1.2.0 Scope of Work
The work shall include but not limited to the following:
1.2.1 Mechanical Equipment
18.104.22.168 Six (6) Nos. Paddle feeders, complete with all electricals, rails, supporting structures, end stops, cable reeling drums, trailing cables and necessary accessories.
22.214.171.124 Complete Belt Conveying Systems including Conveyor Nos. 1A/1B, 2A/2B, 3A/3B, 4A/4B, 5A/5B, 6A/6B, 7A/7B, 8, 9A/9B and 10A/10B complete with conveyor supporting structures, short supports, stringers, deck plate, seal plate etc. drive motors, drive units, pulleys, idlers, gravity take ups, take up structure upto ground level, internal and external belt wipers, pull chord switches, belt sway and zero speed switches, electro-hydraulic thruster brakes, all electricals etc. including all civil, structural and architectural works for conveyor gallery, gallery supporting trestles and their associated foundations.
126.96.36.199 Tripper floor belt conveyors 7A/7B in the bunker building complete with conveyor supporting structures, short supports, stringers, deck plate, seal plate etc. drive motors, drive units, pulleys, idlers, gravity take ups with guides upto ground level excluding the take-up structure, internal and external belt wipers, pullchord switches, belt sway and zero speed switches, electro-hydraulic thruster brakes etc. and all electricals etc.
188.8.131.52 Yard conveyor 8 complete with conveyor supporting structures, short supports, stringers, deck plates, etc., drive motors, drive units, pulleys, idlers, take-ups, take-up structure, internal and external belt wipers, pull – chord switches, belt sway and zero speed switches, electro hydraulic thruster brakes, all electricals, etc. including all civil, structural and architectural works and their associated foundations.
184.108.40.206 Four (4) Nos. Vibrating feeders in Primary Crusher House complete with drives, all mechanical, electrical and accessories. Four Nos. Rotary Breakers complete with drives, all mechanical, electrical including civil and structural works.
220.127.116.11 Two (2) numbers crusher house (one primary crusher house and one secondary crusher house) complete with all civil, structural, architectural and electrical works etc accommodating four nos. crushers and associated vibrating grizzly feeders, gates etc., goods cum passenger lift, conveyors, chute work alongwith actuator operated flap gates, hoists and other equipment such as coal sampling unit, dust suppression & ventilation system etc. as specified elsewhere.
18.104.22.168 Four (4) nos. roller Screens (in secondary crusher house) complete with drives, all mechanical, electricals and accessories.
22.214.171.124 Four (4) nos. crushers complete with drives, all mechanical, electricals including civil & structural works, vibration isolation system with springs & viscous dampers, vibration monitoring system etc.
126.96.36.199 Four (4) sets of Gates each comprising of one rod gate and one actuator operated rack & pinion gate at inlet to each of the above vibrating roller screens complete with drives, all mechanical, electrical, structural works etc.
188.8.131.52 Transfer point TP1 alongwith under ground tunnel and pent house PH-I, TP-6 alongwith underground tunnel and pent house PH’ and drive house for yard conveyor 8 complete with all civil, structural, architectural and electrical works including chutes, monorails, hoists/chain pulley blocks, hoist maintenance platforms, RCC/steel floors, external staircases, hand rails etc. All transfer points shall have separate debris disposal chute right up to the ground floor.
184.108.40.206 All mechanical, electrical equipment to be housed in Transfer points TP-1, TP-2, TP-3, TP-4, T.P-5, T.P-6, T.P-7, drive house of yard conveyor and pent houses including chutes, maintenance / operating platforms, Monorails, electric hoists etc.
220.127.116.11 One (1) no. stacker cum reclaimer machine having rated capacity of 1600 TPH/ 1600 TPH complete with all equipment and conveyors, structural, electricals, cable reeling drums, all trailing cables and accessories, rails, rail foundations, fixing and grouting of rails and other associated civil & structural works to operate in conjunction with yard conveyor 8.
18.104.22.168 Complete chute work along with chute block switches and actuator operated flap gates between various conveyors and equipment at all transfer points and crusher house.
22.214.171.124 Three (3) Nos. passenger – cum – goods elevators with drives, all mechanical, civil, structural & associated foundation works, accessories and electricals to serve various floors of the Primary and secondary Crusher House (CH) and TP-5
126.96.36.199 Two (2) Nos. motorized Travelling Trippers, One (1) each on conveyor 7A/7B. Trippers shall be complete with all mechanical, electrical equipment, rails, rail supporting structure (any structural stools, if required), cables with cable reeling drum, all trailing cables, brakes, rail clamp etc. Grid/ grating over the bunker slot on tripper floor is to be provided by the bidder.
The drive chain equipment for conveyor 7A/7B therefore shall first be placed at the end of unit no. 1 bunkers for commissioning of unit no. 1 and shall be later shifted at the end of the bunker bay at the time of commissioning of unit no. 2. Bidder’s scope of work shall include shifting of the drive chain equipment for conveyors 7A/7B for unit no.2 commissioning including its associated civil and electrical works and making good the bunker floor after shifting of the drive chain equipment to its ultimate location for unit no. 2 commissioning.
188.8.131.52 Adequate number of ventilation for ventilating the track hopper, TP-1, underground portion of conveyor 1A/1B, under ground portion of TP-6 and under ground portion of conv. 9A/9B and bunker bay (housing tripper conveyors) complete with all mechanical, electrical, civil and structural works.
184.108.40.206 Pressurised Ventilation system for all HT Switchgear room, MCC rooms and S&T room complete with all mechanical, electricals, accessories, civil and structural works.
220.127.116.11 Air conditioning of Main CHP control room; operator’s cabin & MCC room on Stacker/Reclaimer complete with all electricals, civil & structural works etc.
18.104.22.168 Minimum nine (9) Nos. sump pumps six (6) nos. in track hopper and three (3) nos. sump pumps each in underground tunnel and Transfer point of Conveyor no. 9A/9B complete with motors, local control panel, level switches, individual discharge piping with fittings and valves to nearest plant drain as specified and as indicated elsewhere.
22.214.171.124 Two (2) Nos. coal sampling units, one for (-) 300 mm size coal complete with all accessories and electricals, supporting structures, approach/ maintenance platforms in unit, in crusher house and one for (-) 20 mm size coal in TP-4 complete with all accessories and electricals, supporting structures, approach/ maintenance platforms.
126.96.36.199 One (1) No. belt vulcanising machines of adequate size complete with all mechanical, electricals, accessories and consumables.
188.8.131.52 Four (4) Nos. Inline Magnetic Separators, complete with reject chutes, reject bins, and all mechanical, supporting arrangement, electricals, civil, structural works and accessories.
184.108.40.206 Four (4) Nos. Electronic Belt weighers complete with all mechanical, supporting arrangement, electricals, and accessories.
220.127.116.11 Complete dust suppression system for control of fugitive dust in track hopper, paddle feeder, transfer points, crusher house, coal stock yard complete with pump houses, water tanks, pumps, drives, piping, valves etc.
18.104.22.168 Belt Sealing arrangement in Bunker bays to operate in conjunction with tripper for control of dust coming out of R.C. Bunkers.
22.214.171.124 Suitable monorails and electrically operated hoist blocks as well as hand operated chain pulley blocks for servicing/ installation / easy replacement of drive machinery, different types of pulleys for all conveyors, GTU and other equipment from ground level to all locations. Electric hoist provided at bunker (Tripper) floor and all transfer houses/crusher house shall also be able to lift one belt drum (including wooden/ Steel drum) safely.
Two nos. 11 kV feeders and two nos. 3.3 kV supply feeders shall be provided from 11 kV & 3.3 kV station board for feeding entire CHP.
The scope of work shall include, but not limited to the following:
126.96.36.199 3.3 KV CHP Switchgears to feed HT drives including Stacker Reclaimer and auxiliary transformers.
188.8.131.52 Auxiliary Transformers :
a) Two (2) nos. 11/3.45 kV, ONAN, out door transformers for 3.3 KV CHP Switchgear.
b) 3.3 / 0.433 KV, ONAN, out door transformers for each of the CHP MCC-I, II, III.
c) One (1) no. 3.3/0.433 KV, Dry type indoor Transformer for S/R machine
184.108.40.206 Three (3) nos. of 415 V CHP MCCs to feed LT loads of entire coal handling plant. These three CHP MCCs are proposed to be located as follows :
a) MCC-II in the MCC room near Track hopper area.
b) MCC-I in the switchgear room at CHP control room building near Secondary Crusher House.
c) MCC-III in the MCC room near Transfer Tower.
220.127.116.11 One (1) no. of 415 V Stacker/Reclaimer MCC.
18.104.22.168 3.3 KV segregated phase bus ducts from 11/3.45 KV transformer to 3.3 KV CHP switchgear alongwith bends, terminations, supports etc.
22.214.171.124 Control desk and Programmable logic controllers (PLCs) :
a) Main control desk with CRT/keyboard and large video screen, PLC panels, remote I/O racks etc. for the control of the entire coal handling plant.
b) PLC system with control desk and I/O racks etc. for Stacker/ Reclaimer machine.
126.96.36.199 AC distribution boards as required.
188.8.131.52 Six (6) nos. DC distribution boards (2 Nos. each at the location of MCC-I, II, III.
184.108.40.206 Local push button stations for all drives.
220.127.116.11 Internal and external illumination system for the complete CHP & coal stock yard, including track hoppers, TPs/ conveyors in bunker area etc.
18.104.22.168 3.3 KV and 1.1 KV grade FRLS, XLPE/ PVC, AI/Cu, Armoured power, control, trailing and special cables for the complete system
a) between equipment supplied under this specification.
b) between equipment supplied under this specification and Purchaser’s equipments.
22.214.171.124 Cable trenches / trestles including trays and supporting arrangement etc., required for the cables including laying & termination / jointing etc.
126.96.36.199 Earthing and lightning protection system for all equipment and buildings.
188.8.131.52 Close circuit TV system.
184.108.40.206 Grouting of bolt holes and underside of base plates.
220.127.116.11 One (1) No. Main CHP control building located adjacent to the secondary Crusher House to house Main Control Desk, PLC panels for the coal handling plant on the first floor and 3.3 KV CHP switchgear, 415V CHP MCCs DCDB, lighting panels etc. on the ground floor. Associated auxiliary outdoor transformers shall be located suitably adjacent to the building.
18.104.22.168 Two (2) no. MCC rooms each to be located near T.P-1 and T.P-5. Each MCC room shall have 415V CHP MCC-1 and CHP-MCC-II respectively, lighting distribution boards, DCDB, I/O panel etc. Associated auxiliary outdoor transformers shall be located suitably adjacent to the building.
22.214.171.124 One (1) no. S&T (signalling & telecommunication) building to be located at exit of track hopper.
126.96.36.199 All MCC room buildings shall be complete with all electrical, civil, structural, architectural works, cable trenches, fire safety walls, foundation / fencing / earthing for transformers etc.
188.8.131.52 All cable/duct tanks/trenches/trestles including civil & structural works.
184.108.40.206 Control & Instrumentation
Operation and Control Philosophy
The coal handling system shall be controlled from the following control points.
220.127.116.11 Coal Handling Plant Main Control Room
Overall, operation of the following equipment of Coal Handling Plant shall be controlled from the main CHP control room.
a) Conveyors, feeders, flap gates, R & P gates, crushers, Vibrating Roller Screens.
b) Paddle feeders (running status with stop facilities).
c) Complete Dust Suppression system & service water system.
d) Ventilation system (group/individual control as required).
e) Vibration Monitoring System
f) In line Magnetic separators (ON/OFF control with indication).
g) Coal Sampling Systems (ON/OFF control with indication).
h) Belt weigher (ON/OFF control with indication)
i) Stacker Reclaimer (ON/OFF status with stop facilities).
j) Mobile trippers over bunkers (tripper position indications).
18.104.22.168 Local Control Panels
Local control stations for following equipment’s shall be provided
a) Paddle feeders along with its dust suppression system
b) Mobile trippers over bunkers
c) Coal Sampling units
d) Belt Weighers
e) Electric hoist – wall mounted control box with pendent push button controls.
f) In line magnetic separators
g) Sump Pump
h) Suspended Magnet
All the above local control panels shall be accessible and located near their respective equipment and shall be complete with all the required controls, interlocks, annunciation’s etc. Further, necessary controls, indications and annunciation’s for all the above equipment shall also be provided at main CHP Control Room as described under relevant clause.
22.214.171.124 Stacker / Reclaimer Control Room
The entire control & operation of Stacker Reclaimer machine shall be from the operator’s cabin on the machine itself.
126.96.36.199 In addition to the remote control of various equipment’s, local stop push button stations shall be provided for all equipment.
Track hopper to the reclaim conveyor shall be controlled from the paddle feeder itself based on instructions from main control room.
1) The following equipment will not come under interlock of the conveyor scheme.
2) Belt sway switch – not operated
3) Under speed switch – closed at 90% speed of the conveyor within designed accelerating time.
4) Motor protection – not tripped
5) Local stop PB – reset
6) Chute Block switch – not operated. Two such switches shall be provided.
7) End of travel limit switches – reset.
188.8.131.52 Annunciation System:
The mimic panel cum Control desk shall be provided with adequate number of facia type annunciation windows operating through PLC for audio-visual fault annunciation purposes. Wherever group annunciation is provided, alarm status of individual equipment shall be provided on CRT.