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TECHNICAL SPECIFICATION

COAL HANDLING SYSTEM

1.00.00 SCOPE OF WORK

The scope of work under this specification shall include design, manufacture, testing
and inspection at manufacturer’s work, supply, receipt of material, unloading and
storage at site, erection, testing and commissioning of Coal Handling System for the
subject power station including to the following:

1 Track Hopper and its equipment

2 Crushers

3 Vibrating Screens

4 Stacker-cum-Reclaimer

5 Conveyors

6 Traveling trippers

7 Accessories of Coal Handling System (including truck unloading hoppers,


dozers/mobile dust suppression/ extraction system)

8 All electrical works for Coal Handing System

9 All control & Instrumentation for Coal Handling System

10 All civil works for Coal Handling System

11 All other items required to complete the Coal Handling System

2.00.00 DESCRIPTION

2.00.01 As a long term transportation option coal will be transported by rail and received at
site marshalling yard from the nearby SECL coal fields. The coal will be unloaded on
track hopper and fed to the belt conveyor by plough feeders or vibrating feeders. The
coal shall be conveyed through the tunnel and fed through belt conveyors to the
crushers. In-motion weigh bridges or in-line belt weighing machines are required to
be provided for better accounting procedures on quantity of coal received and taking
stock.

2.00.02 Double stream belt conveyors are envisaged from track hopper upto crusher house.
Necessary dust suppression system to the coal unloading above ground hopper and
the track hopper will be provided.

2.00.03 Capacity of the unloading, crushing and stacking system will be to meet peak coal
receipt.

2.00.04 ROM Coal may also be received by road trucks in emergency. Coal will be
discharged into a separate truck-unloading hopper from the trucks or dozed into the
track-hopper and feed to crusher. Necessary ramp to suit unloading of coal from
tipper trucks will be provided.

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TECHNICAL SPECIFICATION

2.00.05 Crushing System

The coal unloading conveyors will feed the crushers located in the crusher house to
crush the coal size to (-) 20 mm size for feeding the boiler bunkers. The under size
coal present in the coal will bypass the crusher. This under size is separated in the
vibrating screen and conveyed to the forward run.

Necessary inline magnetic separators will be provided on the conveyors feeding the
crusher house. Adequately sized surge hoppers/ feed chutes / flap gates will be
provided to have maximum flexibility in the flow of material. The crushing and
screening system will be 2x100%. Crushers shall be supported on RCC foundation
and shall be isolated from other foundation work. Necessary anti-vibration dampers
will be provided for the crusher foundation as required.

2.01.00 Stacking and Reclaiming System / Stockpile


Crushed coal will be sent to stockpile when coal is not required in the bunkers.
Stacking/ reclaiming of coal will be done by bucket wheel type stacker / reclaimer
moving on rails. The stacker / reclaimer can stack coal on either sides of the pile.

When coal is required in the bunkers and crusher is not in operation, coal will be
reclaimed by the stacker/ reclaimer and fed to the coalbunkers. An emergency
reclaim hopper will be provided to reclaim coal by dozers when stacker / reclaimer is
not in operation. Required number of dozers / mobile equipment will be supplied.
Number of dozers will be adequate to feed the reclaim conveyors at 125% MCR
requirement.

The stockpile of coal will have adequate storage for at least 15 days coal
consumption considering a plant load factor of 0.9. Coal stockpile will be 8 m high.

The stock pile will be provided with necessary fire hydrant system, compacting and
dust suppression system. Rain water runoff drainage system and effluent/ settling pit
for such water shall be suitably provided as per environmental norms for disposal of
such water.

2.02.00 Conveying System / Bunker Feeding System


The capacity of the forward conveying system from crusher onwards will be to meet
the 24 hour MCR requirement of boiler, in 12 – 14 working hours per day. The
conveyor galleries will have space provision for belt for second Unit.

Coal samplers and belt weigh scales will be provided in the junction tower prior to
bunker feeding conveyor.

In line magnetic separators and metal detectors will be also be provided.

Bunker filling will be done by tripper conveyor arrangement. Bunker top will be
sealed to have effective ventilation system in the bunker floor and necessary tipper
arrangement will also be provided on bunker top.

2.03.00 Fire Fighting System


The coal stockpiles will be provided with ring main headers with hydrant valves
located as per the statutory requirements for fire fighting operations. The stockpiles
will be provided with water spray system and compacted to suppress the dust
generated due to stock piling or reclaiming operations.

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2.04.00 Control Room


The complete coal handling system operation will be controlled from coal handling
control room located in the plant near to crusher house. The stacker/ reclaimer will
be operated from operator’s cabin located on the machine.

2.05.00 Safety Interlocking System


A PC based PLC safety interlocking system for coal-handling plant will be provided
such that sequential starting/shut down of all the equipment due to trip condition of
down stream conveying equipment is ensured. The trip-off of the minimum
equipment in the safest sequence during abnormal operating conditions will be
ensured. The functions of safety interlocking system are as follows.

a) Annunciate/indicate initiating cause for the equipment, which has tripped.


b) Prevent restarting of equipment until safe conditions are restored.
c) Retain flexibility of operation as is consistent with safety.
d) The interlocks provided will permit one stream operation retaining the
flexibility in operation.

3.00.00 SPECIFICATIONS FOR MECHANICAL EQUIPMENTS


3.00.01 The specifications as brought out for mechanical & electrical equipment shall be
applicable to the system of proposed coal handling system and specifically to all
mechanical equipments including their operation & control philosophy. However,
some specific parameters of the entire coal handling system as a whole and the
major equipment are brought out as under.

3.00.02 Codes & Standards

The design, manufacture, inspection and testing of all coal handling plant equipment
shall comply with all the currently applicable statutes, regulations and safety codes in
the locality where the equipment is to be installed. Other internationally acceptable
standards/codes, which ensure equal or higher performance than those specified,
shall also be accepted. Nothing in this specification shall be construed to relieve the
Bidder and/ or Bidder of the required statutory responsibility. In case of any conflict in
the standard and this specification, the decision of the Purchaser shall be final and
binding.

3.01.00 TRACK HOPPER

A track hopper of 210 M length shall be provided. The capacity of hopper shall be
about 3000 MT of coal. At the outlet of track hopper four (4) plough feeders with
hydraulic drives will be provided for each stream. The capacity of the plough
feeders will be suitable for unloading coal at a rate of at least 3 rakes a day in an
emergency situation. The walkway in the tunnel will be minimum 1000 m clear of
the festoon cable trolley arrangement .The plough feeders will also be capable of
being operated from the tunnel floor. The machinery hatch will be able to
accommodate at least two (2) plough feeders at a time. The tunnel below the track
hopper will be provided with 3 sumps with two (1W+1S) sump pumps in each
sump. The sumps will be provided on either side in staggered manner. The drive
motor of all the sump pumps will be mounted at least 1.0 metre above the floor /
ground level. The sump pumps will be suitable to handle coal slurry and impeller
will be of non-clog type. The impeller will be of alloy cast iron with a hardness of
340 BHN.

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The grid will be located on the cone portion of the hopper about 1 to 1.5 m below
the top of the hopper. The line side equipment will include two (2) separate (1w
+1s) compressors. The side wall angle of the track hopper will be minimum 65 deg.
Two (2) access shafts in a staggered manner will be provided on either side along
the length of the track hopper. The track hopper will be provided with minimum 10
mm thick TISCRAL/ SAIL HARD liners. The opening in the grid will be suitable for
passing 200-mm coal lumps. The track hopper will be provided with a canopy and
should have a overhead electric power line for electric traction. The canopy will be
provided with lighting.

3.02.00 CRUSHER (IMPACTOR TYPE)

3.02.1 DESIGN REQUIREMENT

a) Crusher shall be capable of handling the amount of coal as per enclosed Data
Sheet ‘A’ even under maximum moisture content condition and shall reduce
the feed size of indicated hard grove index to the size stipulated in the data
sheet.

b) Crusher shall have Blow Bar type construction.

c) Impactor shall be of a single roll crusher consisting of a well-balanced rotor


with provision for adjustable weights for balancing the rotor as the rotor bars
wear out in use. On the periphery of the rotor, it shall have wedge shaped
notches in which modified Mn, wear resistant, constructed, cast steel
hammers shall be mounted along the entire length of the rotor. The hammers
shall be equally spaced leaving wide gaps between two hammers thus
preventing choking of the crusher due to wet coal. Surrounding the rotor shall
be wear resisting, plate mounted, and adjustable cage. The gap between the
rotor bars and the cage shall be gradually reduced from entry mouth upto the
bottom end discharge point to get the desired coal size.

d) The coal gets crushed due to shear and impact hammering due to the bar
hammer as the coal is dragged inside the wedge gap by the rotor of the
crusher. Adjustable balancing weights shall be provided on both sides of the
rotor to help achieve proper balance. The drive to the crusher shall be
through reversible electric motor connected through a fluid coupling. Drive
assembly shall be selected with V-belt / flat belt drive with hydraulic coupling.
The motor rating shall be selected considering 20% margin over requirement
at designed capacity.

e) Secondary side of hydraulic coupling can start rotation only at 90% motor
cylinder speed. Hydraulic coupling can transmit the rated torque at max. 3%
slip.

f) The crusher shall be provided with a facility for collection of larger tramp iron
to prevent damage from un-crushable materials and its automatic discharge,
if possible. High impact and wear resistant manganese shall be used in all
highest and greatest wear areas.

g) Noise level and vibration shall be low and must be below 85 db at a distance
of 1 M away from the crusher & 1.5 M above the ground level at no load and
load. Vibration isolation system comprising of Gerb springs and visco
dampers shall be provided.

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h) Crusher bearing shall be with Duplex type TD.

3.02.02 VIBRATION MONITORING SYSTEM FOR CRUSHER MOTORS

i. The Crusher bearings Vibration Monitoring system shall monitor continuously


(in x and y directions) the equipment to avoid its regular operation and
consequent damage.

ii. Complete instruments including sensing elements, converters, measuring


module transmitters, indicators etc. supplied by the Bidder along with all
required accessories for the bearing vibration instruments shall be provided.
Indication of the vibrations shall be local as well as remote. The instruments /
equipment shall be of reputed make and shall be subject to Purchaser’s
approval.

iii. Trip contact to Crusher Motor HT Breakers shall be provided along with
remote annunciation for High and Very High vibrations from preset value.

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(IMPACTOR CRUSHER)

Description Unit Data particulars

1 Type - Reversible Impactor


hammer Type

2. Capacity TPH 800 (Rated)

3. Quantity Nos. TWO (2)


(1 running & 1 standby.)

4. Material handled ROM Coal

5. Density of material T/M3 0.8 for volume calculation


. 1.05 for weight calculation

6. Moisture Content % 20%

7. HGI - 50

8. Input Lump Size mm 300

9. Output Size mm (-)20 (not more than 1% less than


5 mm size)

10. Type of coupling between Fluid


Crusher & Motor

11. Hours of operation/ duty Hrs/day 24

12 Tramp Iron Pocket to yes


be provided

13. Material
a) Rotor Impact abrasion resistant alloy steel
having magnetic property
b) Impact Arms Manganese Steel
c) Gears High Tensile Steel

d) Frame Rolled Steel

e) Material of liners Manganese Steel


on housing

f) Cage assembly Mn steel

g) Breaker plate Mn steel

14 (i) Temperature monitoring system Lot


(ii) Vibration monitoring system Lot

15 Type of drive Vee/ flat belt drive

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16 Inspection / maintenance door Yes


to be provided

Note:
1. The crusher motor shall be complete with temperature scanner and indicator,
speed switch and all accessories.
2. The crusher RPM and Motor RPM shall not exceed 600 & 1000 RPM (Syn.)
respectively.

3.03.00 VIBRATING SCREEN

3.03.01 DESIGN REQUIREMENT

a) The vibrating screen shall be suitable for continuous duty and robust in
construction. it shall be capable of absorbing shock loads due to impact of
falling large coal lumps upto 300 mm size and other heavy metallic
components / pieces without damaging the roller disc. An Impact drum before
/ on vibrating screen, if required, to take care of impact of falling coal shall be
provided by Bidder as a part of the scope.

b) The screen rolls with eccentric disc of solid alloy steel shall be provided. The
disc shall be mounted on the shaft running in antifriction bearings. Labyrinth
seals with grease chambers permitting re-lubrication and sealed off against
ingress of dust shall be provided. All rollers shall be so designed that these
can be operated under the worst condition of operation with wet and muddy
coal. The shaft material shall be as per approved manufacturer’s standard.

c) Suitable cleaning devices, consisting of scraper plates mounted below each


rotary shaft shall be provided to clean the gap between the eccentric discs.

d) The vibrating screen shall be of approved and proven design.

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VIBRATING SCREEN

1. Location - Before the Crusher

2. Duty - Continuous

3. Capacity - 800 TPH (Rated)

4. Number Required - TWO (2)

5. Material to be handled - R.O.M. Coal

6. Max. Lump Size - (-) 300 mm


(Input coal)

7. Output Size - (-) 20 mm


8. Material for construction -

i) Discs - Manganese Steel to IS : 275


ii) Shafts - Forged Steel
iii) Gear - Hardened Alloy Steel

9. Moisture content (max.) - 20%

10. bulk density of coal - 0.8 T/M3 for volume calculation


1.05 T/M3 for weight calculation

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3.04.00 CRUSHER HOUSE

3.04.01 DESIGN REQUIREMENT

a) The Crusher house building shall be designed to accommodate the discharge and
feeding ends of conveyors including drive arrangement, crushers complete with
drive units, vibrating screens with drive units and necessary chute work., dust
extraction and ventilation equipments, tramp iron trolley, lifting tackles including
monorail etc.

b) The crusher house shall be of structural steel construction with suitable side
cladding. The crusher house will be provided with ample space for maintenance
and inspection of various equipments. Necessary steel doors, windows, exhaust
fans and roof extractors shall be provided to allow natural light and ventilation.
The dust extraction unit for crusher house shall be housed at the roof of the
building. The floors of the crusher house would be of RCC slab supported on steel
beams. Each crusher will be provided with independent foundation, separate from
the crusher house building foundation so that vibrations due to running of the
crusher are not transmitted to the entire crusher house building.

CRUSHER HOUSE

Description Data / Particulars

Equipment to be Reversible Belt Feeders (as required), vibrating


housed in the building screens, Impactor crushers, ILMS, conveyors,
and chute work, hoist, DE system, D.S. system,
ventilation system etc.

Staircases Outside the Building

NOTE
1. Crusher House building shall be provided with floor sweeping chutes for each
floor of the crusher and chute shall be brought upto the ground level and then
drained to the nearest plant drainage.

2. Roof extractor shall be provided in crusher house for better ventilation

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3.05.00 TRAVELLING TRIPPER AND BUNKER SEALING ARRANGEMENT


Travellling Trippers on bunker conveyors along with belt sealing arrangement shall
be furnished and erected complete with rails, including necessary supporting
structures, approach/ maintenance platforms with ladders and hand railings, trailing
cables, all electricals including machine mounted local control panel & control panel
on one end of Bunker, location of which shall be decided during detail engineering.

3.05.01 Codes & Standards

The Travelling Tripper & Bunker Sealing Arrangement shall conform to the latest
edition of standards and codes. Other internationally acceptable standards/codes,
which ensure equal or higher performance than those specified, shall also be
accepted.
3.05.02 DESIGN REQUIREMENT

3.05.02.01 Mobile Tripper

a) The Mobile tripper on bunker conveyors shall be motor driven type. It shall
consist of structures, supports, walkways, rails, belt scrapper with adjustable
rubber strip, rubber lagged head and bend pulleys complete with shaft
bearings, chutes, stops, limit switches, brakes etc. The tripper shall have
provision for dropping coal on both sides of conveyor into the bunker and
back to the conveyor for the purpose of skipping intermediate bunkers. The
rating of tripper travel motor shall be adequate to move the tripper smoothly
either in same or opposite direction to belt direction under fully loaded
conditions. Adhesive weight requirement and tractive effort calculations shall
be subject to approval of Purchaser. Coefficient of adhesion shall be
considered as maximum 0.15. Minimum two drive axles shall be provided for
tripper travel. Arrangement shall be provided at the starting point of the tripper
to avoid folding of belt.

In case of tripper running at a speed more than its rated speed due to chute
jamming or other reason, conveyor shall trip and annunciation shall appear.

b) Supply of adequate length of rails to cover the runway length for the motor
driven tripper shall be included. The supporting structures for the rails with
necessary end stops shall also be supplied under this specification. Suitable
belt hold down guide pulleys shall be provided over the concave curve of belt
over tripper.

c) The Bidder shall include necessary electricals for traveling trippers such as
motorised cable reeling drum with trailing cables, cable trays for resting the
trailing cables and end limit switches for protection against over travel of the
tripper. The cable reeling drum and trailing cable of each tripper shall be
suitable for the entire length of the bunker bay. Mechanical track stops shall
also be provided. The cables shall have copper conductors, proper insulating
material and braided armouring in accordance with IS:691. Complete
Telephone Communication system between mobile tripper and CHP control
room is in Bidder scope.

d) The travelling trippers shall be provided with fail safe A.C. thrustor operated
brake of totally enclosed type which shall engage as soon as tripper travel

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motor stops. A.C. Thrustor operated rail clamps with hand operation facility
from either side of the tripper shall also be provided.

e) Monorail & electric hoist shall be provided for lifting conveyor drum to bunker
floors. Monorail shall be provided all along the bunker conveyer to facilitate
maintenance of tripper.

3.05.02.2 Bunker sealing arrangement

Bidder shall provide sealing belt for Bunkers. The belt shall rest on 20mm MS round
bars spaced at 150 mm provided over the bunker slot on tripper floor for tripper
conveyor as shown in the tender drawing. Needed guide rollers, bearings, brackets,
safety guards etc. shall be provided by the Bidder. The bunker sealing arrangement
shall keep the bunkers sealed and prevent dust emission into tripper room.

Suitable grating shall be provided in between bunkers in the tripper travel zone by the
Bidder. Tripper floor is by Purchaser. Openings on the tripper floor for level
measurement will be provided. Opening size will be informed to successful Bidder
during the detail engineering stage.

3.05.03 CONSTRUCTION REQUIREMENT

3.05.03.1 Mobile Tripper

i. Suitable dust cover shall be provided over tripper head pulley. Serrated
rubber seal shall be provided at open side to prevent dust nuisance. Suitable
dust tight access doors shall be provided. Counter-weighted type belt cleaner
shall be provided below the tripper head pulley for cleaning the carrying side
of the belt.

ii. The tripper shall run on rails (90 lbs/yard) with double flanged wheels. Rails
for tripper travel shall be mounted on supporting structure of respective
conveyors.

iii. Suitable system for monitoring position of tripper shall be provided. In


addition, travel end limit switches and end stops shall also be provided.

iv. Suitable access platform of chequered plate with ladders, handrailing and
walkways on both sides shall be provided for access/maintenance of
equipment on tripper. In addition, crossover platform shall be provided with
tripper so that operator can cross the belt through the same.

v. Suitable rail cleaners shall be provided on leading and trailing edge of tripper
for either track.

vi. 3mm deck plate continuous shall be provided below carrying idlers on the
trippers.

vii. For specification of flap gates/actuator on trippers relevant clauses of this


specification shall be referred to.

viii. Provision shall be kept for automatic tripping of bunker bay conveyor in the
event of travelling tripper getting dragged (i.e. travel speed in excess of rated
speed).

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TRAVELLING TRIPPER

1.0.0 GENERAL

1.1.0 Mobile Tripper Motor driven type rail mounted.

1.2.0 Bunker Sealing Arrangement Sealing belt type.

2.0.0 DESIGN & CONSTRUCTION

2.1.0 Mobile Tripper

2.1.1 Mounting Rail mounted on rails (90 lbs/yard)


with double flanged wheels.

2.1.2 Drive Motor driven with suitable gearbox.


Suitable for minimum 60 starts/hours.

2.1.3 Pulleys

(a) Head & Bend Pulleys Suitable to Rubber lagged


guide belt over concave curve.

2.1.4 Brakes AC operated electro hydraulic thrustor


type on either side of tripper.

2.1.5 Clamps A.C. operated electro hydraulic


thrustor type on either side of tripper.

2.1.6 Walkways Both sides, 800 mm wide each

2.2.0 Bunker Sealing Arrangement

2.2.1 Sealing Belt As specified

2.2.2 Guide Rollers As per requirements.

2.2.3 Bunker Slot

(a) Width

(b) Cross bars over the slot opening 20 mm MS round bars

(a) Space in between bunkers in the MS Grating removable type.


tripper travel zone.

3.06.00 STACKER –CUM- RECLAIMER

3.06.01 DESCRIPTION:

a) The stacker reclaimer unit shall be provided to stack the material onto the pile or
reclaim the stockpiled material and feed onto the conveyor for bunker feeding.

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b) The rail-mounted machine shall be controlled from the operator’s cabin located
on the machine to avail the maximum range of vision to the operator.

3.06.02 The stacker-cum-reclaimer would comprise of:

- Rail travel mechanism,


- Lower carriage with slewing ring,
- Superstructure,
- Counter-weight boom,
- Bucket wheel complete with drive,
- Bucket wheel boom conveyor,
- Intermediate conveyor,
- Tripper,
- Chutes,
- Steps & platforms,
- Rail clamps,
- Group lubrication system,
- Electrical equipments & controls
- Operator’s cabin.
- Wind speed indicator
- Storm anchoring arrangement

3.06.3 Bucket Wheel:

The bucket wheel shall be mounted on anti-friction bearings and driven by a


squirrel cage motor. A hydraulic coupling shall be provided between the motor and
bucket wheel gear which serves as a slip monitor for the hydraulic coupling and
cuts out the bucket wheel motor when the speed drops due to overload, together
with the subsequent drives such as travel, slewing and luffing drives. The bucket
wheel drive would be reversible type to facilitate withdrawal of wheels in the event
of excessive under cutting.

The material shall be reclaimed by buckets and discharged onto the boom conveyor
through bucket wheel chute and conveyor chute.

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3.06.4 Luffing Device :

Hoisting or lowering of the bucket wheel boom will be done hydraulically. The upper
and lower positions of the bucket wheel boom shall be limited by control & limit
switches.

3.06.5 Bucket Wheel Boom :


Bucket wheel boom shall be provided in the centre of the machine and suspended
on the supporting mast. The bucket wheel boom shall have feed chutes at both
end.

3.06.6 Slewing Mechanism :


The slewing mechanism shall have direct current drives. The D.C. drives shall be
powered via thyristor panel.

The slewing mechanism brakes shall be actuated by thrustors when the slewing
motors are switched.

Slewing shall be around + 105 deg.

3.06.7 Travel Mechanism :


The rail travel mechanism shall have necessary drives. The travel mechanism brakes
shall be actuated by thrustors when the motors are switched. It shall have also
manually operated rail clamps.
The travel mechanism shall be provided with two electro hydraulic operated rail
clamps monitored by limit switches (open & close positions).
The main cable reeling drum and the control cable reeling drum shall be built-on to
the lower frame each of which is driven by an individual Stall torque motor.

3.06.8 Super Structure :


The super-structure shall be of welded plate construction and supported on the
slewing ring. The bucket wheel boom alongwith mast and counter weight boom is
supported onto the super-structure. The hydraulic for the luffing is also supported
to the super-structure.

3.06.9 Lower Carriage :


The lower carriage shall be of sturdy box type design and it is supported on the
travel mechanism

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3.06.10 Operator’s Cabin :


The operator’s cabin shall be made of sheet metal. Adequate number of glass
panels shall be fitted to provide panoramic view. The control panel desk for
operation, A/C unit and lighting etc. will be provided.

3.06.11 Chute :
Necessary chutes would be fabricated from IS:2062 Gr.A/B for mother plate and
liner plate out of 5mm thick SS304

3.06.12 Steps & Platforms :


Necessary steps & platforms furnished with M.S. grating would be provided for
easy access to all machineries and to the control cabin.

3.06.13 Intermediate Conveyor :


The intermediate conveyor would comprise of the structure, walkway with open
grid flooring, railing, belt scraper, head pulley with drive unit, impact idler for
receiving material, chute and supports of welded construction with single wheel
bogies.

3.06.14 Tripper :
A tripper would be provided to operate in conjunction with main line conveyor.
The tripper would comprise of structure, walkway with open grid flooring, railing, belt
scraper, head pulley, bend pulley, chute and supports of welded construction with
single wheel bogies.
The tripper travels on the same rails as those of the main machine. The tripper
discharge end is supported on the support car.

3.06.15 MODE OF OPERATION

3.06.15.1 Control System


Stacker/Reclaimer control shall have the following type of control :-

a) Bucket Wheel boom with Cabin operated raise / lower control through joystick
controller, amplifier card for proportional solenoid valve of boom luffing
hydraulic system.

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Bucket Wheel boom with Cabin operated (slewed) step less control of Slew
platform DC drive through joystick controller.

b) The long travel motion of stacker cum reclaimer shall be through two speed
squirrel cage motors, soft starter.

c) Controllers shall be provided with deadman’s contact interlock contact.

d) Control equipment mounted in the operator’s cabin shall be furnished with


uniform indelible name plates identifying the various controls and indicating
the direction of motion.

3.06.15.2 Protection
Following protections shall be provided :

3.06.15.2.1 Bucket Wheel :


a) Slip monitor.
b) Measurement of motor power input by power transducer for overload
monitoring & control of slewing speed.
c) Pile contact protection at boom end.
d) Overload sensing for overload protection in MCC.

3.06.15.2.2 Boom Conveyor :

a) Belt sway, pull chord, zero speed, overload of motor in MCC.


b) Pulley slipping (zero speed switch)
c) Chute position switches stacking or reclaiming.

3.06.15.2.3 Hoist :
a) Overload protection by pressure monitoring.
b) Oil level monitoring in oil switch.
c) Limit switches in high & low position.

3.06.15.2.4 Slewing :
a) Slew angle limit switch.
b) Proximity switches on sides of boom for collision protection.
c) Proximity for slew operational limit.

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3.06.15.2.5 Travel :
a) Travel limit switches.
b) Buffers
c) Brake thrustor monitoring switch
d) Suitable nos. of aneometers, aneomometer gate alarm & automatic storm
anchoring by thrustor operated rail clamps.

3.06.15.2.6 1. Rail clamps shall be actuated at predetermined high wind velocity.


2. Operation of the overload relays for any of the motors shall trip the main
supply breaker to cut off power supply to all the motors.
3. Undervoltage interlock shall be provided to operate the main supply breaker
and open the main breaker contacts and its holding contact.
4. `Start’ push button of the main supply shall be wired in series with `OFF’
position contacts of all the controllers, thus requiring that all controller handles
are in `Off’ position before the main supply breaker can be switched on.
5. `Deadman’ contacts on all the controllers shall be wired in series to open out
the main breaker.
6. Emergency pull wire switch, belt sway switches and zero speed switches.

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STACKER-CUM-RECLAIMER

1.0 GENERAL

1.1 Type : Rail mounted, Bucket wheel type Stacker cum


Reclaimer with reversible Main Line Conveyor

1.1.1 Location : Outdoor

1.2 Numbers required : One (1)

1.3 Capacity while stacking : 800TPH


(Guaranteed), tph

1.4 Average Capacity while : 800TPH


reclaiming (Guaranteed),tph

1.5 Duty : Machine shall be designed based on continuous


operation for 24 hours/day.

1.6 Maximum Wind Velocity :

a) While operating machine : 20 m/s

b) Non operating condition of: 47 m/s


machine

1.7 Seismic co-efficient : As per IS:1893 (latest)

1.8 Material handled

1.8.1 Material : Compacted crushed coal while reclaiming &


crushed coal while stacking of size (-) 20 mm

1.8.2 Bulk density : 800 Kg/cubic metre for volumetric calculation.


For design of drive equipment, structures and
for loading data shall be 1050 kg/m 3.

1.8.3 Moisture content : 20 percent maximum

1.8.4 Angle of repose : 37 deg.

1.9 Boom Length : 40 m ( From centre line of bucket wheel to slew center )

1.10 Effective length of travel : To suit stock-pile

1.11 Stockpile height above : 8m


rail level

1.12 Tower Structure (Machine Body)

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a) Type of construction : 4-Corner x 3 point support


b) Material of : Structural Steel, IS:2062
construction
c) Type of construction : BOX/Full Web with bracing wherever
necessary
d) Codes followed for design : DIN/ISO/IS
and construction
e) Number of trucks under : 6 Nos.
which carriage support

1.12.1 Detail of Wheels

a) Number/Truck : Two (2)


b) Number/Carriage : 6 Nos. per carriage
c) Material of wheel : Cast alloy Steel, 42 Gr.M04
d) Wheel dia./base : 630/820 mm
e) No. of driven wheels : 12 Nos.
f) Total no. of wheels of : 28 Nos.
main unit

1.12.2 Travelling speed of machine : 15 m/min. (Max.) and 7.5 m/min.


(Min.)

1.13 Stability factor : In accordance with ISO 5049/1

a) For operating conditions of : 1.5 (Live Load only considered


machine with maximum locally)
permissible wind velocity
and maximum live load

b) For operating conditions of : 1.5


machine with maximum
permissible wind velocity
without any live load

c) For non operating conditions : 1.5 (Machine in parking position)


of machine with maximum
permissible wind load

1.17 Bucket Wheel Assembly

a) Material of construction :

I. Bucket Wheel : M.S., IS:2062


ii. Bucket : Abrasion resistant steel
ii. Lips : Magnese Steel

1.17.1 Drive Details (Bucket wheel)

a) Number/Type of drive motor : 1 No. A.C. Sq. Cage


for bucket wheel

b) Motor rating (KW) : suitable

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c) Is bucket wheel drive : Yes


reversible ?

d) Is it possible to remove any: Yes


bucket for replacement ?

e) Fluid couplings for motor : Yes


provided

f) Is speed monitor built on the: Yes


bucket wheel gear included ?

g) No. of bucket discharges : 46 (approx.)


per min.

3.07.00 BELT CONVEYORS SYSTEM

All Conveyors shall be furnished and erected along with necessary supporting
structures, platforms, trestle structure with foundation footings, carrying and return
idlers, , pulleys, drive motors with suitable reduction units and couplings, belting,
transfer chutes, and other necessary accessories as per scope specified.

3.07.01 CODES AND STANDARDS

The design, manufacture, inspection and testing of the Belt Conveyor System
shall comply with all the currently applicable statues, regulations and safety codes
in the locality where the equipment is to be installed. The belt conveyor system
shall confirm to the latest edition of the following standards & codes. Other
internationally acceptable standards/codes, which ensure equal or higher
performance than those specified, shall also be accepted. Nothing in this
specification shall be construed to relieve the Bidder of the required statutory
responsibility. In case of any conflict in the standard and this specification, the
decision of the Purchaser shall be final and binding.

“Belt Conveyors for Bulk Materials” published by Conveyor Equipment


Manufacturers’ Association.

IS:7155 : Codes of Practice for Conveyor Safety.

IS:1891 (Part-I) : General Purpose Belting

IS:8598 : Idlers and Idler Sets for Belt Conveyors

IS:4009 (Part-II) : Conical Head Grease Nipples

IS:8531: Pulleys for Belt Conveyors.

IS:226 : Structural Steel (Standard Quality)

IS:4682 : Codes of Practice for Lining of Vessels and Equipment for Chemical
Processes.

IS:11592 :Code of practice for selection and design of Belt Conveyors.

CAN / CASA - M422 M87 : Canadian standard association.

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3.07.02 DESIGN REQUIREMENT

i. Design of belt conveyor system shall be suitable for coal parameters


specified.

ii. The guaranteed capacity of all conveyors shall be the rated capacity.

iii. Belting for Bunker conveyors shall be designed for 110% of rated
capacity. Design capacity of the conveyor system shall be considered for
the selection of continuous motor rating at 50 deg C Ambient.

iv. The drive chain equipment’s for belt conveyor systems shall consist of
drive motors, fluid couplings, gear reduction units, low speed flexible
couplings and pulleys.

v. Conveyors shall be provided with electro hydraulic thrustor brakes or fly


wheels to adjust the coasting time of conveyors such that there will not be
any build up of material in the chutes. Further conveyor shall come to halt
as early as possible.

vi. Belt conveyor system shall be designed as per the latest edition of ‘Belt
Conveyors for Bulk Materials’ published by Conveyor Equipment
Manufacturer’s Association’ or equivalent International Standard.

3.07.03 CONSTRUCTION REQUIREMENT

3.07.03.1 Belting

The specification of Belting for conveyors shall be as follows:

(i) Material and Width of the Belt : Synthetic, 1000 mm (min.)

(ii) Cover thickness: 5/2 mm

(iii) Average belt strength: 630/4 FR grade

(iv) Rated capacity 600TPH

i. The sealing belt (for sealing slots of tripper floor) shall also be of suitable width
with synthetic cover. Bidder shall provide sealing belt for all Bunkers

ii. Carrying idlers shall be provided with three equal rolls with troughing angle of
35 deg. and 2 deg. forward tilt .

iii. In no case, shall the diameter of the idler roll be less than 152 mm for both
carrying side and return side.

iv. Roller used in idlers shall be made from ERW steel tube. Wall thickness shall
be minimum 4.0 mm without any negative tolerance. The rollers shall be
mounted on EN-8 or equivalent material spindles by means of heavy duty ball
bearings, preferably seize resistant type (SKF/Equivalent), of 30 mm size for
carrying idlers and 20 mm size for return idlers. The bearings shall be
adequately sealed and lubricated for life. The rolls shall be supported from
fabricated steel brackets. Fixing arrangement of rollers with brackets shall be
drop-in type. For adjusting the alignment of the idlers, slotted holes shall be
provided in idler supporting base plates.

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v. Idler rollers shall be waterproof, dust proof and weather proof against a high
velocity water jet. All idlers shall be provided with minimum double labyrinth
dust seal.

vi. Impact idlers used at the loading and transfer point shall be so designed as to
avoid direct loading impact, belt damage and excessive punishment to the
carrier. The material used in construction of this type of idlers shall be of
resilient type.

vii. The return idlers for all conveyors shall be single roll type.

viii. The self-aligning idlers shall be direct acting type, complete with actuating
rollers fitted with the ball bearings and mounted inclined towards the belt. The
idler frame shall be suitably cradled about a vertical pivot, supported in bearing
over a fixed plate.

ix. Transition type troughing idlers shall be used adjacent to all pulleys to permit
proper support of the loaded belt near the pulleys without excessive stretch of
the belt edges. The transition idlers shall be provided with preferably adjustable
concentrator (end) rolls and long center rolls to suit the troughed belt contour
between the last regular troughing idler and the adjacent pulleys. The transition
length and the number of the transition idlers shall be selected depending upon
the tensions, type and size of belt, number of plies and other necessary
governing factors.

3.07.04 Belt Cleaners

External Belt Cleaner

Spring loaded scraper type cleaner with modular segmented and replaceable
polyurethane scrapers blades complete with main cleaner, pre-cleaner (mounted
separately) along with accessories and necessary fines (reject of scrapper) chutes
shall be furnished for conveyors and head pulleys. The modular units shall be
easily replaceable. The scraper assembly shall be easily maintainable from outside
without any interference with the chute arrangement and assembly.

Internal Belt Cleaner

V-plough type belt cleaner made of mild steel flats and hard rubber strips with
automatic wear adjustment and necessary accessories shall be furnished for
cleaning internal surface of the conveyor belt.

3.07.05 Hold Back Devices

Suitable hold back devices for preventing running back of the conveyor belt in case
of conveyor being stopped in loaded conditions due to power failure or during
normal operational delays shall be provided to give positive protection. The hold
back shall instantaneously engage without shock and be capable of protecting
equipment and personnel. It shall be released instantly when ‘power’ resumes or
the ‘delay’ is removed. The holdback devices shall be integral with gearbox.

3.07.06 Pulleys

i. All pulleys shall be provided as per requirements of the coal handling


system.

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ii. The snub pulleys on each conveyor shall be located to provide a belt wrap
on the drive pulleys of not less than 220 deg. wrap is envisaged for single
snub drive only.

iii. All drive pulley surfaces shall be hot lagged with vulcanised natural rubber
lagging grooved in diamond pattern.

iv. All non-drive pulleys shall be vulcanised natural rubber lagged (hot) with
plain lagging.

v. The rubber to be used for lagging of pulleys shall confirm to specifications


listed in data sheet of this section.

vi. The rubber lagging of pulleys and method of lagging and testing the same
shall conform to IS:4682.

vii. The pulleys shall be made from mild steel conforming to IS:2062 (Tested
Quality).

viii. All the pulleys shall be keyed to forged steel shafts of EN-8 or equivalent
material of adequate proportion running in heavy duty roller bearings with
proper greasing arrangement. The plummer blocks for pulleys shall be of
horizontally split type construction with minimum (4) nos. bolts holding the
two split halves and with min (4) nos. foundation bolts. The plummer blocks
shall be dust tight with double labyrinth seals. Conical head shape nipples
conforming to IS:4009, suitable drain plug and eye bolt shall be provided.
Side covers of plummer blocks shall be heavy duty metallic sheets. No
plastic components shall be used.

ix. Pulleys shall be mounted on machined & ground surfaces. Suitable guards
shall be provided for all tail pulleys and bend pulleys for safety of operating
personnel.

x. Suitable stiffening arrangements shall be provided in all pulleys. For


selection of pulley shaft dia of all the pulleys, a margin of atleast 20% shall
be considered on the maximum tension. Selection of pulley diameter, shell
thickness, stiffening and shaft diameter shall be subject to approval of
Purchaser.

xi. Pulleys of same diameter shall be completely interchangeable in totality


and component wise.

3.07.07 Belt Protection Equipment

3.07.07.1 Pull chord Switch

Pull chord type (manually reset type) emergency stop switches shall be located
on both sides of belt conveyors along the walkways for the entire length of
conveyors for emergency stopping of conveyor. The enclosure shall be of cast
aluminum with degree of protection IP-65. It shall have a separate terminal box
with a separate hinged cover which shall be totally sealed from main box
containing actuating mechanism / limit switch etc. Local pull chord actuation shall
be provided by means of mechanical flap. Each switch shall have two NO and
two NC contacts, which shall be wired out to the terminal block. The terminal
block shall have facilities of cable looping. The Contact rating of the switches
shall be rated for atleast 5 Amps, breaking at 240 VAC at 0.3 p.f. lagging.
Adequate length of rope and all accessories shall be furnished.

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3.07.07.2 Belt Sway Switch

Belt sway switches of self resetting type shall be furnished at periodic intervals to
limit belt sway to permissible extent. The enclosure shall be of cast aluminum
having degree of protection of IP-65. It shall have a separate terminal box with a
separate hinged cover totally sealed from the main box containing actuating
mechanism/ limit switch etc. Each switch shall have two NO and two NC contacts
one for alarm and one for trip, which shall be wired upto terminal block. The
terminal block shall have facilities for cable looping. The contacts of the switches
shall be rated for atleast 5 Amps. breaking at 240 VAC at 0.3 p.f. lagging.

3.07.07.3 Zero Speed Switch

Zero speed switch shall be non-contact (proximity) type electronic switch.


Mounting arrangement/ location shall be such that operation, effective sensing
distance, sensitivity etc. shall not be effected by accumulation of dust on rotating
part or surface of probe. Adequate mechanical protection by means of non-
metallic shields shall be provided on top of the switch to prevent any damage due
to falling coal / metallic pieces etc. Each switch shall have two NO and two NC
contacts wired out to the terminal blocks. The contact of the switches shall be
rated for atleast 5 Amps. breaking at 240 VAC at 0.3 p.f. lagging. The monitoring
unit shall have cast aluminum body having IP-65 degree of protection. A separate
terminal box with a separate cover shall be provided. Terminal blocks shall be
suitable for terminating 1.5 mm sq. standard copper cable.

3.07.07.4 Under belt switch

These switches shall be installed under the belt for detecting the presence of
material on the belt whose contacts shall in turn be used for operating solenoid
valves of dust suppression system. The switch and its operating arrangement
shall be suitable for working in dusty areas. The minimum degree of protection of
switch shall be IP-65. The switch shall be capable of detecting three events
simultaneously as follows :

i) Belt loaded

ii) Belt running at more than preset speed.

iii) Preset initial start delay.

3.07.07.5 Chute Blockage Switch

One no. chute blockage switch of proven type (subject to approval of the
Purchaser) shall be provided at a suitable height on each leg of the conveyors
discharge chute nearest to the skirt boards. Chute blockage switch shall trip the
feeding conveyor in case of Chute blockage and protect the feeding conveyor
equipment. Chute blockage switch shall also be provided at each leg of mobile
tripper and shall trip the tripper conveyor.

The switch and its operating arrangement shall be suitable for working in dusty
areas. The minimum degree of protection of switch shall be IP-65. Local
indication of chute blockage switch actuation shall also be provided.

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3.07.07.6 Drive Motors

H.T. motors shall be provided for crushers and any other equipment as required.

Rating of the drive motors in no case shall be less than 120% of the power
required at drive motor output shaft at specified design capacity. The motor rating
shall be at 50 deg C. ambient.

3.07.08 SPECIAL CLEANING, PROTECTION AND PAINTING

All the equipment of belt conveyor system shall be kept clean and protected
during manufacture and shipment. Surfaces to be painted shall be thoroughly
cleaned of loose mill scale, rust etc. All ferrous surfaces shall be applied with one
shop and one site coat of red oxide zinc chromate and two coats of synthetic
enamel finishing paints unless specified otherwise. A minimum of 120 microns
Dry Film Thickness (DFT) after finished coat of paint shall be ensured.

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BELT CONVEYOR

1.0.0 GENERAL

1.1.0 Design Capacity 110% of rated capacity of


800MTPH .

1.2.0 Maximum slope 14 degree

1.3.0 Max. belt Sag between idlers 2%

1.4.0 Minimum Radius

(i) Concave curve 250 m (In case of travelling trippers,


the requirement of minimum radius
can be relaxed only where space
constraints do not permit the same.
However, the minimum radius over
concave curves shall in no case be
less than 150 m. In such case,
suitable belt hold down guide pulley
shall be provided over the concave
curve of belt over the travelling
tripper)

(ii) Convex Curve 50 m

1.5.0 Coal Parameters As specified

2.0.0 DESIGN & CONSTRUCTION

2.1.0 Belting

2.1.1 Type AS specified elsewhere

2.1.2 Cover Grade a) Flame test : Conforming to


ISO:340

b) Drum Friction and Electrical


Surface Resistance Test :
Conforming to Canadian
standard association CAN / CSA
M-422- M87 Grade - C.

2.1.3 Cover Thickness (without negative


tolerances).

(a) Face 5.0 mm (min.)

(b) Bottom 2.0 mm (min.)

2.1.4 No. of plies Minimum 4

2.1.5 Drive Arrangement As specified elsewhere

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2.1.6 Factor of Safety 10 (Minimum)

2.1.7 Normal Working tension at design Less than 80% of max. allowable
capacity working tension

2.2.1 Type

(a) Carrying Three roll, 35 degree troughing,

2 degree forward tilt

(b) Return Single Roll, For conveyors upto

400 m c/c length.

(c) Loading point Impact type

2.2.2 Spacing

(a) Carrying 12 m and 0.6 m for convex curves

(b) Return 3.0 m (for convex curves not more


than 1.5 m.)

(c) Loading point Minimum six (6) with 400 mm


spacing.

(d) Self-aligning troughing At 10 m distance from head & Tail


idlers pulleys with intermediate spacing
15m

(e) Self - aligning return idlers At 10 m distance from Head & Tail
pulleys with intermediate spacing
20m. (Not required for conveyors
more than 400m c/c long where 2
roll return idlers are provided).

2.2.3 Bearings

(a) Carrying Heavy Duty Ball Bearings of min. 30


mm size, lubricated for life.

(b) Return Heavy Duty Ball Bearings of min. 20


mm size, lubricated for life.

2.2.4 Materia

(a) Roller ERW Steel tube min. wall thickness

4.0 mm

(b) Spindle E.N. 8 or equivalent.

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2.3.0 Belt Cleaners

2.3.1 External Spring loaded scraper type cleaner


with modular, segmented and
replaceable PU blades with
separate main-cleaner & pre-cleaner
etc.

2.3.2 Internal V-Plough type, mild steel flats with


hard rubber strips.

2.4.0 Hold Back Device Integral with gear Box

2.5.0 Pulleys

2.5.1 General (for all types of Pulleys)

(i) Minimum shell thickness 16 mm

(ii) Minimum end disc thickness 24 mm

(iii) Maximum allowable deflection 5 minutes


of shaft at the hubs

(iv) Pulley shaft diameter As specified elsewhere

2.5.2 Drive Pulleys

(1) Minimum shell thickness 16 mm

(2) Lagging Hot lagged with vulcanised natural


rubber

(3) Lagging thickness 12 mm thick grooved in diamond


pattern with grooves 6 mm wide x 6
mm deep

(4) Minimum angle of wrap 220° degrees

(5) Maximum Out of roundness 0.5% of nominal diameter

2.5.3 Other pulleys

(1) Minimum shell thickness 16 mm

(2) Lagging Hot lagged with vulcanised natural


rubber

(3) Lagging thickness 12 mm thick plain

2.5.4 Rubber for lagging

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(1) Type Natural rubber blended with styrene

butadiene rubber.

(2) Hardness 55 to 65 durometer (Shore A)

(3) Elongation Over 300%

(4) Strength 160-200 kg/cm2

(5) Abrasion loss 250 mm3 as per DIN 53516

(6) Specific Gravity 1.4 to 1.5

(7) Adhesion Strength 10 kg/cm (minimum)

2.5.5 Bearings for Pulleys

(1) Type Heavy duty roller type

(2) Casing Horizontal Split Type

(3) Sealing Dust tight with double labyrinth


seals.

(4) Lubrication Greasing arrangement with conical


head

shape nipples.

2.5.6 Pulley Material Mild steel conforming IS : 2062

2.5.7 Shaft Material Forged Steel shaft EN-8 or


equivalent material.

2.6.0 Belt Protection Equipment

2.6.1 Emergency Stop Switch System

(1) Type Pull chord type (manually reset)

(2) Location Both sides of conveyors

(3) Spacing Approx 30 m

2.6.2 Belt Sway Switches

(1) Type Limit switches snap action.

(2) Spacing One pair at 50m interval (Minimum


two (2) pairs)

2.6.3 Zero Speed Switches

(1) Type, Location Proximity switch, mounted on Bend


pulley of GTU.

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2.7.0 Drive Motors

2.7.1 Type Three Phase Squirrel Cage


Induction Motors

2.7.2 Mounting (for conveyors) Base mounted

2.7.3 Continuous motor rating(Name plate 120% of actual power requirement


rating) at 50oC at motor output shaft at design
capacity.

3.08.00 CHUTES AND LINERS

Chutes & LINERS and flap gates shall be furnished integral with coal handling
system being supplied. All necessary accessories, electricals etc. shall be provided
to ensure proper flow/storage/bifurcation of coal as per system requirements.

3.08.01 CODES AND STANDARDS

The design, manufacture, inspection and testing of Chutes & Liners shall comply with
all the currently applicable statutes, regulations and safety codes in the locality where
the equipment is to be installed. The chutes shall conform to the latest edition of the
following standards and codes. Other internationally acceptable standards/codes,
which ensure equal or higher performance than those specified, shall also be
accepted. Nothing in this specification shall be construed to relieve the Bidder of the
required statutory responsibility. In case of any conflict in the standard and this
specification, the decision of the Purchaser shall be final and binding.

IS:4682 :Code of practice for lining of vessels and equipment for chemical processes.

IS:2062 : Structural Steel (Standard Quality)

IS:11592 : Code of practice for selection and design of Belt Conveyors.

3.08.02 DESIGN AND CONSTRUCTION

3.08.02.1 Chutes

i. The minimum valley angle of chutes shall be 60 degrees from horizontal.

ii. Transfer chutes shall be adequately sized and sloped to ensure smooth flow of
coal without any accumulation anywhere.

iii. Direct impact of material on conveyor belt shall be avoided by providing an


inclined surface at 60 degrees valley angle at the feeding point to guide the
material in the direction of belt travel. Further, chute construction below flap gate
shaft shall be such that there will not be any accumulation of coal dust between
chute and flap gate in that zone.

iv. Chutes shall be made of minimum 20 mm thick TISCRAL or equivalent with


adequate stiffeners. Hinged inspection doors (generously sized) of leak proof
construction shall be provided for access/ maintenance purpose, at approachable
heights, of the chutes. Chutes should have atleast one inspection door and
suitable access for the same for trouble free maintenance. Maximum distance
between two inspection doors in a chute shall be 2 mtrs. For sealing at inspection
doors labyrinth type arrangement (with rubber inserted in grooves) shall be

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provided. In addition positive locking arrangement, mounting bolts, handle(s) to


tighten the door further against rubber shall also be provided.

v. Bottom side of the chutes on which the coal slides shall be welded to the side
plates to form a trough. Bottom sides along with its adjacent sides shall be
flanged and made from TISCRAL or equivalent material of 20 mm thickness.
The non striking surface i.e. the covers of the trough shall be of 10 mm thick mild
steel and bolted to the flange provided on the trough

vi. Bolted flange joints shall be of dust tight construction and necessary sealing
material shall be provided in all the flange connections for adequate sealing.

vii. Complete chute work in the region of flap gates shall be fabricated from
TISCRAL or equivalent. In case of vertical chute (valley angle more than 80
degree) complete chute work shall be of 20 mm thick TISCRAL or equivalent
material. While finalising the chute work inside the building, arrangement for
shifting and replacing chute legs, proper handling arrangement/wall openings,
trolleys, hoists shall also be provided.

viii. Hoods over the conveyor head pulleys shall be made of suitably stiffened
minimum 4 mm M.S. Plates and shall be provided with hinged and gasketed
inspection doors with suitable access to them. Further, serrated rubber seal shall
also be provided at the very inlet of head chute to minimise dust nuisance.

ix. Separate maintenance sealed door shall be provided for access to belt cleaners in
head pulley hood and shall be of hinged with positive locking facility.

3.08.02.2 Skirt Boards

Skirt board shall ensure centralised loading of conveyor belt to avoid coal spillage.
Suitable ‘Skirt Plates’ of minimum 3.0 meters length shall be provided at each
feeding point of conveyor. The width of the Skirt Boards shall be two-third the
conveyor belt width. In the belts before Crusher House where coal of appreciable
lump size is being conveyed, the gap between the bottom of the skirt board and the
belt shall be made to increase uniformly in the direction of belt travel. The height of
the skirt boards shall be sufficient to contain the material volume as it is loaded on
the belt and shall not be less than 750 mm. The skirt plates shall be fitted with
modular segmented and replaceable rubber skirting pads having facility of adjusting
the pressure on the belt conveyor and shall have provision of on line removal for the
purpose of easy maintenance.

3.08.02.3 Flap Gates

i. The motor operated two (2) position flap gates shall be provided in transfer
chutes as specified and shall be complete with electrically operated actuators.
The gates shall be of robust construction and suitable for trouble free operation.
The face of the flap gate shall be made out of 20 mm thick TISCRAL or
equivalent material.

ii. The equipment shall be capable of being operated for at least 15 switchings per
hour at rated load and thrust and shall be suitable for 10 Nos. consecutive
switchings at rated load and thrust. The equipment shall be shop tested to prove
this requirement.

iii. The motor rating for the actuator shall be so selected as to provide sufficient
thrust for operation of the flop gates against the moving weight of coal and/or flap

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gate. The flap gate travel shall be in the range of 60 deg. to 70 deg. The motor
shall be completely dust tight.

iv. Lever arm shall be provided between actuator and flap gate shaft for obtaining
required thrust.

v. The actuators shall be capable of preventing any over travel. Suitable travel
dependent limit switches controlling the travel of the flop gates on either direction
shall be furnished. These shall be placed internal to the drive unit and shall be
completely dust-proof. The limit switches shall be capable of adjustments to vary
the total length of travel of the gates.

vi. Suitable thrust dependent limit switches shall be provided in the actuator, which
shall trip off the actuator motor in case of excessive thrust due to jamming of the
gates during its travel in either direction. The same shall also be integral to the
drive unit and shall be dust proof.

vii. Provision for alternative manual operation shall also be made using declutchable
hand wheel. The diameter of hand wheel shall be selected considering
convenient force to be applied by a single operator. However, minimum diameter
of hand wheel shall be 500 mm. Limit switch for safety of person operating the
hand wheel shall be provided.

viii. The material of shaft shall be EN-8 or equivalent. The diameter of the shaft shall
be suitable for motor stalled condition and associated twisting.

ix. Approach/maintenance platforms complete with the chequered plate floor, hand
rails, ladders etc. shall be provided for all flap gates.

x. Shaft & flap gate shall be tightly fitted to each other.

xi. On both faces of flap gate main plate, 20mm thick TISCRAL liner plate or
equivalent material shall be provided.

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TECHNICAL SPECIFICATION

CHUTES AND LINERS

1.0.0 GENERAL

1.0.1 Coal Parameters As specified

2.0.0 DESIGN & CONSTRUCTION

2.1.0 Chutes

2.1.1 Minimum Valley Angle 60 degrees

2.1.2 Material :

(a) Chute work

Sliding zones & adjacent sides 20 mm thk. TISCRAL / equivalent

No striking/ Non sliding zones 10 mm thk MS

Chute with valley angle 80 All four sides of 20 mm thk.


degree and above TISCRAL/equivalent material

In the zone of flap gates TISCRAL/ equivalent material

Discharge Hoods over head 4 mm thk M.S. with rubber curtain


pulleys

2.1.3 Size of Chutes Minimum 1000mm X 1200mm (inside


both ways)

2.1.4 Inspection Doors Hinged & leak proof construction

2.1.5 Chute Construction

(a) Corners One face of removable bolted flange


connection

(b) Joints Bolted flange joints of dust tight construction

(c) Bolt size Min. M-16

(d) Bolts spacing Not more than 125 mm C/C

(e) Fixing Arrangement Bolts with plain spring washers

2.2.0 Skirt Boards

2.2.1 Length Min. 3 m for each feeding point

2.2.2 Height Not less than 750 mm

2.2.3 Width 2/3 of belt width

Side plate Min. 10 thk TISCRAL/equivalent

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Top cover 6 mm thk M.S.

2.3.0 Flap Gate

2.3.1 Type Linear actuator operated, 2 position

2.3.2 Travel 60 to 70 deg. (with limit switches on


both sides).

2.3.3 Automatic operation

(i) Drive Dust tight motor driven with suitable


linkages

(ii) Minimum Actuator Rating 2500 kg with 1 m lever arm

(iii) No. of Operation / Hr 15 (with 10 consecutive switchings)

(iv) Protection Travel and Thrust dependent limit

switches.

2.4.4 Manual Operation

(a) Maximum effort Convenient for single operator

(b) Minimum Handwheel 500 mm

Diameter

2.4.5 Flap gate shaft

(i) Diameter minimum 130 mm

(ii) Material EN-8

3.09.00 BRAKES AND CLAMPS


Brakes shall be provided for decelerating driven equipment/conveyor as per
requirement.

Rail clamps shall be provided for traveling trippers on rails as specified for those
machines.

The design, manufacture, inspection and testing of Brakes & Clamps shall comply
with all the currently applicable statutes, regulations and safety codes in the locality
where the equipment is to be installed. The Brakes & Clamps shall conform to the
latest edition of the standards and codes. Other internationally acceptable
standards/codes, which ensure equal or higher performance, shall also be
accepted. Nothing in this specification shall be construed to relieve the Bidder of
the required statutory responsibility. In case of any conflict in the standard and this
specification, the decision of the Project Manager shall be final and binding.

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3.09.01 Electro Hydraulic Thruster Brakes

The necessary Electro Hydraulic Thruster (AC) brakes, totally enclosed and fail safe,
shall be provided as required for various equipment’s. Braking torque shall be
adjustable from 0 to 100% of rated braking torque. The brake shall be actuated by
compression springs. The spring shall apply braking force directly to the shoe without
using lever arm linkages.

3.09.02 Clamps

Rail Clamp shall be designed for holding the machine stationary. Rating of the rail
clamp shall be subject to the approval of Engineer.

Rail Clamp shall be actuated by compression springs. The spring shall apply the
clamping force directly on the Rail clamp mechanism without using lever arm
linkages once power supply is cut-off. The force transmission mechanism from
spring to rail clamp faces shall be very simple with minimum linkages.

3.09.03 CONSTRUCTION REQUIREMENT

3.09.03.1 Thruster Brakes

The electro hydraulic thruster shall be fitted with the brake. Limit switches shall be
provided for brake applied/released positions. The windings shall be provided with
class-B insulation suitable for 415V ± 10% at 50 Hz ± 5% and combined variation of
± 10%. Brake lining shall be asbestos with inter woven brass wires capable of
withstanding 200°C temperature.

The lining shall be fixed to the shoe by counter sunk screws.


3.09.03.2 Clamps
Rail clamp shall be provided between the two travel wheels. Further, limit switches
shall be provided for Rail clamp ‘ENGAGED’ and ‘DISENGAGED’ signals.

Minimum clearance between the Rail clamp face and rail surface shall be 50mm.
However, this clearance may not be uniform for both the faces of Rail clamp
throughout the length of rails. Rail clamp shall operate satisfactorily under this
condition without the need for any adjustments.

Complete Rail Clamp mechanism shall be manufactured from forged steel.

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BRAKES AND CLAMPS

1.0.0 GENERAL

1.1.0 Brakes For conveyors & other equipment, as required

1.2.0 Clamps For various mobile equipment traveling on rails.

2.0.0 DESIGN & CONSTRUCTION


REQUIREMENT

2.1.0 Brakes

2.1.1 Type Electro Hydraulic Thruster brakes A.C.


operated.

2.1.2 Braking Torque Adjustable from 0 to 100% of rated braking


torque.

2.1.3 Brake Shoes Operated directly by spring without lever arm


linkages.

2.1.4 Shoe lining Asbestos with interwoven brass wires, fitted with
counter sunk screws.

2.1.5 Max. Temperature for shoe 200 degree C.


lining

2.1.6 Thrustor Class-B insulation, IP-65 protection.

2.2.0 Clamps

2.2.1 Rating Adequate, subject to approval.

2.2.2 Rail Clamp support Independent from the rails.

2.2.3 Limit Switches “ENGAGED” & "DISENGAGED” signals.

2.2.4 Clearance between Rail clamp Minimum 50 mm


face & Rail surface

2.2.5 Material for Rail clamp Forged steel


Mechanism

2.2.6 Thrustor Class-B insulation, IP-65 Protection

3.10.00 DRIVE EQUIPMENT

Suitable Drive Equipments like electric motors, gearboxes (where applicable), fluid
couplings (where applicable), flexible couplings and other accessories shall be
provided for conveyor systems, mobile trippers, cooling water pumps for oil cooling
of scoop type fluid couplings for H.T.drives, fans for ventilation system and other
equipments as specified. Various requirements for individual equipments shall be
taken into consideration while designing the associated drive equipments.

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3.10.01 CODES AND STANDAR DS

The design, manufacture, inspection and testing of Drive Equipment shall comply
with all the currently applicable statutes, regulations and safety codes in the locality
where the equipment in to be installed. The Drive Equipment’s shall conform to the
latest edition of the following standards and codes. Other internationally acceptable
standards/codes, which ensure equal or higher performance than those, specified,
shall also be accepted. Nothing in this specification shall be construed to relieve
the Bidder of the required statutory responsibility. In case of any conflict in the
standard and this specification, the decision of the Project Manager shall be final
and binding.

IS:3688 : Dimensions for shaft ends

IS:3681: General plan for spur & helical gears

IS:7403 : Code of practice for selection of standard worm and helical gear boxes

3.10.03 DESIGN AND CONSTRUCTION REQUIREMENTS

3.10.03.1 Gear Boxes

i. Gear Boxes shall be of sealed type and mounted on machined or ground


surfaces.

ii. The gearboxes shall be designed for 24 hours continuous duty. For thermal
and mechanical rating of the gearbox the data sheet shall be referred to.
Gearboxes with cooling coils are not acceptable.

iii. The gears used shall be helical conforming to IS:3681 (latest revision) or worm
reduction units or spiral bevel speed reduction units conforming to suitable
Indian Standards. The dimensions of the shaft end shall conform to IS:3688 or
its latest revision. Above 40 kW drive rating, all gearboxes shall be helical or
bevel helical type only.

iv. Recommended oil grade shall be compatible with gear internals like material of
bearing, cages. Further, all gearboxes shall have suitable breather plugs,
dipstick, drain plug etc.

3.10.03.02 Couplings

A) Flexible / Rigid Couplings

Approved type of couplings shall be used for power transmission depending upon
duty requirements. The design of the coupling shall be such that it can take shock
and misalignment without sacrificing its efficiency. Geared type flexible coupling
shall be used on low speed side for all conveyors and other drives where gear box
is provided. Other couplings in the drives shall be either rigid or flexible type,
depending upon the requirement of equipment design and shall be finalised during
detailed engineering.

B) Fluid Couplings

Scoop tube type fluid coupling shall be provided for HT motors Suitable
electrically operated actuators shall be provided for scoop tube operation from local
as well as remote. Suitable provision for alternate manual operation shall also be
kept. Separate pump with motor shall necessarily be provided for circulating the

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fluid coupling oil through oil cooler. Independent arrangement for forced cooling
water supply using 2X100% capacity pumps to oil cooler shall be provided by
Bidder. Suitable interlock using flow switches shall be provided in both oil as well
as water lines to trip the drive motor in the event of flow in either line falling below
acceptable levels. Suitable pressure indicators and flow indicators shall be
provided in the cooling water lines along with all-relevant valves, strainers and
accessories. Necessary isolation valves shall be provided in the oil / water line for
maintenance of any equipment in the line. Necessary interlock shall also be
provided so that the HT motor cannot be started from remote / local unless position
of scoop tube permits no load start of the motor. Tripping of downstream
equipment while the system is under normal operation shall result in scoop tube re-
positioning to permit no load run of the concerned HT motor.

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TECHNICAL SPECIFICATION

DRIVE EQUIPMENT

1.0.0 GENERAL

1.1.0 Continuous Motor Rating (Name Plate Rating) at


50 Degree Centigrade Ambient temp. for
Electric Motors

a) For conveyors of belt conveyor systems 120% of actual power at


drive motor output shaft at
specified design capacity.
H.T. Motors shall be provided
for Crushers and any other
equipment as required.

c) Mobile trippers travel drive, mono-rail hoists *110% of actual power


(travel and hoisting), service water systems, requirement at drive motor
cooling water pump drives. output shaft at guaranteed
(rated) capacity.

d) Ventilation Fans *110% of actual power


requirement at drive motor
output shaft at guaranteed
(rated) capacity. In case of
belt drive, the efficiency of
transmission shall be
considered as 95%.

*The actual power at drive motor output shaft shall be calculated after
considering all the losses of down the line equipment’s of the drive train.

2.0.0 DESIGN & CONSTRUCTION REQUIREMENT

2.1.0 Gear Box

2.1.1 Type

(a) Below 40 KW Helical, worm, bevel as per


requirement without cooling
coil

(b) Above 40 KW Helical / bevel helical without


cooling coil

2.1.2 Service Factor As per accepted engineering


practice / manufacturer's
recommendations

2.1.3 Ambient temperature for Thermal rating 50oC Minimum

2.1.4 Mounting On machined/ground


surfaces

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2.1.5 Continuous Output Rating of gear box Equal or greater than the
following :

a) For belt conveyor systems


Service factor X {1.2 times
the actual power requirement
at drive pulley shaft at design
capacity}

b) For other equipment

Service factor X {1.2 times


the actual power requirement
of the driven equipment }

2.1.6 Duty 24 Hrs. Continuous

2.2.0 Flexible Couplings

2.2.1 Type As per duty requirement.

2.2.2 Rating Not less than motor rating.

2.3.0 Fluid Couplings For all motors having rating


more than 40 KW.

2.3.1 Type

(a) L.T. Motors Traction type

(b) H.T. motors Scoop tube type.

2.3.2 Rating Not less than motor rating

3.11.00 DUST EXTRACTION (DE) / SUPPRESSION (DS) SYSTEM AND SERVICE WATER
SYSTEM

a. DE units will be provided on the plough feeders for extracting dust generated

during unloading of coal. DE units shall also be provided for Crusher House ,
Bunkers and Bunker floor.
b. There will be two (2) service water pumps (1 working + 1 standby) which supply
water to (a) local water storage tanks of D.S. system of stockyard, transfer
houses, junction towers and crusher house. (b) Service water tap points for
plant cleaning, toilets etc. Each DS system will be provided with two (1 working
+ 1 standby) pumps.
c. The quantity of water to be sprayed for the stockyard DS system will be
calculated so that dust will be suppressed to the maximum extent but no

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unnecessary moistening will occur. The operation of each section of sprinklers


will be sequential.
d. Service water piping will be provided all along the tunnels and galleries with tap
off points at 30 metres interval to enable cleaning of walkways / deck plates
using flexible hose.
e. Service water piping with tap off points (with isolating valve and quick
connecting coupling) will be provided for each floor of junction towers, transfer
houses and crusher house.
f. Each tap off point will contain isolating valve with quick connecting coupling to
enable fixing of hoses.
g. Each water spray header in DS system will be provided with a solenoid valve to

stop the water spray when the concerned plant and equipment of coal handling
system do not operate.
h. Each DS System will be operated from the local control panels and will be

interlocked with the respective conveyor / equipment.


i. Dust suppression system will be provided for coal stockpile, and conveyor
transfer points.
j. Water spray arrangement will be provided for two (2) waiting wagons before the

track hopper.

3.12.00 COAL YARD DRAINAGE


Around the coal stockyard, drainage channels will be constructed to take all the
effluent from the coal stockyard (rain / leach water), which will be ultimately led to a
pond. Run-off water from rain is the main effluent from coal storage yard which
needs special attention and the discharge limits will be as per World Bank
Guidelines/state pollution control board guidelines. Such effluent water shall be led
to a suitable pond and coal dust will settle down in this pond and clear water will be
discharged to the Effluent Water Treatment Plant.

3.13.00 VENTILATION SYSTEM

3.13.01 GENERAL DESCRIPTION


The air quantity for mechanical ventilation system shall be estimated based on
equipment and solar heat loads and the temperature rise inside the building. Dust
extraction system shall be provided for tripper floor, crusher house etc. Exhaust clean
air shall be discharged at a suitable height above building.

3.13.02 Codes & Standards

The design, manufacture, inspection and testing of Ventilation System shall comply
with all the currently applicable statutes, regulations and safety codes in the locality
where the equipment is to be installed. The Ventilation shall conform to the latest
edition of the following standards and codes. Other internationally acceptable
standards/codes, which ensure equal or higher performance than those specified,
shall also be accepted. Nothing in this specification shall be construed to relieve

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the Bidder of the required statutory responsibility. In case of any conflict in the
standard and this specification, the decision of the Owner shall be final and
binding.
IS:3588 : Specification for electrical axial flow fans.
IS:2312 : Propeller type AC Ventilation fans

3.13.03 DESIGN REQUIREMENT

3.13.03.1 Axial Fans

i. Design duty point of the fan shall match with the average value of maximum and
minimum flow rates of the fan in the stable operation zone. The speed of the fan
shall not exceed 960 rpm for fan with impeller diameter above 450 mm and 1440
rpm for fan with impeller diameter 450 mm and less. The first critical speed of
rotating assembly shall be at least 25% above operating speed.

ii. Impellers shall be axial flow type single piece.

iii. For design purpose out door ambient temperature shall be taken as 50 deg.C.

iv. The motor shall be rated for continuous operation and conform to companion
electrical specification. However, motor rating shall not be less than the max.
power demand throughout the entire range of operation of fan.

v. All fan mountings shall have adequate arrangement for vibration isolation.

vi. The reverse flow through non-working fan shall be automatically and positively
prevented by Modutrol motor operated discharge dampers. The dampers shall
be made out of 18 SWG MS sheets.

vii. Design duty point of the fans shall match with the average value of maximum
and minimum flow rate of the fan in the stable operation zone.

3.13.03.02 Filters

Metallic Filters
Metallic cleanable filters shall be provided as required. Maximum air velocity
considered shall be 2 m/sec. Metallic cleanable filters shall consist of V-fold
galvanised wire mesh inter spaced with a flat layer of galvanised wire mesh. The
density of the filter medium shall increase in the direction of airflow. Wire mesh edges
shall be suitably hemmed to eliminate the danger of abrasion during handling. Filter
medium shall be supported on either side by galvanised expanded metal casing.
Filter frame shall be constructed from galvanised sheet of thickness not less than 18
gauge.

HDPE Filters

HDPE filters should have an efficiency of 90% down to 5 microns. Velocity across
the filter shall be limited to 2.5 m/sec.

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High efficiency filter (for A/C purpose). Filtration efficiency shall not be less than
99.9% down to 5 microns. Pressure drop across the filter under clean condition
shall not be more than 10 mm wc.

3.13.04 CONSTRUCTION REQUIREMENTS

General construction details of various equipment under Bidder’s scope shall be


as elaborated in subsequent clauses below.

3.13.04.1 Axial Flow Fans

i. Axial flow fans shall be provided as required.

ii. Impellers shall be axial flow type and single piece cast aluminum with
aerofoil blades construction. It shall be finished all over and balanced
dynamically. Impeller shall be mounted directly on the motor shaft.

iii. Casing shall be of heavy gauge construction properly reinforced for rigidity.
It shall be provided with suitable supports. Access door shall be provided
in the casing for easy access to motor and impeller. Suitable arrangement
for mounting of motor shall be provided.

iv. Rain protection cowls will be designed to suit wall exhausters/supply fans
for protecting fans/motors from rain. It will be provided with bird screen.

v. Inlet cone or bell and outlet cone shall be provided as required. It should
be made of G.I. or M.S.

vi. Motor shall be of totally enclosed type complying with the companion
electrical specification. Suitable rain/sun shade for motors shall also be
provided.

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VENTILATION SYSTEM

1.0.0 GENERAL

1.1.0 Mech. Ventilation System To provide ventilation and


dust extraction systems in
tripper bay, crusher house,
electrical rooms etc. as
required.

1.1.1 No. of air changes per hour

(a) For over ground building Not less than 10

1.1.2 Equipment

Bunker floor Axial fans

2.2.0 Axial Fans

2.2.1 Capacity 10% more of actual


requirement

2.2.2 Head 20% more of actual


requirement

2.2.3 Speed

(a) Impeller dia above 450 mm Max. 960 rpm

(b) Impeller dia less than or equal to 450 Max. 1440 rpm
mm

(c) Critical speed 25% above operating speed.

2.5.0 Filters

2.5.1. Metallic Filters

(1) Max. air velocity 2m/sec.

2.5.2 HDPE filters

(1) Efficiency 90% down to 5 microns

(2) Max. velocity 2.5 m/sec.

(3) Testing As per BS 2831 / Sqv.

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3.14.00 MONORAILS AND HOISTS

Suitable handling arrangements shall be provided for handling equipment of coal


handling system. Bidder shall provide monorails and hoist blocks with cross travel
facility.

3.14.01 CODES AND STANDARDS

The design, manufacture, inspection and testing of Monorails and Hoists shall
comply with all the currently applicable statutes, regulations and safety codes in the
locality where the equipment is to be installed. The Monorails & Hoists shall conform
to the latest edition of the following standards & codes. Other internationally
acceptable standards/codes, which ensure equal or higher performance than those
specified, shall also be accepted. Nothing in this specification shall be construed to
relieve the Bidder of the required statutory responsibility. In case of any conflict in
the standard and this specification, the decision of the Project Manager shall be final
and binding.

IS:3938 : Specification for Electric Wire Rope Hoist


IS:2429 : Round steel short link chain
IS:3109 :Short link chain grade M(4)
IS:3815 :Points hooks with shank for general engineering purposes
IS:210 : Cast Iron Castings
3.14.02 DESIGN REQUIREMENTS

1. For the Hoists with more than 2.0 tonne lifting capacity or more than 10.0 M
lift, motor operated hoist blocks for both long travel and lift shall be provided.
Other hoist blocks shall be of hand operated type for both travel and lift.
However, monorails coming out of the building shall be provided with electric
hoist blocks, irrespective of load and lift. Adequate length of Cantilever shall
be provided in monorails to lower the equipment to ground level clearing the
building sidewalls.

2. The exact lift/travel and the number of the hoisting mechanisms and the mode
of lifting equipment’s to various floors of the buildings shall be as decided by
the Purchaser during detailed engineering. It shall preferably be avoided to
use one single hoist for handling more equipments. Clear height shall be
maintained when handling one equipment over other, in such case no
dismantling of any equipment is admissible. The center line of monorail shall
not deviate by more than 500 mm from the center of gravity of any equipment
that is to be lifted.

3. Monorails shall be extended outside the building to handle the equipment to


ground level. Suitable machinery well and removable handrailing/grating shall
be provided on various floors of buildings, as necessary.

4. Electrically operated monogirder type hoists shall consist of following major


components.

(a.) Electrically operated trolley complete with drive motor (Trolley travel
speed maximum 15 m/min.).

(b.) Hoist cable, hoisting block and hooks complete with drive motor
(Hoisting speed maximum 6m/min.).

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(c.) Limit switch to prevent overhoisting, over lowering and over


travel.

(d.) Festoon arrangement of feeding power to trolley assembly.

(e.) Erection hardware.

(f.) Pendent control station suspended from hoist.

5. The hoist shall be designed and constructed in accordance with the latest
revision of IS:3938 and shall be suitable for duty class 2.

6. Trolley movement and hoisting shall be effected by using two separate motors.
The motors shall be suitable for 150 starts per hour at 40% CDF.

7. Trolley shall be designed to accommodate a wide range of I beams and shall


be capable of travelling on straight as well as curved monorails with the design
being such to maintain uniform distribution of pressure on the flanges.

8. Motor operated geared trolley shall have two (2) pairs of wheels, one pair of
which shall be driven through motor.

9. Wire rope shall be of pre-formed type, hemp cored, regular lay 6/36
construction with a breaking strength of 160-175 kgf/ sq. mm. Reverse bend of
ropes is not acceptable. Minimum number of falls of rope shall be four (4).

10. All gears and pinions shall be of hardened and tempered steel with machine
cut teeth in metric modules. Surface hardening of steel is not acceptable.
11. All running shafts and wheels shall be fitted with roller bearings with a rated life
not less than 20 years based on equivalent running time as per IS:3938.

12. An electromechanical brake shall provide restraining torque. Brake lining shall be
of asbestos.

13. Cast iron parts, wherever used, shall be of minimum grade 30, IS:210.

14. Hoists shall be selected to have minimum headroom and shall be selected to lift
heaviest piece of equipment. Further, it shall be possible to handle any
equipment without disturbing other equipment.

3.14.03 CONSTRUCTION REQUIREMENT

i. The hoist mechanism shall consist of a grooved rope drum driven by


electric motor through gears. Each end of the rope shall be anchored to
the drum in such a way as the anchorage is readily available for
maintenance. Each rope shall have not more than two (2) full turns of the
drum when the hook is at its lowest position and one (1) spare groove
when the hook is at its highest position.

ii. Rope drum, gear box, block etc. should be fabricated out of weldable
quality steel.

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iii. Trolley wheels shall be of single flange type in the taper treads. The
wheels shall be mounted on antifriction bearings and shall be easily
removable for repair/replacement.

iv. The load hook shall be swiveling type forged circular shank section and
shall confirm to IS:3815.

v. All gears and bearings shall be lubricated by grease. All lubricating points
shall be grouped together in easily accessible position.

vi. The bottom block shall be of enclosed type and shall have guard against
rope jamming in normal use. It shall have standard forged swivel shank
hook fitted on antifriction thrust bearing. Lock to prevent hook from
rotation and locking arrangement to prevent accidental unlocking shall be
provided. Pulley of the bottom block shall be provided with antifriction
bearings.

vii. All parts requiring replacement/inspection/lubrication shall be accessible


without need for dismantling of other parts/structures.

viii. All components of hoists of identical capacity and duty shall be


interchangeable.

ix. Hoists shall have permanent inscription in English on each side readily
recognizable from floor level stating safe working load.

x. Pendant shall be provided with up/down/forward/reverse travel push


buttons and indicating lamps. Its power supply shall be limited to 24V
AC.

xi. The control panel shall be Pendant type / wall mounted type & easily
approachable from the floor by a person in standing position.

xii. For Inspection / maintenance of hoist components a fixed platform with


ladder shall be provided for each hoist.

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MONORAILS AND HOISTS

1.0.0 GENERAL
1.1.0 Functional Requirement : To transfer equipment’s to
maintenance area or outside the
building.
2.0.0 DESIGN & CONSTRUCTION
REQUIREMENT
2.1.0 Hoists
2.1.1 Drive
(i) More than 2.0 tonne or more than Motor driven for both travel & lift.
10.0 m lift or hoists coming out-side the
buildings
(ii) Others Manual for both travel & lift.
2.1.2 Maximum trolley travel speed for electric 15m/min
hoists
2.1.3 Maximum Hoisting speed for electric 6 m/min
hoists
2.1.4 Drive Motors SQIM, Separate for travel & lift
2.1.5 No. of starts for drive motor 150 starts/hr at 40% CDF
2.1.6 Wire Rope
(i) Type/Construction Pre-formed type, hemp cored,
regular lay 6/36 construction
(ii) Breaking Strength 160-175 kgf/sq. mm
(iii) Minimum No. of falls four (4)
2.1.7 Bearing
(i) Type Roller bearing
ii) Life 20 years
2.1.8 Brake Electro Mechanical type with
asbestos lining.
2.1.9 Load Hook Swiveling type forged circular
shank section.
2.1.10 Duty Class -2
2.2.0 Monorail location/layout
2.2.1 Cross section I beam
2.2.2 Distance between C/L of monorail & Maximum 500 mm
C.G. of equipment to be lifted
2.2.3 Power Cables Support Festoon type arrangement

2.3.0 Manual Hoists


2.3.1 Maximum manual effort for operation. 30 Kg

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HOIST SCHEDULE
(tentative & shall be as per actual requirements)
S.No. Location Minimum Minimum Type *
Capacity (T) Quantity
1 Track Hopper 10 2 E
Complex
2 JT 15 1 E
3 Crusher house 10 1 E
4 Crusher house 2 1 M
5 Crusher house 2 1 M
6 SR 2 1 E
7 JT 15 1 E
8 JT 2 1 E
9 Bunker floor 10 1 E

* Type E – Electric Operated


Type M – Manual Operated

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