R0 Date: 26/May/10
ITEM : COAL HANDLING PLANT
PROJECT :
DESEIN PRIVATE LIMITED CONSULTING ENGINEERS
COAL HANDLING SYSTEM FOR 2 x 800 MW UNIT OF SRI DAMODARAM SANJEEVAIAH THERMAL POWER PROJECT AT
KRISHNAPATNAM
TATA PROJECTS LIMITED, HYDERABAD
DOC NO. : TPL-069-0788-I-DOC-053
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED
OPERATIONAL AND CONTROL PHILOSPHY FOR COAL HANDLING PLANT
TECPRO SYSTEMS LIMITED
Issue/Rev.:
OPERATIONAL AND CONTROL PHILOSPHY
FOR
COAL HANDLING PLANT
COAL HANDLING SYSTEM FOR 2 x 800 MW UNIT OF SRI DAMODARAM SANJEEVAIAH THERMAL POWER PROJECT AT KRISHNAPATNAM
OWNER : ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED
OWNER'S CONSULTANT : DESEIN PRIVATE LIMITED CONSULTING ENGINEERS
B.O.P. CONTRACTOR : TATA PROJECTS LIMITED, HYDERABAD
C.H.P. CONTRACTOR : TECPRO SYSTEMS LIMITED
Issue/Rev Date By Chkd.
R0 26/May/10 VS KM
Signed (Initials)
Reason for Issue
FOR INFORMATION
KRISHNAPATNAM
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 1 of 48
OPERATIONAL AND CONTROL PHILOSPHY
TABLE OF CONTENTS SECTION No. TITLE PAGE No.
1 SYSTEM DESCRIPTION 2
2 ELECTRICAL SYSTEM DESCRIPTION
8
3 INSTRUMENTATION 10
4 TECHNICAL & OPERATIONAL DETAILS OF PLC
13
5 OPERATIONAL & CONTROL PHILOSPHY WITH SYSTEM
DESCRIPTION
19
6 ANNUNCIATION SYSTEMS 35
7 SEQUENTIAL INTERLOCK FOR CONVEYORS & OTHER
EQUIPMENTS
37
8 ELECTRICAL CONDITION FOR DRIVES
41
9 CONVEYOR START UP & STOP SEQUENCE
43
10 DUST SUPPRESSION & EXTRACTION SYSTEM
48
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 2 of 48
It is recommended to study this document with reference to i) FLOW DIAGRAM : TPL-069-0788-M- FD-001.
ii) PLANT LAYOUT : TPL -069-0788-PLT-001.
1.0 SYSTEM DESCRIPTION A brief description of the proposed coal handling system is furnished below:The coal handling system comprises the following
1 Crushing 2 Stacking 3 Reclaiming 4 Blending 5 Bunker Feeding System
Conveying into plant Coal will be received at the jetty by ship, unloaded and sent to the plant Crusher house through a cross country conveyor. (By others). a) Crushing • Coal as received inside the crusher house will be screened, crushed and conveyed.
• Coal of (-) 300 mm size is received and single stage crushing is envisaged. • Two nos. of screens and crushers are considered. Eccentric Disc type Roller screens has been
provided in the crusher House to screen out (-) 25 mm coal. (+) 25mm coal will be fed to the crushers where the same will be crushed to (-) 25mm size.
• Ring granulator type crushers has been provided in the crusher house for crushing the coal.
• Rated capacity of each screen and crusher will be of 1600 TPH. After crushing, coal will be
fed into belt conveyors BCN- 1A/1B which will feed the coal into junction tower JNT-1. From there coal will be diverted, stock piled, blended and fed into the bunkers.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
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Date Description By
ITEM Operational & Control Philosophy
Page 3 of 48
b) Stacking
• Crushed domestic coal received at JNT -1 will be conveyed through BCN-3 conveyor and will be stockpiled through Stacker cum reclaimer (SCR-1). Two (2) nos. of domestic stock piles are envisaged by using SCR-1. Also, a portion of crushed domestic coal received at JNT-1 is conveyed through BCN -2A/2B and fed to JNT-3. In JNT -3, coal is received and conveyed through BCN-4 and stock piled using SCR-2 on the southern side.
• Crushed imported coal received at JNT-1 is conveyed through BCN -2A/2B and fed to JNT -
3. Coal from JNT -3 is received and conveyed through BCN-4 and stock piled using SCR-2 on the Northern side.
• Two numbers of Stacker cum Reclaimers viz., SCR-1 and SCR-2 mounted on trunk
conveyors BCN-3 and BCN-4 respectively have been envisaged. Bucket wheel drives are variable type to adjust the feeding capacity.
c) Reclaiming
• The reclaim system will be controlled from operator station in the CHS control room. The coal can be reclaimed by bucket wheel system of SCR or an emergency reclaim system.
• The coal form stock pile will be reclaimed by stacker cum reclaimers (SCR-1 and / or SCR-
2), and feed to trunk conveyors BCN-3 and /or BCN-4, which will feed coal to bunkers through series of conveyors and traveling trippers.
• Whenever the reclaimer is not available, coal will be reclaimed by dozers into the
emergency reclaim hopper (ERH). Two sets of emergency reclaim hoppers has been provided out of which one will be for domestic coal and another for imported coal. Below the each of the reclaim hoppers rod gate, rack & pinion gate and vibrating feeders has been provided for feeding coal to the belt conveyors BCN-5&7. Vibrating feeders are driven by variable frequency drives thus adjusting the feed capacity.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
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Date Description By
ITEM Operational & Control Philosophy
Page 4 of 48
d) Blending
• Blending of domestic coal and imported coal will be done by reclaiming coal from the respective stock pile at the required proportion (70:30) and conveyed to the succeeding conveyors where they get mixed and fed in to the bunkers.
Domestic (70%) : 1120 T/h (Rated) Imported (30%) : 480 T/h (Rated)
• The coal can be blended in the following options,
i) Direct Feeding domestic coal by 70 % and Reclaiming imported coal by 30 %. ii) Direct Feeding imported coal by 30 % and Reclaiming domestic coal by 70 %.
iii) Reclaiming domestic coal by 70 % and Reclaiming imported coal by 30 %. (i) Direct Feeding Domestic coal by 70 % and Reclaiming Imported coal by 30 %. Option-1
• Crushed domestic coal will be sent to JNT-1 through Conveyor BCN – 1A/1B. At JNT-1 coal will be divided as 70 % and 30% by the flow divider (FD-1 and or FD-2). 70 % of domestic coal will feed into Trunk conveyor BCN-3 and remaining 30% coal will feed into conveyor BCN-2A/2B. Conveyor BCN-2A/2B will convey the coal to JNT-3 and which will then feed the coal to Trunk conveyor BCN-4.SCR-2 will receive and stock the 30% domestic coal on the southern side
• Imported coal 30% will be reclaimed by bull dozer which will be fed into the Emergency
reclaim hopper ERH-2. Rod gate, rack & pinion gate and vibrating feeders are provided below ERH-2 for feeding into Conveyor BCN – 7, which will then convey the same to JNT-4.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
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Page 5 of 48
• Domestic coal from trunk conveyor BCN – 3, Conveyor BCN-6A/6B and Imported coal from Conveyor BCN – 7 will be blended in JNT-4. From there blended coal will be fed through series of conveyors for feeding into boiler bunkers.
Option-2
• Crushed domestic coal will be sent to JNT-1 through Conveyor BCN – 1A/1B. At JNT-1 coal will be divided as 70 % and 30% by the flow divider (FD-1 and or FD-2). 30 % domestic coal will feed into trunk conveyor BCN-3 and remaining 70% coal will feed into Conveyor BCN-2A/2B. Conveyor BCN-2A/2B will convey the coal to JNT-3 and which will then feed the coal to trunk conveyor BCN-4. SCR-1 will then receive and stock the 30% domestic coal either on the southern or northern side.
• Imported coal 30% will be reclaimed by Bull dozer which will be fed into the Emergency
reclaim hopper ERH-2. Rod gate, rack & pinion gate and vibrating feeders are provided below ERH-2 for feeding into Conveyor BCN – 7, which will then convey the same to JNT-4.
• Domestic coal from trunk conveyor BCN – 4 and Imported coal from Conveyor BCN – 7 will
be blended in JNT-4. From there coal will be fed through series of conveyors for feeding into boiler bunkers.
Option-3 • Crushed domestic coal will be sent to JNT-1 through Conveyor BCN – 1A/1B. At JNT-1 coal
will be divided as 70 % and 30% by the flow divider. 30 % domestic coal will feed into trunk conveyor BCN-3 and remaining 70% coal will feed into conveyor BCN-2A/2B. Conveyor BCN-2A/2B will convey the coal to JNT-3 and which will feed to trunk conveyor BCN-4. SCR-1 will then receive and stock the 30% domestic coal either on the southern or northern side.
• Imported coal which will be reclaimed by stacker cum reclaimer of SCR-2, and Domestic
coal form Conveyor BCN – 4 will be blended in the JNT- 4. From there coal will be fed through series of conveyors for feeding into boiler bunkers.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
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Date Description By
ITEM Operational & Control Philosophy
Page 6 of 48
(ii) Direct Feeding Imported coal by 30 % and Reclaiming domestic coal by 70 %.
• Crushed imported coal will be sent to JNT-1 through Conveyor BCN – 1A/1B. At JNT-1 coal will be divided as 70 % and 30% by the flow divider (FD-1 and or FD-2). 30 % imported coal will feed into trunk conveyor BCN-3 and remaining 70% coal will feed into Conveyor BCN-2A/2B. Conveyor
BCN-2A/2B will convey the coal to JNT-3 and which will feed the coal to trunk conveyor BCN-4. SCR-2 will then receive and stock the 70% imported coal on the northern side.
• SCR-1 will reclaim 70 % coal of domestic coal and feed the same into trunk conveyor BCN-3
which will then feed to JNT-2.
• Domestic coal reclaimed from SCR-1 and diverted imported coal will get blended in JNT-2. From there blended coal will be feed through series of conveyors for feeding into boiler bunkers.
(iii)Reclaiming domestic coal by 70 % and Reclaiming imported coal by 30%. Option-1
• Domestic coal 70% will be reclaimed by SCR-1 and fed into the trunk conveyor BCN-3 which will feed in to JNT-4 through conveyor BCN-6A/6B. Imported coal 30% will be reclaimed by SCR-2 and fed into the trunk conveyor BCN-4 which will feed into JNT-4. At JNT-4 both the coal will get blended and fed into boiler bunkers through series of conveyors.
Option-2
• Domestic coal 70% will be reclaimed by SCR-1 and fed into the trunk conveyor BCN-3
which will feed into the JNT-4 through conveyor BCN-6A/6B. Imported coal 30% will be reclaimed by Conveyor BCN – 7 and fed into JNT-4. At JNT-4 both the coal will get blended and fed into boiler bunkers through series of conveyors.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
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Page 7 of 48
Option-3
• Domestic coal 70% will be reclaimed by SCR-2 and fed into the trunk conveyor BCN-4 which will feed into the JNT-4. Imported coal 30% will be reclaimed by Conveyor BCN – 7 and fed into the JNT-4. At JNT-4 both the coal will be blended and fed into boiler bunkers through series of conveyors.
e) Bunker Feeding System
• The coal as received in JNT-4 will be fed into steam generator bunkers through a series of belt conveyors BCN-8A/8B, BCN-9A/9B, BCN-10A/10B, BCN-11A/11B and BCN- 12A/12B, and traveling trippers as shown in the flow diagram.
• Other Auxiliary equipments like belt weigh scales, inline magnetic separator; metal
detectors, dust extraction system, dust suppression, sampling system and ventilation system etc., will be provided as per flow diagram.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
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Date Description By
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Page 8 of 48
2. ELECTRICAL SYSTEM DESCRIPTION
The electrical power distribution system is provided at 3.3 kV & 415V, 3-phase; and 240V, 1-phase, voltage levels to supply power to the drives and other electrical equipments / systems of the CHP (Coal Handling Plant). 3.3 kV power shall be distributed power supply to 3.3 kV motors for Belt Conveyor BCN-8A/B, BCN-3, BCN-5, BCN-1A/B, BCN-4, BCN-7, Ring Granulator and Stacker Reclaimer machine Transformer. Three Electrical rooms are envisaged. ER-1 shall be located near to JNT-6 and shall receive power via two(2) no 11/0.433 KV service transformers. ER-2 shall be located near to JNT-4 and shall receive power via two (2) no 11/0.433 KV service transformers. ER-2 has been considered as the control room of the CHP and PLC, back up panel etc shall be housed in ER-2. ER-3 shall be located near to crusher House and shall be fed by two(2) no 11/0.433 KV service transformers.
ER-1 shall feed to the equipments in and around JNT-6 and shall house the following
panels/equipments a) Service Transformer. b) PMCC-1. c) Welding Distribution Board. d) Main Lighting Distribution board. e) Power distribution board. f) PLC IO racks. ER-2 shall feed to the equipments in and around of JNT-4(CHP CONTROL ROOM) and shall house the following panels/equipments a) Service transformers. b) PMCC-2 c) Main Lighting Distribution Board d) Welding Distribution Board e) Power distribution Board f) PLC Panels g) UPS.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 9 of 48
h) 220 V DC Battery. i) Battery Charger. ER-3 shall feed to the equipments in and around of Crusher House and shall house the following panel/equipments a) Service Transformers b) PMCC-3 c) Main Lighting Distribution Board d) Welding Distribution Board e) Power distribution Board f) PLC IO racks g) UPS.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 10 of 48
3. INSTRUMENTATION
All the conveyors will be provided with following instruments / safety protections to ensure safe and trouble free operation a) Pull Cord Switch:
All the conveyors will have pull ropes, connected to Pull Cord Switches on both sides. Switches shall be placed at 15M from either side and at intermediate spacing of 30M.In case of any abnormality or emergency, the operating personnel can stop the conveyor immediately by pulling the pull cord. Control room personnel will get corresponding TRIP indication on the PLC. Once operated, the lever of the pull cord switch will latch and the conveyor can not start without manually resetting the operated pull cord switch. Alarm and annunciation shall be generated from Pull cord switch operated in operator station and in Annunciation facia of back up panel.
b) Belt Sway Switches:
Belt Sway Switches are provided in pairs on both sides of conveyor . Switches shall be placed at 15M from either side and at intermediate spacing of 50M. If the belt runs away from the conveyor centreline by a significant amount, the switch gets acted and trips off the conveyor to prevent any damage to the belt edge. Control Room person will get a corresponding trip indication in the PLC. Service staff then should correct the problems causing the belt misalignment or run out and then only the conveyor should be started again. Alarm and annunciation shall be generated from Belt Sway switch operated in operator station and in Annunciation facia of back up panel.
c) Local Control Station
Local push button station shall be provided for all the drive motors of the plant.
• Start/Stop push buttons for unidirectional motors. • FWD Start / Stop / REV Start push buttons for bidirectional motors and only start push
buttons for Emergency motors.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 11 of 48
d) Zero Speed Switch:
Zero Speed Switch is installed on the Bend Pulley of the Conveyor to check for any belt slippage. If the belt speed falls below 85% of the Nominal Speed, the Zero Speed Switch will initiate TRIP command and stop the conveyor to prevent any damage to the belt. Service staff should correct the problem and then only the conveyor should be started.
e) Bearing & Winding Temperature Detectors:
All the HT Motors shall be provided with 12 Nos. Simplex Winding temperature detector & 2 Nos. Duplex bearing temperature detector to continuously monitor the Winding & Bearing Temperature. Conveyor Trip command will be initiated in case a high Winding & bearing temperature is detected by the RTD to safeguard the bearing.
f) Level Measurement:
Ultrasonic type level transmitter with 2 wire type transmitter with 4-20mA output with HART protocol shall be provided for continous level monitoring of Boiler bunkers. These level indicators shall be provided with local LCD indicator and shall provide the continous level of the bunker in the CHP control room. Radar type, top mounted level switch shall also be provided to provide high and low level alarm in the control room.
g) Hooters:
Hooters shall be provided one each in all the proposed transfer points & Bunker units. These hooters
will alarm the people in the vicinity of the conveyor before starting the conveyor to move away from
the conveyor. After the horn, people will have 1-2 min (adjustable) time to leave the conveyor and
move to a safe location. The range of hooter shall be 500 m.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 12 of 48
h) Space heater: All HT motors/LT motors 30 kw and above will be provided space heaters using 240V AC supply. It is
used to protect the motors from moisture when the supply is off.
i) Heavy Duty Limit Switches Heavy duty roller type limit switch shall be provided to indicate the position and to stop the carriage before over travel. These switches shall be provided for Tripper to indicate the position, at remote. Travel limit switches shall be provided at each end of tripper carriage, for limiting the travel drive between two ends of the track. Each of these travel limit switches shall be duplicated with another limit switch. The first one shall be normal limit and the second one for over travel limit. On operation of normal limit switch, drive shall trip & the same shall be annunciated on the Local Control Panel. For some reason, if the machine over travels & operates over travel limit switch, then the control supply of Local Control Panel shall be cut.
j). VIBRATION MONITORING AND ANALYSIS SYSTEM
Vibration monitoring and analysis system (VMAS) shall provide condition monitoring and analysis of the bearings of HT Motors on continous on line basis. Vibration sensors shall be provided for both DE and NDE side of all HT motors and respective driven equipments. Vibration monitoring system shall consists of Velocity type vibration sensor. These sensors shall be mounted in both X and Y axis at 90 deg to each other. VMAS shall be microprocessor based system (PC based) and shall be interfaced with CHP PLC through redundant communication link. 4-20 mA output to PLC shall be considered to indicate the vibration level in the HMI. The Vibration analysis system shall determine the exact nature of the fault like misalignment, shaft crack, dynamic unbalancing etc. The analysis system shall perform the following analysis
a) Bode plot b) Time wave form c) Orbit analysis d) Shaft centre line e) Cascade plot
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
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Page 13 of 48
f) Water fall g) Bar graph h) Current values i) Spectrum j) Alarms- amplitude and spectral
Vibration analysis system shall be provided with one(1) no 21” TFT, VDU, keyboard/mouse, Vibration analysis software, Bulk data storage etc.
4. TECHNICAL DETAILS & OPERATIONAL DETAILS OF PLC:
The control & Instrumentation shall be through microprocessor based PLC system for the entire Coal handling plant covering the total functional requirement of sequence control, interlock & protection, monitoring, alarm, data logging. The CHP PLC shall be hot redundant and will have 100% redundancy features in CPU, power supply , communication and network interface. However, Inputs modules shall be non redundant and Output modules shall be redundant only for critical drives. Information peripherals at the output hierarchy i.e. TFT, printer etc. will be connected within main processor. Redundant UPS system will be incorporated for smooth functioning in CHP control room.
The PLC system shall be an integrated control and data acquisition system for providing control & monitoring of coal handling plant equipment from a Main CHP Control Room Building (ER-2) located near JNT-4.The control Room operator shall be provided with color graphic displays of the Coal handling plant and with sufficient details to allow proper control & monitoring of the plant functions. The PLC system consists of PLC panel, operating station (OS), Engineering station (ES) & alarm annunciation. ER-2 shall house the redundant PLC. Remote IO panels shall be provided in ER-1 & 3 for the equipments located near to the respective control rooms. Stacker cum reclaimer machine shall be provided with separated independent redundant PLC system. Stacker cum Reclaimer machine PLC shall be housed in Electrical House on the machine. One (1) no independent redundant bi-directional OPC link with Ethernet based TCP- I/P protocol in
envisaged for interfacing with main plant DCS. Two (2) nos VDU/KB based operator station(OS) and
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
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Date Description By
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Page 14 of 48
one (1) nos engineering work station each with single VDU and single keyboard/optical
mouse/trackball has been envisaged. Engineering and Operator station shall constitute of 21” TFT
monitor with optical mouse/ track ball/. Resolution shall be 1280 X 1024 pixels. Main memory
capacity shall be 8 MB with 160 GB hard disk and shakll have DVD/CD RW drive.One nos. Large
Video Screen (LVS) with complete accessories suitable for operation and monitoring of plant
equipment/system is also envisaged.
The PLC shall be time synchronized from Master Clock System. PLC Port connectivity provision for
GPS link from Master Clock (Time Protocol / NTP / IRIGB NTP / any other standard protocol). System
shall be with redundant configuration
Spare philosophy for PLC 1. Spare I/O Channels: All types of I/O modules shall be provided with 10 % spare channels. Spare channels shall be wired and shall be distributed among the Control processors. 2. 10% hot spare I/O modules (installed) shall be provided. 3.10% spare slots for I/O modules distributed among the control processors. UNINTERRUPTED POWER SUPPLY(UPS) Redundant UPS shall be provided in ER-2 (CHP control room) & ER-3(near crusher house). The system shall be provided with redundant UPS power supply. The power supply provision shall be such that on failure of one power supply the other power supply shall cater to the requirement of the equipment so as never to hinder the functioning of the system in any manner due to power supply failure.
4.1) LARGE SCREEN VIDEO DISPLAY SYSTEM (LVS)
The overall screen size shall be 84” Diagonal to be used as an integrated, single large screen and also
to have picture in picture facility. The Large Screen System shall have the functionality to pre configure
and save various display layouts to be accessed at any given point of time with a simple mouse click.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
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Date Description By
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Page 15 of 48
This LVS shall be used as an OWS with its own dedicated electronics.
The Large Screen Graphics Wall for each unit in Control Room will primarily be used for :
a) Display of important data, graphics coming from the PC, Workstation, Video, SCADA etc.
b) To provide real time clear luminous view to share information to
operators and visitors.
c) The Large Screen Graphics Wall shall be installed in the Control Room. d) The overall screen size shall be 84” diagnol to be used as an integrated, single
large screen and also to have picture in picture facility.
d) The overall resolution of the graphics wall shall be min 2560mmX2048mm pixels.It should be possible to have the whole screen of the Large Screen Graphics Wall should behave as a single logical screen or in multiple nos of screens (min 4 nos) and the control of the same should be from a dedicated Graphical Control Unit (Controller) having a Keyboard & mouse.
e) The complete system shall be interfaced on 10/100 MBPS LAN.
f) The Large Screen System should have the functionality to pre configure and
save various display layouts to be accessed at any given point of time with a simple mouse click.
g) The system should be possible to show the mirror images of operator
workstations in freely resizable and repositionable windows. h) The system should be configured such that any of the operators sitting on
the same Ethernet should be able to work on the Large Screen sitting at his own position with his local keyboard & mouse.
. i) The offered system should be able to work in 24/7 days environment
and is of industrial nature.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 16 of 48
The Rear Projection Module shall have the following
specifications:
1. The Graphics Wall should be made up of 3 nos. of rear projection modules placed in a single row.
2. The rear projection modules must be based on Single Chip DLP Rear
Projection technology.
3. Each of the Rear Projection Module shall have a resolution of 2560 x 2048 pixels and offer 3.7 million colours.
4. Each Rear Projection module should be equipped with a long life,
low power redundant UHP lamp. The average lamp life shall be 6,000 hrs (for 110 Watt UHP Lamp). The system should have an in-built lamp redundancy for the availability of the system in the event of a sudden failure of the lamp.
5. The brightness uniformity shall be >95%.
6. The contrast shall be equal to better than 600:1.
7. The luminance on each rear projection module shall be min.
250 cd/m2 (typical) using single lamp.
8. The system should have an in-built optical dimmer to match the brightness of the various projection modules automatically to get a fully uniform display wall.
9. The screen to be used shall be double element-stitched
screen. The seam between adjacent screens shall be <0.4mm. The screen surface should not be reflective.
The input to projection module shall be digital to have a flicker free
image on the large screen graphical wall. 10. The system should be designed such that the expansion shall be
possible on top as well as on sides.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 17 of 48
11. The system should have rear access only for the maintenance
purposes to avoid any misalignment of the screens in the front.
12. Each of the projection modules has power consumption less than 220W in cold standby mode and less than 380W in hot standby mode.
j). The Display Controller shall have the following specifications:
1. In an industrial 19” rack mounted casing based on PIV 2.4 Ghz
(Min.).
2. The min. memory of 256MB expandable upto 1 GB.
3. The unit should be equipped with a 48X or better CD ROM, 3.5” Floppy Drive.
4. The hard Disk should be of 60 GB, 7200 rpm.
5. Should have 10/100 Mbps Ethernet port for LAN connection.
6. Supplied with a Keyboard and mouse with 20 m cable
extension.
7. Based on Windows 2000 OS.
8. Min. 6 Graphics Output to be connected to 3-rear projection modules.
9. The system should have future expansion possibilities.
10. As full hardwired backup has been envisaged, the LVS should ensure operation of the plant in case of total failure of all operator stations.
k). Interfacing with Video signals, to receive & project pictures from CCTV,
Employer's live camera, VCP/VCD player/DVD player, SCADA & DDCMIS. Remote unit for switching between video signal & MMI signal, selecting the video signal channel (live camera no./location typically) shall be provided.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 18 of 48
l). LVS shall be designed for continuous viewing (24 hours in a day) under
normal room ambient lighting without any need to darken the room. Suitable darkening of the projection screen for light absorption shall be provided for this purpose.
m). Suitable mounts on installation should perform adjustment of the
projections and all other components shall be adjusted in the factory and shall not require further adjustment at site. Maintenance work on the LVS shall be confined to easy replacement of the lamps and cleaning of the fans, which shall be performed in few minutes by the Purchaser's staff without any special training. Suitable means (Operating Hours displays etc.) shall be provided to indicate the need of replacement of lamp. Power switch shall be provided for isolation during replacement of the lamps.
n). The LVS and its accessories shall be designed in such a way that the
brightness in the centre of the screen and the edges of the screen is uniform and there is no perceivable difference in the quality of the picture on the centre and on the edges of the screen.
4.2) LVS Annunciation
Following indicates the guidelines for implementing LVS annunciation functionalities.
1) The LVS annunciation will emulate salient features of the conventional hardware annunciations while presenting more flexibility.
2) The annunciation points will be presented on topmost area of LVS
screens. This “annunciation area” will be reserved for soft- annunciations only and no process graphics/system window/application windows will occupy this area.
3) In alarm window alarm text will be displayed when point is in alarm.
There will be one alarm for each alarm window. The font type and size of message text shall be such that it is legible to operator.
. 4) For each LVS annunciations, a menu based options to acknowledge,
reset, configuration etc. is to be provided. Through configuration utility
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 19 of 48
operator can view and edit alarm list, tag nos. etc. of all points in all LVS. The configuration utility shall be password protected for any modifications. However, with one acknowledge/reset action, all alarm point(s) of all band(s) of that LVS will be acknowledged/rest.
4.3) BACK UP PANEL : Back up control panel shall be provided with the following facilities 1) Hardwired Annunciation System(HAS) :The Hardwired Annunciation system shall be drive from PLC. Audio-visual window based hardwired annunciation for system /equipment faults shall be provided with back up panel. Hooter for annunciation system shall be arranged in such way as to provide a high volume audio for every alarm annunciation. The detail of annunciation system is also provided in Sl no.6 2)DIGITAL DISPLAY UNIT(DDU) :Digital display unit shall be provided for selected important parameter in back up panel. Seven segment type display provided to display digital value. 3).MIMIC DIAGRAM: Process MIMIC indicating the material flow diagram shall be mounted in the back up panel . Run & Trip indications shall be provided for all belt conveyors and for all major equipments. Position indications for flap gate, RPG & travelling tripper shall be indicated. 4)Push buttons with lamps shall be provided for all major equipments. Push buttons provided with sequence start and stop of belt conveyors & sub systems.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 20 of 48
5. OPERATION & CONTROL PHILOSOPHY The coal handling system is controlled from the following control points.
Coal Handling Plant Main Control Room
Operation of the following equipment of coal handling plant is controlled from the main CHP control room.
a) Belt Conveyors. b) Ring Granulators. c) Roller Screens. d) Vibrating Feeders. e) Flap gates. f) Scoop couplings. g) Inline magnetic separators . h) Coal Sampling Units. .
Local Control Panels
Local control panel (Relay based) for following equipment will be provided. Operation of the following equipment of coal handling plant shall be manual from local panel located near the drives. However , status may be available at main CHP control room.
a) Mobile trippers over bunkers b) Hydraulic scoop coupling c) Belt weighers d) Metal Detectors e) Electric hoist – Pendent push button controls. f) Inline Magnetic Separators g) Coal Sampling Units h) Sump pumps. i) Dust Suppression system.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 21 of 48
j) Dust Extraction system. k) Ventilation system
5.1). 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 TFT/Keyboard to select any one of the following conveying paths.
Path –I - From Conveyor BCN -1A/1B to coal bunker.
Path –II - Reclaiming from SCR-1 to coal bunker.
Path –III - Reclaiming from SCR-2 to coal bunker.
Path –IV - From tunnel conveyor BCN -5 to coal bunker via pent house (PH-1)
Path –IV - From tunnel conveyor BCN -7 to coal bunker via pent house (PH-2).
Path –V - From Combination of Conveyor BCN- 3 i.e yard Conveyor of SCR-1 with BCN -5 i.e tunnel conveyor of ERH-1.
Path –VI - From Combination of Conveyor BCN-4 i.e. yard Conveyor of SCR-2 with
BCN-7 i.e. tunnel conveyor of ERH-2.
Path –VII - From Combination of Conveyor BCN-6A/6B of JNT-4 with BCN-7 i.e. tunnel conveyor of ERH-2.
Path –VIII - From Combination of Conveyor BCN-6A/6B of JNT-4 with BCN-4 i.e. yard
Conveyor of SCR-2. The coal handling system operator will select any one of the above existing paths from Operator
station or via various push buttons and selector switch on the back up panel. Permissive for the flow
stream path is then by positioning different flap gates at desired positions by means of keyboard or
from the back up panel. Once the system is in the operation, the gates cannot be moved from their
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 22 of 48
positions and path. Flap gates which do not come in the stream in which coal flow is taking place can
be operated at any time. However, for the flap gates in bunker area conveyors, it is possible to
change flap gate position while the conveyor is in operation.
The control system will be designed for “Auto” & “Manual” operation of the conveyors in the selected
path. Auto/Manual selection will be done from operator station or from control desk.
AUTO MODE : In the “Auto” mode, the conveyors & related equipment will start
sequentially when the ”system start” is activated. 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 will start the conveyor system, in the
same sequence as in Auto mode from Keyboard. The operator will also stop the
conveyor system, by pressing “System stop” or individual “Stop” push
buttons/command from Keyboard in the reverse sequence.
During “Sequence Start” in both Auto & Manual modes, first the required number of hooters 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 will be indicated on the panel by glowing of lamp “Coal handling
sequence start”. The starting permissive will 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 started will be withdrawn. The system cannot
be started again unless the “Sequence start” push button is again pressed & the hooters sound
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 23 of 48
again, as described before. Those conveyors & equipment, which have already started, will continue
to run.
The status indication in the graphic display against all conveyors and equipment in selected
stream/path will start slow flickering. However all status indications against all flap gates in the
selected path will glow steadily. Therefore, from the selected flow stream path of the 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 indication against that conveyor / equipment will
change to steady glow indicating that it is running.
Graphic display status indicators associated with a particular motor/equipment will flicker fast in case
of fault/trip.
In addition, emergency stop push button for immediate shut down of complete plant is also provided.
For ease of operation, a Control Desk housing the MIMIC will be provided at ER-2(CHP CONTROL ROOM).
Operation device like push button, selector switch will be segregated on the control desk for ease of
operation. The following control devices will be provided on Control Desk Selector Switch
I. Three Way selector switch for AUTO/OFF/MANUAL Mode.
II. Three way selector switch for STREAM-A/STREAM-A&B/STREAM-B for PATH-I.
III. Three way selector switch for STREAM-A/STREAM-A&B/STREAM-B for PATH-II.
IV. Three way selector switch for STREAM-A/STREAM-A&B/STREAM-B for PATH-III.
V. Three way selector switch for STREAM-A/STREAM-A&B/STREAM-B for PATH-IV.
VI. Three way selector switch for STREAM-A/STREAM-A&B/STREAM-B for PATH-V.
VII. Three way selector switch for STREAM-A/STREAM-A&B/STREAM-B for PATH-VI.
VIII. Three way selector switch for STREAM-A/STREAM-A&B/STREAM-B for PATH-VII.
IX. Three way selector switch for STREAM-A/STREAM-A&B/STREAM-B for PATH-VIII
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 24 of 48
Illuminated Push Buttons
a. AUTO START Push Button for Path-I to Path-VIII Start.
b. STOP Push Button for Path-I to Path-VIII stop.
c. START push button for individual conveyors (as per drive list)
d. STOP push button for individual drives (as per drive list)
e. Positioning push button for Flap gates and R&P gates.
f. Lamp test push button for MIMIC lamps & Annunciation facia
g. Fault Acknowledge push button
h. Fault reset push button
i. Start push button for Stacker cum Reclaimer-I machine in stacking mode
j. Start push button for Stacker cum Reclaimer-I machine in reclaiming mode
k. Stop push button for Stacker cum Reclaimer-I machine
l. Start push button for Stacker cum Reclaimer-II machine in stacking mode
m. Start push button for Stacker cum Reclaimer-II machine in reclaiming mode
n. Stop push button for Stacker cum Reclaimer-II machine
o. Emergency STOP Mushroom head latching type ( with red hinged cover / flapper )
Process MIMIC as per flow diagram attached will be provided on the back up panel. Following minimum
indication shall be available in MIMIC to indicate the operation status
a. Start Indicator for each conveyor.
b. Start Indicators for each drives.
c. Position indication of each Flap Gate.
d. Start Indicators for Stacker cum Reclaimer in Stacking mode.
e. Start indicators for Stacker cum Reclaimer in Reclaiming mode.
f. High and Low indication for each Bunker
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 25 of 48
If stream-A is selected for any PATH, then only stream-B can be selected for other path. If stream-A&B is
selected for any path, no other PATHS can be selected. The operator will select the mode of operation
(AUTO/OFF/MANUAL) from the selector switch in control desk. The operator will select the path by means
of PATH selection selector switch. The PATH selection selector switch is a three way selector switch
(STREAM-A/STREAM-A&B/STREAM-B). The flap gate shall be manually positioned. If selected in AUTO
mode the operator will give the START command by pressing the START pushbutton of the selected path.
On energizing the “START” command, hooter will be energised for a period of 1 minute (adjustable).After
the hooter stops, a preset time of two –minute (adjustable) is allowed for the movement of personnel . Then
the equipment will be started automatically in sequence with time interval. The conveyors and related
equipment will start sequentially when in AUTO mode and PLC will control the starting sequence. If stream-
A&B is selected, then equipment corresponds to both the stream can be started. Hence, equipments to be
selected in the Operator work station or to be manually started by energizing push buttons in the control
desk.
If selected in MANUAL mode, the operator will have to manually start the equipments .
There is emergency stop push button in control desk located at SHP control room for immediate shutdown
of complete plant.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 26 of 48
5.3). STACKER RECLAIMER: (i) Description: The Stacker Reclaimer unit can stack the material onto the pile or reclaim the stockpiled material and feed
onto the main-line conveyor. While stacking, the material is being feed from the main-line conveyor onto
the boom conveyor of the Stacker-cum-Reclaimer through Tripper. During reclaiming, the material is
discharged onto the boom conveyor by the bucket fitted to the bucket wheel body and, the boom conveyor
feeds the material onto the main-line conveyor.
The rail-mounted machine is controlled from the operator's cabin, which is conveniently located to avail the
maximum range of vision to the operator.
The Stacker-cum-Reclaimer would comprise of:
• Rail Travel Mechanism • Lower Carriage with Slewing Ring • Super Structure • Counter-weight Boom • Bucket Wheel complete with drive • Bucket Wheel Boom Conveyor • Tripper, • Chutes • Steps & Platforms • Rail Clamps • Group Lubrication System • Electrical Equipment, & • Operator’s Cabin & E-house
(ii) Bucket Wheel : The bucket wheel will be cell-less type and fabricated from steel. Bucket fixing holes will be provided with
wear resistance renewable steel bushes. Direct Hydraulic Motor will drive bucket wheel. The hydraulic
drive will be complete with power pack, pump & motor, filters, all necessary valves, oil cooler, pressure
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 27 of 48
switches, piping, fittings, etc. The bucket wheel drive would be reversible type to facilitate withdrawal of
wheels in the event of excessive under cutting.
The material is reclaimed by buckets and discharged onto the boom conveyor through bucket wheel chute
and conveyor chute.
(iii) Luffing Device : Hoisting or lowering of the bucket wheel boom will be done hydraulically. The upper and lower positions of
the bucket wheel boom are limited by control & limit switches.
(iv) Bucket Wheel Boom : Bucket wheel boom shall be pivoted in the centre of the machine and suspended on the supporting mast.
The boom would take up the bucket wheel with its drive units and reversible boom conveyor. The conveyor
must only be able to be started after the brake shall be released and for this check necessary interlocks
are provided. The switch over in conveying direction is automatic according to selection of operation i.e.
stacking or reclaiming. The bucket wheel boom shall have feed chutes at both ends, having rear plates,
which can be opened or closed. Depending upon the direction of flow one or the other of the chute rear
plate shall be opened, so that, the material can discharges on that end. The opening & closing of the
plates shall be carried out by electric actuators, which are automatically coupled with direction in which the
belt runs. The plate adjustment shall be monitored by limit switches and can, therefore, only function when
the boom conveyor belt is running.
(v) Slewing Mechanism The slewing mechanism shall be provided with Hydraulic Drive with Common Power Pack of Bucket Wheel Drive integral hydraulically operated brake and proportioning valve to ensure smooth motion of the
turn table reversal. Two numbers of hydraulic motors for slew drive shall be provided for machine
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 28 of 48
(vi) Travel Mechanism
The rail travel mechanism has drives (as specified in Technical Parameters). The travel mechanism brakes
are actuated by thrusters when the motors are switched. All brakes must be released before it is possible
to start the motors and for this check necessary interlocks are provided (brake release check).
The travel mechanism is provided with two electrically operated rail clamps which are monitored by limit
switches (open & close positions). Travel shall be provided with Rotor Resistance Box with slip ring
assembly for Two speeds.
The Power Cable Reeling Drum and the Control Cable Reeling Drum are built- on to the lower frame each
of which is driven by an individual Geared motor & Contorque Unit. The arrangement would be such
that, it must not be possible to start the travel motors before these two cable drums are running.
(vii) Super Structure : The super-structure is of welded plate construction and supported on the slewing ring. The bucket wheel
boom along with mast and counter weight boom is supported onto the super-structure. The hydraulic for
the luffing is also supported to the super-structure.
(viii) Lower Carriage :
The lower carriage is of sturdy box type design and it is supported on the travel mechanism. It has statically
determined three points support, which ensures stability and guarantees an even distribution of load over
the entire assembly. The slewing ring is supported on the lower carriage.
(ix) Operator's Cabin : The operator's cabin is made of sheet metal. Adequate number of glass panels is fitted to provide
panoramic view. The control panel for the entire electrical equipment, ventilation and lighting will be
provided. The operator's cabin and control room will be adequately ventilated.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 29 of 48
(x) Chute : Necessary chutes fabricated from structural steel plates would be provided.
(xi) Steps & Platforms : Necessary steps & platforms furnished with MS grating would be provided for easy access to all
machineries and to the control cabin.
(xii) Tripper A tripper would be provided to operate in conjunction with main line conveyor. The tripper would comprise
of structure, walkway with open grid flooring, railing, belt scraper, head pulley, bend pulley, chute and
supports of welded construction with single wheel bogies. The tripper travels on the same rails as those of
the main machine. The tripper discharge end is supported on the support car.
(xiii) Belt Scale : One number belt scale would be provided on the boom conveyor of stacker Reclaimer. The control panel
with feed rate indicator and six-digit totalize would be provided in the operator's cabin. The accuracy of belt
scale mounted on boom conveyor will be + 0.5 % of actual weighment.
Stacker Reclaimer machine shall be provided with dedicated redundant PLC mounted on the machine itself.
Some of the signals shall be hardwired to the CHP PLC. Operator from the Control room can only initiate the
start command to the PLC of the Stacker cum Reclaimer machine for Stacking or Reclaiming mode.
5.4). FLAP GATES 24 Nos. of Flap gates has been provided including tripper flap gates.
All flap gates will be motorized and remote controlled from the Operator station or from the back up
panel. Their position will be indicated on the 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 gates.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
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Page 30 of 48
Description Position-A Position-B
Flap gate-3 Towards Conv BCN-1B Towards Conv BCN-1A
Flap gate-4 Towards conv BCN-1B Towards Conv BCN-1A
Flap gate-5 Towards conv BCN-1B Towards Conv BCN-1A
Flap gate-6 Towards conv BCN-1B Towards Conv BCN-1A
Flap gate-7 Towards conv BCN-1B Towards Conv BCN-1A
Flap gate-8 Towards conv BCN-1B Towards Conv BCN-1A
Flap gate-9 Towards conv BCN-2B Towards Conv BCN-2A
Flap gate-10 Towards conv BCN-2B Towards Conv BCN-2A
Flap gate-11 Towards conv BCN-6A Towards Conv BCN-6B
Flap gate-12 Towards conv BCN-6B Towards Conv BCN-6A
Flap gate-13 Towards conv BCN-8B Towards Conv BCN-8A
Flap gate-14 Towards conv BCN-8B Towards Conv BCN-8A
Flap gate-15 Towards conv BCN-8B Towards Conv BCN-8A
Flap gate-16 Towards conv BCN-8A Towards Conv BCN-8B
Flap gate-17 Towards conv BCN-9B Towards Conv BCN-9A
Flap gate-18 Towards conv BCN-9B Towards Conv BCN-9A
Flap gate-19 Towards conv BCN-10B Towards Conv BCN-10B
Flap gate-20 Towards conv BCN-10A Towards Conv BCN-10A
Flap gate-21 Towards conv BCN-12B Towards Conv BCN-12B
Flap gate-22 Towards conv BCN-12A Towards Conv BCN-12A
Flap gate-23 Towards conv BCN-11A Towards Conv BCN-10A
Flap gate-24 Towards conv BCN-11B Towards Conv BCN-10B
Flap gate-25 Towards conv BCN-12B Towards Conv BCN-12A
Flap gate-26 Towards conv BCN-12A Towards Conv BCN-12B
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
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Page 31 of 48
5.5). METAL DETECTORS 2 Nos. of Metal detectors will be provided on the conveyor(s) as per the flow diagram (i.e on BCN 9A/B).
The capacity of metal detector will be to detect minimum 25 mm aluminium cube. Indicating marker will be
provided with the metal detector.
Hooter with audible range of min 500 m will be provided.
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 resetting of metal detector & putting back the marker bag in position.
Metal detector ON/OFF push buttons will be provided in main control room also.
• 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 3. Metal Detector Faulty.
5.6). MAGNETIC SEPARATOR 2 Nos. of In-line magnetic separator will be provided on belt conveyors BCN-8A/8B i.e. in JNT-5.
Minimum operating height above belt conveyor is 500 mm.
It is possible to start the conveyor only after energizing the magnet of ILMS or Suspended Magnet.
Further, if conveyor system trips magnetic separators will get de-energized after a time lag &
suspended magnet will remain energized and can be de-energized locally. Also if drive motor of
cleated belt of ILMS trips, Magnetic separator will not get de energized, but conveyor system will trip
and annunciation will appear at main CHP control room.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
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Page 32 of 48
Following individual indications are provided on Local control panel
1. Magnetic separator ON. 2. Incoming supply ON
5.7). BELT SCALE Inline conveyor belt weigh scales will be provided on belt conveyors BCN -9A/9B to record the quantity
of coal received at the plant.
The belt scales will be of electronic / microprocessor based.
Each Belt scale will give output to PLC for display of flow rate indicator and totalizer on TFT & print
out at main CHP control room. Each Belt scale will also have rate flow indicator & totaliser mounted
near the unit.
5.8). VENTILATION SYSTEM (i) Bunker Ventilation system:
Cyclone separator with dry type bag filter will be provided for bunker ventilation system (BVS) in bunker unit 1 near JNT-6 and in bunker unit-2 near JNT-7.
(ii) Tunnel ventilation system:
Tunnel ventilation system shall be provided for Emergency Reclaim hopper area (ERH-1 and ERH-2). Centrifugal fans shall be provided for tunnel ventilation.
(iii) MCC Rooms ventilation:
Pressurised ventilation system shall be provided for MCC rooms. MCC room-2 near JNT-4 (CHP CONTROL ROOM) and MCC room -3 near crusher house. Ventilation system shall also be provided for Toilet room and for Battery room.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 33 of 48
5.9). HOISTS Adequate number of hoists (manual / electrical) with monorails will be provided for handling the
equipment / components, etc. in junction towers, crusher house, reclaim hoppers and other
places. The hoists 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.
5.10). TRAVELLING TRIPPERS
Trippers will be driven by wheel drive, independent of main conveyor drive and will be through
electric motor, helical gear box, Cable Reeling Drum etc.
It will have two - way chute with a flap gate arrangement for discharge to bunker.
Travelling trippers will operate in conjunction with main line conveyor. 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 and over travel limit switch are also provided.
Travel drive motor will start only when brake and rail clamps are in disengaged condition. 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. Following individual indications are provided on local control panel.
i. Motor ON/OFF/TRIP ii. Flap gate position iii. End travel limit switch. iv. Over travel limit switch. v. Each coal bunker levels.
Indication of tripper flap gate positions is given in the main CHP control room.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 34 of 48
5.11). COAL SAMPLING SYSTEM Coal Sampling Unit has been provided in JNT-1 and in JNT-6.
Coal sampling unit is controlled through main coal handling plant PLC. Controls & interlocks for proper material flow is provided similar to conveyor system.
Start/stop push button along with selector switches for Local /Remote modes of operation of coal sampling system will be provided for automatic operation of complete coal sampling system. This control facility will be provided at main CHP PLC as well as locally. Local start/stop of individual equipment will only be possible when the Local mode has been selected from PLC. In any case, local push button stations will be provided for all individual equipment of coal sampling system near the equipment. Following indications are provided on Local Control Panel:
i. System ON/OFF/TRIP ii. Primary cutter stuck up between parking positions.
In case of primary cutter getting stuck between parking positions, preceding conveyor will trip.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.
5.12). CONVEYOR SYSTEM The starting sequence of the conveyors will follow a direction opposite to that of flow of material i.e. 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 and the respective Flap gate suitable positioned. Stop / Tripping of any equipment from running condition will trip all preceding equipment in the system. Adequate no of Pull cord switches at suitable intervals are provided along the length of each belt
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 35 of 48
conveyor, which will enable the respective conveyor to be stopped immediately. Interlocking of various conveyors is achieved with Flap gate, Limit switches and Zero speed switches. 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. . Where ever Scoop type coupling provided for HT motors, the coasting time of respective conveyor, thruster brake, actuator selection and the chute size will be so selected such that there is no spillage of coal from any down stream conveyors during next start.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 36 of 48
6. ANNUNCIATION SYSTEM: Back up panel shall be provided with adequate number of facia type annunciation windows operating
through PLC for the following audio-visual fault annunciation purposes. Wherever group annunciation
is provided, alarm status of individual equipment shall be provided on TFT. Group annunciation shall
be provided on CHP back up panel .
a) 415V PMCC-1 Breaker Trip
b) 415V PMCC-2 Breaker Trip
c) 415V PMCC-3 Breaker Trip
d) 415 PMCC-1 bus under Voltage. e) 415 PMCC-2 bus under Voltage f) 415 PMCC-3 bus under Voltage g) PMCC-1 Transformer group fault h) PMCC-2 Transformer group fault i) PMCC-3 Transformer group fault j) Belt Sway Switch operated (Group) k) Pull cord switch operated (Group) l) Zero Speed Switch operated (Group) m) ILMS group fault n) Metal Detected
o) Vibration high group alarm
p) HT motor bearing / winding temp. high alarm(group) and trip (group)
q) HT motor trip on electrical fault (Group) r) Stacker cum Reclaimer group fault
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 37 of 48
For identification of the fault for a particular conveyor or equipment, status indication against that
Conveyor / equipment in the mimic will start fast flickering and the annunciation window will be
blinking against that particular fault. In addition, a buzzer (alarm) will start sounding. After
acknowledgement of the fault, the buzzer will stop, but the fast flickering on the mimic and the
steady glow on the annunciation window will continue until the fault is cleared and the reset push
button isPressed. When the fault is cleared and the reset push button is pressed, the status
indication of that Conveyor / equipment on the mimic will start slow blinking if it is on selected path
otherwise it will go off and the steady glow in the annunciation window will go off. However,
pressing of the Reset pushbutton before clearance of the fault, will have no effect on the lamps.
At the time of a fault, the faulty conveyor / equipment, as well ad the preceding conveyors /
Equipment in the interlock sequence will stop except H.T. motors for which only scoop coupling
Will be disengaged and motor will continue to run for process fault. In case of motor fault, H.T. 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.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 38 of 48
7. SEQUENTIAL INTERLOCK FOR CONVEYORS & OTHER EQUIPMENT:
7.1).LT CONVEYOR
Permissive conditions (conveyor can be started automatically or manually when all the conditions given below are available)
1) Electrical conditions are healthy. 2) Local Stop Not Pressed /Reset 3) PCS not operated 4) BSS not operated 5) Succeeding conveyor main motor on & SCOOP COUPLING engaged ( applicable for only HT
motor) and only one flap gate is in position to feed succeeding conveyor & other flap gate can be positioned on the same conveyor only if the same upstream conveyor not running.
6) ILMS/SM is energized (On feedback) (if applicable). 7) MD is energized ( On feedback)
Trip conditions (conveyor will trip if any of the given below are available):
1) Local stop operated 2) PCS operated. 3) BSS operated. 4) ZSS Operated with on delay of 60 Sec. 5) Metal is detected. 6) Succeeding conveyor main motor off or scoop coupling dis-engaged (applicable for only HT
motor) and running conveyor feeding to that conveyor is off. 7) More than one flap gate are positioned to same conveyor & more than one upstream
conveyor running. 7.2).HT CONVEYOR & RING GRANULATORS
When start command is given first the command will go to start respective Oil circulating pump for scoop coupling of equipment then will go to equipment main motor, after starting main motor, command will go to engage (OUT) scoop through actuator for scoop coupling of equipment. If off command is given to equipment, first the scoop will get dis-engaged then main motor stops and finally oil circulating pump stops. HT motor will continue to run on no load by disengaging the fluid coupling in case of failure of any process interlock. The HT motor will however be tripped in case of any O/L, high motor winding temperature etc. in addition, in case of normal stop command, after running of the system, motor will stop.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
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Date Description By
ITEM Operational & Control Philosophy
Page 39 of 48
7.3).Main equipment Motor:
Permissive conditions (equipment can be started automatically or manually when all the conditions given below are available)
1) All winding temperature less than 120 deg C. 2) Bearing temperature (DE and NDE) less than 70 deg C. 3) Actuator scoop coupling is IN position (dis-engaged position) 4) Electrical conditions are healthy. 5) Local Stop Not Pressed /Reset
Trip conditions (equipment will trip if any of the given below are available):
1. Any winding temperature is more than 130 deg C. 2. Any bearing temperature (DE and NDE) is more than 80 deg C. 3. Local stop operated
7.4).Oil Circulating Pump for Scoop Coupling of equipment:
When command to equipment is given, it will auto start oil circulating pump and when equipment 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): 1. Local Stop Not Pressed /Reset. 2. Electrical condition healthy. 3. Discharge Pressure not LOW.
Trip conditions (Oil circulating pump will trip if any of the condition will be present):
1. Oil circulating pump oil temp. high (temp. switch operated) 2. Oil pump will trip, if the respective equipment main motor is OFF after pre set time delay of 300
sec. 3. Oil circulating pump oil flow switch not operated with delay of t=10 sec. (oil flow not healthy). 4. Local Stop Operated. 5. Discharge Pressure Low.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 40 of 48
7.5).Actuator for Fluid Coupling Of equipment:
When start command to equipment it will engage (OUT) scoop coupling and when equipment is given off command then it will dis-engage (IN) scoop coupling automatically.
Permissive conditions (actuator for scoop coupling will OUT (engaged) scoop automatically when all the below conditions are present):
1) Oil circulating pump for respective conveyor is ON. 2) Main motor of respective conveyor is ON. 3) PCS (Pull cord switch) is not operated.(Applicable for conveyor) 4) BSS (Belt sway switch) is not operated. (Applicable for conveyor) 5) Electrical conditions are healthy. 6) 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 the same conveyor only if the same upstream conveyor not running.
7) Local Stop Not Pressed /Reset.
Trip conditions (actuator for scoop coupling will IN (dis-engage) scoop if any of the condition will be present):
1) PCS (Pull cord switch) is operated.(Applicable for conveyor) 2) BSS (Belt sway switch) is operated. (Applicable for conveyor) 3) ZSS (Zero speed switch) is operated with on delay of 60 sec. 4) Oil circulating pump OFF. 5) Respective equipment main motor is OFF. 6) Succeeding conveyor main motor off or scoop coupling dis-engaged and running conveyor feeding to that conveyor. 7) More than one flap gate are positioned to same conveyor & more than one upstream conveyor running.
7.6). ILMS (INLINE MAGNETIC SEPERATOR).
Permissive conditions:
1. ILMS should be selected in remote. 2. Local stop not pressed / Reset condition
Trip conditions:
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
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Page 41 of 48
1. Respective conveyor off with on delay of 5 minutes. 2. ILMS fault.
7.7).MD (METAL DETECTOR)
Permissive conditions: 1. MD should be selected in remote. 2. MD haelthy.
Trip conditions:
1. Respective conveyor off with on delay of 5 minutes. 2. Metal detected.
7.8) BS (BELT SCALE).
Permissive conditions:
1. BS should be selected in remote. 3. Local stop not pressed / Reset condition. 4. Respective Conveyor is ON.
7.9) FG (FLAP GATE)
Permissive conditions: Feeding conveyor “NOT ON” will be permissive for forward and reverse direction (Not applicable for bunker flap gate from FG-19, FG-20, FG-21 and FG-22).
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
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ITEM Operational & Control Philosophy
Page 42 of 48
8. ELECTRICAL CONDITIONS 8.1 HT DRIVES
For HT drives all the conditions mentioned below shall be present to start the drive from PLC (Electrical conditions healthy):
1. TCS not operated. 2. Ready to start available
HT drive, will be tripped from PLC if any of the following conditions is present (Electrical trip conditions are present):
1. TCS operated. 2. Under voltage
8.2 LT DRIVES
For LT drives all the conditions mentioned below shall be present to start the drive from PLC (Electrical conditions healthy):
1. Feeder Healthy 2. Overload trip not operated.
LT drive, will be tripped from PLC if any of the following conditions is present (Electrical trip conditions are present):
1. Feeder not healthy 2. Overload trip operated
8.3 ILMS
For ILMS, all the conditions mentioned below shall be present to start the drive from PLC (Electrical conditions healthy):
1. ILMS not faulty. 2. ILMS remote selected
For ILMS, commands to either direction will be withdrawn from PLC if any of the following conditions is present (Electrical trip conditions are present):
1) ILMS Faulty
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
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Page 43 of 48
2) Under Current Relay trip operated. 8.4 METAL DETECTOR
For MD, all the conditions mentioned below shall be present to start the drive from PLC (Electrical conditions healthy):
1. Panel Fault not occurred 2. Remote selected
For MD, commands to either direction will be withdrawn from PLC if any of the following conditions is present (Electrical trip conditions are present):
1. Panel Fault occurred
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 44 of 48
9 CONVEYOR START UP SEQUENCE 1).Following requirements must be met with before proceeding to start any conveyor.
1.1 Ensure availability of Power and Control Supply. 1.2 Ensure the availability and correct operation of following minimum utility systems.
1.2.1 Fire Fighting System 1.2.2 Dust Suppression System 1.2.3 Process Water 1.2.4 Potable Water 1.2.5 Plant Air System
1.3 Ensure correct line up of the Flap gates etc for the desired stream. 1.4 Ensure that all interlocks, protections and instrumentation are in working condition.
1.5 Ensure availability of start permissive for conveyors in the selected stream (e.g. no pull cord
switches, EPB etc are activated, equipment are in REMOTE mode etc.)
1.6 Carry out visual inspection and ensure that there is no material/dust build up or foreign material on or around the Conveyors to be started.
1.7 Ensure correct lubrication of Motor/GB/Fluid Coupling/Pulleys.
1.8 Ensure that all safety guards are in place.
1.9 Ensure that the belt is not fouling anywhere against stationary parts.
1.10 Ensure the correct operation/positioning/readiness of other upstream and downstream equipments like Stacker Reclaimer and permissive is received from operator at site at cabin/radio control.
Once the above requirements are fulfilled, conveyor stream can be started as follows.
1.11 Start the last equipment downstream 1.12 Wait for the starting current to normalize before proceeding to start the next conveyor.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
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Page 45 of 48
1.13 Local Operator to confirm that there is no abnormality and the belt is running in the centre.
1.14 Proceed to start the conveyors on upstream side one by one in the same way.
1.15 Once the whole stream is thus started, start feeding on the stream by starting the feeding
equipment upstream (Conveyor / Stacker Reclaimer/Reclaim hopper).
1.16 Monitor the operating parameters for all the conveyors.
1.17 For shut down, reverse sequence shall be followed i.e. first stop the feeding equipment (Conveyor / Stacker Reclaimer/Reclaim hopper) and wait till all conveyor belts are completely empty.
1.18 Proceed to stop the conveyors downstream of the feeding equipment one by one upto the last
equipment downstream (Conveyor / Stacker Reclaimer/Reclaim hopper depending on the stream).
2). PATH SELECTION PROCEDURE
The control procedures are implemented from the operator station and the back up panel .
In Operator station, operator has to access to the main menu, wherin the mode of operation has to be selected. There are two modes of operation as listed below and as already described above.
a) Auto mode b) Manual Mode
After selection of the mode of operation, operator has to select the path and the stream-A/A&B/B. Flap Gate has to be positioned. If Stream-A&B is selected, then after selection of flap gate position, conveyors desired to be operative, to be selected. Then initiate the start command.
In Back Up panel, operator has to select the mode of operation from the Auto/Manual selector switch provided. The selector switch for Stream-A/A&B/B to be positioned and flap gate of the desired path to be positioned. Then path start sequence push button to be initiated. If stream-A&B is selected in back up panel, then conveyor desired to be operative, to be selected from operator station and then path start sequence push button to be initiated from back up panel.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
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ITEM Operational & Control Philosophy
Page 46 of 48
3).START UP SEQUENCE
Step-1: Material flow path to be decided and Stream-A/A&B/B to be selected.
Step-2: If bunker filling path is selected then, Bunker level to be checked and Tripper floor operator to
be instructed to position the tripper in the required bunker. If stockyard filling is selected, then,
Stacker Reclaimer to be selected in stacking mode.
Step-3: Required flap gate to be positioned.
Step-4: If stream-A&B is selected then the conveyor desired to be selected.
Step-5 :Auto start sequence is activated. The conveyor and equipment would be started in the order
reverse to that of feed material flow, in order to ensure that there is no spillage of the feed
material. The starting permissive will be available for the period of 5 minutes (adjustable). In
the event of the last conveyor/equipment is not started within this preset time of 5 minutes, the
start command for equipment not started will be withdrawn. The sequence cannot be started
again unless the sequence start push button is pressed again and the hooters sound again.
Those conveyors and equipment that have already started will continue to run
4).STOP SEQUENCE When the Path is running, its stop can be caused by :
• Normal Stop Voluntary action on the Path-stopping push button integrated in the back up panel.
Voluntary action on the Path stopping button integrated in the HMI.
An end filling stopping order generated by the path destination (Stacker).
• Stop generated by fault such as Pull Cord Switch, Belt Sway Switch, Zero Speed switch activated. Any motor within the running path trips. Electrical fault
• Stop generated by emergency stop mounted on back up panel/ operator station.
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
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Page 47 of 48
When the fault appears relative to one conveyor or relative to auxiliary equipment of the conveyor
All the upstream conveyors (failed conveyor included) immediately stop. All the down stream conveyors remain running
When the fault appears relative to one conveyor or relative to auxiliary equipment of the conveyor :
• All the upstream conveyors (failed conveyor included) immediately stop.
• All the down stream conveyors remain running.
If the operator wants to stop the down stream running conveyors, he activates the “stop” push button(related to that route), the stopping sequence according to the emptying delay begins.
Stop generated by safety devices/equipment local emergency stop :
• The concerned equipment stops immediately.
• Upstream conveyors of that route stops immediately.
The operator can stop the sequence with the “stop” push button or begin the new starting sequence with “start” push button if the fault has disappeared and acknowledged.
Stop generated by general emergency stop :
“Emergency stop” push buttons are installed on the back up panel and operator station. The activation of the both induces a general tripping of the plant. All the paths will stop immediately .
Document No. TPL-069-0788-I-DOC-053 By VIVEK Approved By KM
Tecpro Systems Ltd. Date 26/05/10
ISSUE/REV R0
Project COAL HANDLING PLANT FOR 2 X 800 MW OF SRI DAMODARAM SANJEEVAIH TPP KRISHNAPATNAM.
Client M/s TATA PROJECTS LTD.HYDERABAD.
CONSULTANT FICTHNER INDIA ENGG.PVT LTD.
ISSUE/
Rev.
Date Description By
ITEM Operational & Control Philosophy
Page 48 of 48
10.DUST SUPPRESSION & EXTRACTION SYSTEM AND AIR CONDITIONING SYSTEM 10.1) DUST SUPPRESSION SYSTEM FOR STOCK PILE & ERH and DRY FOR DUST SUPPRESSION SYSTEM The Sprinkler type dust Suppression System has been Considered for the stockpiles & Dry fog dust suppression system has been considered for all JNT’s (from JNT-1 to JNT-7) with nozzles to form fine mist and suppress the dust. One common Pump house near JNT-4 has been considered for both DS & DFDS. The pumps shall be located in pump house (Near JNT - 4) takes water from the on ground RCC Storage tank adjacent to the pump house and Supplies to a common header. 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 at an interval and the Vertical riser are mounted on the ring headers. Each Sprinkler shall be pivoted with a manually operated globe valve for Controlling of water flow through the Sprinkler. Dedicated reciprocating compressors will be provided for dust suppression system 10.2) DUST EXTRACTION SYSTEM DE system shall be provide in Crusher house & in both bunker units with the recommendation of “American Conference of Governmental Industrial Hygienists” All extraction points shall be provided with butterfly type dampers. The DE fans shall have straight but backwardly inclined blades. The bag filter material shall be fire proof with antistatic property. The design construction and testing will confirm to IS:4894. 10.3) AIR CONDITIONING SYSTEM Package type air conditioning system shall be provided for CHP control room.
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