unit with the software needed to integrate the different
readings. The arrangement includes a transmitting unit communicating with the CMC in question via the
local PLC-controller.

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6. SYSTEM APPLICATION & SAFETY
6.1 APPLICATION, IMPROPER USE, MIS-USE
6.1.1 Application
This system is designed only for the transporting of baggage. Any other use not in accordance with the
designated application must be avoided. Stepping or riding on the transport system is forbidden.
Inter-Roller accepts no liability for any damage or malfunction arising from misuse of the system. The user
must bear and be responsible for such risks. Only trained personnel are allowed to operate the system.
For safety reasons, do not alter or modify the system without consulting Inter-Roller.
6.1.2 Improper use
It is important to use this system according to the instructions. Any improper use may cause the following:
• Damage to the system
• Unnecessary down-time and cost.
• Reduce the lifespan of components or parts.
Improper use of the system is defined as:

• Use of the system which is not in accordance with the instructions.
• Operating the system with safety devices disabled.
• Improper start-up and operating of the system.
• Safety devices or safety protection not installed properly according to instructions and
procedures.
• Unauthorised changes or modifications of system by third party.
• Incompetent repair by unauthorised third party.
6.1.3 Mis-use
• Stepping on or riding on transporting conveyors is forbidden.

• Setting foot on, walking across sensors or over components is forbidden whether the
system is in operation or stationary.
• Any infringement of the safety procedures must be reported immediately to the
technical officer or supervisor in-charge.
For a safe and reliable system, the system shall be inspected, maintained
and operated by professionally trained personnel.

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6.2 SAFETY
6.2.1 General Safety
The following symbols and/or warnings are used in the documentation to indicate instructions of particular
importance
Note! Note refers to technical features and to methods for facilitating work.
CAUTION! CAUTION indicates procedures to be followed in order to prevent material

damage to assemblies, the system or other material assets of the user.
WARNING! WARNING indicates procedures that must be exactly followed in order to

prevent injuries to persons.
This also includes the CAUTION warning.
All persons before involving with the start up,

inspection, operation or maintenance of this
system must read and follow all instructions
given in this manual carefully.
To achieve a safe and trouble-free operation of
this system, it is very important that all personnel
involved must have a good knowledge of the
applicable safety instructions and regulations.
This manual contains important instructions for
the safe operation of the system.
Recommendations and regulations relating to
accident prevention at site should be followed
accordingly
Only trained personal is allowed to operate and

service the conveyor system.

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6.2.2 Objectives
The Safety Policy is based on the conviction that the well-being of who works on the system must be one of
the major considerations in all operations. People are the most important asset, and their safety is one of
the greatest responsibilities.
Note!
6.2.3 Operation and Maintenance Personnel
Note! Only persons who have successfully completed a relevant course of

training may be permitted to operate the conveyors or modules.
Basic knowledge of the other specialized areas must be sufficient to permit simple jobs (e.g. disconnection/
reconnection of electrical motors by mechanical maintenance personnel) to be carried out without
assistance.
If several persons work on one conveyor or module, there must be a clear definition of who is responsible
for each individual task. Safety aspects require that there be no uncertainty with regard to authority for the
performance of specific tasks.
6.2.4 Safety Devices
A conveyor or module may only be operated if all protective and safety-related devices such as e.g.
emergency-stop devices are in place and fully functional.
Under no circumstances may safety devices be removed, rendered non-functional or their functionality
impaired. Any manipulation of the safety devices will result in the following risks:
1. Serious injury

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2. Danger to life
3. Material damage to the conveyor or module
WARNING! Do not remove side guards, railings or safety devices!
WARNING! Secure the machine against reactivation when carrying out any
maintenance and/or repair work.
6.2.5 Safety instruction on conveyor system
6.2.5.1 Operational safety instruction
WARNING! The safety devices of the conveyor system must not be taken out of
operation or abused.
WARNING! The system must only be used for the predefined purpose.
The individual machines and modules are designated exclusively for the
transport and sorting of passenger hold baggage in accordance with the
conditions laid down in the purchasing agreement. The performances of
the machines and/ or modules are specified in the technical data of the
maintenance manuals
Guarantee according to contract is only valid when the instructions for
operation and maintenance are observed.
CAUTION! Do not load items outside the design specifications of: Dimension, Weight,
Form, Texture, Presentation, etc.

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WARNING! Do not climb or step on moving conveyors!
WARNING! look appropriate CAUTION, DANGER or WARNING signs to get alert to

hazards
Note! Use of the equipment for any other purpose must be regarded as being
outside the limits of the designated use
The risk of such misuse lies entirely in the user
Designated usage of the machinery also includes observation of the
instructions contained in the operator’s and maintenance manuals, and
compliance with the specified inspection and maintenance intervals

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WARNING! Before start of the system all personal must be at proper distance from it.
The area around the system must be kept free from any hindrances.
WARNING! You are not allowed to sit, step, walk or run on the system. Avoid
overloading the system.
WARNING! Keep clothes, hair and body parts away from the system and do not alter
the covers and safety devices.

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WARNING! Note the location of start/stop and control units and keep them free of any
hindrances.
WARNING! Do not point handheld scanners at others. Avoid looking into handheld
scanners.
6.2.5.2 Precautions to be taken in case of manual retrieval of baggage items
This is applicable in the case of a system breakdown and a longer recovery period is experienced. If the
situation demands, the bags that were already under transport should be retrieved from the BHS. This
activity should be properly coordinated between all concerned parties. The following precautions are to be
taken:
Personnel should not wear loose vests and/ or

other clothing that is not tightly secured to their
bodies.

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The complete area should be isolated by use of

the Emergency Stop Push Button.
For additional safety, the respective electrical

panel shall be switched off.
The affected/working area, from where the bags

are being retrieved, should be properly
barricaded to avoid trespass of unauthorized
personnel.
Proper ladders, if required, are to be adequately

secured to the BHS supporting structure or other
available stable supporting structure shall be
used.
Properly built mobile scaffold platforms, placed

on a level ground, with wheels adequately
secured, shall be used if required.

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Personnel should use safety harnesses, if they

have to work on heights.
Personnel should be aware of the dangers when

they are retrieving bags from areas where BHS
components are in operation.
After the activity has been completed, one

should ensure that all personnel have been
evacuated from the area. Only after re-
confirmation should the System should be re-
energized and started.
6.2.5.3 Prerequisites for operation
The user agrees to operate machinery only when it is in safe working condition. This requires the individual
conveyors and modules to be cleaned, maintained and repaired according to specification. Any changes
occurring in the individual conveyors or modules that impair safety must be remedied immediately.
The intervals for regular tests and inspections must be observed. Information on inspection and
maintenance is contained in the appropriate maintenance manuals.
All safety devices fitted must be checked regularly in accordance with the inspection intervals specified in
the Maintenance Schedule Section of the appropriate maintenance manual.

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Maintenance manuals for the individual conveyors or modules must be kept permanently at the relevant
positions of installation and made available to the operating and maintenance personnel.
All safety instructions and hazard warnings attached to the conveyor or module must be kept in a legible
condition and must not be removed.
The user must provide the necessary protective equipment for the personnel. In addition, the user is
required to ensure that personnel use the necessary protective equipment properly.
6.2.5.4 Protective Clothing
Personnel must wear close-fitting clothing to prevent accidents. No ties, rings or chains, which could get
caught in moving machine parts, should be worn. Long hair should be covered by suitable headgear.
WARNING! Keep clothing, hair, hands and other parts away from the conveyor!
Use close-fitting clothing!
It is recommended that operating and maintenance personnel wear the following protective clothing:
Eye Protection
Unbreakable protective glasses with closed sides must be worn during all
drilling, grinding and cutting work. Swarf thrown off can lead to severe eye
injuries.
Protective goggles or face-shields are also to be used during welding.
Gloves
Protective gloves with rubber surfaces must be used when working with
cleaning agents.
Ear Protection
Continuous exposure to loud noise results in damage to hearing. Ear protection
must be worn during grinding and cutting work. Do not remove noise protection
devices.

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Shoes
Safety shoes with steel caps must be worn to prevent feet from being crushed.
Safety Helmet
A safety helmet must always be worn if there is a danger of head injury, in
particular when performing overhead assembly or disassembly work and when
working with a crane.
6.2.5.5 Retrofitting and Modification
The individual conveyors and modules should not be modified, converted or receive any additions. This is
also valid for the installation and adjustment of safety devices and safety valves and for welding performed
on load-bearing parts of the conveyors and modules.
6.2.5.6 Spare Parts
Spare parts must comply with the technical requirements specified. This is always ensured by the use of
original spare parts.
6.2.6 Safety Regulations
6.2.6.1 General Safety Regulation
The operator’s manual, and in particular the section on SAFETY, must be read and fully understood before
any work is carried out on or with the machine.
If any safety-related changes or functional faults occur on a conveyor or module, the relevant conveyor or
module is to be immediately shut down and secured. Report the fault to the department or person
responsible, and have the fault remedied immediately.
CAUTION! Report all damages concerning safety to your supervisor!

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Refrain from any method of work that might prejudice safety.

Ensure that a conveyor or module endangers nobody before switching on or starting up any machinery.
WARNING! Make sure that nobody is in the conveyor, or working on them,
before switch it on!
WARNING! Never modify the software of programmable control systems that affect the
machine’s safety.
Keep the operator stations and any equipment access routes free from tools, auxiliary materials and other
objects. Make sure that the working areas at and around the conveyors and modules are clean and tidy.
CAUTION! Do not block the area surrounding the conveyor!

Keep the access and escape route free!
Always make sure that any safety instructions and warnings attached to the conveyors or modules are
complete and perfectly legible.
Note! The safety keys for:
1. Electrical switch boxes

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2. Control cabinets
3. Terminal boxes
4. Access doors or safety-relevant equipment
May only be kept by persons who have successfully completed the
requisite training and who are authorized to perform work on these devices
Do not operate electrical limit switches, or any other elements or actuators involved in the control process
without proper knowledge. The consequences could be personal injury or damage to the conveyor or
module.
Personnel must check for the presence of moving parts and their range of movement before performing any
work or observations in the danger zone of any conveyor or module. Ensure a safe escape rout from the
danger zone.
Always make absolutely sure that nobody is within the danger area of the relevant machinery before putting
any conveyor or module back into operation.
6.2.6.2 Specific Safety Regulations
WARNING! Most elements of the baggage system normally operate fully

automatically and thus can be set into motion without warning at any
time.
The following safety precautions must always be taken before starting maintenance and repair work:
1. Switch off the conveyor or module (see operator’s manual)
2. Pull out the disconnect plug to the unit, switch off the main switch and secure against
accidental activation with a safety lock in Position 0
3. If applicable, switch off any external electrical circuits
4. Where necessary, seal off a wide area around the maintenance point and set-up warning
signs.
5. The Emergency Stop Push Button should be pushed, and the button-head should be left
'pushed-in' to avoid accidental re-start.
WARNING! Personnel should be aware of the 'energy save' mode of the BHS. This
means that the System, even though it appears to be non-operational in
this mode, can be re-started by any (manual) interventions on the field
devices, such as proximity switches, photo cells etc.
WARNING! During repair work, make absolutely sure that:

1. The machine is disabled
2. All electrical power is switched off
CAUTION! When replacing larger assemblies, attach them carefully and securely to
lifting gear

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CAUTION! Always use the specified ladders and working platforms, or safe alternative
equipment, when carrying out overhead assembly work
CAUTION! Never use machine parts as a climbing aid.
CAUTION! Wear a safety harness when carrying out maintenance work at greater
heights.
CAUTION! Keep all handles, steps, handrails, platforms, landings and ladders free
from dirt and lubricants.
Keep all handles, steps, handrails, platforms, landings and ladders free from dirt and lubricants.
The General Accident Prevention Rules have top priority. These additional measures represent a
supplement hereto.
Trained and authorized personnel who must observe the safety regulations may only enter the baggage
system at specified entrances.
All direction and warning signs must be observed.
In case of danger, a unit or system can be stopped immediately using the emergency-stop button.
Walking on moving transport elements is prohibited.

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Operation in maintenance mode may only be carried out by maintenance personnel.
The power supply must be switched off before any work is carried out on equipment or system elements.
The main switch has to be secured with a safety lock to ensure that it cannot be switched on again while the
work is being performed.
Control and display elements must be tested before commencing operation and continuously watched
during operation. Inform maintenance personnel of any deviations from normal
Take care when using cranes or other types of lifting gear. Never walk or stand underneath a suspended
load.
Maintenance openings or access hatches must be secured against accidental closure.
Maintenance openings covered with grids and opened for maintenance purposes must be specially
protected and clearly marked.
Maintenance openings must be closed immediately after finishing work.

Unauthorized repairs or alterations to system elements of the baggage handling system by operating
personnel are prohibited.

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Opening of switch-boxes, fuse boxes, terminal boxes, operator panels, input terminals, printers, etc. by the
operator is prohibited. Authorized maintenance personnel may only perform this.
If abnormal noises occur during the operation of individual system elements, the emergency-stop button
must be pressed immediately and maintenance personnel informed.
If the insulation of electrical cables is damaged, the equipment must be switched off immediately. The
maintenance personnel must be informed. Warning signs have to be placed to mark the area as potentially
hazardous. Under no circumstances are the cables to be touched or moved.
Maintenance work must be very visibly and clearly marked at all times to avoid any accidents.
6.2.7 Cleaning Machinery
Regular cleaning of all machinery and electrical sensors (e.g. photocells, reflectors etc.) is an important part
of maintenance work. In addition to regular scheduled cleaning, always clean equipment – particularly those
units standing in the open – after sandstorms or in conditions of high humidity coupled with low night time
temperatures.
Do not use any substances, which are corrosive or injurious to health, or environmental pollutants such as
chlorinated hydrocarbons (perchloroethylene, Trike).
CAUTION! Under no circumstances should general cleaning be carried out with

steam jets, high-pressure water jets or compressed air as this can
cause dirt and cleaning agents to penetrate the bearings and seals.
This will result, at the least, in considerable shortening of the service
life of the relevant module and can lead to immediate destruction of
some components.
Make sure that cleaning agents are disposed of in accordance with local environmental regulations.
6.2.8 Safety Summary

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7. GENERAL START UP AND SHUTDOWN PROCEDURES
7.1 INTRODUCTION
The Departure System of Baggage Handling System is well designed to start and operate by following two
methods taking into consideration of the condition of Tilt tray sorter system (hereinafter called Sorter).
Case 1: All the sub-systems are healthy

Case 2: Fall back scenario when all the other sub-systems are healthy except Sorter
But operation of the Arrival System (A1 to A6) doesn’t depend on the Sorter system and also can able to
start and stop separately, irrespective of Sorter operation.
Normally, all the sub-systems are started from MDS. When the MDS is faulty, the sub-systems may be
started from the individual control panels.
When any sub-system is started and if no bags are detected for a continuous period of time usually 15
minutes (time can be adjusted during testing), the conveyors will automatically stop.
7.2 CASE 1: SORTER IS RUNNING
If the Sorter system is in READY condition and able to run, the Operator must choose the following step-by-
step procedure to start the entire BHS control system in defined sequence manner;
7.2.1 Starting of Sorter System
1. Start and Run the Sorter system.

2. Before starting the individual sub-systems ensure that the sorter is running.
3. Based on SAC flight allocation, start the required departure system 1, 2, 3 & 4.

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7.2.2 Starting of Departure System - 01
Step-01: Keep the plough diverter (L1D-40) in “Retract” position. If it is not, then divert the plough to the
“Retract” position.
Step-02: Start Check-in (L1) sub system and following conveyor line will start to run automatically in reverse
cascade manner (from downstream to upstream);
1. Make-up carousel (M1) will start to run.
2. Sorter to Make-up carousel conveyor line (SM1) will start to run in reverse cascade manner from
conveyor SM1-05 to SM1-02.
3. Departure Conveyor line (L1D) will start to run in reverse cascade manner from conveyor L1D-43 to L1D-
23.
4. Check-in Conveyor line (L1) will start to run in reverse cascade manner from Conveyor L1-22 to L1-03.

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7.2.3 Starting of Departure system -02
29.

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29.

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23.

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7.2.6 Starting of No-read, (NR1) Transfer (TR1) and Early baggage (ER1) system
Start No-read line (NR1) sub system and following conveyor line will start to run automatically in reverse
Step-01: No read conveyor line (NR1) will start to run in reverse cascade manner from conveyor NR1-24 to
NR1-02.
Step-02: Transfer baggage conveyor line (TR1) will start to run in reverse cascade manner from Conveyor
TR1-08 to TR1-01.
Step-03: Early baggage conveyor line (ER1) will start to run in reverse cascade manner from conveyor
ER1-06 to ER1-02.
7.2.7 Starting of No-read, (NR2) Transfer (TR2) and Early baggage (ER2) system
Start No-read line (NR2) sub system and following conveyor line will start to run automatically in reverse
Step-01: No read conveyor line (NR2) will start to run in reverse cascade manner from conveyor NR2-21 to
NR2-02.
Step-02: Transfer baggage conveyor line (TR2) will start to run in reverse cascade manner from Conveyor
TR2-08 to TR2-01.
Step-03: Early baggage conveyor line (ER2) will start to run in reverse cascade manner from conveyor
ER2-05 to ER2-02.

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7.3 CASE 2: SORTER IS NOT RUNNING
If the Sorter system is NOT READY and in FAULT mode, the Operator should avoid the Sorter system and
choose the following step-by-step procedure to start the BHS system in defined sequence manner;
Based on SAC flight allocation, start the required departure system 1, 2, 3 & 4. As the sorter is faulty, no-
read lines (NR), transfer lines (TR) & early baggage lines (ER) need not be started. Those bags have to be
manually handled.
Step-01: Keep the plough diverter (L1D-40) in “Extended” position. If it is not, then divert the plough to the
“Extended” position.
1. Make-up carousel conveyor (M1) will start to run alone.
2. Sorter to Make-up carousel conveyor line (SM1) will start to run in reverse cascade manner from the
conveyors SM1-05, SM1-04 & SM1-03.
3. Backup conveyor line (L1B) will start to run in reverse cascade manner from conveyor L1B-110 to L1B-
101.
23.

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1. Make-up carousel conveyor (M2) will start to run.
2. Make-up carousel conveyor line (SM2) will start to run in reverse cascade manner from the conveyors
SM2-05, SM2-04 & SM2-03.
101.
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SM3-05, SM3-04 & SM3-03.
101.
29.

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SM4-05, SM4-04 & SM4-03.
101.
23.

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7.4 STARTING OF ARRIVAL SYSTEM
Start Arrival subsystem (A1 to A6) individually according to the requirement and the respective carousel &
conveyor line will start to run automatically in reverse cascade manner (from downstream to upstream).
Arrival Carousel A1:

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7.5 SHUT-DOWN PROCEDURES
System Shut-down Procedure via Main Control Panels
1. Press ‘Stop’ push button on the Main Control Panel.

2. When the system does not detect any bag on a conveyor in a pre-defined time, the conveyors
would be shut down in a cascade manner i.e. from the up-stream conveyors. i.e. Power Save Stop.
3. Once all the conveyors stop, the ‘Start’ pilot light at both the Main Control Panel and the check-in
Control Panel would be extinguished.
Shutdown Procedure via Maintenance Diagnostic System (MDS)
1. Select the appropriate system stop button on the MDS menu. Click ‘Stop’ button.
2. MDS would prompt for confirmation.
3. Click ‘Yes’ button.
4. Selected Sub-system graphic display would turn to steady Cyan colour when system is successfully
stopped.

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8. GENERAL MAINTENANCE INSTRUCTIONS
8.1 GENERAL
Maintenance is defined as those activities that must be carried out according to the given check lists.
Additional activities, such as replacement of defective components are considered as repairs. Repair
activities may need higher levels of skill and qualifications. Before carrying out any maintenance, ensure
that the conveyor must be turned off and the surrounding area must be cleared and closed.
To ensure proper maintenance, follow the maintenance instructions for each of the conveyors accordingly.
8.2 GUIDELINES FOR A PREVENTIVE MAINTENANCE PROGRAMME
8.2.1 Daily informal programme

A well-qualified maintenance staff should be selected to start and / or walk the entire system. His
responsibility will be to inspect and log all possible malfunctions by unit number. This not only sets an
accurate “fix up” programme but gives supervisors a daily record of the system capability.
Specifically he should:
1. Observe all belt conveyors while the units are running. Check for proper belt tracking, i.e.
belt running true and centred on the conveyors. Make sure belts are not excessively tight.
Belts should be just tight enough to prevent slippage between the belt and the drive
pulley under full load.
2. Observe if any belt is damage. This could be caused by interference or jams. Check take-
up assemblies to assure the pulley is not in either extreme position.
3. Listen for any excessive noise from bearings, reducer, motor and rollers.
4. Check geared motor for oil leaks.
In addition to the daily tour, all persons working in the conveyor areas should be instructed to report any
obvious or suspected excessive conveyor wear or malfunction.
8.2.2 Periodic program

This programme is an enlargement of the daily programme to include all procedures and steps of daily
programme, plus the preparation of an inspection check sheet for all power operated equipment (motor).
The checklists accomplished through this programme are best considered to be a permanent record. One
reason for this event is that every failure can be traced back to improper or neglected maintenance.
The maintenance people are responsible for performing detailed scheduled maintenance on all conveyors
at least once every six months. This includes cleaning, lubricating, adjusting and repairing all units both
powered and non-powered. This is the second basic function of the general maintenance programme, i.e.
line maintenance.

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9. LIMITED WARRANTY
General
Inter-Roller Engineering Ltd (IREL) warrants that the Work manufactured or supplied shall be free from
defects for a period of not less than twenty-four (24) months from the date of Start of Operation. Any fault
due to design, materials, workmanship or structural faults during the warranty period shall be made good by
IREL at its own expenses which shall include the cost of labour and replacement of parts.
The warranties provided herein shall apply to any repair and rework due to any part or parts found to be
defective within the warranty period (defects liability period). The warranty period covers the time between
start of Staff Training and the Start of Full Operation and twelve (12) months after Start of Full Operation of
the Equipment by Purchaser. This warranty shall not apply with respect to any defects or unsuitability which
are attributable to repair, alteration, misuse or abuses by any persons other than IREL, in non-compliance
with IREL’s defined maintenance procedures. IREL’s liability shall be limited to repairing or replacing
defective or non-performing part or parts at no cost to Purchaser.
IREL warrants that the Equipment shall comply with all relevant statutory provisions including approved
building codes, fire prevention codes, safety codes, etc, of local law, rules and regulations, and all pertinent
statutory provisions issued by any government authorities of the Singapore.
Purchaser’s remedies for defects in the IREL’s System are available only if :
IREL has been notified of the defects within a period of 24 months from the date of signature of the Hand-
Over Certificate
Procedures for Warranty Claims
¾ If the defect required immediate action due to the risk of resultant damage or further damage,
Purchaser can apply any necessary but reasonable measures to prevent or limit the damage and to
notify IREL immediately.
¾ Upon notification of a defect from Purchaser, IREL shall apply such due & proper measures as IREL
may decide to remedy the defect with such speed, as the circumstances required.
¾ A suitable time schedule shall be reached depending on the circumstances between both parties.
¾ Apart from the above, no remedies are available for Purchaser, as well as defects in the IREL’s System
and the IREL failure to remedy defects.
¾ Purchaser’s remedies do neither extend to deficiencies or shortcomings caused by Purchaser’s

negligence or deficiencies which arises after Hand-Over not being caused by the IREL 's negligence,
including but not limited to the following causes:
A. Errors or inaccurate information in drawings or other technical documents, or work supplied

or carried out by Purchaser;
B. Circumstances which have arisen after Hand-Over, such as improper or insufficient

maintenance, incorrect operations, unsuitable storage or inappropriate variations by
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Purchaser, who is obliged to follow all operating and maintenance instructions issued by the
IREL;
C. Improper repairs carried out by Purchaser.
D. Parts not from IREL
¾ The IREL is not liable for business interruption, loss of profit or other indirect costs or losses or any
consequential damages of any nature whatsoever.
¾ Where a third party brings a claim for injury and/or property damage against IREL, Purchaser shall
indemnify IREL against the claim to the extend that the injury or/and damage was not caused by
any breach of obligation attaching to IREL hereunder or by its direct negligence or omissions.

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TAN SON NHAT INTERNATIONAL AIRPORT

BAGGAGE HANDLING SYSTEM

TAN SON NHAT INTERNATIONAL AIRPORT

BHS SYSTEM INTRODUCTION

© Inter Roller Engineering Limited

Copyright © Inter Roller Engineering Limited 2007. All Rights Reserved.

Responsible for the contents

© Inter Roller Engineering Limited

© Inter Roller Engineering Limited

6.1 APPLICATION, IMPROPER USE, MIS-USE ................................................................................................................... 24

© Inter Roller Engineering Limited

© Inter Roller Engineering Limited

2.1 DOCUMENT OBJECTIVE

1. Operation and Maintenance Operators

© Inter Roller Engineering Limited

1. BHS Baggage Handling System

© Inter Roller Engineering Limited

4. BAGGAGE HANDLING SYSTEM OVERVIEW

© Inter Roller Engineering Limited

© Inter Roller Engineering Limited

4.2 PASSENGER HANDLING CAPACITY

4.3 SYSTEM FLOW DECSRIPTION

4.3.1 System Flow for Check-in Baggage

© Inter Roller Engineering Limited

© Inter Roller Engineering Limited

4.3.2 System Flow for Arrival Baggage

4.3.3 System Flow for Transfer Baggage

International-to-international and international-to-domestic transfer baggage are transported to the

4.3.4 System Flow for Early Baggage

4.4 FALL BACK MODE

© Inter Roller Engineering Limited

4.5 BAGGAGE CHARACTERISTICS

4.5.1 Normal Baggage

4.5.2 Oversize Baggage

Non-Acceptable baggage items are:

3. Round, cylindrical or oval items

4.5.5 Tub Usage

Tubs are to be used to handle the following baggage items:

1. Round, cylindrical or oval items

© Inter Roller Engineering Limited

5. SYSTEM MAIN COMPONENTS INTRODUCTION

5.1 MECHANICAL CONVEYOR SYSTEM

5.1.1 Check-in weighing conveyor

5.1.2 ABS 950 Baggage Weighing Scale

5.1.3 Check-in Dispatch Conveyor

Belt Width : 6050 mm.

5.1.4 Transport Conveyor

5.1.5 Queuing Conveyor

The queuing conveyor facilitates the queuing of baggage.

© Inter Roller Engineering Limited

5.1.6 Power Curves

5.1.7 Arrival and Make-up Carousels

5.1.8 45 Degrees Merge Conveyor

5.1.9 Single-plow Diverter

© Inter Roller Engineering Limited

Motor : 0.75 kW for Arm Belt

5.2 CONVEYOR PLC CONTROL AND AUXILIARY SYSTEM

5.2.1 Conveyor PLC Control System

PSU CPU Ethernet

PFC INPUT OUTPUT

PFC INPUT OUTPUT

© Inter Roller Engineering Limited

5.2.2 Auxiliary Systems