Target group – Graduate Engineering Trainee / PG DC

Class Notes on Coal Handling Plant

INTRODUCTION

The coal handling plant (CHP) in a thermal power station covers unloading of coal, its crushing, storage and
filling of boiler bunkers. The planning and design of the CHP is site specific and depends on the following
factors:

i) Station capacity
ii) Coal source and quality
iii) Coal transportation mode
iv) Topography and geometry of the area for coal handling system

Station capacity

Station capacity determines the quantum of coal to be handled by coal handling plant and thus the capacity of
coal unloading system, crushers, coal conveying system etc. Generally for unit size of 500 MW and above, one
coal handling plant is provided to cater for two units. Coal conveying system may cater to maximum three units
to limit the outage of units in the event of failure of coal handling plant. Provision of interconnection between
separate CHP’s may also be provided.

If a plant consists of non-identical units (in terms of size), then separate CHPs may be necessary to cater to
different bunker floor levels due to non-uniformity of unit sizes. Alternatively, plants with non-identical units can
have some facilities like unloading, crushing, storage in common and separate conveyors may be used to feed
different bunker floors.

Coal source and quality

Sources of coal for a thermal power station may vary i.e. indigenous run of mine coal, indigenous washed coal
or imported coal. Quality of the coal (GCV, HGI, moisture content etc.) determines the specification of coal
handling equipment apart from the quantity of coal to be handled.

Presently need for providing facilities for blending of indigenous and imported coal is also being felt in view of
the shortage of Indian coal. Some time coal blending may also be resorted for environmental reasons. Blending
can be done in many ways. One method is to provide facility in coal handling system to lay indigenous and
imported coal in layers on the belts while conveying coal to bunkers. These coal layers would get mixed while
falling into bunkers. The other method is to stock indigenous and imported coal in layers in stockyard. Yet
another method in use is dedicating one mill for firing imported coal and then adjust the mill parameters to
achieve the optimum heat load of the burners.

Coal transportation mode

The selection of particular mode of transportation of coal depends on the location of power plant with respect
to coal mines/ coal sources and other site conditions. Various transportation means such as rail or other
captive systems such as merry go round (MGR), belt conveyors are adopted. For coastal stations, coal is
received at ports by ships/barges and transported through belt/pipe conveyor system or rail etc.

Most of the power stations receive coal through rail. Power stations located near to the indigenous coal source
(i.e. mine mouth) receive coal through their own MGR and those located far away (load centre stations) from the
coal mines receive coal rakes through Indian Railway network. Conveyor Belt may also be used as an
 Target group – Graduate Engineering Trainee / PG DC

alternative to MGR. This type of transportation system is preferred when the coal mine or port is close to the
power plant.

The coal received at power station may be unloaded by means of track hopper or wagon tippler or by
combination of both depending on the type of wagons (BOBR or Box-N wagons) in the coal rakes expected to
be received at the station.

Topography and geometry of the area for coal handling system

Layout of coal handling system varies with topography, geometry of the area, coal storage requirements as
well as wind direction. No. of transfer points may also vary with topography and geometry of the area.

2.0 BRIEF DESCRIPTION OF COAL HANDLING PLANT SYSTEM

2.1 Coal unloading system

As mentioned above, the coal received at power station may be unloaded by means of wagon tippler or track
hopper or by combination of both depending on the type of coal rakes to be used for transportation of coal to
the station. Generally coal rake consists of 59 wagons, each wagon carrying payload of 60 tons. The two
unloading systems are briefly described below:

Track hopper unloading system

The coal received through bottom opening bottom release (BOBR) wagon rakes is unloaded in under ground
R.C.C. track hopper. Paddle feeders are employed under track hopper to scoop the coal and feeding onto
underground reclaim conveyors. Belt weigh scales are provided on these conveyors for measurement of coal
flow rate.

Wagon tippler unloading system

The coal received from Box-N wagons is unloaded in underground RCC hoppers by means of rota side type
wagon tipplers. Side arm chargers are employed for placement of wagons on the tippler table and removal of
empty wagon from tippler table after tippling. Apron feeders are employed under each wagon tippler for
extracting coal from wagon tippler hopper and feeding onto underground reclaim conveyors. Belt weigh scales
are provided on these conveyors for measurement of coal flow rate. Provision is kept for shunting locomotives
for placing the rakes in position for the side arm charger to handle and begin unloading operation.

2.2 Coal crushing

Coal unloaded in the wagon tippler hoppers/track hoppers is conveyed to crusher house by belt conveyors via
pent house and transfer points depending on the CHP layout. Suspended magnets are provided on conveyors
at pent house for removal of tramp Iron pieces. Metal detectors are also provided to detect non-ferrous materials
present in the coal before crushers. In case the sized coal is received, then the coal is sent directly to stockyard
and the crusher is by-passed.

Conveyors leading to crusher house have facility for manual stone picking, at a suitable location after
penthouse. In line magnetic separators are also provided at discharge end of conveyors for removal of
remaining metallic ferrous tramp from the coal before it reaches the crushers. Coal sampling unit is provided to
sample the uncrushed coal.

The size of the coal received is normally (-) 300 mm which may, however, depend on coal tie up. The received
coal is sized in crushers (ring granulators) from (-) 300 mm to (-) 20 mm. Screens (vibrating grizzly type or
 Target group – Graduate Engineering Trainee / PG DC

roller screens) provided upstream of the crushers screen out (-) 20 mm coal from the feed and (+) 20 mm coal
is fed to the crushers. A set of rod gates and rack & pinion gates is provided before screens to permit
maintenance of equipment downstream without affecting the operation of other stream.

The crushed coal is either fed to coal bunkers of the boilers or discharged on to conveyors for storage in coal
stockyard through conveyors and transfer points.

2.3 Coal Stacking & Reclaiming at Stockyard

Crushed coal is sent to stockyard when coal bunkers are full. Stacking/ reclaiming of coal is done by bucket
wheel type stacker-cum- reclaimer moving on rails. The stacker-cum- reclaimer can stack coal on either sides of
the yard conveyor. During stacking mode coal is fed from conveyors on boom conveyor and while in reclaim
mode, boom conveyor discharges coal on the yard conveyor for feeding coal to bunkers through conveyors and
transfer points. The yard conveyor can be reversible type depending on layout requirement.

When direct unloading from rakes is not in operation, coal is reclaimed by the stacker – cum-reclaimer and fed
to the coal bunkers. Emergency reclaim hopper (ERH) can be provided to reclaim coal by dozers when stacker
–cum- reclaimer is not in operation. Emergency reclaim hopper can also be used for coal blending. Coal
stockpile is provided with required storage capacity depending on location of plant vis-à-vis coal source.

Metal detectors and in-line magnetic separators are also provided before feeding to bunkers for removal of
metallic ferrous tramp from reclaimed crushed coal. Coal sampling unit is provided to sample crushed coal of (-)
20 mm size. Belt weigh scales are also provided, on conveyors for measurement of flow rate of as fired coal.

2.4 Dust Control System and Ventilation system

The dust control system is required for control of fugitive dust emissions from dust generation points such as
transfer points, feeders, crushers etc. Dust control is achieved by dust suppression and extraction system.
Dust suppression is achieved by two methods viz. Plain Water Dust Suppression System and Dry Fog Type
Dust Suppression System.

Ventilation system is provided for all the working areas/ locations/ buildings/ underground structures of CHP.
The required ventilation is achieved by mechanical ventilation system/ pressurised ventilation system
depending on the area requirement. The pressurized ventilation system is capable of pressurizing slightly
above atmospheric pressure to prevent ingress of dust from outside. The MCC/switchgear room areas of coal
handling plant are provided with pressurised ventilation system while other areas have mechanical ventilation.
The control rooms, office room and RIO (Remote Input/ Output) room are provided with air conditioning system.

2.5 Miscellaneous facilities

The Coal Handling Plant is also provided with sump pumps at suitable location in underground buildings to
drain out water. Necessary monorails with manual or electric hoist are provided for handling various
equipments of CHP. Flap Gates or movable head system are provided at transfer points for dropping coal from
one conveyor to other conveyor and also changing the coal flow stream. Necessary service water, potable
water and cooling water system is provided in CHP area as per requirement.

3 DESIGN CRITERIA AND BROAD FEATURES

3.1 Capacity of CHP and Major Equipment

i) Peak daily coal requirement shall be met by 14 hrs operating hours of coal handling plant so that
balance 10 hrs per day are available for upkeep and maintenance. Ten (10%) percent margin shall be
 Target group – Graduate Engineering Trainee / PG DC

considered over the peak daily coal requirement (based on GCV of worst coal and normative heat rate) for
arriving at the rated capacity of the coal handling plant. Margin is provided to take care of the variation in the
GCV of the coal received, aging of the equipment and different operating conditions of the CHP equipment.
Typically for a 2x500 MW plant, capacity is worked out as under:

Typically, two streams of conveyors and equipment shall be provided for coal handling system with rated
capacity of 1600 TPH for a 2 x 500 MW power plant. The two streams of conveyors shall be interlinked at
transfer points for conveyor changeover for flexibility of operation in the event of breakdown of any conveyer.
Rated capacity would vary with calorific value of the coal intended to be used.

ii) Capacities of different equipment for 2x500 MW plant shall be under.

@ Applicable for track hoppers served by MGR. In case of coal supply by Indian Railways, track hopper
capacity may be considered as 6000 MT.

*Normally a CHP should require only 1x100% S-R for 2x500 MW units. At some sites, depending on layout of
stockpiles, 2x100% S-R may be required due to constraint in stock pile length.

3.2 DESIGN REQUIREMENTS

3.2.1 Mechanical Equipment / Systems

The sizing and selection of the vital equipment viz. crushers, screens, paddle feeders etc. covered under the
system shall be based on the following characteristic of coal and operating conditions:

i) All mechanical, civil and structural system design shall consider:

a) Simultaneous running of both conveyors at rated capacity.

b) Round the clock operation of coal handing plant

ii) The coal delivered to the power station shall be of size 300 mm & below. However occasionally 1-
2% coal of 400 mm lump size may also be encountered.

iii) HGI of the coal shall be between 45 to 65. Normally moisture content in coal will vary between
12% to 15%. However for design purposes, moisture content of 20% shall be considered.

iv) Due to open cast method of mining involved, the coal may contain shale and sand stone as high
as 20%. Also occasionally metal pieces like broken shovel teeth, brake shoe, wires etc., may also come
along with coal from open cast mine.

v) The coal “as received” shall contain varying percentage of fines. Coal with such fines may tend to
form adhesive lumps, particularly during monsoon when surface moisture is at its maximum value.

vi) For the purpose of volumetric computation, the bulk density of the coal shall be taken as 800
kg/m3. Therefore, for calculation of belt conveyor capacity, their drives and drive motors kW requirement,
and sizing (volume calculations) of chute, hoppers etc. the above bulk density shall be considered. For all
other purposes viz. for stresses/ load on structures, torque calculations the bulk density of the coal shall be
taken as 1200 kg/ m3.

vii) The motors, gear boxes, couplings and pulleys for conveyors shall be standardized and no. of types
shall be limited to minimum possible.
 Target group – Graduate Engineering Trainee / PG DC

viii) All hoppers and tunnels shall be provided with sump pumps (1 operating + 1 standby). The drive
motor of all the sump pumps shall be mounted at least 1.0 metre above the floor / ground level. The sump
pumps shall be suitable to handle coal slurry and impeller shall be of non-clog type.

ix) The Coal Unloading System shall be capable of unloading the rake within the time as stipulated in
the latest Commercial Policy (Freight) of Indian Railways. The currently applicable Policy of 2007 stipulates 7
hours unloading time for a coal rake for BOX, BOX-N, BOXNHA etc type wagons and 2 hours 30 min for
BOBR type wagons.

Wagon Tipplers

x) Wagon tipplers shall be suitable to handle any type of wagons being used by Indian Railways as
on date for transportation of coal as per IS-10095 (Latest edition) and shall conform to all stipulations with
regard to suitability for handling wagons having width, height and length over coupler faces as indicated by
RDSO at the time of approval of wagon tippler drawings.

xi) The wagon tippler shall be ‘rotaside’ type suitable to unload a coal wagon by lifting and rotating it
sideways. The angle of tip shall be at least 150° giving 60° angle to the side of the wagon for emptying the
coal contents into the hopper below. The wagon tippler design shall conform to latest edition of G-33 and its
amendments issued by RDSO.

xii) The tippler shall be designed to allow passage of all standard broad gauge (1676 mm) Indian
Railways diesel locomotives over tippler table at creep speed. The tippler shall be designed to
accommodate 150 Tons locomotive as per G-33 requirement.

xiii) An electronic static weighing system shall be provided to measure / record the quantum of coal,
wagon wise on the wagon tippler table before & after tippling. It shall have a minimum accuracy of 1% of the
gross weight of the wagon.

Side arm charger

xiv) The side arm charger shall be suitable to handle 59 nos. of loaded wagons weighing 110 Tons.
Thus, side arm charger shall be used for indexing forward the rake of 59 nos. loaded wagons, placing
decoupled wagons on the tippler table and out hauling the empty wagons.

Wagon Tippler Hopper

xv) The wagon tippler hopper shall be of RCC construction and adequately sized to accommodate the
coal load for at least three (3) nos. 8 wheeled wagons (180 tons) of RDSO design used by Indian Railways.

xvi) For effective volumetric capacity computation of the hopper, the angle of repose of coal shall be
considered as 37°. The minimum valley angle of the hopper shall be considered as 60°.

xvii) Steel gratings of mesh size 300 mm x 300 mm over wagon tippler hopper shall be provided. The
hopper and gratings shall be designed for movement of front end loader/bulldozer over them. Bull-dozer
weight shall be considered as about 35T.

Track Hopper

xviii) Track Hopper shall be under ground RCC structure and gunited with 50mm thick guniting with
effective coal holding capacity of 4500 Tonnes. The valley angle shall not be less than 60 deg. Track
hopper complex shall be provided with covered structural shed. Track hopper shall be 200 m long with one
 Target group – Graduate Engineering Trainee / PG DC

maintenance bay of 15 m on each side of track hopper with hatches & monorail with hoist. Provision shall be
made for compressed air connections for opening / closing the wagon doors during unloading. Track hopper
shall have removable type steel grating cover with opening of 300 mm x 300 mm.

In case of coal supply by Indian Railway wagons, the track hopper capacity may be 6000 MT with hopper length of
300 meters in line with Railway guidelines. Track hopper capacity of 6000 MT with hopper length of 250 m is also
acceptable but the invert level of track hopper shall increase in such a case.

xix) For effective volumetric capacity computation of the hopper, the angle of repose of coal shall be
considered as 37°.

xx) There shall be Electric hoist / manual hoist for handling of the equipment during maintenance. The
path way of monorail shall be close enough for easy handling of the equipment to be lifted. Extension of the
monorail out side the building shall be minimum three (3.0) meter from the out side of the wall / column of the
building.

Apron Feeder

xxi) Apron feeders shall be of robust construction and designed for handling ROM coal as specified and
without any choking particularly during rainy season when coal is wet. A dribble conveyor shall be provided
below apron feeder for proper clean up.

Paddle Feeder

xxii) Each paddle feeder shall have capacity to scoop out coal at the guaranteed capacity in both
forward and reverse motions with no indication of wheel slipping.

xxiii) The carriage shall automatically reverse its motion, when two paddle feeders operating on the same
track come within a predetermined distance. Suitable anti- collision device (infrared and mechanically
operated limit switch type) shall be provided.

xxiv) Rope actuated stop switches shall be provided along the traveling structure for emergency use.

Metal Detector

xxv) Metal detectors shall have high reliability with enough sensitivity to detect 25mm aluminum sphere
below the burden of coal in case of synthetic belting. However, for steel cord belting the sensitivity shall be
40 mm. It shall also detect other metals, like brass, copper, stainless steel, manganese steel, bars, scraps
etc. It should ignore magnetite/iron and shall distinguish between metal pieces and magnetite/iron.

Electronic Belt Weigher

xxvi) The electronic belt weighers for measurement of coal flow rate and quantity shall be provided at
following locations:

a. Unloading conveyors to determine coal receipts rates.

b. Boom conveyor of stacker-reclaimer to know the coal reclaim rates.

c. ERH belt conveyors to know the quantity of coal reclaimed/blended.

d. Conveyors feeding bunkers to know fuel feed rates to coal bunkers.

 Target group – Graduate Engineering Trainee / PG DC

xxvii) The electronic belt weigher System shall be complete with flow rate indicator, totaliser, control
panel etc. These shall be designed for continuous automatic weighing, metering and printing of coal flow
rate.

xxviii) Belt weigher shall be designed for a range of 20% to 120% of rated capacity with an accuracy of
atleast (+) 0.25 percent throughout its range. Belt weigher provided on Stacker Reclaimer Boom Conveyor
shall have accuracy (in the horizontal position of Boom) of (+) 1 percent for the range of 20% to 120% of
boom conveyor rated capacity.

In-line Magnetic Separator and Suspended Magnet

xxix) The magnet shall be able to separate M20 bolts & nuts, and 50 kg MS plates / MS bars of L/D ratio
of less than 5. Strength of magnet at the specified mounting height shall not be less than 1000 gauss (at the
centre point of belt). Mounting height shall be 450mm in the conveyors carrying uncrushed coal & 400 mm in
the conveyors carrying crushed coal measured between top of conveyor belt or bottom of falling material
trajectory and the surface of magnetic separator belt.

xxx) The magnetic separator shall be located such that it picks-up tramp iron from coal trajectory after it
has been discharged from head pulley.

Coal Sampling Unit

xxxi) The coal sampling units suitable to give “Samples” conforming to ASTM-D-2234 shall be provided
for taking samples from any of the two streams running at guaranteed capacity.

xxxii) The normal input feed size shall be considered as (-) 300 mm for coal sampling unit before coal
crusher. However occasionally (-) 400 mm lumps may also arrive. Coal lump size after crusher (as fired coal)
shall be (-) 20mm. However occasionally (-) 50 mm lumps may also arrive in crushed coal.

Vibrating Grizzly Screen

xxxiii) The screen shall be capable to segregate the (-) 20 mm size of coal alongwith coal dust, any muck &
muddy coal (which is likely to be encountered during rainy season) etc. The segregated material shall be
directly fed onto the corresponding belt conveyors/feeders through separate hoppers/chutes provided under
each screening feeder. The width of vibrating screening feeder shall match to feed the material uniformly
over the entire length of crusher rotor without any deflectors in the feeding chute.

Crushers

xxxiv) Ring granulator type crusher shall be provided for sizing the input coal to (-) 20 mm size. Crusher
shall be supplied complete with accessories and subsystems. The crusher shall be capable of delivering the
normal rated output even when handling damp sticky coal having maximum moisture content. No clogging or
building up of material on the crushing element shall develop. The entire inside surface of crusher coming in
contact with coal shall be provided with abrasion resistant steel liners of requisite thickness.

Stacker – cum- Reclaimer

xxxv) Stacker-cum-reclaimer shall operate on rail track running for adequate length to cover the entire
coal stockyard. The wheel load of stacker-reclaimer shall not exceed 27.0 tonnes. The ratio of boom length
(as specified) to the rail track gauge shall not exceed 5. Top of rail level shall be maintained at 0.7 m above the
ground level, i.e., coal pile base level unless specified otherwise. Suitable number of rail scrappers shall be
provided.
 Target group – Graduate Engineering Trainee / PG DC

xxxvi) The minimum track gauge for Stacker-cum-Reclaimer shall be 7 m.

xxxvii) Buckets shall be sized for 125% of rated capacity. Rate of bucket discharges shall not exceed 55 per
minute.

Stockpiles

xxxviii) The stockpiles of coal will have adequate storage for at least as per the table given below and the
coal consumption for this purpose shall be based on normative heat rate and average GCV of design and
worst coal.

Maximum coal stockpile height shall be 10 m. Angle of repose of stored crushed coal shall be 37 degree.

A coal pile run off pit shall be provided close to the stockpile area. Drains shall be provided around the
stockpile. During monsoon, the rain water from the coal pile would be collected in drains and led to the coal pile
run off pit. The size of the pit would depend on the intensity of rainfall in the area and size of the stockpile. Pit
shall be of RCC construction with a baffle wall in the middle. Coal particles in water collected in the pit would
settle down in the first compartment and relatively clear water would flow to the second compartment. The
water would be pumped from the second compartment to guard pond for further utilisation. Coal particles shall
be removed from the pit using backhoe and trucks. Suitable ramp for the movement of backhoe shall be
provided. This coal will be dumped in coal stockpile.

Chutes and Hoppers

xxxix) The minimum valley angle of chutes shall be 60 degrees from horizontal. Hoppers and Chutes shall
be made of minimum 20 mm thick TISCRAL / SAILHARD /LSLAS07 or equivalent material. Sliding zones &
adjacent sides shall be 20 mm thick, while non striking/ non sliding zones shall be 10 mm thick MS. In case of
vertical chute (valley angle more than 80 degree) complete chute work shall be 20mm thick TISCRAL /
SAILHARD / LSLAS07 or equivalent.

xl) Transfer chutes shall be adequately sized and sloped to ensure smooth flow of coal without any
accumulation anywhere. Minimum cross sectional area of chute should be 5.0 times the area of cross load of
the preceding conveyor.

xli) 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.

Drive Selection

All equipment drives except crusher drive shall be capable of starting on full load. xliii)

The motor rating for belt conveyors shall have a minimum margin of 20% over the required kW. For all other
drives, a minimum margin of 10% over the required kW shall be taken. The service factor for selection of
gearboxes, flexible couplings, brakes, etc., shall be minimum 1.5 on the motor rating.

xliv) Single LT drive motors shall be used for conveyor drive ratings up to 160 kW. For conveyor drive rating
beyond 160 kW, single HT drive shall be used for conveyors. However for boom conveyor drive and
intermediate conveyor drive on stacker- reclaimer, single LT motor may be used above 160 kW also. For the
bunker conveyor (tripper conveyors) drives only, single snub LT drive motor shall be used upto 200 kW rating.
 Target group – Graduate Engineering Trainee / PG DC

The type of high speed coupling between motor and gear box shall be as follows:

a) For motor rating up to 30 kW - Resilient type flexible coupling

b) For LT motors of above 30 kW - Traction type fluid coupling/ Delayed fill type fluid coupling

c) For HT motors - Actuator operated scoop type fluid coupling

Belt Conveyor System

xlvi) Belt conveyor system shall be designed as per the latest edition of as per IS:11592. or ‘Belt Conveyors
for Bulk Materials’ published by Conveyor Equipment Manufacturer’s Association’

xlvii) Slopes of conveyors, wherever applicable, shall not exceed 16 degree depending on the lump size and
other governing factors. The conveyor shall be horizontal at the feed point as far as possible. In case the same
is not possible, the inclination at the feed point shall be limited to 6 degree.

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.

xlviii) The belting shall be of either synthetic fabric such as Nylon-Nylon/Polyster- Polyamide, Steel Cord. etc.
with rubber covers of adequate flexibility to give a troughing angle of 35 deg.

xlix) Fire resistant covers shall be provided for all conveyor belting breaker fabric shall be provided for all belts.
The covers shall be FR Grade conforming to CSA- M422M87 type-C / Equivalent DIN 2.2 to 3 of Canadian
Bureau of Mine specification belting for surface installation. The belt shall have 5 mm top cover & 3 mm bottom
cover (min). Minimum number of plies shall be four (4). Ratio of calculated maximum working tension to rated
belt tension shall not exceed 0.8 Accordingly belt selection shall be done. The flame test shall be carried out as
per ISO 340 stipulation.

l) All overground and overhead conveyors shall be located in suitably enclosed bridge structure. The
conveyor bridge shall have permanently colour coated steel sheeting covers on roof and both sides, properly
screwed or locked to steel structure as required. Adequate provision of windows shall be kept. A continuous
slot opening of 500 mm shall be provided on both sides just below the roof sheeting.

Belt Protection Equipment

li) Pull chord type (manually reset type) emergency stop switches shall be located on both sides of belt
conveyors at a spacing of 20 m along the walkways for the entire length of conveyors for emergency stopping
of conveyor.

lii) Belt sway switches of self resetting type shall be provided at a spacing of 45 m to limit belt sway to
permissible extent.

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

liv) One no. chute blockage switch of proven type shall be provided at a suitable height on each leg of the
conveyors discharge chute, vibrating screens by pass chutes, crusher feeding chutes, tripper discharge and
feeding chutes nearest to the skirt boards. Chute blockage switch shall trip the feeding conveyor in case of
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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.

Stone Picking

lv) Manual Stone Picking arrangement at a suitable location in the conveyor gallery before the crusher house
shall be provided complete with platforms, overhead lighting, handrailings, suitable seating, safety hook &
holding arrangement for manual pickers, disposal chutes to ground level etc.

Dust Control (Dust Extraction and suppression) System

lvi) Design and construction features of Dust control system shall be generally in conformity with the
recommendation of “American Conference of Governmental Industrial Hygienists”.

lvii) Type of dust suppression system to be provided at various locations shall be as given below:

o Around the track hopper and wagon tippler – Plain water dust suppression.
o Wagon Tippler hopper complex - Dry fog type dust suppression system
o Crusher receipt and discharge points - dry fog type dust suppression
o For all transfer points - Dry fog type dust suppression system
o For stock pile - Plain water type dust suppression system with swiveling nozzles.
o Boom belt discharge of stacker – reclaimer - Dry fog type dust suppression system

Plain water type dust suppression system:

a) Pressure at inlet (Plain water) shall be 2.5 kg/sq. cm for Track Hopper and 4.5 Kg/sq. cm for wagon
tippler, coal stock piles.

b) Spray heads shall comprise of swiveling type spray units spaced at an interval of approximately 40
meters around each coal pile.

Dry fog type dust suppression system:

Spray head pressure at inlet (dry fog) shall be min. 0.5 kg/cm2 for water and min 5 kg/cm2 for air

Dust extraction System shall be provided at following locations:

o For Bunker floor

o For crusher house

lxi) The dust extraction system shall be of Venturi scrubber system. One independent dust extraction system
for each stream shall be provided. The dust collection efficiency shall be 95% down the 10 micron size.

Ventilation System

Ventilation system shall be designed and installed conforming to “Industrial Ventilation”

lxiii) The MCC/switchgear room areas shall be provided with pressurised ventilation system while other areas
shall have mechanical ventilation.
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lxiv) The pressurized ventilation system shall be designed considering 15 air changes per hour to maintain these
areas pressurised slightly above atmospheric pressure to prevent ingress of dust from outside.

lxv) The air quantity for mechanical ventilation system shall be estimated based on equipment and solar heat
loads and the temperature rise inside the building. Necessary air filters shall be provided to supply only clean air
into building. Exhaust air shall be discharged at a suitable height above building.

lxvi) No. of air changes per hour shall not be less than 10 supply air changes & 7 exhaust changes for over
ground building. No. of air changes per hour shall not be less than 15 supply air changes & 7 exhaust air
changes for underground areas.

3.2.2 Electrical System

For design requirements of Electrical System, Section 8 of this document may be referred to.

3.2.3 Instrumentation and Control

i) Control System for coal handling plant shall be Programmable Logic Controller (PLC) based or
shall be implemented through micro-processor based distributed control system (DCS) covering total
functional requirements of sequence control, interlock & protection, monitoring, alarm and data logging.
Remote I/O cabinets shall be provided wherever required depending upon distance/location.

ii) It shall be possible to select any coal flow path from the Operator’s work station located in the CHP
control room viz.

a) Wagon tippler/ track hopper to coal bunkers

b) Wagon tippler/ track hopper to crushed coal storage via stacker cum reclaimer

c) Wagon tippler/ track hopper – one stream to crushed coal stockpile and other stream to coal bunkers

d) From crushed coal stockpile to coal bunkers via stacker cum reclaimer

e) From crushed coal stockpile to coal bunkers via emergency reclaim hoppers

iii) Entire CHP shall be controlled from following points:

a) CHP control room near crusher house consisting of Operator Work Station (OWS) and Large Video
Screen (LVS) for the control of entire CHP. Some I/O may be located remotely in Wagon tippler MCC room
and on bunker floor.

b) OWS for the control of each stacker cum reclaimer.

c) OWS for the control of wagon tipplers/track hoppers.

d) Dust extraction / suppression system shall be operated from the respective control panel provided
locally with the equipment / system. Dust extraction/suppression system shall operate when the coal
conveying system is in operation and bunker ventilation systems shall operate round the clock. DE / Dust
suppression system shall be provided with remote operation from main CHP control room except for Bunker
floor DE operation which will be local.
 Target group – Graduate Engineering Trainee / PG DC

e) Control system for stacker cum reclaimer, wagon tipplers, dust extraction / suppression system shall
be interfaced to the CHP control room.

f) Local start/stop push button stations, de-interlock switches to be mounted near each equipment for
start / stop during maintenance of the system.

iv) For design requirements of Control & Instrumentation system, Section 8 of this document may be
referred to.

4.0 Calculation basis for CHP capacity (2x500MW)

Plant Capacity 1000 MW
Heat Rate 2450 kCal/kWh
PLF 100 %
GCV of Worst Coal 3150 kCal/kg
Specific coal requirement 0.78 kg/kWh
Daily Coal Requirement 18666.67 Tons
Hourly Coal Requirement 777.78 TPH
Peak daily coal requirement for BMCR flow 833 TPH
Working Hours 14 Hrs
Plant Capacity 1428 TPH
Add 10% margin 142.8 TPH
Rated Capacity 1570.8 TPH
Rated Capacity (rounded off) 1600 TPH

4.1 Calculation basis for CHP capacity

Sl No Equipment No. of equipment Typical rated
capacity of each
equipment for 2x500
MW plant
1A OR Track Hopper@ 1 4500 MT
1B* Paddle Feeder 2x75% (W)+ 2x75% (S) 1200 TPH
Wagon Tipplers 2 (W) +1 (S) 20 Tiplings/hr
Apron Feeders 2 (W) +1 (S) 1200 TPH
2 Crushers 2x55% (W)+ 2x55% (S) 880 TPH
3 Vibrating grizzly screens 2x55% (W)+ 2x55% (S) 880 TPH
4 Vibro - feeders for emergency reclaim 4 nos. 450 TPH
hoppers
5 Stacker-reclaimer * (S-R) 1X100% 1600 TPH
6 Conveyors 2x100% (1W+1S) 1600 TPH
7 Yard Conveyor 1 per S-R 1600 TPH

4.2 Calculation basis for stockyard capacity

Sl No Plant location Coal stock, (in terms of no. of days of coal consumption)
1 Pit head 15 days requirement
2 Load center 30 days requirement
3 Coastal 30 days requirement
 Target group – Graduate Engineering Trainee / PG DC

CHP Equipment & System.

M1 Flap Gate
M2 Belt Conveyors
M3 Steel Hopper & Chutes
M4 Bar Grid /Track Hopper
M5 Rotary Discharge Machine
M6 Grizzly Feeder
M7 Crusher
M8 Belt Weigher
M9 In Motion Weigh Bridge
M 10 Metal Detector
M 11 Inline Magnetic Separator
M 12 Suspended Electromagnet
M 13 Sump Pump
M 14 Fixed Tripper
M 15 Traveling Tripper
M 16 Belt Sealing Arrangement
M 17 Belt Vulcunisng Machine
M 18 Dust Suppression System (Dry Fog Type)
M 19 Dust Suppression System (Plain Water Type)
M 20 Dust Extraction System
M 21 Ventilation System
M 22 Sampling System
M 23 Hoist & Mono Rails
M 24 Stacker & Reclaimer Machine
M 25 Window Air Conditioner

5.0 Typical Scope of works for Coal Handling Plant

5.1 SCOPE OF WORK

The scope of coal handling plant typically covers the design, engineering, manufacture, inspection and testing
at manufacturer's works, supply, packing and delivery at project site, unloading, storage and in plant
transportation at site, erection, supervision, pre- commissioning, testing, successful commissioning,
performance testing and handing over of coal handling plant of the thermal power project. Scope of work shall
include all mechanical, electrical, C&I, accessories, civil, structural and architectural works to make the system
complete.

Typical scope of work for 2x500 MW thermal power project includes:

5.2 Mechanical

i) Underground RCC track hopper with four (4) Nos. paddle feeders

Three (3) nos. rota side wagon tipplers alongwith side arm chargers and electronic weighing bridges, three (3)
nos. wagon tippler hoppers and three (3) nos. apron feeders

Note: Stations with track hoppers may also additionally have wagon tipplers to take care of eventuality of non-
availability of BOBR wagons. In such a case, two (2) nos. wagon tipplers may be provided with hoppers and
apron feeders
 Target group – Graduate Engineering Trainee / PG DC

ii) Belt conveyors (2x100% streams) from wagon tippler hoppers/track hopper upto crusher house
complete with tunnel, conveyor gallery, pent house and transfer points. Covered conveyor galleries with steel
trestles shall be provided for all over-ground conveyors. Following shall also be provided on each belt
conveyer before crusher house:

a) Suspended magnets for removal of tramp iron pieces

b) Metal detectors

c) Electronic belt weighers

d) Manual stone picking platforms

e) Coal sampling unit alongwith online analysers

f) In-line magnetic separators for removal of small and tramp iron pieces escaped from suspended
magnets

iii) Four (4) nos. vibrating grizzly screens before crushers.

iv) Sets of gates each comprising of one rod gate and one actuator operated rack & pinion gate at inlet to
each of the vibrating grizzly screens and at inlet to vibro feeders in emergency reclaim hoppers.

v) Crusher house (CH) accommodating four (4) nos. crushers and associated vibrating grizzly screens,
gates, passenger cum goods elevator, conveyors, chute work alongwith actuator operated flap gates,
monorails & hoists, hoist maintenance platform, external and internal staircases, hand rails and other
equipments such as coal sampling unit, dust suppression, dust extraction system etc.

vi) Four (4) nos. crushers including crusher supporting foundations, vibration isolation system with
springs & viscous dampers, vibration monitoring system etc.

vii) Belt conveyors (2x100% streams) from crusher house upto coal bunkers complete with conveyor
gallery and transfer points.

viii) Belt conveyors (2x100% streams) from crusher house upto yard conveyor for coal stacking complete
with conveyor gallery and transfer points.

ix) Reversible Yard conveyor (1x100%) with independent drives for stacking and reclaiming modes.

x) One (1) nos. reversible Stacker cum Reclaimers with electronic belt weighers mounted one on each
reversible stacker reclaimer.

xi) Emergency reclaim hoppers with vibro feeders and belt conveyors (2x50%) complete with conveyor
gallery and transfer points for interconnection with conveyor between crusher house and bunkers.

xii) Belt conveyors from yard conveyor complete with conveyor gallery and transfer points for
interconnection with conveyor between crusher house and bunkers.

xiii) Following shall also be provided on each belt conveyer before coal bunkers:

a) Electronic Belt weighers

 Target group – Graduate Engineering Trainee / PG DC

b) Coal sampling unit alongwith online coal analyser

c) In-line magnetic separators

d) Metal detectors

xiv) Complete chute work and motor operated flap gates between various conveyors in all Transfer points
and crusher house.

xv) Four (4) Nos. motorized traveling trippers, two (2) nos. for each unit.

xvi) Two (2) nos. passenger - cum – goods elevators to serve various floors of the crusher house (CH)
and one (1) no. passenger – cum – goods elevator in transfer point near boilers.

xvii) Adequate number of ventilation equipment for ventilating the track hopper, wagon tippler hoppers,
emergency reclaim hoppers, underground tunnels, transfer points, crusher house and bunker bays (housing
tripper conveyors)

xviii) Pressurised ventilation system for all switchgear rooms, MCC rooms.

xix) Exhaust fans in all battery rooms and toilets

xx) Air conditioning of main CHP control room, local control rooms for track hopper, wagon tipplers,
stacker/reclaimer and office rooms.

xxi) Adequate number of sump pumps in hoppers, transfer points complete with individual discharge
piping with fittings and valves upto nearest plant drain.

xxii) One (1) No. belt vulcanizing machine along with belt jointing facilities

xxiii) Complete dust suppression system for control of fugitive dust in track hopper/wagon tippler hopper,
paddle feeder, transfer points, crusher house, coal stock yard complete with enclosed pump houses, water
tanks, pumps, drives, hoisting arrangements, piping, valves etc. as briefly specified below :

a) Plain water dust suppression around the Track Hopper top and wagon tippler top through fogging
nozzles.

b) Plain water dust suppression around stockyard through swiveling sprinklers

c) Complete plain water dust suppression system with two (2) nos. pumps and one (1) tank mounted on
paddle feeder or on trolley including ring header inside track hopper for supplying plain water.

d) Complete dry fog type dust suppression system at all Transfer Points, wagon tippler complex, S-R
boom conveyor discharge and Crusher House (both at discharge and loading points) including all electrical
and accessories.

e) Belt Sealing arrangement in Bunker bays for control of dust coming out of coal Bunkers.

xxiv) Complete dust extraction system for control of fugitive dust in crusher house and bunker floor with
complete water tanks, pumps, drives, hoisting arrangements, piping, valves etc.

xxv) Service water, potable water system and cooling water system for complete coal handling plant.
 Target group – Graduate Engineering Trainee / PG DC

xxvi) 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 and
other equipment from ground level to their locations and vice-versa.

xxvii) Four number bull dozers of minimum 400 BHP diesel engine for dosing coal into emergency reclaim
hoppers and coal stockpile maintenance

xxviii) Drainage of all CHP buildings, track hopper, wagon tippler hopper, emergency reclaim hoppers,
tunnels, conveyor galleries and coal stock yard including all civil & structural works.

xxix) Fire protection provisions to meet TAC and IS – 3034.

5.3 Electrical System / Equipment

Two no. feeders shall be provided from 11 kV Station Switchboards for Coal Handling Plant. Further, distribution
of power supply at 3.3kV and 415V voltage levels and all other required electrical equipment for putting coal
handling plant into successful operation shall be in the scope of work of CHP supplier. The 415V supply shall be
arranged either through 11/ 0.433kV or 3.3/ 0.433kV LT auxiliary transformers. However, 415 V supply for boiler
floor MCC shall be arranged from respective 415 V unit PMCC. Typically, following electrical equipment shall be
included:

i) 11/ 3.3kV and 11/0.433kV or 3.3/0.433kV auxiliary transformers

ii) 11kV, 3.3kV and 415V Switchgears
iii) HT and LT busducts
iv) Power and control cables including cables from 11 KV station switchboards and 415 V unit PMCC.
v) Cable laying alongwith cabling accessories, cable trays and termination/ jointing kits of cables, and
fire sealing
vi) HT and LT Motors
vii) 220V DC system comprising of battery banks, chargers and DC distribution boards
viii) Complete illumination system for internal and external lighting of associated plant and building
ix) Complete grounding and lightning protections and its interconnection with nearest earth mat
x) Emergency stop push button for all HT and LT motors

5.4 Instrumentation

i) Microprocessor based programmable logic control (PLC) system for operation, control and
monitoring of the Coal handling plant from the coal handling system control room. Operator Work station
housing TFT / keyboard, and Large Video Screen shall be provided in the main control room of CHP along
with I/O racks, PLC panels and power supply arrangement. Remote I/Os may be provided depending on
distance/location.

It shall be possible to monitor the coal handling plant from the main DCS in the Unit Control Room through soft link.

ii) Independent PLC based control system, comprising of OWS, PLC panels, I/O racks and power
supply arrangement etc., for stacker cum reclaimers with facility to communicate important signals with CHP
control room through hard wiring.

iii) PLC based control system comprising of OWS, PLC panels, I/O racks and power supply
arrangement etc.. for coal unloading at wagon tippler/track hopper complex along with static weigh bridges
 Target group – Graduate Engineering Trainee / PG DC

iv) Local control panels for traveling trippers, dust extraction / suppression system. These local
panels shall be interfaced to the CHP control room.

v) Communication facility between CHP Control Room and all the strategic workings areas such as
Wagon Tippler/track Hopper Control Room, Stacker-Reclaimer Control Cabin, bunker floor, unit control
room etc.

vi) Instrumentation and control cables including laying and termination

vii) Power supply system for C&I system including redundant UPS system, batteries, charges etc.

viii) All Instruments integral to CHP equipment for control, monitoring and operation of the
equipment/plant/ systems such as:

a) Belt sway switches

b) Pull chord switches
c) One No. zero speed switch at tail end for each conveyor.
d) Vibration monitoring system for crushers and drives
e) Motor overload switches for conveyor drives
f) RTDs for conveyor drive motors and crusher motors (for HT motors only)
g) Level switches in dust suppression system water tanks and other field devices as required.