59928126 Operation Control Philosophy

PROJECT NLC TUTICORIN TPP-CHP

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L&T O9113-M-BM-CS-DB-0097

LARSEN & TOUBRO LIMITED APML TIR1-EPC-CHP-DM-W-0097

ECC DIVISION DATED 30.11.2010

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OPERATION & CONTROL

PHILOSOPHY OF

COAL HANDLING SYSTEM

(NLC TUTICORIN-TPP)

TABLE OF CONTENTS

PREPARED GSRK/ARUN DOCUMENT TITLE

OPERATION & CONTROL PHILOSOPHY OF

COAL HANDLING SYSTEM FOR NLC TUTICORIN-TPP

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SECTION TITLE

1.0.0 SYSTEM DESCRIPTION

2.0.0 OPERATION & CONTROL PHILOSOPHY

2.0.1 COAL HANDLING PLANT CONTROL ROOM

2.0.2 STACKER / RECLAIMER CONTROL ROOM

3.0.0 SYSTEM OPERATION

3.1.0 CONVEYOR SYSTEM

3.1.1 FLAP GATES / FLOW DIVIDERS

3.1.2 METAL DETECTORS

3.1.3 INLINE MAGNETIC SEPARATOR

3.1.4 IN-LINE CONVEYOR SCALE

3.1.5 COAL SAMPLING UNIT

3.1.6 TRAVELLING TRIPPERS

3.1.7 3-D BUNKER LEVEL TRANSMITTER

3.1.8 HOISTS & CRANES

4.0.0 UTILITIES

4.0.1 SWP/PWP/CWP/WTDP/WTP/DSP/THP/PFP/DFDS SYSTEM:

4.0.2 CYCLONE TYPE DE SYSTEM

4.0.3 VENTILATION SYSTEM

4.0.4 AIR CONDITIONING SYSTEM

5.0.0 SEQUENTIAL INTER-LOCK FOR CONVEYORS & OTHER EQUIPMENTS

6.0.0 THE PERMISSIVE CONDITONS FOR OPERATION OF CHP

COAL FLOW CIRCUIT:




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6.0.1 FLOW PATH- I: SHIP UNLOADERS TO STOCKYARD VIA CRUSHER HOUSE

6.0.2FLOW PATH-II : SHIP UNLOADERS TO BUNKER UNITS VIA CRUSHER HOUSE

(WITHOUT STACKING)

6.0.3FLOW PATH-III : SHIP UNLOADERS TO BUNKER UNITS VIA CRUSHER HOUSE

(WITH STACKING)

6.0.4 FLOW PATH-IV: STOCK YARD TO BUNKER UNITS.

6.0.5 COMBINATION OF ABOVE

7.0.0 ANNUNCIATION SYSTEM

8.0.0 STATUS INDICATION ON OWS

1.0.0 SYSTEM DESCRIPTION

This description shall be read in conjunction with the following drawings.

Flow Diagram - L&T drawing no. O9113-M-BM-CS-FD-0002 & Project drawing no.

NTPL/TA2/BE/02/0502

General Plant layout - L&T drawing no. O9113-M-BM-CS-PP-0001 & Project drawing no.

NTPL/TA2/BE/02/0501

COAL HANDLING SYSTEM (CHS) is a Turnkey package including Civil, Structural, Mechanical,

Electrical, Instrumentation & Communication etc. for Stacking, Reclaiming and conveying coal to

Bunker Unit (BU).

The coal handling system shall consist of two conveying streams from unloading to coal bunkers

with one stream normally operating and the second stream as stand by. However, it shall be

possible to operate both the streams simultaneously.

The material to be handled by the proposed system is Coal. Processed coal is required to be

conveyed to Bunkers. Coal would be received at the plant boundary by Ship.

1. Coal will be received at the dedicated new jetty at the Tuticorin port. Coal will be




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unloaded from the ships with help of shore unloaders and will be conveyed to conveyors 1A/1B.

Conveyor 1A/1B conveys coal to Conveyor 2A/B at Junction house JT-1. Two nos Metal

detectors (MD1 mounted on Conv 1A & MD2 mounted on Conv 1B) are provided for detecting

metallic materials present in the “As received” coal. Two nos In line magnetic separators (ILMS

-1 on Conveyor 1A & ILMS – 2 on Conveyor 1B) are mounted on discharge end of respective

conveyors at JT-1 for removal of metallic ferrous tramp present in the “As received “coal. Further

Conveyor 1A/1B is having facility for manual stone picking at a suitable location.

2. Conveyor 2 A/B will feed coal to either of Conv 3A1/B1 in JT-2 by means of flap gates FG

1 & 2. Conveyor 3 A1/B1 will feed coal to either of Conv 3A2/B2 in JT-2A by means of flap gates

FG 1A & 1B. Conveyor 3 A2/B2 will feed coal to either of Conv 4A/B in JT-3 by means of flap

gates FG 2A & 2B. Conveyor 4 A/B will feed coal to either of Conv 5A/B in JT-4 by means of flap

gates FG 3 & 4.

3. Two nos. Belt Weigh scale (BW-1 & BW-2) are mounted on Conv 3A2/3B2 respectively

for metering of “As Received” coal. Two nos Metal detectors (MD3 mounted on Conv 3A1 & MD4

mounted on Conv 3B2) are provided for detecting metallic materials present in the “As received”

coal.

4. Coal from each incoming conveyor 5A/5B to Crusher house will have two paths through

FG 5 & 6. 2 nos Roller Screens each of capacity 1250 MTPH (RS-1 & RS-2) are provided in one

path which permits the coal of size -50mm to their respective conveyors (6A/6B) & by pass the

oversized coal to their respective crushers each of capacity 1250 MTPH (CR-1 & CR-2) for

reducing the coal size to -50mm. The crushed coal is then allowed to fall over the respective

conveyors (6A/6B). The other path by passes the coal from conveyor 5 A/B to conveyor 6 A/B

through FG 5 & 6 if the received coal size is -50mm.

5. Two nos. In line magnetic separators (ILMS – 3 over Conv 5A & ILMS – 4 over Conv 5B)




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are provided at the head end of respective conveyors for removal of metallic tramp from the “As

received” coal. Two nos Metal detectors (MD5 mounted on Conv 5A & MD6 mounted on Conv

5B) are provided for detecting metallic materials present in the “As received” coal.

6. Conveyor 6 A/B will feed coal to either of Conv 7A/7B by means of FG 7 & 8. Conveyor

7A/B will further discharge the coal in JT-5 through Diverter Gate DG 1 & 2 to either Conveyor

18A/B for stacking coal in the crushed coal stockyard or on to Conveyor 8A/B for onward

conveying to Boiler Bunkers. Two nos. Belt scale (BS-3 & BS-4) are mounted on Conv 7A/7B

respectively for metering of “As fired” coal.

7. Conveyor 8A/8B conveys coal to Conveyor 9A/B at Junction House JT-6 through flap

gates FG 9 & 10. Conveyor 9A/B will feed coal on to Conveyor 10A/B at JT-8 through flap gates

FG 11 & 12. Conveyor 10A/10B will feed coal on to the bunker conveyor 11 at JT-9 or Conv

12A/B at JT-9 through flap gates FG 13 & 14. Conveyor 12A/12B will feed coal on to the bunker

conveyor 13 at JT-10 or Conv 14A/B at JT-10 through flap gates FG 16 & 17. Conveyor 14A/14B

will feed coal on to the bunker conveyor 15 at JT-11 or Conv 16A/B at JT-11 through flap gates

FG 21 & 22. Conveyor 16A/16B will feed coal on to the bunker conveyor 17 at JT-12.

8. One no Coal sampling unit (CSU-1) is placed on Conv 9A/9B at JT-8 for sampling of “As

fired coal”. Two nos. In line magnetic separators (ILMS – 5 over Conv 9A & ILMS – 6 over Conv

9B) are provided at the head end of respective conveyors for removal of metallic tramp from the

“As fired” coal. Further Conveyor 9A/9B is having facility for manual stone picking at a suitable

location. Two nos Metal detectors (MD7 mounted on Conv 9A & MD8 mounted on Conv 9B) are

provided for detecting metallic materials present in the “As fired” coal.

9. Two nos. Belt scale (BS-7 & BS-8) are mounted on Conv 10A/10B respectively for

metering of “As fired” coal.




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10. One number Travelling Tripper is mounted on each of the Bunker conveyor 11/13/15/17

(i.e. total four nos. of traveling trippers – TT-1 to TT-4) to feed the coal into Raw coal bunkers of

the boiler units (Unit 1 & 2).

11. From JT-5, Conveyor 18A/18B conveys coal to Yard Conveyor 19 & conveyor 20 A/B in

JT-13 through flap gates FG 27 & 28. Conveyor 20A/20B conveys coal to Yard Conveyor 21.

12. Two nos. unidirectional type stacker reclaimer of 2000 MTPH (stacking) / 1200 MTPH

(reclaiming) capacity are provided on Yard conveyors 19 & 21 respectively. The Stacker

Reclaimer machine operates on rails for stacking / reclaiming the coal in the stock yard area.

During reclaiming operation the reclaimed coal will be conveyed to the yard conveyors 19 & 21

by the Boom conveyor of the respective S/R machine which in turn will feed the same to

Conveyor 22A/B by means of flap gates FG 29 & 30 at JT-15 and at JT-16 respectively. Two

nos. Belt scale (BS-5 & BS-6) are mounted on Conv 19 & 21 respectively for metering of

“Stocking & Reclaiming” coal.

13. The reclaimed coal from Conv 22A/B can be fed on to Conv 9A/B at JT-7. From JT-7, the

coal can be conveyed to the raw coal bunker by Conv 9A/B, 10A/B, 12 A/B, 14 A/B 16A/B &

11/13/15/17 to the desired row of bunkers.

14. Three nos Passenger cum Goods Elevator are installed one each at Crusher house, JT-8

& JT-12 to facilitate movement of man & material in these buildings.

MAJOR EQUIPMENTS IN THE HANDLING PLANT ARE:

2 nos. Stacker Cum Reclaimer, capacity 2000 TPH (stacking) & 1200TPH (reclaiming).

2 nos. Roller screens (-50 mm), capacity 2000 TPH.




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2 nos. Ring Granulator Crushers (-300 mm), capacity 1000 TPH.

4 nos. Travelling Trippers, capacity 1200TPH

Conveyor stream capacity 2000 /1200 TPH.

1 no. Coal sampling Unit.

3 nos. Passenger cum Goods Elevator.

2.0 OPERATION & CONTROL PHILOSOPHY

The COAL HANDLING PLANT is controlled from the Control Room located in PMCC-2 near to

Crusher House.

2.0.1 COAL HANDLING PLANT CONTROL ROOM

The PLC Automation system for Coal and Handling Package shall be as per Automation System

Configuration diagram L&T Drg No. O9113-E-BM-CS-DD-300 and APML Drg. No. TIR1-EPC-CHP-DI-

F-300.




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Operation of the following equipment of coal handling plant is controlled from the main CHP control

room.

• Conveyors, Flap gates, Scoop Type Fluid Couplings, Crushers & Screens.

• Stacker Reclaimer (ON/OFF status with stop facilities)

• Travelling Trippers (tripper position indications).

• Complete Dust Suppression system

• Complete Service water system, Potable water system, Cooling water system

• Ventilation system (group/individual control as required)

• Inline magnetic separators (ON/OFF control with indication)

• Metal detectors (ON/OFF control with indication)

• Coal Sampling Units

• In line Belt Weigh Scale (ON/OFF control with indication).

The following Sub-Systems will be controlled through Dedicated PLC With Control Desk:

• Stacker-Cum-Reclaimer

The following Sub-Systems will be controlled through Micro-PLC:

• Travelling Tripper

The following Sub-Systems will be controlled through Relay Based Local Control Panels:

• Coal sampling units.

• Scoop Coupling System.

• Inline magnetic separator.

• Inline belt conveying system.

• Metal Detector.

• Sump Pump (Only Local Operation).

• Dust Extraction system.

• Dust Suppression system.




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All the above mentioned local control panels are accessible & located near their respective equipment

& will be complete with all the required controls, interlocks, and annunciations etc. Necessary controls,

indications and annunciations for all the above equipment will also be provided at main CHP control

room. In addition to the remote control of various equipments, Local stop push button stations will be

provided for all equipment.

2.0.2 Stacker / Reclaimer Control Room

The entire control & operation of Stacker Recamier machine will be from the operators’ cabin on

the machine itself.

3.0. SYSTEM OPERATION

Typical operation philosophy of the plant is mentioned below to develop the control & monitoring

scheme of plant & equipment under the package. Coal flow path selection will be done from HMI to

select any one of the following conveying paths.

• Ship Unloaders to Stock yard via Crusher House.

• Ship Unloaders to Bunker Units (BU-1, BU-2, BU-3 & BU-4) via Crusher House.

• Stock yard to Bunker Units (BU-1, BU-2, BU-3 & BU-4) via Crusher House.

• Combination of above.

Operator will select any one of the above paths from HMI located in the Control desk from CHP Control

Room in PMCC-2. The flow stream path is then selected by positioning different Flap Gates/Diverter

gates at desired positions by means of keyboard available at the control desk. Once the system is in

the operation, the gates cannot be moved from their positions and path. After the selected path is in

operation the movement of path selector will not have any effect on the system. Flap gates which do

not come in the stream in which coal flow is taking place, can be operated at any time.

The control system will be designed for “Auto” & “Manual” operation of the conveyors in the selected

path. Auto/Manual selection will be done from faceplate in HMI.




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AUTO MODE: In the ‘auto’ mode, the conveyors and related equipment shall start sequentially when

the ‘system start’ is initiated. During stopping, when the ‘system stop’ is activated, all conveyors will

also stop sequentially (in the reverse sequence) allowing time delays for clearing the belts.

MANUAL MODE: In manual mode, the operator shall start the conveyor system, in the same sequence

as in auto mode from MMI. The operator shall also stop the conveyor system, by pressing ‘system stop’

or individual ‘stop’ command from MMI in the reverse sequence.

During ‘sequence start’ in both auto and manual modes, first the required number of hooters (3 phase

induction motor type) will be energized simultaneously for a preset time of 1 minute or so (adjustable at

site) as per the program. After the preset time, the hooters will stop and a preset time of two minutes

(adjustable at site) as per program will be allowed for the movement of the personnel and for the

permissive of the conveyor system operation. This condition shall be indicated on the panel by glowing

of lamp ‘COAL HANDLING SEQUENCE START’. The starting permissive shall be available for a

period of 5 minutes (pre-programmed and adjustable in the field). In the event the last conveyor /

equipment is not started within this preset time of 5 minutes, the start command for equipment not

activated shall be withdrawn. The system cannot be started again unless the ‘sequence start’ push

button is again pressed and the hooters sound again, as described before. Those conveyors and

equipment, which have already started, shall continue to run.

The status indication in the graphic display against all conveyors and equipment in the selected path /

stream shall start slow flickering. But all status indications against all flap gates in the selected path

shall glow steadily. Therefore, from the selected flow stream path of the flap gates, the operator will

come to know the conveyors and equipment to be started for the selected path / stream. After a

conveyor / equipment are started, the status indications against that conveyor / equipment shall change

to steady glow indicating that it is running.

Graphic display status indicators associated with a particular motor / equipment shall flicker fast in case

of fault / trip.

In addition, emergency stop push button for immediate shut down of complete plant shall be provided in




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the CD Console.

For changeover of feed from one row of bunkers to another row of bunkers without stopping of the

CHP, provision shall be made for interlock bypass on the control panel for flap gates of all conveyors in

boiler area for the preset period. If the changeover, in above specified time, is not completed then the

entire CHP shall stop.

3.1.0 CONVEYOR SYSTEM

• Adequate numbers of Belt sway switches, at every 30m interval, are provided to protect

against the damage to the edge of the belt due to excessive sideways movement. In addition,

each conveyor is provided with one (1) no. Speed detection devices (Zero Speed Switch).

These Zero speed switches will be designed to sense belt speed. In case of speed of belt goes

below 90% of rated speed, it will trip the conveyor.

• The starting sequence of the conveyors will follow a direction opposite to that of

flow of material i.e.

In case of direct conveying of coal to boiler bunkers, start from bunker conveyor &

end up with Conveyor 1 A/ 1B.

In case of stacking of coal in stock yard, start from yard conveyor and end up with

Conveyor 1 A/ 1B. However, for yard conveyor to start, the Stacker Cum Reclaimer

should be in operation.

In case of reclamation of coal from stock yard, start from bunker conveyors and end

up with yard conveyor along with Stacker / Reclaimer.

The starting of mobile trippers are interlocked with operation of the respective bunker

bay conveyors.

Once a conveyor trips, flap gate directing coal from this conveyor shall change over

its position with a time delay and shall come back to the original position again.

• Interlocking of yard conveyor with stacker-cum-reclaimer boom conveyor is provided.




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• Any individual equipment (belt conveyor etc.) should not be allowed to start unless the

equipment immediately following the same in the direction of flow of material is already in

operation.

• Stop / Tripping of any equipment from running condition will trip all preceding equipment

in the system, except Crushers but will not affect succeeding ones which will continue to

operate.

• Adequate no of Pull cord switches at 30m intervals are provided along the length of each

belt conveyor, which will enable the respective conveyor to be stopped immediately. Belt

Protection switches, Pull Chord Switch & Belt Sway Switch, will be identified/addressed by a

specific number in the Main Control Room.

• Means are provided to pre-warn personnel working nearby when starting any conveyor,

Stacker – cum - Reclaimer & Travelling Tripper by providing Sirens.

• Interlocking of various conveyors is achieved with Flap gate, Flow Dividers Limit

switches and Zero speed switches.

• Motors will start only when the brake/rail clamp if provided, is in ‘Not applied’ condition.

Limit switches are provided to get the signal from brake for the above purpose.

• Ring granulators are provided with Speed and vibration monitoring instruments. Ring

granulators will trip in case Speed/vibration is going beyond tolerable limits of design.

Temperature sensing devices are installed on all bearings of each of the ring granulator to trip

the same in case of temperature goes beyond limit. Audio-visual annunciation is provided in

OWS.

• Tripping of the respective conveyor is provided in case any of Travelling Trippers starts

running along with conveyor belt at speed higher than the rated speed by providing an over

speed sensing device on the equipment.

• It is possible to bunker conveyor & Yard conveyor from Travelling tripper & Stacker cum

Reclaimer respectively.• Wherever Scoop type coupling provided for HT motors, the coasting time of respective

conveyor, thrustor brake, actuator selection and the chute size will be so selected such that




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there is no spillage of coal from any downstream conveyors during next start.

INTER-LOCKING:

a) Plant Interlock Scheme:

The entire CHP System will have three modes of control.

• Local de-interlock mode control will be carried out by local push button station (LPBS) for each

individual equipment/mechanism.

• Remote interlocked individual drive control from the HMI at Control Room.

• Remote interlocked route wise control from the HMI at Control Room.

The following material conveying systems/sub-systems shall come under Plant Inter-Locking Schemes:

Conveyors

Crushers

Flap Gates & Flow Dividers.

In Line Magnetic Separators

Metal Detectors

In Line Belt Weigh Scale

Stacker cum Reclaimer

Travelling Tripper.

The following Systems will not come under the interlock of Conveyor scheme.

All dust suppression systems & service water system.

Ventilation systems.

Hoist(Local operation only)

Elevator(Local operation only)

Crane(Local operation only)

Sump Pump(Local operation only)

All conveyors & equipment will have local push button stations each consisting of:




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Pos – I, Pos – II & stop button for flap gate and Pos – I, Pos – II, Pos - III &

stop button for Diverter gate.

Local Start & Emergency stop push button (Red) for other equipment.

Belt scale shall be started when relevant conveyors are started.

The dust suppression systems will be energized as soon as the conveyors at the transfer points are

energized.

Coal handling plant shall be tripped in case of detection of fire.

b) Interlock Of HT Motor:

HT motors used will continue to run on no load by disengaging the fluid coupling in case of failure of

any process interlock. The HT motors will however be tripped incase of any motor fault like O/L, high

motor winding temperature etc. In addition, in case of normal stop command, after running of the

system, motors will stop.

3.1.1 FLAP GATES/FLOW DIVIDERS

All flap gates / Flow Dividers / Diverter gates will be motorized and remote controlled from the main

control desk. Their position will be indicated on the mimic of main control room. Once a conveyor trips,

flap gate directing coal from this conveyor will change over its position with a time delay and will come

back to the original position again. This is to prevent jamming of gate.

3.1.2 METAL DETECTORS

• It is possible to start the conveyors only after energizing the metal detector and metal

detector ‘reset’ condition. Once the metal is detected, the corresponding conveyor will trip. It will

be possible to restart the conveyors, after local resetting of metal detector & putting back the

marker bag in position. Metal detector ON/OFF facilities is provided in the OWS.

• In case of tripping of conveyor system, metal detector will get de-energized after a time lag.

• Following individual indications are provided on Local Control panel

1. Metal Detector ‘ON’

2. Metal Detected




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3. Metal Detector ‘reset’

4. Metal Detector Faulty

3.1.3 IN LINE MAGNETIC SEPARATORS

• It is possible to start the conveyor only after energizing the magnet of ILMS. Further, if

conveyor system trips magnetic separators will get de-energized after a time lag. Also if drive

motor of cleated belt of ILMS trips, Magnetic separator will not get de energized, but

conveyor system will trip and audio-visual annunciation will appear at main CHP control

room.

• Following individual indications are provided on Local control panel

1. Magnetic separator ON.

2. Incoming supply ON

3. Under current relay operated.

4. Cleated belt motor ON/OFF/TRIP.

5. Oil temperature high

3.1.4 IN LINE BELT WEIGH SCALE

Each Belt scale will give output to DDCMIS for display of flow rate and totalizer on Remote Flow rate

Indicator & Remote Totalizer respectively at main CHP control room. Each Belt scale will also have rate

flow indicator & totaliser mounted near the unit.

3.1.5 COAL SAMPLING UNIT

1 set of Coal sampling unit, CSU-1 in JT-8 building for taking samples of Coal has been provided.

a. Coal sampling unit is controlled through CSU control panel located in the respective

building (JT-8) and Starter Panel/DB for the same shall be located inside the Buildings of MCC-3 &

MCC-6 respectively. Controls & interlocks for proper material flow is provided similar to Conveyor

system.

b. Only one start/stop push button for coal sampling system will be provided for




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automatic operation of complete coal sampling system. In any case, local push button stations will

be provided for all individual equipment of coal sampling system near the equipment.

c. All necessary automatic controls will be provided for meeting the requirements of

ASTM-D-2234.

d. In case of primary cutter getting stuck between parking positions, preceding

conveyor will be tripped.

e. There will be protection in the primary coal sampler to trip the conveyor belt in case

primary sampler falls on running conveyor due to coupling failure etc.

OPERATIONAL WRITE UP FOR COAL SAMPLING SYSTEM -1(CSU-1) AT JT-8

3.1.6 MOBILE TRIPPERS

• Mobile tripper unit is locally controlled from the operating platform suitably located with the unit

as per instructions given from main CHP control room.

• End travel limit switches are also provided.

• Travel drive motor will start only when brake and rail clamps are in disengaged condition.

• It will be possible to trip the bunker conveyors from tripper.

• When the last bunker is full, it will not be possible to change over the tripper flap gate from

bunker feeding position to last bunker feeding position.

• As soon as bunker conveyor trips, tripper flap gate will change over its position after a time lag.

• Operator will operate the mobile tripper on bunker conveyors from its carriage. Two nos.

emergency stop button, one on each side will be provided on tripper to stop the machine at any

position. The control unit on tripper will be provided with start / stop push button and indication lamp

for travel / gate. The tripper brakes & rail clamps will be energized (released) when the tripper

motors are ON and the brakes will be applied when the travel motors are OFF. Two travel limit

switches will be provided at either end of tripper carriage for limiting the travel drive between two

ends of the track. The first one will be normal limit and the second one for over travel limit. In




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addition to above, position indication for bunker position of tripper will be provided through limit

switches in Main control room.

Following individual indications are provided on local control panel.

Motor ON/OFF/TRIP

Brakes applied

Rail clamps applied

Flap gate position

• Indication of tripper flap gate positions is given in the main CHP control room.

• It is possible for operator to manually trip the coal feeding equipment viz paddle

feeders or Stacker / reclaimers from the tripper.

• Chute blockage switch is provided at each leg of chute & will trip the tripper conveyor in

case of blockage.

3.1.7 3-D Type Level Transmitter

3-D Level Transmitter (4-20mA type) shall be provided for boiler bunkers present in Bunker Unit 1,

Bunker Unit-2, Bunker Unit-3 & Bunker Unit-4. The 3-D level Scanner employs an array of three

antennas to transmit low frequency pulses and to receive echoes of the pulses from the content of the

Bunker/Container. Using three antennas the unit measures not only the time/distance of each echo but

also its direction.

Local display and annunciation shall be provided for High and Low level signals on the instrument and

level reading shall be available for operator at Control Room by means of 4-20mA.

In case of level high LH in bunker level, the feeding conveyor shall be stopped. Bunker level shall be

continuously displayed with low, low-low, high and high-high indications on the HMI.

3.1.8 HOISTS AND CRANES




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The hoists and cranes will be controlled through Pendent. The same will be approachable from the

floor. The pendant control panel will be provided with up / down / forward / reverse travel push buttons

and indicating lamps for operating the same.

4.0.0 UTILITIES.

The Utility System of Coal handling System at NLC Tuticorin-TPP consists of

SWP/PWP/CWP/WTDP/WTP /DSP /THP/DFDS system, DE system, Ventilation system and Air

conditioning system.

4.0.1 SWP/PWP/CWP/WTDP/WTP/DSP/THP/PFP/DFDS SYSTEM:

The pump house is installed near to the coal transfer area, RCC water tanks is placed close to the

pump station. Water from the tank shall be supplied to the service points by the pumping system The

water pumps located in Pump House. The pumps shall be centrifugal multi stage type suited for

continuous operation selected on the basis of best efficiency. The water pumping system shall consist

of Duplex strainer with SS element 250 microns in the suction side of the Pump. . Each pump shall

have a gate valve at the suction and discharge. Each pump shall have a check valve at the discharge.

A pressure relief valve with a bypass Globe & gate valve shall be provided at the return line of each

pumping system so that the excess water is discharged back to the water tank.

Pumping system so that the excess water is discharged back to the water tank. Water tanks shall be

with accessories like motorized butterfly valve/ Gate valve at inlet of tank, Level Switch, Gate valve for

Drain. Motorized valves will be operating /controlled by level switch. In case of low level MOV shall

open and make-up water will be filled-up. In case of high level MOV shall closed. The water pump shall

be interlocked with low level switch of the water tank to prevent the pump from dry running.

The pumps will be operated from control room. Following individual inputs will be provided to

DDCMIS system for alarms / indications:

1. Motor On, Off & Trip

2. Discharge water pressure low




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3. Water level is low in tank

4. Water level is high in tank

5. Compressor On, Off & Trip

6. Air receiver pressure High, Low

Pressure switch is introduced in the delivery line to maintain the minimum set pressure during the

operation. If the pressure falls down below the set pressure the standby pumps will start

automatically after time delay. Even after the pressure is not healthy inside the system the pump

will trip automatically after certain predetermined set time.

The control circuit should be designed to meet the fallowing interlocks.

• Both pumps cannot run together. Only one at a time in any mode.

• Pumps should not be started when the water level is lowest in the tank.

• Low contact of Level switch to be interlocked.

• After starting the pump if the pressure is not built within the specified time the running pump

should be stopped and other pump can be tried. If it is the same case with other pump too then

the system should stop and announce the alarm.

• Differential pressure switch in the duplex strainer gives the filter clogged signal. This No contact

to be used to announce the alarm “FILTER CLOGGED”.

• Along with the above interlocks regular motor protection like OL and SC to be used in the circuit.

4.0.2 SERVICE WATER SYSTEM:

Service water system is primarily intended for cleaning building floors, conveyor galleries / tunnels,

electrical rooms and toilets.

Service water connections shall be provided in conveyor galleries/tunnels at 30 m intervals. Minimum 2

nos of Tap points shall be provided at each floor in the junction towers, 4 nos at each floor of crusher

house, 1 no at toilets of MCC and Control rooms. Each service water connection shall be provided with

a globe valve and quick coupler of 25 NB size. 25 NB flexible hose of 25 m long shall be provided with




Sheet 19 Of 71

CHECKED MS/NH


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REV NO: A

storage boxes at each building and conveyor gallery. The service water pump (SWP-1A/B) located in

Pump House (near Stock pile) takes plain water (cooling tower blow down water) from the on ground

RCC storage tank-1 adjacent to the Pump House and supplies to various service water tapings nearby

surrounding buildings through network of pipe.

The service water pump (SWP-1A/B) capacity has been designed considering one tap point at each

conveyor gallery & JNT/ crusher house and toilets of MCC/control room under simultaneous operation

and each tap point consuming 12.5 lpm at 2.5 kg/cm2.

1000 ltrs. PVC water tanks shall be provided on the top of MCC/control room for storage of service

water.

Group Pump Tag No. Application Area OWSP.B in Pump

House

SWS SWP-1A/BAs per Schematic

diagramStart & Stop Start & Stop

POTABLE WATER SYSTEM:

Potable water connections shall be provided at all control rooms / MCC rooms, and complex

building of coal handling plant.

Potable water pump (PWP-1A/B) located in Pump House shall take potable water from RCC PW

tank-3 located adjacent to the Pump House and supplies to the overhead PVC potable water

storage tanks (1000 Liters.) located at roof top of above mentioned buildings. No PVC tank shall

be provided for Transfer Points and junction house. Client shall ensure the quality of drinking

water as per IS: 10500.Potable water from the overhead PVC tank shall flow to the potable water

tapping of respective building by gravity.


House




Sheet 20 Of 71

CHECKED MS/NH


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REV NO: A

PWS PWP-1A/BAs per Schematic


STOCKPILE DUST SUPRESSION SYSTEM:

Sprinkler type dust suppression system shall be provided for stockpiles.

The pumps for plain water (CTW & ROW) DS system shall be located in Pump House and takes plain

water from the on-ground RCC storage tank-2 adjacent to the Pump House. It supplies water to a

common header of DS system. Water from the common header goes to the ring headers around

stockpiles (one no for each stockpile). The swiveling sprinklers are mounted on vertical riser, whose

height of spray shall match with the stockpile height 10m), at an interval of 35 meter and the vertical

risers are mounted on the ring headers. Each sprinkler shall be provided with a manually operated

globe valve for controlling of water flow through the sprinkler. 4 nos sprinkler shall be mounted on one

sub-header which will be connected with main header through solenoid valve (with manual over-rider)

as shown in schematic diagram. The pump capacity has been designed considering 6.25 ltrs of water

per hour per ton of coal stocked in section of 90 m length of stock pile. Three nos of 50% capacity

centrifugal pumps (DSP-1A/B/C) shall be provided for the system.2 no of pumps shall be working and 1

no of pump shall be stand by for the system. 4 nos of sprinklers of capacity of each 22.2 m3/hr at

pressure 4.0 kg/cm2 shall work on both side of stock pile when one (1) pump is in operation.

Dust control is accomplished by spraying water on large stockpile areas. Water is sprayed in at regular

intervals depending on the site condition. The dust control is achieved by the agglomeration of dust

particles with finely atomized water droplets equal to / close to / larger than the dust particles as the

case may be, the Collision between the water droplets and dust particles plays an important role in the

process of agglomeration and heavier mass thus formed settles down to the source.

Plain water at a pressure of about 4.0 Bar is sprinkled over the stockpile area. This system is envisaged

to control the dust generated in the stockpile area. Water header will be provided along both sides of




Sheet 21 Of 71

CHECKED MS/NH


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REV NO: A

the coal stockpile, sufficient number of sprinklers suitably installed in a header to cover the entire

tockpile area produces water spray over the stockpile. The sprinklers are of swiveling type.

The operation of the sprinklers for stock piles is automatic by means of Sequential Control Panel and

Solenoid Valves for every two sprinklers. And each stockpile shall have solenoid valve with strainer

at the header inlet. Before each sprinkler globe valve shall be provided.


House

DS-5 DSP-1A/B/CAs per Schematic


Programmed logic control panel is used for sprinkling system of coal stock pile. Total 128 sprinklers are

controlled by 64 solenoids. Two solenoids of opposite side sprinklers are made as pair and they get ON

together. At a time any eight sprinklers can be switch ON.

Manual Mode: Solenoid pairs can be switched ON/OFF by using Push Buttons provided. In the

Solenoid box. These push buttons are provided for Stacking & reclaiming purpose. Any sprinkler

switched ON in manual mode continues in ON status till it is switched off/mode is changed.

Corresponding indicator glows in the panel when any solenoid is ON.

Auto Mode: In auto mode control of the sprinklers are R1 to R32 can be used for this purpose.

Switching the relay R1 turns ON Solenoid 1 and 2. R2 for S3 and S4. Like wise it continues up to S128.

This is maintained type contact. Till the relays are ON solenoids remains ON. Sprinkler ON time and

sequence can be programmed as per the requirement of the client. At a time more than one relay

should not be switched ON, is the only one interlock which client has to take care. Pumps are rated for

only eight sprinklers. If more than one is switched ON at a time, required through will not be available

from the sprinklers.

DRY FOG DUST SUPRESSION SYSTEM:




Sheet 22 Of 71

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REV NO: A

The dry fog dust suppression system will consists of centrifugal pump (vertical) with drive motor, air

compressor with drive motor, local control panel, Flow control unit, pressure regulating unit, solenoid

valve, Nozzles, Nozzle headers, displacer operated level switch, pressure gauge, pressure switch,

duplex strainer with differential pressure gauge & differential pressure switch etc.

The pumps will start automatically. Load sensing units will be installed in the MCC, which will measure

the current consumption of each conveyor motor. When the current drawn by conveyor exceeds a

predefined set value, the load sensing unit will send signals to pumps. On receipt of signals from load

sensing unit, pumps will be operated.

The compressor will also start automatically taking signal from pressure switch (low) installed on

compressor and it will trip automatically taking signal (high) from pressure switch installed on air

receiver.

The Flow Activation Stations have provision for both manual and automatic operation. For manual

operation, the system becomes operational with selector switch in manual mode and in auto mode, the

fogging operation starts on receiving a signal either from a Respective conveyor current load monitor

or Flap gate limit switches installed at a strategic location in the material Conveyor line or potential

free contact from the drive motor of equipment as per requirements.

Each application point is provided with requisite number of spray bar assemblies with Air Atomized

Nozzles. FAS are provided at group of application points.

FAS can be connected to one or more PRU. A PRU is used to regulate the air and water pressure for a

group of headers.

Dry Fog type Dust Suppression System will be used for suppressing dust by means of air atomized

nozzles that are caused during the operation of above mentioned areas. This system is envisaged to

control the dust generated during the operation of above mentioned areas, Headers are provided at

dust generating points for respective nozzles. Water will be stored in a tank. In the makeup waterline to

the water tank Float valve will be provided. Water from the water tank shall be supplied to the spray

headers by a pump. The water pump shall be interlocked with low-level switch of the water tank to




Sheet 23 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

prevent the pump from dry running. A pressure switch at the pump discharge line shall be provided to

bypass water to store tank in case the pressure increases above the set value. The pumping system

along with control panel is placed in a pump house near the water tank. Compressor shall be mounted

in the pump house with an air receiver.A FAS shall be provided for a group of material transfer points.

The FAS shall be interlinked with the signals for running of Conveyors and equipments to ensure that

the spray is activated only when the Conveyors are running with load. Additionally the pressure switch

at the FAS ensures that the solenoid valves at the air and water lines are switched ON only when there

is adequate air pressure at the system.Each application point shall have a set of spray bar of air and

water. The nozzles shall be fixed at the discharge hoods/suction hoods and shall be connected by

flexible tubing with the headers.Each PRU shall have air and water pressure regulators to ensure that

the medium at the required pressure is flowing through the nozzles. This in turn ensures proper

atomization of the water which is essential for the effective dust suppression.


House

DS-6 DFP-1A/BAs per Schematic


SC-A1/A2/A3As per Schematic


FLOW ACTIVATION STATION (FAS)-OPERATION:




Sheet 24 Of 71

CHECKED MS/NH


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REV NO: A

Operation: In FAS Box Electrical Controls are provided in the top compartment. An Isolation from

Mains Incomer is provided by a MCB, Solenoids operation is by both modes Manual & AUTO through

Auto/Manual Selector Switch for Dry fog Dust Suppression System.

Modes

Manual Mode: AIR Line pressure is monitored continuously through PRESSURE Switch inside

FASBox, If the pressure drops below the set point, Pressure Healthy indicator goes off. This will also

not allow switching on any Solenoid in any mode.

AIR & WATER solenoids can be switched on /off by respective Push Buttons. IN auto mode Solenoids

can be switched on by client PF (Potential Free) Signal, or UBS Signal or any other Remote system

Signal, any one of the signal will open solenoids & remain ON condition until contacts in closed

position. Terminals provided for this signal inside FAS Box is X1-3 TO X1-6.

Following Indication are provided:

Type Lamps

Control supply healthy : L1

Pressure healthy : L3

Solenoids open : L2

FLOW CONTROL UNIT (FCU)

Operation: In FCU Box Electrical Controls are provided in the top compartment.

Isolation from Mains Incomer is provided by a MCB, Solenoid operation is by both modes

Manual & AUTO through Auto/Manual selector switch for Plain water system.

Modes

Manual Mode:WATER Solenoid can be switched on /off by respective Push Buttons.

Auto Mode:In auto mode Solenoid can be switched on by client PF (Potential Free)Signal or UBS

Signal or any other remote system signal any one of the signal will open Solenoid & remain ON until

this contacts are closed. Terminals provided for this signal inside FCU Box is X1-3 TO X1-6

Following Indication are provided




Sheet 25 Of 71

CHECKED MS/NH


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REV NO: A

Type Lamps

Control Supply Healthy : L1

Water solenoid open (ON) : L2

SOLENOID OPERATING CONDITIONS FOR DS/DFDS SYSTEMS.

1. STOCK PILE DUST SUPPRESSION SYSTEM Sl. No. Location Spray Location Signal for Solenoid valve1

Stockpile-1Stockpile Header side-1 From sequential Panel / LCP

2 Stockpile Header side-2 From sequential Panel / LCP3






8 Stockpile Header side-2 From sequential Panel / LCP100 NB Solenoid valves has been considered for each stock pile at header inlet From sequential Panel / LCP2. DRY FOG DUST SUPPRESSION SYSTEM

Sl. No. Location Spray Location Signal for Solenoid valve1

JNT

- 1

Discharge of Conv.5A to FG Conv-5A Current load signal

2 Discharge of Conv.5B to FG Conv-5B Current load signal

3 Receipt of Conv.6A from FG 5AConv-5A Current load signal

+FG signal

4 Receipt of Conv.6A from FG 5BConv-5A Current load signal

+FG signal

5 Receipt of Conv.6B from FG 5AConv-5B Current load signal

+FG signal

6 Receipt of Conv.6B from FG 5BConv-5B Current load signal

+FG signal7

JNT

-

2

Discharge of Conv.6A Conv-6A Current load signal

8 Discharge of Conv.6B Conv-6B Current load signal




Sheet 26 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

9 Receipt of RBF-1Conv-6A Current load signal

+FG signal10 Discharge of RBF-1 side- 1 RBF -1 motor signal

11 Discharge of RBF-1 side- 2 RBF -1 motor signal

12 Receipt of RBF-2Conv-6B Current load signal

+FG signal13 Discharge of RBF-2 side- 1 RBF -2 motor signal

14 Discharge of RBF-2 side- 2 RBF -2 motor signal

15 Discharge of Conv.7 Conv- 7 Current load signal

16 Discharge of Conv.9 Conv- 9 Current load signal

17 Receipt- 1 of Conv.10A from FGConv-10A Current load signal

+FG signal

18 Receipt- 2 of Conv.10A from FGConv-10A Current load signal

+FG signal

19 Receipt- 1 of Conv.10B from FGConv-10B Current load signal

+FG signal


+FG signal


+FG signal


+FG signal

23 Receipt- 1 of Conv.10C from FGConv-10C Current load signal

+FG signal

24 Receipt- 2 of Conv.10C from FGConv-10C Current load signal

+FG signal

25 Receipt of BCN- 9RBF- 1 running / discharge

Signal

26 Receipt of BCN- 7RBF- 2 running / discharge

Signal

27

TH

- 1

Discharge of AFD- 1Apron feeder -1 running

signal

28 Receipt of Conv.2A from AFD- 1Conv-2A Current load signal

+FG signal

29 Receipt of Conv.2B from AFD- 1Conv-2B Current load signal

+FG signal30 T H

- 2 Discharge of AFD- 2 Apron feeder -2 running




Sheet 27 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

signal


+FG signal


+FG signal

33

TH

- 3

Discharge of AFD- 3Apron feeder -3 running

signal


+FG signal


+FG signal36

TH

- 4

Discharge of Conv. 1A Conv-1B Current load signal

37 Discharge of Conv. 1B Conv-1A Current load signal

38 Receipt of Conv.2A from 1AConv-2A Current load signal

+FG signal

39 Receipt of Conv.2B from 1BConv-2B Current load signal

+FG signal40

TH

- 5

Discharge of Conv.2A Conv-2A Current load signal

41 Discharge of Conv.2B Conv-2B Current load signal

42 Receipt of Conv.6A from FG 2AConv-6A Current load signal

+FG signal

43 Receipt of Conv.6A from FG 2BConv-6A Current load signal

+FG signal

44 Receipt of Conv.6B from FG 2AConv-6B Current load signal

+FG signal

45 Receipt of Conv.6B from FG 2BConv-6B Current load signal

+FG signal

4.0.3 CYCLONE TYPE DE SYSTEM

OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR BOILER BUNKER

AREA UNIT- 1, 2, 3 & 4:

The following sequence to be maintained for start the equipment’s

1) Start Screw conveyors of bag filter & cyclone outlet




Sheet 28 Of 71

CHECKED MS/NH


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REV NO: A

2) Start RAV of Cyclone & bag Filter

3) Power to sequential controller

4) Start Centrifugal Fan Motor

5) Open motorized damper of fan inlet

The equipment will be interlocked with following instruments for smooth operation of DE system

1) DPS will energize at pre set pressure and will command to sequential controller for solenoid

valve (24 V DC) energization.

2) After air purging in sequence of solenoid valves through sequential controller with pre set

pause and on time the DPS will be de-energized at fixed differential set pressure.

3) Sequential controller will not provided output to solenoid valve if air pressure at compressed

air line will be low from the desired pressure as per preset pressure of Pressure Switch. In that

case the whole system will be shut down immediately.

4) ZSS of the system will show rotation of rotating part of the RAV during running

Condition. If any RAV of cyclone, Bag filter fail to run then the whole system will be shut down

Immediately.

OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR JUNCTION HOUSE -

4

The following sequence to be maintained for start the equipments




4) Open motorized damper ( 2 nos) installed at receipt points of conv.BCN-12A & 12B depending

on flap gate position and discharge of material from conv.11A & 11B.







Sheet 29 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

1) DPS will energize at preset pressure and will command to sequential controller for solenoid




3) Sequential controller will not provide output to solenoid valve if air pressure at compressed

airline will be low from the desired pressure as per preset pressure of Pressure Switch. In that



condition. If any RAV of cyclone, Bag filter fail to run then the whole system will be shut down

immediately.

OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR JUNCTION HOUSE –

5 to 9 & 11 to 15





4) Open motorized damper ( 2 nos) installed at receipt points of conv.BCN-12A & 12B; 13A & 13B; 14A

& 14B ;15A & 15B; 16A & 16B; 17A & 17B;18A & 18B; 19A & 19B; 20A & 20B;24A & 24B;25A &

25b;26A & 26B; 27A & 27B; 28A & 28B; 29A & 29B depending on flap gate position, FTR

1A/1B,2A/2B,3A/3B,4A/4B & 5A/5B position and discharge of material from respective conveyors.










Sheet 30 Of 71

CHECKED MS/NH


DOC NO




REV NO: A


3) Sequential controller will not provided out put to solenoid valve if air pressure at compressed





immediately.

OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR JUNCTION HOUSE –

10 &16




















Sheet 31 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

immediately

OPERATIONAL LOGIC FOR BAG FILTER & CYCLONE OF DE SYSTEM FOR CRUSHER HOUSE


1) Open Slide gate at bottom of screw conv. depends on conv. running of 11A/11B/23A/23B.




5) Open motorized damper on line as per followings when stream – 1 & stream -2 (conv.BCN-

10B & conv.BCN-10C running)

Motorized Damper no. 15 & 16 will open & Motorized Damper 17 will close.

Motorized Damper no. 11/12 will open when RSC will discharge material on BCN-11A/B.

Motorized Damper no.13 &14 will open

Motorized Damper no.9/10 will open when RSC will discharge material on BF- 1/2..

Motorized Damper no. 7/8 will open when SC-2 will discharge material on BF-1/2.

Motorized Damper no.5 & 6 will open when BF-1/2 will discharge material .

Motorized Damper no.3/4 will open as per Flap gate position of BF-2 discharge to conv.

BCN- 23A/B.

Motorized Damper no. 1/2 will open as per Flap gate position of BF-1 discharge to conv.

BCN- 23A/B.

Open motorized damper on line as per followings when stream – 2 ( conveyor BCN-10A in

running condition )

Motorized Damper no. 17 will open and Motorized Damper no. 15 & 16 will close. All other

dampers will close.

The schematic is enclosed






Sheet 32 Of 71

CHECKED MS/NH


DOC NO




REV NO: A











immediately.

4.0.4 VENTILATION SYSTEM:

Below mentioned ventilation system for the application areas can be operated in-group/individual

through keyboard/OWS. The operation of each group/individual indication is available in main CHP

control desk monitor.

All other Ventilation system except for Boiler bunkers can be operated from OWS.

All ventilation fans will have local start/stop facility (wherever required).

i) SCHEDULE FOR MECHANICAL VENTILATION SYSTEM (SUPPLY FAN)




Sheet 33 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

Sl.No System No.

Catering Area OWS

1 VS-1 to VS-3

Track Hopper underground portion Start & Stop

2 VS-4 Wagon Tippler – 1 & 2 and TH-1 & 2 underground portion

Start & Stop

3 VS-5 Wagon Tippler – 3 and TH-3 underground portion U/G portion of Conveyor 2A/B tunnel

from TH-3 up to TH-1 & 2

Start & Stop

5 VS-7 U/G portion of Conveyor 2A/B tunnel from TH-1 & 2 up to TH-4, U/G portion of TH-4 and U/G portion of Conveyor 2A/B from TH-4 up

to TH-5

Start & Stop

6 VS-8 U/G portion of TH-5 Start & Stop

7 VS-8A U/G portion of Conveyor 5A/B tunnel up to pent house

Start & Stop

8 VS-9 U/G portion of Crusher house Start & Stop

9 VS-10 U/G portion of Conveyor 23A/B tunnel up to pent house

Start & Stop

10 VS-11 U/G portion of Conveyor 11A/B tunnel up to pent house

Start & Stop

ii) SCHEDULE FOR MECHANICAL VENTILATION SYSTEM (EXHAUST FAN)




Sheet 34 Of 71

CHECKED MS/NH


DOC NO




REV NO: A




Sheet 35 Of 71

CHECKED MS/NH

Sl.No. System No.

Catering Area OWS

1 VE-1 to VE-3

Track Hopper underground portion Start & Stop

2 VE-4 Wagon Tippler – 1 & 2 and TH-1 & 2 underground portion

Start & Stop

3 VE-5 Wagon Tippler – 3 and TH-3 underground portion U/G portion of Conveyor 2A/B tunnel

from TH-3 up to TH-1 & 2

Start & Stop

5 VE-7 U/G portion of Conveyor 2A/B tunnel from TH-1 & 2 up to TH-4, U/G portion of TH-4

and U/G portion of Conveyor 2A/B from TH-4 up to TH-5

Start & Stop

6 VE-8 U/G portion of TH-5 Start & Stop 7 VE-8A U/G portion of Conveyor 5A/B tunnel up to

pent houseStart & Stop

8 VE-9 U/G portion of Crusher house Start & Stop 9 VE-10 U/G portion of Conveyor 23A/B tunnel up to

pent houseStart & Stop

10 VE-11 U/G portion of Conveyor 11A/B tunnel up to pent house

Start & Stop

11 VE-12 Battery room of MCC-1 Start & Stop 12 VE-13 Battery room of MCC-2 Start & Stop


DOC NO




REV NO: A

iii) SCHEDULE FOR PRESSURISED VENTILATION SYSTEM (SUPPLY FAN)

Sl.No System No.

Catering Area OWS

1 VS-12 MCC-1 Start & Stop 2 VS-13 MCC-2 Start & Stop 3 VS-14 MCC-3 Start & Stop 4 VS-15 MCC-4 Start & Stop 5 VS-16 MCC-5 Start & Stop 6 VS-17 MCC-6 Start & Stop 7 VS-18 MCC-7 Start & Stop

4.0.5 AIR CONDITIONING SYSTEM:




Sheet 36 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

Air Conditioning system is generally provided for the treatment of air so as to control, simultaneously,

its temperature, humidity, cleanliness and distribution to meet the comfort requirements of occupants,

of the conditioned space. Air Conditioning system consists of hermetic compressor (scroll/rotary type),

direct expansion multi row deep cooling coil of copper having mechanically bonded aluminum fins

complete with refrigerant distributor & thermostatic expansion valve, v-belt driven (in case of Packaged

Air Conditioning system) evaporator with air blower (s) suitable for external static pressure.

All air conditioning systems will have local start/stop facility (wherever required).

SYSTEM SUMMARY FOR PACKAGED AIR CONDITIONING SYSTEM

Sl. No. Building & Location

1. Control Room - 1, near WT-1



4. Main CHP Control Room cum RIO room in MCC-2, Near Crusher House

SCHEDULE FOR WATER COOLED PAC SYSTEM CONDENSER PUMPS

Sl.No System No. Catering Area1 ACP-1A/B Control room-1

2 ACP-2A/B Control room-2

3 ACP-3A/B Control room-3

4 ACP-4A/B Main CHP control roomSYSTEM SUMMARY FOR WINDOW AIR CONDITIONER UNIT

Sl. Building & Location




Sheet 37 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

No.1. RIO Room in MCC-1 (On wall)

2. RIO Room in MCC-3, 4, 5 , 6 & 7 (On wall)

5.0.0 SEQUENTIAL INTERLOCK FOR CONVEYORS & OTHER EQUIPMENT System Stop: When system stop command is given, first all feeding equipment (Like Stacker

Reclaimer) will stop &after some time delay all equipments will stop sequentially.

Emergency Stop: In case of emergency stop PB pressed all drives shall be stopped immediately.

Fire Protection: In case of fire detection all drives shall be stopped immediately.

5.0.1 CONVEYOR

When start command to conveyor is given first the command will go to start respective Oil circulating

pump for scoop coupling of conveyor and release the brake (simultaneously), after releasing the brake

command will go to conveyor main motor, after starting main motor, command will go to engage (OUT)

scoop through actuator for scoop coupling of conveyor. If off command is given to conveyor, first the

scoop will get dis-engaged then brake is applied after which main motor stops and finally oil circulating

pump stops.

Main conveyor Motor:

There is no auto-on and auto-off commands for conveyor (except sequence start/stop

commands).Permissive conditions (conveyor can be started from Remote/Local when all the conditions

given below are available)

All winding temperature less than 120 deg C.

Bearing temperature (DE and NDE) less than 70 deg C

Brake for respective conveyor is released




Sheet 38 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

Actuator scoop coupling is IN position (dis-engaged position)

Electrical conditions are healthy.

Local Stop Not Pressed /Reset.

Trip conditions (conveyor will trip if any of the given below are available):

Any winding temperature is more than 130 deg C.

Any bearing temperature (DE and NDE) is more than 80 deg C.

Electrical trip conditions are present.

Brake for respective conveyor not released.

Brake for Conveyor:

When command to main conveyor is given, it will auto on (release) the brake and when conveyor

motor is off or fluid coupling dis-engaged then brake will be applied automatically.

Permissive conditions:

1) Electrical conditions are healthy.

Trip condition:

1) Electrical conditions are not healthy.

Oil Circulating Pump for Scoop Coupling of Conveyor:

When command to main conveyor is given, it will auto start oil circulating pump and when conveyor

motor is given off command then oil circulating pump will stop automatically after some time delay (30

Sec Adjustable).

Permissive (All the below conditions should be present to start oil circulating pump for scoop coupling

of conveyor):

DP across filter < 0.5bar

Oil Line pressure ≥ 1.2 bar

Oil temp ≤ 90 deg C.

Oil Cooler fan started.




Sheet 39 Of 71

CHECKED MS/NH


DOC NO




REV NO: A


Electrical condition healthy.

Trip conditions (Oil circulating pump will trip if any of the condition will be present):

DP across filter 1.1 bar˃

Oil Line pressure < 0.8 bar

Oil temp 110 deg C. ˃

Oil Cooler fan motor fails.

Local Stop Pressed.

Electrical trip condition present.

Actuator For Fluid Coupling Of Conveyor:

When start command to main conveyor is given, it will engage (OUT) scoop coupling and when

conveyor motor is given off command then it will dis-engage (IN) scoop coupling automatically.

Permissive conditions (actuator for scoop coupling of conveyor will OUT (engaged) scoop automatically

when all the below conditions are present):

Oil circulating pump for respective conveyor is ON.

Main motor of respective conveyor is ON.

Both the CBS (chute block switch) are not operated.

PCS (Pull cord switch) is not operated.

BSS (Belt sway switch) is not operated.

ILMS is energized(On feedback) (if applicable).

MD is energized (On feedback) (if applicable).


Succeeding conveyor main motor on & scoop coupling engaged and only one Flap gate/shuttle

head drive is in position to feed succeeding conveyor & other flap gate can be positioned on




Sheet 40 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

the same conveyor only if the same upstream conveyor not running (if applicable according to

Down stream Feeders)


Trip command from machines (Stacker Reclaimer, Travelling Tripper) to respective conveyors.

• Applicable for Conv. 19 & 21 - Trip Command from Stacker

Cum Reclaimer-1 & Stacker Cum Reclaimer-2 respectively.

• Applicable for Conv. 11/13/15/17 - Trip Command from Travelling

Tripper-TTR1, TTR2, TTR3 & TTR4 respectively.

Trip conditions (actuator for scoop coupling of conveyor will IN (dis-engage) scoop if any of the

condition will be present):

Any of the CBS (chute block switch) is operated.

PCS (Pull cord switch) is operated.

BSS (Belt sway switch) is operated.

ZSS (Zero speed switch) is operated with on delay of 60 sec.

Oil circulating pump OFF.

Respective conveyor main motor is OFF.

Succeeding conveyor main motor off or scoop coupling dis-engaged and running

conveyor feeding to that conveyor.

Electrical trip conditions are present

ILMS cleated belt or under current trip. (if applicable)

Metal is detected (if applicable)

More than one flap gate are positioned to same conveyor & more than one upstream

conveyor running.

5.0.2 CRUSHER:




Sheet 41 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

When start command to crusher is given first the command will go to start respective oil circulating

pump for scoop coupling of crusher then that command will go to crusher main motor, after starting

main motor, command will go to engage (OUT) scoop through actuator for scoop coupling of crusher.

Main Crusher Motor:

There are no auto-on and auto-off commands for crusher (except sequence start/stop commands).

Permissive conditions (crusher can be started automatically or manually when all the conditions given

below are available)

All winding temperature less than 120 deg C.

Bearing temperature (DE and NDE) less than 70 deg C.

Actuator scoop coupling is IN position (dis-engaged position).



Hydraulic door closed.

Trip conditions (Crusher will trip if any of the given below are available):

Any winding temperature is more than 130 deg C.

Any bearing temperature (DE and NDE) is more than 80 deg C.


Coupling Cooling Oil Circulating Pump for Crusher:

When command to main crusher is given, it will auto start oil circulating pump and when crusher motor

is given off command then oil circulating pump will stop automatically after some time delay (30 Sec

Adjustable).

Permissive (All the below conditions should be present to start oil circulating pump):

DP across filter < 0.5bar

Oil Line pressure ≥ 1.2 bar




Sheet 42 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

Oil temp ≤ 90 deg C.

Oil Cooler fan started.


Electrical condition healthy.

Trip conditions (Oil circulating pump will trip if any of the condition will be present):

DP across filter 1.1 bar˃

Oil Line pressure < 0.8 bar

Oil temp 110 deg C. ˃

Oil Cooler fan motor fails.

Local Stop Pressed.

Electrical trip condition present.

Actuator For Fluid Coupling Of Crusher:

When start command to main crusher is given, it will engage (OUT) scoop coupling and when crusher

motor is given off command then it will dis-engage (IN) scoop coupling automatically.

Permissive conditions (actuator for fluid coupling of crusher will be OUT (engaged) automatically when

all the below conditions are present):

Oil circulating pump for respective crusher is ON.

Main motor of respective crusher is ON.

Crusher ZSS (Zero speed switch) is NOT operated.

Both the CBS (chute block switch) are not operated.

Respective Downstream feeder, i.e. BF/SC/RSC, is ON .



Hydraulic door closed.




Sheet 43 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

Trip conditions (actuator for fluid coupling of crusher will be IN (dis-engage) if any of the condition will

be present):

Any of the CBS (chute block switch) is operated.

Crusher ZSS (Zero speed switch) is operated with on delay of 60 sec.

Oil circulating pump OFF.

Respective crusher main motor is OFF.


Respective Down stream feeder, i.e. BF/SC/RSC, is OFF.

Respective Crusher Vibration Trip.

Hydraulic door open.

5.0.4 TRAVELLING TRIPPER


Bunker Conveyor running.


Motor O/L not tripped.

Over travel limit switch not tripped.

Trip conditions:

Local Stop Pressed.

Motor O/L tripped.

Over travel limit switch tripped.

5.0.5 ILMS (INLINE MAGNETIC SEPERATOR)

There is no Auto ON/OFF Conditions.


ILMS should be selected in remote.




Sheet 44 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

Under current relay trip signal not available.

Control supply should be healthy.

Local stop not pressed / Reset condition

Trip conditions:

Respective conveyor off with on delay of 600 sec.

Under current relay trip signal available.

Control supply not healthy.

Cleated belt trip.

5.0.6 MD (METAL DETECTOR)



MD should be selected in remote.

Metal Detector is in Reset condition.(Metal Not detected)

Local stop not pressed / Reset condition

Trip conditions:

Respective conveyor off with on delay of 600 sec.

Metal detected.

5.0.7 IN-LINE BELT WEIGH SCALE:



BS should be selected in remote.

Respective Conveyor is ON.

5.0.8 FG (FLAP GATE)

There is no Auto ON/OFF Conditions:-





Sheet 45 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

Feeding conveyor “OFF FEEDBACK” will be permissive for forward and reverse direction ( Not

applicable for bunker flap gate from FG-30 to FG-41 for BU-1,2&3 and FG-52 to FG-59 for BU-

4&5).Flap gate can be changed (FG-30 to FG-41 for BU-1,2&3 and FG-52 to FG-59 for BU-4&5) only

when succeeding conveyor running.

5.0.9 FLOW DIVIDER (FD)



Feeding Conveyor/Equipment “OFF FEEDBACK” will be permissive for forward and reverse directions.

5.0.10 ROLLER SCREEN




Local stop not pressed / Reset condition.

Respective Crusher ON

Respective BF/SC/RSC is ON

CBS (chute block switch) is not operated.

Trip conditions:


Respective Crusher OFF

Respective BF/SC/RSC is OFF

CBS (chute block switch) operated.

5.0.14 UTILITY PUMP’S (SWP, PWP, THP, WTP, WTDP, DSP, DFP):

When running pump trips standby pump starts automatically.

Electrical Condition: Same as LT drive.






Sheet 46 Of 71

CHECKED MS/NH


DOC NO




REV NO: A


Centrifugal Pump (Running/Standby) Selected by Selector Switch (In Soft)

Centrifugal Pump (Running + Standby) Water Level Permissive

Centrifugal Pump (Standby) Not running.

Trip conditions:


Centrifugal Pump (Running + Standby) Water Level Low

Centrifugal Pump (Running) Discharge Pressure low with delay of 60 sec.

Ann. Condition : DP switch (In pump suction) high will be annunciated

5.0.15 SOLENOID VALVES (FOR DUST SUPPRESSION SYSTEM):

Auto ON Conditions

Current value of respective conveyor above cut-off value (I≥8mA).

Auto OFF Conditions

Current value of respective conveyor below cut-off value (I< 8mA)


Centrifugal Pump running.

Trip conditions:

Centrifugal Pump not running.

5.0.15 VENTILATION SYSTEM: CENTRIFUGAL FAN / AXIAL FAN (For VE, VS):


Electrical Condition: Same as LT drive.




Trip conditions:




Sheet 47 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

Electrical conditions are not healthy.

6.0.0 THE PERMISSIVE CONDITONS FOR OPERATION OF CHP

* Feeding Flap gates to be positioned after selection of path.

6.0.1 FLOW PATH – 1: SHIP UNLOADERS TO STOCKYARD

S.No. Equipment Permissive conditions

1

CONV. 19(STACKING)

OR

CONV. 21(STACKING)

STACKER STR-1 IS RUNNING

OR


2CONV. 18 A

CONV. 19 (STACKING) IS RUNNING AND FLAP GATE FG 27

IS POSITIONED (POS-1) TO FEED CONV. 19

OR

CONV. 20 A IS RUNNING AND FLAP GATE FG 27 IS

POSITIONED (POS-2) TO FEED CONV. 20 A

3CONV. 18 B



OR

CONV. 20 B IS RUNNING AND FLAP GATE FG 28 IS

POSITIONED (POS-2) TO FEED CONV. 20 B

4

CONV. 20 A

OR

CONV. 20 B

CONV. 21 (STACKING) IS RUNNING

5 CONV. 7 ACONV. 18 B IS RUNNING AND DIVERTER GATE DG -1 IS

POSITIONED (POS-1) TO FEED CONV. 18 B.




Sheet 48 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

6 CONV. 7 BCONV. 18 A IS RUNNING AND DIVERTER GATE DG -2 IS

POSITIONED (POS-1) TO FEED CONV. 18 A.

7 CONV. 6 A

CONV. 7 A IS RUNNING AND FLAP GATE FG -7 IS


OR

CONV. 7 B IS RUNNING AND FLAP GATE FG -7 IS


8 CONV. 6 B



OR



9 CONV. 5 A



OR

ROLLER SCREEN 1 & CRUSHER 1 ARE IN OPERATION AND

FLAP GATE FG -5 IS POSITIONED (POS-2) TO FEED

ROLLER SCREEN AND CONV. 6 A IS RUNNING.10 CONV. 5 B CONV. 6 B IS RUNNING AND FLAP GATE FG -6 IS


OR


FLAP GATE FG -6 IS POSITIONED (POS-2) TO FEED




Sheet 49 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

ROLLER SCREEN AND CONV. 6 B IS RUNNING.

11 CONV. 4 A

CONV. 5 A IS RUNNING AND FLAP GATE FG-3 IS

POSITIONED (POS-1) TO FEED CONV. 5 A AND ILMS-3 &

MD-5 ARE ON.

OR

CONV. 5 B IS RUNNING AND FLAP GATE FG-3 IS

POSITIONED (POS-2) TO FEED CONV. 5 B AND ILMS-4 &

MD-6 ARE ON.

12 CONV. 4 B


POSITIONED (POS-1) TO FEED CONV. 5 A AND ILMS-3 &

MD-5 ARE ON.

OR


POSITIONED (POS-2) TO FEED CONV. 5 B AND ILMS-4 &

MD-6 ARE ON.

13 CONV. 3 A2

CONV. 4 A IS RUNNING AND FLAP GATE FG-2A IS


OR

CONV. 4 B IS RUNNING AND FLAP GATE FG-2A IS


14 CONV. 3 B2

CONV. 4 A IS RUNNING AND FLAP GATE FG-2B IS


OR

CONV. 4 B IS RUNNING AND FLAP GATE FG-2B IS


15 CONV. 3 A1 CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1A IS

POSITIONED (POS-1) TO FEED CONV. 3 A2 AND MD-3 IS




Sheet 50 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

ON.

OR

CONV. 3 B2 IS RUNNING AND FLAP GATE FG-1A IS

POSITIONED (POS-2) TO FEED CONV. 3 B2 AND MD-4 IS

ON.

16 CONV. 3 B1

CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1B IS

POSITIONED (POS-1) TO FEED CONV. 3 A2 AND MD-3 IS

ON.

OR

CONV. 3 B2 IS RUNNING AND FLAP GATE FG-1B IS

POSITIONED (POS-2) TO FEED CONV. 3 B2 AND MD-4 IS

ON.

17 CONV. 2 A

CONV. 3 A1 IS RUNNING AND FLAP GATE FG-1 IS

POSITIONED (POS-1) TO FEED CONV. 3 A1.

OR

CONV. 3 B1 IS RUNNING AND FLAP GATE FG-1 IS

POSITIONED (POS-2) TO FEED CONV. 3 B1.

18 CONV. 2 B



OR


POSITIONED (POS-2) TO FEED CONV. 3 B1. 19 CONV. 1 A CONV. 2 A IS RUNNING 20 CONV. 1 B CONV. 2 B IS RUNNING

21FROM SHIP

UNLOADERS

CONV. 1 A IS RUNNING AND ILMS-1 & MD-1 ARE ON.

OR




Sheet 51 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

CONV. 1 B IS RUNNING AND ILMS-2 & MD-2 ARE ON.

6.0.2 PATH- II: SHIP UNLOADERS TO BUNKER UNITS VIA CRUSHER HOUSE WITHOUT

STACKING

1 TTR-4BUNKERS OF BUNKER UNIT BU-4 ARE NOT FULL

2 CONV. 17BUNKERS OF BUNKER UNIT BU-4 IS NOT FULL (AND)

TRAVELLING TRIPPER TTR-4 IS RUNNING AND FLAP GATE

FG-25 OR 26 IS POSITIONED (POS1/2) TO FEED BU-4

3

CONV. 16 A

OR

CONV. 16 B

CONV. 17 IS RUNNING

4 CONV. 14 A


POSITIONED (POS 1) TO FEED CONV. 16 A.

OR

CONV. 15 IS RUNNING AND FLAP GATE FG-21 IS

POSITIONED (POS 2) TO FEED CONV. 15.

5 CONV. 14 B


POSITIONED (POS 1) TO FEED CONV. 16 B.

OR



6 TTR-3B

UNKERS OF BUNKER UNIT BU-3 ARE NOT FULL





Sheet 52 Of 71

CHECKED MS/NH


DOC NO




REV NO: A



8 CONV. 12 A



OR



9 CONV. 12 B



OR


POSITIONED (POS 2) TO FEED CONV. 13.10 TTR-2 BUNKERS OF BUNKER UNIT BU-2 ARE NOT FULL

11 CONV. 13

BUNKERS OF BUNKER UNIT BU-2 IS NOT FULL (AND)



12 CONV. 10 A



OR






Sheet 53 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

13 CONV. 10 B



OR



14 TTR-1 BUNKERS OF BUNKER UNIT BU-1 ARE NOT FULL

15 CONV. 11




16 CONV. 9 A


POSITIONED (POS 1) TO FEED CONV. 10 A AND BW7 IS ON.

OR


POSITIONED (POS 2) TO FEED CONV. 10 B AND BW8 IS ON.

17 CONV. 9 B



OR



18 CONV. 8 A


POSITIONED (POS 1) TO FEED CONV. 9 A AND ILMS5 & MD7

ARE ON.

OR


POSITIONED (POS 2) TO FEED CONV. 9 B AND ILMS6 & MD8

ARE ON.19 CONV. 8 B CONV. 9 A IS RUNNING AND FLAP GATE FG-10 IS




Sheet 54 Of 71

CHECKED MS/NH


DOC NO




REV NO: A


ARE ON.

OR



ARE ON.

20 CONV. 7 ACONV. 8 A IS RUNNING AND DIVERTER GATE DG-1 IS


21 CONV. 7 BCONV. 8 B IS RUNNING AND DIVERTER GATE DG-2 IS


22 CONV. 6 A



OR



.

23 CONV. 6 B



OR



24 CONV. 5 ACONV. 6 A IS RUNNING AND FLAP GATE FG -5 IS





Sheet 55 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

OR


FLAP GATE FG -5 IS POSITIONED (POS-2) TO FEED ROLLER

SCREEN AND CONV. 6 A IS RUNNING.

25 CONV. 4 A


POSITIONED (POS-1) TO FEED CONV. 5 A AND ILMS-3 & MD-

5 ARE ON.

OR


POSITIONED (POS-2) TO FEED CONV. 5 B AND ILMS-4 & MD-

6 ARE ON.

26 CONV. 4 B



5 ARE ON.

OR



6 ARE ON.

27 CONV. 3 A2



OR



28 CONV. 3 B2CONV. 4 A IS RUNNING AND FLAP GATE FG-2B IS





Sheet 56 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

OR



29 CONV. 3 A1

CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1A IS

POSITIONED (POS-1) TO FEED CONV. 3 A2 AND MD-3 IS ON.

OR


POSITIONED (POS-2) TO FEED CONV. 3 B2 AND MD-4 IS ON.

30 CONV. 3 B1



OR



31 CONV. 2 A



OR



32 CONV. 2 B



OR






Sheet 57 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

35FROM SHIP

UNLOADERS


OR


6.0.3PATH- III: SHIP UNLOADERS TO BUNKER UNITS VIA CRUSHER HOUSE WITH

STACKING1 TTR-4 BUNKERS OF BUNKER UNIT BU-4 ARE NOT FULL

2 CONV. 17




3

CONV. 16 A

OR

CONV. 16 B

CONV. 17 IS RUNNING

4 CONV. 14 A



OR



5 CONV. 14 B



OR



7 CONV. 15







Sheet 58 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

8 CONV. 12 A



OR



9 CONV. 12 B



OR



10 TTR-2BUNKERS OF BUNKER UNIT BU-2 ARE NOT FULL

11 CONV. 13




12 CONV. 10 A



OR






Sheet 59 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

13 CONV. 10 B



OR







16 CONV. 9 A



OR



17 CONV. 9 B



OR



18 CONV. 8 A



ARE ON.

OR




Sheet 60 Of 71

CHECKED MS/NH


DOC NO




REV NO: A



ARE ON.

19 CONV. 8 B



ARE ON.

OR



ARE ON.

20 CONV. 7 ACONV. 8 A & CONV. 18 B ARE RUNNING AND DIVERTER

GATE DG-1 IS POSITIONED (POS 3) TO FEED BOTH

CONV. 8 A & CONV. 18 B.

21 CONV. 7 BCONV. 8 B & CONV. 18 A ARE RUNNING AND DIVERTER

GATE DG-2 IS POSITIONED (POS 3) TO FEED BOTH

CONV. 8 B & CONV. 18 A.

22

CONV.

19(STACKING) OR

CONV.

21(STACKING)


OR


23CONV. 18 A



OR

CONV. 20 A IS RUNNING AND FLAP GATE FG 27 IS




Sheet 61 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

POSITIONED (POS-2) TO FEED CONV. 20 A

24CONV. 18 B



OR

CONV. 20 B IS RUNNING AND FLAP GATE FG 28 IS


25

CONV. 20 A

OR

CONV. 20 B

CONV. 21 (STACKING) IS RUNNING

26 CONV. 6 A



OR



27 CONV. 6 B



OR



28 CONV. 5 A



OR



SCREEN AND CONV. 6 A IS RUNNING.




Sheet 62 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

29 CONV. 5 B



OR



SCREEN AND CONV. 6 B IS RUNNING.

30 CONV. 4 A



5 ARE ON.

OR



6 ARE ON.

31 CONV. 4 B



5 ARE ON.

OR



6 ARE ON.

32 CONV. 3 A2



OR



33 CONV. 3 B2CONV. 4 A IS RUNNING AND FLAP GATE FG-2B IS





Sheet 63 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

OR



34 CONV. 3 A1

CONV. 3 A2 IS RUNNING AND FLAP GATE FG-1A IS


OR



35 CONV. 3 B1



OR



36 CONV. 2 A



OR



37 CONV. 2 B



OR



40FROM SHIP

UNLOADERS


OR




Sheet 64 Of 71

CHECKED MS/NH


DOC NO




REV NO: A


6.0.4 PATH- IV: STOCK YARD TO BUNKER UNITS 1 TTR-4 BUNKERS OF BUNKER UNIT BU-4 ARE NOT FULL

2 CONV. 17




3

CONV. 16 A

OR

CONV. 16 B

CONV. 17 IS RUNNING

4 CONV. 14 A



OR



5 CONV. 14 B



OR



7 CONV. 15




8 CONV. 12 A



OR





Sheet 65 Of 71

CHECKED MS/NH


DOC NO




REV NO: A


9 CONV. 12 B



OR



11 CONV. 13




12 CONV. 10 A



OR



13 CONV. 10 B



OR




15 CONV. 11



FG-15 OR 16 IS POSITIONED (POS1/2) TO FEED BU-116 CONV. 9 A CONV. 10 A IS RUNNING AND FLAP GATE FG-11 IS




Sheet 66 Of 71

CHECKED MS/NH


DOC NO




REV NO: A


OR



17 CONV. 9 B



OR



18 CONV. 22 A

CONV. 9 A IS RUNNING AND FLAP GATE FG- 31 IS


ARE ON.

OR



ARE ON.

19 CONV. 22 B

CONV. 9 A IS RUNNING AND FLAP GATE FG- 32 IS


ARE ON.

OR



ARE ON.

20 CONV. 19SR 2 RECLAIMER IS RUNNING & CONV. 22 A IS RUNNING

AND FLAP GATE FG-30 IS POSITIONED (POS 1) TO FEED

CONV. 22 A.




Sheet 67 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

OR

SR 2 RECLAIMER IS RUNNING & CONV. 22 B IS RUNNING


CONV. 22 B.

21 CONV. 21

SR 1 RECLAIMER IS RUNNING & CONV. 22 A IS RUNNING


CONV. 22 A.

OR

SR 1 RECLAIMER IS RUNNING CONV. 22 B IS RUNNING AND

FLAP GATE FG-29 IS POSITIONED (POS 2) TO FEED CONV.

22 B. 22 GROUND HOPPER CONV. 22 A OR CONV. 22 B IS RUNNING

6.0.5 COMBINATION OF ANY OF THE ABOVE:

7.0.0 ANNUNCIATION SYSTEM

Alarms shall be available at HMI for the following audio-visual fault annunciation purposes. Wherever

group annunciation is provided, alarm status of individual equipment will be provided on HMI.

a) 6.6 KV Breaker Trip (group wise for each board)

b) 415 V PMCC Breaker Trip (PMCC wise)

c) 415V MCC Breaker Trip (MCC wise)

d) Bus under voltage for LT MCC Buses( Group Wise)

e) Bus under voltage for HT switch gear buses (Group Wise)

f) Following group wise annunciation is provided for transformers: -

1) Buchholz alarm

2) Winding / oil temp. High alarm




Sheet 68 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

3) Oil level low alarm

4) Buchholz trip

5) Winding / oil temp. High trip

g) AC control supply failure

h) DC control supply failure

i) Stand-By CPU in service.

j) Both CPU fail.

k) HT motor trip on electrical fault (Group)

l) LT motor overload tripped (Group)

m) Belt sway switch operated (Group)

n) Pull cord switch operated (Group)

o) Zero speed switch operated (Group)

p) Chute blocked (Group)

q) Magnetic separator fault and cleaning belt trip(Group)

r) Metal detector fault (Group)

s) In-line conveyor scale fault (Group)

t) Sampling System faults and trips (Group)

u) Crusher low speed & crusher bearing temperature – high.

For identification of the fault for a particular conveyor or equipment, the status indication against that

conveyor/equipment in the graphics window will start fast flickering and the alarms will be flickering

against the particular fault. Also a buzzer will start sounding. After acknowledgement of the fault, the

buzzer will stop, but the fast flickering on the mimic & the steady glow on the HMI will continue until the

fault is cleared and the alarm is acknowledged. When the fault is cleared and the alarm acknowledged,

the status indication of that conveyor/equipment on the graphic will start slow blinking if it is on selected

path.




Sheet 69 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

At the time of fault, the faulty conveyor / equipment as well as the preceding conveyors / equipment in

the interlock sequence, will stop except HT motors will continue to run for process fault. In case of

motor fault, the HT motor will trip but the succeeding conveyors / equipment will continue to run. The

status indication against the preceding conveyors / equipment will start slow blinking while the faulty

conveyor / equipment will be fast blinking.

Start command will not be indicated alarm is acknowledged after clearance of fault.

The sequence of operation of the annunciation system will be as follows:

Sequence Condition Status

NormalAnnunciation window. OffStatus Indication Steady GlowBuzzer Off

FaultAnnunciation window. FlickeringStatus Indication Fast FlickeringBuzzer Sounding

Press Accept PBAnnunciation window. Steady GlowStatus Indication Fast FlickeringBuzzer Off

Press Reset PB

Annunciation window. OffStatus Indication Steady Blinking (if on Selected path)

Off(if not on selected path)Buzzer Off

. 8.0.0 STATUS INDICATION IN OWS (OPERATOR WORK STATION)

The following individual status indications will be provided in LVS.

1. Conveyor ON

2. Flap Gate/ Flow Divider

3. In-line conveyor scale flow rate indication & totalizer




Sheet 70 Of 71

CHECKED MS/NH


DOC NO




REV NO: A

4. Belt Sway switch operated for each conveyor

5. Pull cord switch operated for each conveyor

6. Zero speed switch operated for each conveyor

7. Crusher ON

8. Vibrating feeders ON

9. MD / ILMS /CSU ON

10. Bunker level.




Sheet 71 Of 71

CHECKED MS/NH

59928126 Operation Control Philosophy

Documents

apml dated rev

diverter gate dg

flap gate fg

pull cord switch

line magnetic separators

manual stone picking

tripper flap gate

bag filter fail