KUDREMUKH IRON ORE COMPANY LTD TURNKEY TECHNICAL SPECIFICATION FOR PULVERISED COAL INJECTION SYSTEM AT MANGALORE
11.0 MATERIAL HANDLING FACILITIES 11.01 Brief Description of Coal handling system: Coal storage is envisaged near the yard. The coal arriving by trucks is unloaded in the covered storage shed and dosed by Front-end loaders to achieve the required storage capacity. Then the coal is reclaimed by front end loader and fed to feed hoppers provided on Reclaiming conveyor. The reclaiming conveyor C1 in turn feeds to another belt conveyor C2, which is feeding the coal bunker in the PCI Building. The coal from bunker is fed to grinding mill through belt weigh feeder. CONVEYOR SYSTEM & RELATED EQUIPMENT a.
Conveyor
Design Basis • •
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Shall generally conform to; IS: 11592-2000. Utilization of cross sectional area – max 80 % of theoretical cross sectional are as indicated in IS 11592-2000 (for computation of belt speed) Design capacity of belt conveyors- 20% more than rated capacity to be considered while calculating motor power o Troughing angle - 35 Friction factor (for kW calculation) of belt conveyors0.03
Belting - EP Grade • • •
Top cover thickness - 6 mm(min) Bottom cover thickness - 3mm(min) Fire resistant for conveyors handling Coal.
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Chapter 11
Sheet 1 of 14
KUDREMUKH IRON ORE COMPANY LTD TURNKEY TECHNICAL SPECIFICATION FOR PULVERISED COAL INJECTION SYSTEM AT MANGALORE
Idlers •
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Idler construction shall conform to IS 8598-1987 Carrying Idlers – 139.7mm; Outer Diameter with 4.85 mm shell thickness Return Idlers – 127 mm Outer Diameter with 4.85 mm shell thickness Carrying idler spacing spacing -1000 mm. Spacing in the convex curve position of conveyor shall be limited to half the normal spacing of carrying idlers Return idler spacing - 3000 mm spacing Training Idler (with guide rollers) spacing a) Carrying side - 15 m b) Return side - 30 m Impact idler spacing - 500 mm or less - (min. 6 Nos.) Eccentricity of the idlers shall be such that the total indicator reading shall not exceed 0.8mm. Eccentricity of the idlers near belt weigh scale shall be limited to 0.1mm. Minimum bearing life of idlers & rollers shall be 30,000 working hours and they shall be grease packed for life.
Deck plate - 3.15 mm thick all along conveyor to be provided.
Pulleys. •
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Drive pulley –12 mm thick. Hot vulcanized rubber o lagging, minimum durometer hardness of 55 shore A scale and minimum tensile strength of 17 MPa and elongation 400% at break. Pulley Shell thickness shall be 16 mm minimum. Diamond grooved rubber lagging shall be provided. Tail/ Bend/take-up pulley – 10 mm thick hot vulcanized o rubber lagging, minimum durometer hardness of 45 shore A scale, and shell thickness 12 mm minimum. Plain rubber lagging shall be provided for all non drive pulleys.
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Sheet 2 of 14
KUDREMUKH IRON ORE COMPANY LTD TURNKEY TECHNICAL SPECIFICATION FOR PULVERISED COAL INJECTION SYSTEM AT MANGALORE
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Pulley face width - As per IS 8531-1986, Reaffirmed in 1993. Pulley Shaft –shaft diameter up to 160mm- class-4 as per IS 1875-1992. More than 160mm - EN-9/BS 970 or equivalent forged quality. Pulleys having shaft diameter of 200mm and above at bearing shall be provided with expandable shaft hub connection (Ring feeder type). Pulleys having shaft diameter of less than 200mm at bearing may be provided with Gib head key or parallel key. Pulleys having shaft diameter 160mm or more at bearing shall be provided with turbo diaphragm type of end disc wherein the end disc and hub shall be of integral steel casting. The dimensional tolerance on pulley diameter shall not exceed ±3mm and out of roundness shall be limited to ±1mm prior to lagging. Plummer blocks shall be grease filled and of a triple labyrinth seal type Pulley bearing life shall be minimum 40,000 working hours. Plummer block shall be of cast steel construction for pulleys having shaft diameter at bearing are 160mm and above.
Gear boxes
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Chapter 11
Sheet 3 of 14
KUDREMUKH IRON ORE COMPANY LTD TURNKEY TECHNICAL SPECIFICATION FOR PULVERISED COAL INJECTION SYSTEM AT MANGALORE
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Brakes •
On all inclined conveyors to prevent roll back. Rating minimum 1.5 times the maximum calculated torque.
Take up •
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D.C. electromagnetic brakes on conveyors wherever required to prevent roll back or where stopping time regulation is required.
Roller type hold back device. •
All gears shall be of hardened and ground and made of suitable alloy steel with machine cut teeth. Splash lubrication shall be used in the gear boxes. The housing for gear boxes shall be of cast steel or fabricated. Fabricated gear boxes shall be stress relieved. Double V-lip type seal shall be provided on input and output shaft. Gear box mechanical rating shall be 1.5 times of consumed KW or 1.25 times of motor KW rating which ever is higher for all conveyors. Worm gear box shall not be used.
For Conveyors up to 40 m length. - Screw take up with protected thread – Screw of stainless steel with brass nut. For Conveyors of length 40 m and above – Vertical / Horizontal gravity take up.
High speed coupling: •
Gear coupling / resilient coupling for drive less than 30 kW and for all drives with hydraulic / VVVF Drives.
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Sheet 4 of 14
KUDREMUKH IRON ORE COMPANY LTD TURNKEY TECHNICAL SPECIFICATION FOR PULVERISED COAL INJECTION SYSTEM AT MANGALORE
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Fluid coupling for drives with 30 kW & above.
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Pin bush coupling - Not Acceptable
Low speed coupling: •
External scraper •
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Multi sprung blade (in segments) mounted on elasto mount system. Primary and Secondary type at Discharge pulleys of Conveyors and Trippers. Blade material – metallic blade with tungsten carbide tips Material scraped shall fall into main chute.
Internal scraper •
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Gear coupling / resilient coupling
V shaped for unidirectional conveyors and diagonal type for reversible conveyor. Mounted on carrier assemblies with elasto-mount and non-metallic polyurethane blade. To be provided on the return belt prior to Tail pulley, Take-up pulleys.
Belt sway switch •
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A pair of switch shall be installed near the head end and a pair near the tail end. Pair of switch shall be installed at 100 m interval thereafter. A pair of switches shall also be provided before the belt weighing scales.
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Sheet 5 of 14
KUDREMUKH IRON ORE COMPANY LTD TURNKEY TECHNICAL SPECIFICATION FOR PULVERISED COAL INJECTION SYSTEM AT MANGALORE
Zero speed switch – on non driving pulley
Pull cord switch •
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Discharge Hood •
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6mm thick mild steel plate for portion above the pulley centerline. 10 mm for the balance portion. Easily adjustable baffle plates in the hood to control trajectory of materials.
Guards •
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30 m interval on both sides for each conveyor, starting at 4000 mm from drive end. All pull cord switches shall have individual local indication lamps to indicate when operated.
Guards on the conveyor shall comply with the relevant IS/IPSS Standard. The guards shall be of expanded metal conforming to IS: 412 (current) Safety guards shall be provided for all couplings, brakes etc. of the conveyor drive and screwed on the above base frame.
Skirt Boards •
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Skirt boards of minimum 3000 mm length at the loading points of all conveyors, however wherever dustsuppression system with water spraying arrangement is provided – the length & height of the skirt shall be suitably designed. The thickness of skirt plate shall be minimum 10 mm. The top cover plate where provided shall be minimum 3 mm thick. The arrangement for fixing rubber curtain and rubber on
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Sheet 6 of 14
KUDREMUKH IRON ORE COMPANY LTD TURNKEY TECHNICAL SPECIFICATION FOR PULVERISED COAL INJECTION SYSTEM AT MANGALORE
skirt boards shall be such as to ensure quick adjustment. The thickness of rubber curtains shall be minimum 10 mm. Skirt rubber shall be in segments and the design shall ensure automatic flexing of rubber for proper sealing. o Shore hardness of skirt rubber shall be min. 55 A. Skirt rubber shall be minimum 10 mm thick. Liners •
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Chutes: Chutes shall be provided with minimum 16mm thick UHMWPE liner. Dribble Chutes below the snub pulley shall be provided with 5mm thick stainless steel liners.
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Skirt board: Skirt plate shall be provided with minimum 12mm thick UHMWPE liner.
Chute Jamming Detectors •
Chute jamming detectors shall be provided on each chute.
Motors •
Motor for conveyors shall be of continuous duty energy efficient squirrel cage type. The motor speed shall be restricted to 1500 RPM for all conveyors.
11.02 ELECTRIC HOIST •
Electric hoists shall conform to class-I duty as per IS: 3938-1983.
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Sheet 7 of 14
KUDREMUKH IRON ORE COMPANY LTD TURNKEY TECHNICAL SPECIFICATION FOR PULVERISED COAL INJECTION SYSTEM AT MANGALORE
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Electrical hoists with electrically movable trolley shall be provided in the junction houses for the maintenance of the equipment. The capacity of the hoist shall be decided based on the heaviest item to be lifted. Hoisting speed shall be 3-5m/min and CT speed shall be 15-20m/min. Brakes of Hoists of SWL of 5.T and above, only DC Electromagnetic shoe Brake of BCH Make. For lower capacities DC electromagnetic disc brakes acceptable. All flexible trailing cables shall be clamped with PVC or non metallic clamps. The wheels shall be mounted on anti friction ball/roller bearings & shall be easily removable for repair and maintenance. The wheel diameter shall be selected such that skidding does not take place even under unloaded condition.
11.03 MANUAL HOISTS. •
The Chain Pulley Block shall conform to class-I duty as per IS: 3832-2005.
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Ball and roller anti friction bearing only shall s hall be used.
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Only triple -spur geared type shall be considered.
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Swiveling type standard shank hook mounted on grease lubricated anti-friction thrust bearing shall be used.
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Only ball and roller anti-friction bearing shall be used.
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Load chain shall conform to Grade 80 as per IS: 6216 –
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Sheet 8 of 14
KUDREMUKH IRON ORE COMPANY LTD TURNKEY TECHNICAL SPECIFICATION FOR PULVERISED COAL INJECTION SYSTEM AT MANGALORE
1982. •
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Hand chain shall be of 6.0 mm nominal size and shall conform to Grade 30 as per IS: 2429 (part – 2) – 1970. Geared traveling trolley for the chain pulley block shall be supplied along with the chain pulley block wherever specified.
11.04 GROUND HOPPER: •
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11.05
Hopper mounted on conveyor shall be fabricated from minimum 10mm thick steel plate. Plate inside shall be lined with minimum 5mm thick stainless steel liner. Hopper shall be provided with rod gate at bottom. Hopper shall be designed such that the material shall flow freely on to the conveyor. Minimum slant angle of hopper plate shall be 70degree. Hopper effective storing capacity shall be minimum 3 10m .
INLINE MAGNETIC SEPARATOR & METAL DETECTOR: •
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Inline magnetic separator with one number metal detector shall be installed on belt conveyor C-1 for removal of stray iron. The Inline magnetic separator shall be complete with belt, magnet, rectifier, control push buttons, suspension bars, frame and drive unit. The magnetic separator shall be used for separating magnetic particles from the material being conveyed. The separated magnetic materials shall be discharged at a suitable place away from conveyor to the ground through a suitable chute.
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Chapter 11
Sheet 9 of 14
KUDREMUKH IRON ORE COMPANY LTD TURNKEY TECHNICAL SPECIFICATION FOR PULVERISED COAL INJECTION SYSTEM AT MANGALORE
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The magnetic separator shall be trolley mounted with locking arrangement so as to have provision for moving the magnetic separator during maintenance of Conveyor C-1 drive pulley. The magnetic separator shall be suspended from the top through turnbuckles and Dshackles of suitable capacity. The minimum adjustment in turnbuckles shall be 200mm. The following shall be considered for design / selection of Inline magnetic separator
1. Type Type 2.
3. 4. 5. 6. 7. •
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Inline Inline magnet magnetic ic separa separator tor (4 pulley type) Weight Weight to be lifted lifted Min. 50mm long nail and Max. 1000mm long rod (max.15kg) Coil Coil windin winding g Double Double fibre fibre glass glass covered copper strips Cool Coolin ing g Air Air cool cooled ed Class Class of insula insulatio tion n Class Class – H Min. Min. ope opera rati ting ng hei heigh ghtt 500 mm to be considered Duty Duty Cont Contin inuo uous us duty duty
Non-magnetic pulley shall be provided for the discharge pulley of conveyor C-1. Technical Parameters 1. Material: a. b. c.
Size : (-) 30 mm Moisture (maximum) : 15% Bulk density : 0.85 t /cu.m
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Sheet 10 of 14
KUDREMUKH IRON ORE COMPANY LTD TURNKEY TECHNICAL SPECIFICATION FOR PULVERISED COAL INJECTION SYSTEM AT MANGALORE
2. Belt
conveyor:
650mm (Belt (35 deg. troughed)
width)
11.06 BELT WEIGH FEEDER: •
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The belt weigh feeder shall be complete with all mechanical components, drive motor with VFD for speed control, weighing device, structural framework, skirt board assembly, discharge chute, belt scraper, feed chute etc. and control panel with display. Belt weigh feeders shall be designed for heavy duty capable of extracting, weighing and conveying specified material under specified environmental conditions. The belt weigh feeder shall incorporate highly reliable weight measuring system and the drive unit shall be shaft mounted geared motor with VVVF speed control. The housing of the gearbox shall be cast steel or fabricated steel. The gear reducer service factor shall be minimum of 1.25 based on installed motor power. Worm gear reducers are not acceptable. Conveyor belting shall be of EP, with fire resistance cover grade and shall conform to relevant clauses of IS: 1891 - (Part1) - 1988 or any other standard of International repute acceptable to Owner. The belt shall have adequate number of plies to handle the tensions likely. Belting shall be free from longitudinal and traverse buckling, wavy cords or other unevenness that would cause localized points of flexing when belt is in service. Top and bottom cover thickness shall be minimum 6 and 3 mm.
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Chapter 11
Sheet 11 of 14
KUDREMUKH IRON ORE COMPANY LTD TURNKEY TECHNICAL SPECIFICATION FOR PULVERISED COAL INJECTION SYSTEM AT MANGALORE
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All components of the idler assemblies shall be designed, manufactured and tested as per IS : 8598 - 1987 or any other standards of International repute acceptable to Owner. Pulley shall be of extra heavy-duty type. The pulley assemblies shall be completely balanced before assembly. Pulley shall be made of welded steel and stress relieved before machining. Pulley shall be rubber lagged of diamond type construction for the drive pulley. Other pulleys shall have plain rubber lagging. Lagging thickness shall be minimum 12mm for drive pulley and 10mm for other pulleys.
The weigh feeder is provided below the bunker. The inlet-connecting chute between the bunker and the weigh feeder is included in the scope. The chute shall be provided with manually adjustable vertical gate for adjusting the bed height.
No cast iron part shall be used except for electrical equipment and no wood or other combustible material shall be used. LINER UHMWPE liners of minimum 16mm thick shall be provided in the inlet connecting chute, skirt board and discharge chute of the belt weigh feeders.
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CONTROL SYSTEM
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Sheet 12 of 14
KUDREMUKH IRON ORE COMPANY LTD TURNKEY TECHNICAL SPECIFICATION FOR PULVERISED COAL INJECTION SYSTEM AT MANGALORE
The total belt weigh feeder system shall be controlled from -
Control panel to be located at a convenient location.
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Local control box mounted near the Belt feeder.
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CONTROL PANEL The control panel shall consist of variable voltage variable frequency drive for the belt motor. The panel shall consist of Feed rate setting potentiometer, Totaliser circuit, Start, Stop push buttons. Feed rate and Totaliser indications (digital display), Fault indications (LEDs), Motor current Ammeter and voltmeter on the incomer. The panel shall include necessary control transformer, electronic circuits, VVVF drive cards, speed setting, I /O modules for taking Field inputs from Belt sway, LCB, pull cord and zero speed switches.
11.07 LIST OF PREFERRED MAKES: SL. NO.
ITEM
MAKE
1
Bearings
SKF / FAG
2
Gear reducers
FMG / NAW / ELECON.
3
Flexible gear coupling
HICLIFF / CONCORD / WELLMAN INCANDESCENT / DAVID BROWN / GREAVES / NAW / ELECON
4
Flexible spring resilient GBM / WELLMAN INCANDESCENT coupling
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Sheet 13 of 14
KUDREMUKH IRON ORE COMPANY LTD TURNKEY TECHNICAL SPECIFICATION FOR PULVERISED COAL INJECTION SYSTEM AT MANGALORE
5
Fluid couplings
VOITH / PEMBRIL / ELECON
6
Belt
PHONEIX YULE / NORTH LAND / HILTON
7
Idlers
KALI / TRF/ ELECON
8
Belt scraper
HOSCH / KAVERI
9
LT Motors
Alstom / ABB/ CGL
10
VFD panel
Siemens/ L&T/ ABB/ Allan Bradley
11
Belt Weigh Feeder
SCHENCK / PBL / TRANSWEIGH
12
Electrical Hoist
ARMSEL / VOLTAS/UNITEK/TUOBRO FURGUSON
13
Chain Pulley Block
Mechanical Movement / MH BRADY / Armsel /Tractor- Tirfor
14
Magnetic Separator
EMI / POWER BUILD / ELECTROMAG
14 15
Pull chord, Belt sway , Telemechanic, Jayashree,Technocrat Zero speed switches DCEM brakes BCH / STROM CRAFT
16
Metal Detecter
MR Equipment / PBL
Note: 1) Items for which preferred makes are not indicated shall be procured only after approval of the make by owner / consultant. 2) Specific approval shall be taken taken from the Owner/ its Consultant Consultant after checking its merit for the additional makes as suggested by the tenderer.
MEC/01/02/196M/TS-001 “© 2008 MECON Limited. Limited. All rights reserved” reserved”
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Sheet 14 of 14
